Foundation Fieldbus-1

©2002 Emerson Process Management. All rights reserved. View this and other courses online at www.PlantWebUniversity.com.
Fieldbus 101
Introduction to FOUNDATION fieldbus

• Overview
• What is FOUNDATION fieldbus?
• The digital bus advantage
• An established standard
• Interoperability
• Safe and effective process control
Overview
Why should I care about FOUNDATION fieldbus?
You wouldn't be reading this if you didn't already suspect that FOUNDATION fieldbus could help
you improve process and plant performance.
The fact is, it can. It offers distinct advantages over traditional analog and discrete wiring or
even other digital buses — at lower total installed cost and lower ongoing costs.
FOUNDATION fieldbus can deliver these benefits because it's different from traditional
communication technologies. That doesn't mean it's harder to learn or to use — just different.
To help you understand those differences, this introductory course offers a brief overview of
FOUNDATION fieldbus and some of its advantages. Other courses provide more details about
the technology and its benefits, as well as practical tips on putting FOUNDATION fieldbus to
work for you.
Hint: As you go through the topics in this introductory course, watch for answers to these
questions:
• How can FOUNDATION fieldbus carry more information than 4-20 mA wiring?
• Who controls FOUNDATION fieldbus technology?
• For what kind of application was FOUNDATION fieldbus originally designed?
What is FOUNDATION Fieldbus
FOUNDATION fieldbus is an all-digital, serial, two-way communications system that serves as

the base-level network in a plant or factory automation environment.
It's ideal for applications using basic and advanced regulatory control, and for much of the
discrete control associated with those functions.
Two related implementations of FOUNDATION fieldbus have been introduced to meet different
needs within the process automation environment. These two implementations use different
physical media and communication speeds.
• H1 works at 31.25 Kbit/sec and generally connects to field devices. It provides

communication and power over standard twisted-pair wiring. H1 is currently the most
common implementation and is therefore the focus of these courses.
• HSE (High-speed Ethernet) works at 100 Mbit/sec and generally connects input/output
subsystems, host systems, linking devices, gateways, and field devices using standard
Ethernet cabling. It doesn't currently provide power over the cable, although work is
under way to address this.
The digital bus advantage
Conventional analog and discrete field instruments use point-to-point wiring: one wire pair per
device. They're also limited to carrying only one piece of information -- usually a process
variable or control output -- over those wires.
As a digital bus, FOUNDATION fieldbus doesn't have those limitations.
Multidrop wiring. FOUNDATION fieldbus will support up to 32 devices on a single pair of wires
(called a segment) -- more if repeaters are used. In actual practice, considerations such as
power, process modularity, and loop execution speed make 4 to 16 devices per H1 segment
more typical.
That means if you have 1000 devices -- which would require 1000 wire pairs with traditional
technology -- you only need 60 to 250 wire pairs with FOUNDATION fieldbus. That's a lot of
savings in wiring (and wiring installation).
Multivariable instruments. That same wire pair can handle multiple variables from one field
device. For example, one temperature transmitter might communicate inputs from as many as
eight sensors -- reducing both wiring and instrument costs.
Other benefits of reducing several devices to one can include fewer pipe penetrations (for
improved safety and reduced risk of fugitive emissions) and lower engineering costs.
Two-way communication. In addition, the information flow can now be two-way. A valve
controller can accept a control output from a host system or other source and send back the
actual valve position for more precise control. In an analog world, that would take another pair of
wires.
New types of information. Traditional analog and discrete devices have no way to tell you if
they're operating correctly, or if the process information they're sending is valid. As a
consequence, technicians spend a lot of time verifying device operation.
But FOUNDATION fieldbus devices can tell you if they're operating correctly, and if the
information they're sending is good, bad, or uncertain. This eliminates the need for most routine
checks -- and helps you detect failure conditions before they cause a major process problem.
The PlantWeb advantage

In a PlantWeb architecture, Emerson field devices can provide status
information that helps reduce maintenance cost by eliminating routine checks
of device operation.
Their predictive diagnostics can also help increase plant uptime and performance by
detecting or predicting deteriorating performance and failure conditions before they cause
problems.
Control in the field. FOUNDATION fieldbus also offers the option of executing some or all
control algorithms in field devices rather than a central host system. Depending on the
application, control in the field may provide lower costs and better performance -- while enabling
automatic control to continue even if there's a host-related failure.
An established standard
FOUNDATION fieldbus is covered by standards from three major organizations:
• ANSI/ISA 50.02
• IEC 61158
• CENELEC EN50170:1996/A1
The technology is managed by the independent, not-for-profit Fieldbus Foundation, whose 150+
member companies include users as well as all major process automation suppliers around the
globe.
Some suppliers have even donated fieldbus-related patents to the Fieldbus Foundation to
encourage wider use of the technology by all Foundation members.
Interoperability
Interoperability simply means that FOUNDATION fieldbus devices and host systems can work
together while giving you the full functionality of each component.
How do you know it's interoperable? Instruments can earn "registered"

status (and the right to carry a FOUNDATION fieldbus checkmark logo) by
passing rigorous tests to demonstrate they meet the requirements for
interoperability.
And to ensure that users have a choice of fieldbus products, the Foundation doesn't allow
devices to bear the FOUNDATION fieldbus interoperability "checkmark" until at least two
products of the same type — from different manufacturers — have passed its tests.
Host interoperability testing. Host systems undergo Foundation-supervised tests to

demonstrate their support for specific interoperability features. The features a given host system
supports are listed on the Foundation's web site, but host systems aren't registered and don't
bear the checkmark logo.
In addition, some automation suppliers and users have cooperated to perform extensive
interoperability testing between different brands of instruments and host systems — both in the
lab and in real-world plants.
Intelligent field devices used in PlantWeb architecture were among the first
to earn the Foundation's "checkmark" logo. Our DeltaV™ automation system
was also one of the first to successfully undergo host-system testing. And
Emerson has been a leading participant in multi-vendor interoperability tests.
As a result, in addition to the performance and reliability our devices and systems are known
for, you get the flexibility to put together an interoperable solution that meets your needs.
Interoperable isn't interchangeable. Interchangeable means you can freely substitute one
device for another and still get exactly the same functionality. Interoperable, on the other hand,
means different devices from different manufacturers can work together -- but individual devices
can have different functionality.
For example, you may have two pressure transmitters from different manufacturers. One
transmitter may provide only analog input functionality, while the other transmitter also offers
PID control and custom diagnostic capabilities. You can't replace the more capable transmitter
with the less capable one and still get the same total functionality. But both transmitters can
work together on the same fieldbus segment.
Fieldbus 201 covers interoperability in more detail.
Safe and efficient process control
Some communication protocols that were originally designed for factory or office automation are
proving useful in specific niche applications in process plants. But none of these protocols was
designed with the full requirements of process control in mind. As a result, they are less-than-
optimum choices for providing safe and effective process control.
FOUNDATION fieldbus H1, on the other hand, was developed specifically to meet the needs of
the process industry.
• It can withstand the harsh and hazardous environment of process plants.

• It delivers power and communications over the same pair of wires.
• It can use existing plant wiring.
• It supports intrinsic safety.
In short, it's designed to operate where your process does.

Control you can count on. FOUNDATION fieldbus also provides deterministic process control:
control communications happen on schedule, without delays caused by other traffic on the bus.
If a message doesn't get through, it tries again.
Control reliability doesn't stop there. If fieldbus devices lose their connection to the host system,
they are capable of maintaining safe and effective control across the bus.
Keeping the user informed. FOUNDATION fieldbus devices always know whether the
information they're providing is good and provide this status information with the process
variable. For the safest plant operation, both the control strategy and the operator need this
status information delivered through the host so they can respond safely and predictably during
failure modes.
The bottom line: FOUNDATION fieldbus is designed to deliver the performance and reliability
needed for mission-critical process control.
Fieldbus 102
Fieldbus communications
• Overview
• The communications model
• Physical layer
• Data link and application layers
• User layer
• Scheduled communications
• Unscheduled communications
• Parameter status
• Application clock
• Link active scheduler
• Device address assignment
• Find tag service
Overview
How does data get where it's needed -- when it's needed?
One of the most important aspects of FOUNDATION fieldbus is its ability to collect and deliver
vast amounts of information -- not only process variables and control signals, but other types of
instrument and process data as well.
It does this consistently and reliably, while also providing interoperability between devices from
different manufacturers -- and compatibility with existing wiring. This course describes key
features of the technology that make this possible.
Hint: As you go through the topics in this course, watch for answers to these questions:
• What kinds of information are transmitted using unscheduled communications?
• How does FOUNDATION fieldbus improve alarm and event time-stamping?
• What are the three possible labels that FOUNDATION fieldbus can use to describe the
status of a process parameter?
The communications model
The FOUNDATION fieldbus communications model has three parts:
• The physical layer

• The data link and application layers
• The user layer
The physical layer and the data link and application layers make up the communications stack.
The user layer sits on top of the stack and enables you to interact with the other layers and with
other applications in your system.
You don't have to remember the details of the communication model to use FOUNDATION
fieldbus. But the information on this and the next three pages will help you understand the
relationship between different aspects of fieldbus technology.
Physical layer
The first functional layer of the FOUNDATION fieldbus communications model is the physical
layer, which deals with translating messages into physical signals on the wire -- and vice versa.
The physical layer also provides the common electrical interface for all FOUNDATION fieldbus
devices. FOUNDATION fieldbus H1 segments require 9-32 volts DC power and approximately
15-20 mA of current per device. They operate at a communication speed of 31.25 kbaud.
The FOUNDATION fieldbus physical layer is defined by approved standards (IEC 61158-2 and
ANSI/ISA 50.02, part 2). It can run on existing field wiring over long distances, supports two-wire
devices, and offers intrinsic safety as an option. In short, it's an ideal match for a typical
process-automation environment.
Data link and application layers
The second part of the communication model combines several technologies that together
control transmission of data on the fieldbus.
The data link and applications layers provide a standard way of "packaging" the data, as well as
managing the schedule for communication and function-block execution. They enable process
control while providing standardization and interoperability.
User layer
The user layer sits on top of the communications stack, where it enables you to interact with the
other layers and with other applications.
The user layer contains resource blocks, transducer blocks, and function blocks that describe --
and execute -- device capabilities such as control and diagnostics. Device descriptions enable
the host system to interact with and understand these blocks without custom programming.
Blocks and device description language are covered in more detail in later courses.
Scheduled communications
All devices and function blocks on a FOUNDATION fieldbus segment execute and communicate
process control information on a regular, repeating cycle.
Timing for this type of communication is determined by a master schedule in a Link Active
Scheduler, which is a function residing in the host system or one of the devices on the segment.
You'll learn more about the Link Active Scheduler later in this course.
These scheduled (also called "cyclic") communications use a publisher/subscriber method.

This means data is sent on the bus or "published" once, and all devices that need the data listen
to or "subscribe" to the same transmission. A specific parameter can therefore be used by as
many different devices or functions as you want, without increasing traffic on the bus or
potentially affecting control performance.
These communications are also deterministic. This means that they always occur on a pre-
determined schedule, so information is certain to be broadcast (and received) precisely when
it's needed.
The result is regular and precise execution of communication and control, which helps reduce
process variability. For fast or time-critical control loops, control on FOUNDATION fieldbus can
improve plant performance.
Unscheduled communications
FOUNDATION fieldbus supports a great deal of information beyond process loop control data.
These other types of information include
• Configuration information sent to devices or a central database

• Alarm, event, and trend data
• Information for operator displays
• Diagnostic and status information.
This information is important, but not as time-critical as loop control information. If it's
transmitted 1/8 second early in one communication cycle and 1/8 second late in the next cycle,
there's no impact on process control or plant operation.
Flexible timing. FOUNDATION fieldbus gives this information a lower priority on the segment
than scheduled control-loop-related communications. However, a certain amount of time in the
communication cycle is reserved for these unscheduled (or "acyclic") communications to ensure
that the segment is not too loaded to carry the information.
During this time, a token-passing method gives each device on the segment the opportunity to
transmit messages until it has finished or an allotted time has expired.
Parameter status
FOUNDATION fieldbus supports a variety of data redundancy checks to avoid message-bit

errors. Two additional features that help ensure data reliability are an application clock (the
next topic in this course) and a status associated with every parameter.
Each device is designed to check for problems and label the data it sends accordingly. This
status label shows whether the quality of the data is good, bad, or uncertain.
For example, a bad status signal could indicate a device failure, such as a failed sensor on a
temperature transmitter.
An uncertain status indicates that the quality of the data is unknown. For example, a pressure
transmitter reading that's 110% of the device's upper limit may be accurate -- or it may be
inaccurate because the device has saturated high and the actual pressure is even higher.
Practical pointer
Device status information is made available to the host system, but not all hosts use this
information. You should therefore check for this functionality in any host system you
consider. The host should display this status information to the operator and support use of
the information to modify the control action if appropriate.
In a PlantWeb architecture, the DeltaV and Ovation systems read device

status Information and propagate it through the system. As a result,
• Operators can know the validity of information they use for decision-making.
• Control strategies can be configured to modify their control action depending on

device information status.
• Advanced Control strategies such as Model Predictive Control or Neural Network

Control can be notified if the data they're using is bad or suspect.
• AMS Suite applications present the information to maintenance

personnel so they can verify proper operation, or more quickly identify and localize
actual or predicted error conditions.
Application clock
Every device on a FOUNDATION fieldbus segment shares the same time.
A system management function called the application clock periodically broadcasts the time --
either local time or Universal Coordinated Time -- to all devices. Each device uses an internal
clock to keep time between these synchronization broadcasts.
Alarms and events are time-stamped at the device where they occur, when they occur --not
later when they're received by a historian, alarm log, or other application on a host system.
Because of this approach, FOUNDATION fieldbus provides superior time resolution and
accuracy for activities such as sequence-of-events recording and analysis.
Link active scheduler
The link active scheduler (LAS) function maintains the central, deterministic schedule for
communication between devices on a segment. It improves overall communication reliability by
compelling each device to transmit cyclic data when it's scheduled to do so.
Message retries also increase communication reliability. If a device doesn't respond to the LAS
"compel data" message -- for example, if a momentary electrical transient at a device prevents it
from communicating -- then the LAS will re-send the message to compel the device to publish
its information.
The LAS resides in a device or host system component (such as an H1 interface card) on the
segment. If the LAS fails, then a backup LAS in another device or host system component
takes over as master scheduler.
There can be more than one backup LAS on a segment. If the first backup fails, the second
backup takes over, and so on. This means that FOUNDATION fieldbus is designed to degrade
gracefully, further increasing reliability.
Device address assignment
As a digital, multidrop bus, FOUNDATION fieldbus carries signals to and from several devices
over the same cable. To identify which information is associated with which device, each device
is assigned an address.
Depending on the communication protocol, addresses can be assigned in several ways, from
dip switches or off-line addressing to automatic online assignment.
Methods such as using dip switches or offline addressing carry the risk of human errors, such
as inadvertently assigning an address to more than one device. These addressing errors can
cause communication problems, or in extreme cases prevent the bus from working. That's why
FOUNDATION fieldbus doesn't allow these methods of address assignment.
Online addressing helps avoid problems such as duplicate devices with the same address, but
by itself does not guarantee there are no addressing errors. You can avoid this risk if addresses
are assigned automatically by a configuration tool or host system as each device is connected
to the segment.

In the PlantWeb architecture, the DeltaV and Ovation configuration tools
automatically assign device addresses to eliminate unnecessary work and
the possibility of duplicate assignments.
FOUNDATION fieldbus reserves some addresses for hosts and for temporary devices such
as maintenance tools. The DeltaV and Ovation systems’ automatic address assignment
makes sure these reserved addresses aren't assigned inappropriately.
Finally, you can override the default addresses and assign specific addresses to certain
devices when necessary.
Find tag service
Many communications protocols require the user to identify devices and parameters, and then
link them by address and/or register assignment. This can be a difficult and error-prone process.
FOUNDATION fieldbus, on the other hand, is a tag-based bus. Instead of requiring a hardware
or register address, it can find devices or variables by tag (such as "FT-101").
To find a specific tag, a find tag query is sent out on the bus. As each device receives the
query, it searches itself for the requested tag.
When a device finds the tag, it sends back complete path information and all necessary
parameters and descriptors associated with the tag. The host or maintenance tool can then use
the path to access the data for the tag. This feature also helps avoid duplicate tag assignments.
Fieldbus 103
Loop scheduling
• Overview
• Basic scheduling
• Multiple loops on the same segment
Overview
What makes each control action happen when it should?
Good process control is time-dependent. If control actions don't happen when they should, the
resulting process variability can increase energy and feedstock use, reduce yields, and reduce
product quality.
FOUNDATION fieldbus solves this problem by executing control on a deterministic, real-time

schedule. The technology is designed to accommodate the full range of control situations you're
likely to face.
This course summarizes how FOUNDATION fieldbus does this.
• What determines when a function block or communication action begins?
• How do you avoid overlapping communications when you have more than one loop on
the same segment?
• How can you accommodate both fast and slow loops?

Basic scheduling
In FOUNDATION fieldbus, control-related communications and function blocks execute at

precisely defined intervals, and in the proper scheduled order for correct process control.
Methods for ensuring correct timing of fieldbus communications — including the application
clock and link active scheduler — are covered in the previous course, and the course that
follows this one covers function blocks in detail. This section explains how the two are
synchronized to provide the best possible control performance.
The overall schedule is called a macrocycle. The macrocycles for all devices on a segment are
precisely scheduled and all use the same absolute start time. Function blocks and
communications execute at specified offsets from this absolute time.
This diagram shows the schedule for a typical loop where the PID function is in the valve
controller (Device 2). Each activity occurs at a defined offset from the absolute start time.
This cycle repeats on an exact, ongoing schedule. Unscheduled (acyclic) messages can be
communicated any time scheduled (cyclic) messages are not being sent.
Practical pointer
Use some caution in scheduling loops. Functions will execute in the order you specify, even
if that order is incorrect. Scheduling the AO first, the PID next, and the AI last will add a large
and needless delay to your overall loop processing.
PlantWeb architecture makes loop scheduling a breeze. Scheduling is

done automatically within the DeltaV and Ovation configuration tools. You
simply drag and drop blocks on a graphical configuration sheet. As the blocks
are dropped in place, they are automatically numbered in execution order and
macrocycle is automatically calculated. If you build them in the order they are to execute, no
further scheduling is needed.
If you decide to change the order of execution, the DeltaV and Ovation configuration tools let
you change the order of execution by simply clicking on the blocks in the order you want
them to execute.
Multiple loops on the same segment
As this example shows, you can have several function blocks executing at the same time on the
same segment, provided that they're in different devices and have different start times. The
example has three loops, with PID in the valve controller.
However, you can't have more than one device communicating on the bus at the same time.
The example schedule prevents communication overlap by staggering the function block
communication start times so one block doesn't start until the previous one has finished.
For the sake of simplicity, the diagram shows blocks executing in sequence, with no processing
overlap. In reality, multiple blocks can execute at the same time as long as they're in different
devices, and the data can be communicated as soon as the processing is complete. Multiple
devices cannot communicate at the same time.
Practical pointer
Don't assume all devices have equal performance. Different devices may require different
times to execute a function block. For example, one device may execute a PID block in 30
ms; another may take 75. Check with your vendor to see if they offer an automated
scheduling tool that takes different device execution times into consideration.
Fieldbus 104
Fieldbus blocks
• Overview
• What is a resource block?
• What is a transducer block?
• What is a function block?
• FOUNDATION fieldbus function blocks
• Basic FOUNDATION fieldbus function blocks
• Advanced FOUNDATION fieldbus function blocks
• How do function blocks get into devices?
• Instantiating blocks into devices
• Device descriptions
Overview
What are fieldbus blocks? And what do they do for me?
Think of fieldbus blocks as small, sealed software modules. Each block has a defined set of
inputs and/or outputs for a specific function or type of information. You don't have to manage
the internal processing that turns the inputs into outputs. That's up to the manufacturer who
provides the block as part of a fieldbus device or host system.
FOUNDATION fieldbus uses three types of blocks:
• Resource blocks
• Transducer blocks
• Function blocks
Why they matter. Resource and transducer blocks provide valuable information about devices,
sensors and actuators, and their performance. Function blocks are the engines of open,
interoperable, device-independent control. Together, these three types of blocks make it easier
for you to improve equipment performance and process control.
This course introduces you to the three types of blocks and how they're used.
• What kinds of information does a resource block provide? A transducer block?
• What key capability do function blocks provide? Do all function blocks work the same
way?
• Who decides how many blocks of each type are used in a particular device?
What is a resource block?
The resource block deals with the overall device. It contains information such as manufacturer,
device type, and serial number. Each device has one resource block.
In addition, the resource block also often provides information about the health or status of the
device as a whole. Access to this additional information may be one of the most important
features of FOUNDATION fieldbus because it can enable you to detect potential device
problems before they affect the process.
During project execution, the resource block is used to identify a device, tag it, and commission
it. During ongoing operations, it's used by maintenance technicians to obtain overall device
configuration and status information, and to run some types of device-specific diagnostics.
There is one resource block for each device.
What is a transducer block?
The transducer block deals with the "wetted parts" of a device. It provides the local input/output
functions needed to read sensors and to command actuators, displays, or other output
hardware. It's the link between the physical world of sensors and actuators and the "data world"
of process control.
The transducer block contains information such as calibration data, sensor type, materials of
construction, and in many cases the health and operating status of actuators and sensors.
In the FIELDVUE® digital valve controllers used in PlantWeb architecture, for

example, the transducer block provides information that's used in valve-signature
diagnostics and in checking for performance problems such as stiction. Similarly,
the transducer block in a transmitter can be used to check for a variety of sensor failure
conditions.
Special transducer blocks are also used to provide statistical process monitoring, predict
sensor life, detect plugged impulse legs, and similar functions.
During project execution, transducer blocks are used for calibrating the device, setting units,
and other tasks related to providing an accurate and reliable input or output. During ongoing
operations, maintenance technicians use these blocks to troubleshoot and calibrate devices, to
perform diagnostic checks, and to carry out other tasks to maintain device health and
performance.
There may be several transducer blocks in a single device. For example, one transducer block
may deal with the sensor or actuator, another with a local display, and a third with diagnostics.
PlantWeb architecture is designed to take advantage of the tremendous diagnostic

potential of resource and transducer blocks — from full 0-to-100%-stroke valve
diagnostics, to sensor life and performance diagnostics, to diagnostics of external
equipment like impulse legs.
Maintenance functions can tap this wealth of information through AMS Suite: Intelligent
Device Manager software, and operators can see the equipment status right on the
operations display.
What
What is ais a function
function block? block?
Function blocks provide control-system behavior within the fieldbus environment. Analog and
discrete input and output blocks, and a wide variety of control algorithms such as characterizer,
splitter, or PID, can be linked across the fieldbus to perform process control.
It's even possible -- in many cases, advantageous -- to run a control loop completely in field
devices, without involving the host system.
A simple device may have only a single input or output function block. More-complex devices
may have several input and output blocks, as well as blocks for monitoring and control.
During project execution, control engineers use function blocks to implement the control
strategy. During ongoing operations, the function blocks provide the process-control information
and functions the operators use to run the plant.

PlantWeb was designed from the beginning to use fieldbus function blocks
throughout the architecture -- in devices as well as the host DeltaV system.
You use the same tools to configure all function blocks, no matter where they run. You can
move blocks from one device to another (or to the host) with no change in the way they run.
You can also combine analog and fieldbus devices in a single loop, or even assign a
configuration designed for traditional analog installation to run in fieldbus devices instead.
The benefits: unprecedented flexibility and tremendous savings in engineering time -- with
fewer errors as there is no manual mapping of function blocks between field devices and the
DeltaV system.
FOUNDATION Fieldbus function blocks
The Fieldbus Foundation has defined standard sets of basic and advanced function blocks.
Manufacturers decide which of these standard blocks -- as well as other, non-standard blocks --
will be supported in each fieldbus device.
Interoperability built in. If a device conforms to the FOUNDATION fieldbus specification for a
function block, that function block will be interoperable -- that is, the inputs and outputs will
enable the block to work together with other blocks according to the FOUNDATION fieldbus
specification regardless of device or host manufacturer.
Exactly how those inputs are converted to outputs is not defined by the specification. Each
manufacturer can choose the algorithm they use to make that happen. So while standard
function blocks will work together, they may not work exactly the same.
Room for innovation. Device and system manufacturers can also provide blocks or functions
that aren't specified by the FOUNDATION. For example, a manufacturer might provide a fuzzy
logic block (which isn't currently defined by the fieldbus specifications), or add an auto-tuning
feature to a standard PID block.
These custom blocks are interoperable with standard function blocks. That's because the
FOUNDATION fieldbus specification defines inputs, outputs, modes, and other parameters even
for custom blocks.
Basic FOUNDATION fieldbus function blocks
The Foundation has defined specifications for the following basic functions:
Basic Specified Continuous Blocks
Analog Input AI Reads analog input
Analog Output AO Sends analog output
Bias Gain B Scaling
Control Selector CS Override control
Manual Loader ML Manual Control
PID Control PID PID Control
PD Control PD PD only control
Ratio Control RA Ratio Control
Basic Specified Discrete Blocks
Discrete Input DI Reads discrete input
Discrete Output DO Sends discrete output

Advanced FOUNDATION fieldbus function blocks
The Foundation has defined specifications for the following advanced functions:
Advanced Specified Continuous Function Blocks
Complex AO Provides extensive interlocking
Splitter 1-in-3-out + logic -- for split ranging
Selector 4-in-1-out (min., max., mid., avg.)
Setpoint Generator SP generator for Batch applications
Characterizer Has interpolation and tracking
Integrator Integrate flow or pulse + reset
Calc_A 1131-C inst. - 50 steps - analogs
Lead/Lag Dynamic compensation
Dead Time Delay for analog feedforward control
Analog Alarm Provides alarm response
Advanced Specified Discrete Function Blocks
Digital HMI Operator input - reference by tag
Pulse Input Pass pulses to integrator
Timer Count up/down, debounce
Digital Alarm Provides alarm response
Step Control SP control using discrete actuators
Calc_D 1131-C inst. - 50 steps - discretes
Complex DO Provides extensive interlocking
Device Simple 2 or 3 state devices (pumps)
Dead Time Delay for analog feedforward control
Analog Alarm Provides alarm response

The Fieldbus Foundation adds new block type specifications on an ongoing basis. See the
Fieldbus Foundation web site for the most current list.
How do function blocks get into devices?
Fieldbus function blocks enable field devices to contain control capabilities that were previously
restricted to a central control system.
As a result, fieldbus-based architectures can scale up more smoothly than traditional

architectures. That's because it's usually easier and cheaper to add more devices than to
expand the central control system. You may not even have to add more devices, if those
already installed can accommodate the functions you want to add.
But how do those functions get into the devices?
One way is for the manufacturer to include a fixed set of function blocks for each device. While
some blocks can be expected in a specific device type -- such as an AI block in a transmitter, or
an AO block in a valve controller -- the number and type of blocks supported will vary from
device to device and vendor to vendor. One may include PID in a pressure transmitter, while
another may not.
The other way is to let the user decide -- within manufacturer-set limits -- which types and how
many function blocks will reside in a device. This approach is called instantiation.
Instantiating blocks into devices
Instantiation is the process of creating a new instance (or copy) of a function block in a device.
It's an easy, affordable way of adding capabilities without increasing the number of devices.
For example, a pressure transmitter may be supplied with one AI block for its primary process
variable, pressure. But suppose the pressure-sensor module also includes a temperature
sensor to detect freezing or overheating conditions that can cause device failure. If the
transmitter supports instantiation, you can instantiate a second AI block in the transmitter to
monitor this temperature measurement.
Instantiation can be used for any type of function block. If you're doing cascade control, for
example, you could add a second PID block to a valve controller.
Instantiation isn't possible in every situation:
• The manufacturer must design the device to allow instantiation. Some do, and some
don't.
• The device must have enough available memory and processing power to support
added blocks
• The device must support the specific type of function block to be added. If a transmitter
only supports AI blocks, you can instantiate multiple blocks of that type — but not PID or
other block types.
Device descriptions
Standard fieldbus blocks provide the basis for interoperability. But what happens if the Fieldbus
Foundation adds to the list of standard function blocks, or if a manufacturer wants to offer a
proprietary block or extend the capabilities of a standard block? How can existing host systems
recognize the new data and capabilities provided by these blocks -- without reprogramming or
upgrading the system?
The answer is a FOUNDATION fieldbus device description -- a software file that provides the
information a host system needs to understand both the meaning of the data and the
capabilities of the device. It serves as a "driver" for a device, much as a printer driver tells your
PC how to access the capabilities of your printer.
For example, a device description might provide (among other things):
• The label for a parameter

• Engineering units
• Help text
• Diagnostic menus
• Methods for device-related tasks such as calibration
A method is a predefined sequence of operations executed in a device. This predefined

sequence is typically used to simplify device operations such as setup and commissioning,
configuration, calibration, or diagnostics. For example, a setup method in a valve instrument can
guide a technician through the proper entries and options to optimize performance of the
valve/actuator combination. Some devices use methods, some do not.
The Fieldbus Foundation provides device descriptions for all standard function blocks and
transducer blocks, as well as distributing device descriptions that manufacturers have provided
as part of the device interoperability-certification process. This ensures that users have a way to
access the full capability of a device, independent of any vendor.
Fieldbus 105
Diagnostics with fieldbus

• Overview
• More than device maintenance
• Equipment diagnostics
• Loop diagnostics
• Improving plant performance
• Reducing process variability
• Improving process availability
• Enhancing safety and environmental compliance
• Managing alarms and alerts
Overview
I already have enough to do. Why should I make the added effort to use diagnostics?
By enabling you to identify both the source and the nature of a problem — often before it affects
the process — diagnostics can actually reduce the effort required to keep your process and
equipment running as they should.
Predictive diagnostic alerts also enable a shift from reactive and preventive maintenance
practices to predictive maintenance practices. This shift can significantly reduce maintenance
workload and cost while improving overall plant availability.
FOUNDATION fieldbus provides a framework for implementing a vast array of device and
process diagnostics. The actual diagnostics, however, aren't specified by the Fieldbus
Foundation. Instead, they're device- and vendor-specific. That's why it's important to choose
devices and vendors that provide the diagnostic capabilities you need to meet your plant
objectives.

PlantWeb architecture builds on the capabilities of FOUNDATION fieldbus,
as well as Emerson's 100+ years' experience with the process industries,
to deliver a wide range of diagnostic capabilities that can help you detect and
solve real-world problems — and improve your plant's bottom line.
This course explores some of the diagnostic possibilities available in PlantWeb architecture.
These diagnostics leverage the capabilities of FOUNDATION fieldbus but represent specific
PlantWeb implementations.
• What kinds of problems can be detected by statistical process monitoring?
• How do diagnostics affect process variability and availability?
• How can you avoid being overwhelmed with diagnostic alarms and related information?
More than device maintenance
Much of the publicity about diagnostics centers on improving the maintenance of field devices,
such as measurement instruments and control valves.
That's understandable. Quickly detecting a failing sensor as the cause of a measurement

problem, or identifying which valves need service during a plant turnaround, can substantially
reduce maintenance costs and downtime.
But diagnostics can also help you improve the performance of other process equipment, as well
as keep the process itself up and running at its best.
The next three sections of this course will explain how diagnostics can improve equipment
performance, loop performance, and process performance.
Equipment diagnostics
Diagnostics can be used to detect and alarm problems not only with field devices, but also with
other process equipment.
For example, statistical process monitoring can identify a wide variety of problems with
process equipment — from leaks in pipes to fouling in heat exchangers, filters, and similar
equipment.
The advanced diagnostic transducer block available in Emerson FOUNDATION fieldbus

devices allows up to four control or process variables to be monitored for changes in mean and
standard deviation. Statistical process monitoring analyzes how these four user-selectable
factors change in relation to each other to detect equipment problems.
As heat exchangers and filters foul and clog, for example, the diagnostics can detect a mean
change in the differential pressure across the unit without a corresponding mean change in
setpoint or flow rate — and alert the operator or maintenance shop of the problem.

PlantWeb provides both pre-configured solutions and user-configurable
monitoring.
For example, flow and level loop diagnostics are pre-configured. For user-defined monitoring,
you simply identify by tag the variables to be monitored by the field device, then set the
thresholds of mean and standard deviation change to generate alarms.
Statistical process monitoring is also "self-learning." When the process is running correctly,
you just set the device to "learn." The device will learn and verify the process dynamics, then
automatically switch to monitoring the process.
Loop diagnostics
PlantWeb diagnostics can also be used to detect and alarm problems at the loop level.
Here again, statistical process monitoring provides a good example: detecting wet-leg
evaporation in a liquid level loop by monitoring process variable (PV) setpoint, output, and
actual valve position.
How does this work?
Liquid level is maintained at setpoint by comparing the actual process level to the reference
level in a wet leg. But if the liquid in the wet leg evaporates, the reference level drops — and the
control function responds by moving an outflow valve to a more open position to lower the
process operating level accordingly.
When this happens, the diagnostic function detects that both control demand and actual valve
position are more open without a change in setpoint or measured process variable. This means
the measurement has drifted, so an alert is generated. Here is an example of an alert.
Improving plant performance
You probably have enough problems to deal with already. Why do you need diagnostics to help
you find more?
Because finding and solving those problems can help you meet plant efficiency and economic
objectives.
For example, the diagnostics available with PlantWeb architecture can help you reduce process
variability, improve process availability, and enhance safety and environmental compliance.
The next three sections of the course explain how.
Reducing process variability
Process variability increases production cost by increasing material and energy costs, and
reduces plant production by producing off-spec product that must be blended, reprocessed, or
disposed of.
One tool for reducing process variability in Emerson valves is the valve signature diagnostic,
which (among other purposes) can be used to detect a wear-induced condition called stiction.
Stiction causes a valve to stick at one position until there's a large change in actuator force.
Then the valve moves a significant amount — perhaps several percent. As a result, the valve
spends most of its time at the wrong position.
This condition can be revealed by the valve signature diagnostic. If stiction is present, the
signature shows valve movement as a series of "bumps" — rather than the normal smooth line
— as actuator force is increased or decreased.
Economic consequences of stiction can be significant. For example, excess variability in steam
flow to a distillation column can increase utility costs in excess of $1,000,000 per year.
Another example is sensor fouling detection.
Fouling of analytical probes causes bad readings that can lead to excess material consumption,
off-spec product that must be reprocessed or discarded, or even safety problems.
Sensor fouling detection in Emerson analytical devices can help you avoid these costs by
triggering maintenance requests or even automatically initiating cleaning the sensor.
Improving process availability
Diagnostics can improve process availability both by reducing the length of scheduled
shutdowns and by eliminating unscheduled shutdowns.
For example, you can reduce the length of scheduled shutdowns by knowing which valves need
repair and which don't, so you pull only the ones that need it. Through valve diagnostics,
engineers for one of Emerson's customers found that only 14 of the 188 valves scheduled to be
pulled out and rebuilt actually needed that level of services.
Detecting a problem in critical equipment before it fails completely can also help you take action
to avoid a process trip and unexpected shutdown. But diagnostics can also help you avoid "on-
stream" availability problems.
For example, a bad pH reading in a fermentation application can ruin a complete batch —
causing a loss of production even though the actual plant equipment is online. The sensor
fouling detection diagnostic described in the previous section can help you detect problems
like this.
Enhancing safety and environmental compliance
Diagnosing device and equipment problems from the control room or maintenance shop
enhances safety by reducing the time technicians spend locating and fixing problems in
hazardous areas.
Consider the example of a valve that controls the flow of an acid. If technicians can check the
valve's packing friction and other operating parameters from the maintenance shop, they don't
have to put on protective gear and go out to the valve's location -- or expose themselves to
hazardous conditions.
Diagnostics can also help you detect problems that could lead to equipment failures with safety
or environmental consequences.

One example of how PlantWeb can help improve safety is plugged impulse
line detection.
When impulse lines to a pressure transmitter become plugged, the pressure at the time of
plugging is trapped in the line -- giving the appearance of a valid process variable. Besides
reducing process quality, this false reading can affect safety (especially in gage pressure
applications) by masking overpressure conditions.
Often the only indication of a plugged line is a variable that is TOO stable, without the normal
level of variability. PlantWeb's plugged impulse line detection diagnostic uses this change in
variability to detect both single and double line plugging and send an alert.
Managing alarms and alerts
Plant personnel are drowning in a sea of alarms, alerts, advisories, events, and other
automation-generated data. Diagnostics can either help the situation or make it worse.
Diagnostic information should only be sent to people who will be affected by the situation the
diagnostic detects, or those who will use the information to correct problems or improve
performance. In addition, the level of detail each person receives should be appropriate to the
action that person can take.
In PlantWeb architecture, the DeltaV system and AMS Suite: Intelligent

Device Manager software provide alarm and alert management for
appropriate alarm logging, annunciation, filtering and suppression, level of
detail for the recipient, and alarm destination.
Alarm broadcasting and narrowcasting. You can configure each type of alarm or alert
to go to personnel with specific job functions, or to specific individuals. Alarms can even
be sent via pager, cell phones, or other methods.
Alarm annunciation. To ensure that the operator only receives meaningful diagnostic
alarms and alerts, all diagnostic alarms and alerts are evaluated within the device and
only those that have operating impact are displayed to the operator.
Alarm detail. The level of detail in alarms is appropriate to the function of plant
personnel. For example, the operator can be notified that a field device is non-
operational or will need maintenance soon, while a maintenance technician receives
information needed to repair or maintain the equipment.
Alarm filtering and suppression. Alarms can be filtered and suppressed to minimize
nuisance alarms. For example, if a point has intermittent diagnostic alarms, the alarm
can be suppressed for the operator and redirected to the maintenance team. Once the
cause is fixed it can be redirected to the operator and enabled.
Alarm and alert logging. Alarms and alerts generated both by devices and by the
DeltaV system are integrated in the DeltaV logs. These alarms and alerts can be
displayed on log and historian displays, as well as trend displays.
Fieldbus 201
Fieldbus Interoperability
• Overview
• What is interoperability?
• Field-device interoperability
• Testing devices for interoperability
• When device capabilities evolve
• Host-system interoperability
• Off-line interoperability
Overview
Can I use fieldbus products from different suppliers?
The whole point of having an interoperable fieldbus is being able to use fieldbus products from
different suppliers — and have them work as they were designed. That's been the prime
directive of the Fieldbus Foundation since day one.
Freedom of choice. The architects of the Fieldbus Foundation realized years ago that one of
the greatest limitations to proprietary technology and "closed" plant automation systems was
that the end user often became "locked in" to a single supplier's products. For users in this
situation, implementing the best technology often wasn't an option. The interoperability of
FOUNDATION fieldbus, on the other hand, makes these constraints a thing of the past.
This course will help you understand fieldbus interoperability.
• How does the Fieldbus Foundation define interoperability?

• Who conducts interoperability tests?
• Are host systems certified for interoperability?
What is interoperability
The Fieldbus Foundation defines interoperability as "the ability to operate multiple devices,
independent of manufacturer, in the same system, without loss of functionality."
The term multiple devices refers to a set of fieldbus products that may include a mix of field
devices such as valves and transmitters, and host devices such as control systems.
Independent of manufacturer means vendor independence. That is, having the freedom to
choose the best technology for the task, regardless of which vendor makes the product.
In the same system means within the mix of control equipment that operates as a single
automation solution. There are, of course, guidelines for the number and type of devices that
should be combined together within individual segments of the fieldbus network, primarily for
electrical and intrinsic safety purposes. We'll get into this topic later in the course.
Without loss of functionality means the devices operate without the loss of any of their
designed features. That is, being part of an interoperable network doesn't interfere with any of
their functions.
In the next section, we'll look specifically at interoperability between field devices.

Interoperability is a key feature of PlantWeb field-based architecture from
Emerson Process Management.
• Emerson has the world's largest number of interoperable field device types
• Emerson has over 4 years run-time of PlantWeb field devices with other suppliers'
host systems, and of other suppliers' field devices with a PlantWeb host system.
• PlantWeb supports over 60 devices from other suppliers. New device types are quick
and easy to add.
• PlantWeb's DeltaV automation system was among the first hosts to pass host
interoperability testing.
Field device interoperability
Interoperability between field devices basically means that field devices from different
manufacturers can work together, sending and receiving information related to their specific
function in the process.
The Fieldbus Foundation has established guidelines for interoperability between field devices on
a fieldbus segment. These guidelines address different aspects of device interoperability such
as physical characteristics, communication, and software functionality.
To be truly interoperable, devices must
• Be physically and electrically compatible with the fieldbus segment (as defined by the
ISA 50.02-2 Physical Layer Specification).
• Include a communication stack that passes the Fieldbus Foundation's Stack
Conformance Test.
• Correctly implement the Function Block Application Process Model defined in the
FOUNDATION fieldbus specification. This means a device's function blocks must
interconnect and interoperate with the function blocks of other devices on the network.
The figure below illustrates interoperability requirements.
Testing devices for interoperability
Interoperability testing, using a prescribed set of consistent and rigorous test procedures, helps
ensure that all devices will operate together.
The Fieldbus Foundation has established two tests for this purpose: the Stack Conformance
Test and the Device Interoperability Test.
The Stack Conformance Test ensures that the device interfaces correctly with the bus; that is,
electrical characteristics and bus access are consistent with the fieldbus specification.
The Device Interoperability Test ensures that the device's function blocks will interact with
other blocks correctly, and will provide accurate information and mode behavior.
These tests are continuously enhanced based on actual field experience. This means that all
tested devices receive the maximum benefit of the features available in FOUNDATION fieldbus.
When a device has successfully completed these interoperability tests, it is recognized as a

registered device and can bear the Fieldbus Foundation's interoperability "checkmark" logo.
A list of registered devices can be found on the Fieldbus Foundation's web site at
www.fieldbus.org.

Emerson Process Management wants to make sure our products will be
highly reliable in your plant environment. That's why we go beyond standard
interoperability testing to include real-world stress testing of other suppliers'
fieldbus devices with our host system, and other suppliers' host systems with
our devices.
Some of our tests include:
• Segments with a large number of different device types from different vendors
operating continuously for long periods of time
• Segments with very heavy message loading
• Segments with high device count, maximum segment or spur length, and minimum
voltage conditions at some nodes
Not all suppliers do testing with multi-vendor test beds. Emerson Process Management does.
When device capabilities evolve
FOUNDATION fieldbus allows suppliers to enhance and differentiate their products while
maintaining the interoperability users want.
Adding blocks. A device is registered for the defined set of blocks tested during the Fieldbus
Foundation's interoperability test. If a supplier adds additional blocks to the same device, the
device may be retested and reregistered for the additional blocks.
Alternatively, the supplier can offer the blocks as unregistered functionality. In some cases, that
may be the only option -- no function block type can be registered unless at least two suppliers
offer the block in their products, and both products pass interoperability testing for that block
type.
Devices may also be retested and registered following other changes, such as firmware
revisions.
Different capabilities. Bear in mind that the interoperability test determines interoperability, not
functionality. The internal operation of a device's control algorithms is determined by the
manufacturer. Registered devices can work quite efficiently with each other on the network, but
exhibit different behavior due to varying control algorithm characteristics.
Host system interoperability
In most cases, a host system is used to configure fieldbus devices, set up the control strategy,
and display all information available from the field devices. The host system may also
participate with field devices in providing process control.
To do all this, the host system must be able to access, use, and display FOUNDATION fieldbus
data from all devices involved. The Host Interoperability Support Test (HIST), consisting of
18 separate tests, shows how well a host system interoperates with specific standard
capabilities of FOUNDATION fieldbus devices.
Although field-device testing is mandatory, host testing is optional. A host can undergo none,
some, or all of these tests to demonstrate its support for specific functions.
Understandably, the HIST doesn't cover proprietary capabilities that suppliers may add to their
products. However, it's still possible for a host to access those capabilities if the device supplier
provides a Device Description (DD) and if the host includes DD Services to read it.
In short, the HIST ensures that the host is a good citizen on the fieldbus segment, but not that it
will access, display, or use device information completely or to its best advantage.
Unlike field devices, host systems are not actually certified. However, the Fieldbus Foundation
lists on their web site the tests each host has passed. The DeltaV system that's part of
PlantWeb architecture was among the first to be listed.
Off-line interoperability
Up to this point we've focused on "on-line" interoperability, where field devices are physically
connected to the host system as they are being configured. Quite often, however, field devices
are not available at the time configuration is being done by the host system.
Capabilities files. To help solve this dilemma, the Fieldbus Foundation has issued a Common
File Format specification which defines a Capabilities File that can be used to describe
information about a fieldbus device that would normally only be available by reading it from the
device itself.
An interoperable host system that supports off-line configuration uses this Capabilities File,
along with the Device Description, to build an offline configuration of the field devices.
Capabilities files are provided by the device manufacturer and are available for download from
the Fieldbus Foundation website.
Any-time configuration. Off-line interoperability allows those doing configuration, such as

engineering and consulting firms, the capability to configure an entire fieldbus network—off line.
This means that much of the engineering for a FOUNDATION fieldbus network, including
configuration of the devices and control strategy, can be accomplished prior to acquisition of the
actual devices.
For this to happen, each device supplier must provide Capabilities Files and Device
Descriptions for its devices. In addition, the host system supplier must support off-line
configuration using information from the device Capabilities Files.
Fieldbus 202
Reliability and redundancy

• Overview
• Wiring reliability
• Segment reliability
• Total system reliability
• How much redundancy is enough?
• Transmitter redundancy
• Valve and piping redundancy
• Control redundancy
• Host redundancy options
• Other redundancy options
• Link active scheduler and backup LAS
Overview
Can I really put all those devices on one pair of wires?
This is often the first question asked by those new to the fieldbus world. That's not surprising:
After years of "one set of wires for each device," at first you might wonder about the reliability of
using one wire pair for several devices.
But the wires themselves are only a minor factor in overall reliability. With good design and
installation practices, FOUNDATION fieldbus actually offers significant advantages in total
system reliability.
This course examines the issue of reliability, along with methods for improving it -- including
redundancy.
• What are the major external factors affecting fieldbus network stability?
• What parts of a fieldbus system can be made redundant?
• Where is control most reliable, in a field device or in the host system?
Wiring reliability
The major concern with wiring is not failure of the media itself, but external factors that affect the
wiring.
Fewer wires mean faster repairs. Consider the damage if a physical event affects an entire
wire bundle. In the world of analog point-to-point wiring, this catastrophe could involve
hundreds, maybe thousands, of severed wires.
In the digital fieldbus world, however, where many devices can be connected to the same set of
wires, the same number of I/O points would be on far fewer wires.
Service would be interrupted in either case. But the time to repair would be significantly less in
the fieldbus scenario because there are fewer wires, and wiring checkout is faster for each wire
pair. And the faster the repair, the sooner production resumes.
Reasons for assurance. Excluding external events, wire reliability is determined by the
reliability of the physical wire itself -- and wire has the lowest complexity level of the system and
generally the lowest failure rate.
The reliability of the wire can be greatly enhanced by following installation and maintenance
procedures that avoid accidental shorting or grounding. Those are the most common causes
of wiring failures.
You can also enhance reliability by selecting the wire, cable routes, and connectors that shield
exposed media from physical contact with electrical discontinuities. In addition, fieldbus junction
boxes are available that isolate a short-circuit to a single drop on a segment.
Segment reliability
The total fieldbus network is divided into segments for the purpose of aligning sections of the
network with process, hazardous, or geographic areas, or with specific device combinations.
From a reliability standpoint, each segment can be treated as a separate entity, and thus can be
handled separately. If a host H1 interface card connects to more than one segment, and
represents a failure point that could impact more than one segment, then all segments attached
to that interface card should be considered as a whole.
Segment reliability depends upon several factors such as
• Segment power and power conditioners

• Segment terminators
• The segment wire itself
• Various connectors
• Field devices connected to the segment
• The segment host (if present).
The greatest threat to overall segment reliability is loss of power, which affects the entire
segment. One way to counter this threat is redundant segment power, coming from different
sources.
Another threat to segment power involves electrical transients such as
• Lightning
• Solar storms
• Electrical noise.
Good installation practices, backup power with uninterruptible power suppliers (UPSs), and
surge suppressors minimize disruption from these electrical transients.
Proper installation can also reduce the chances of improper grounding -- another major cause of
reliability problems.
Total system reliability
A system's reliability is only as good as the reliability of each of its parts. So it makes sense that
the fewer the parts, the higher the potential reliability of the system.
Fieldbus allows the control "system" to have fewer parts because control can now be done in
the field.
That is, control does not have to go through all the host system's terminations, input cards,
controllers, output cards, and so on — each a potential failure point.
With control in the host system, all these parts must be working properly for the control loop to
be working. Failure of any of these components in a non-redundant system will cause loop
failure. The number of loops affected can range from 8-16 for an I/O card failure to hundreds or
even more if a controller or controller power fails.
In a FOUNDATION fieldbus environment using control in the field, however, the entire host
system can fail without loss of control. That's because control is being done in the field devices.
The host system is being used as the interface to a truly distributed "field control system."
Closing the loop in the field can be much more reliable than through the host.
How much redundancy is enough?
How much redundancy to have in the plant, and how to provide it, depends on the situation. It's
based on things like mean-time-between-failure, system availability -- and experience. It's also
based on how critical particular devices, loops, and processes are to safe and effective plant
operation.
Options range from redundant measurements to redundant process streams and everything in
between.
The next five topics describe some of these options.
Transmitter redundancy
Transmitter redundancy in a fieldbus environment is implemented basically the same way as in

a traditional, analog environment. The primary difference is that FOUNDATION fieldbus
provides additional information that improves the reliability of the measurement.
Analog transmitter redundancy. Analog transmitter redundant schemes often require triple
redundancy. When two of the transmitters report different values, the value from the third
transmitter "breaks the tie." All three measurements are sent to an input selector which chooses
the input that gets sent to the PID. Sometimes the operator receives all three values and
manually chooses the value that "looks best."
The FOUNDATION fieldbus input selector block available in some transmitters supports a broad
range of input selection criteria -- from selecting the high, low, or middle value, to calculating the
average of the three inputs, to eliminating the reading with the greatest deviation from the
others.
FOUNDATION fieldbus transmitter redundancy. FOUNDATION fieldbus provides status

information that helps automatically identify if a measurement is good, bad, or uncertain. A bad
or uncertain quality reading can be eliminated from consideration before it's presented to the
operator.
This capability may even eliminate the need for triple redundancy, since the third device is no
longer needed to determine which signal is the bad one.
FOUNDATION fieldbus H1 does not support redundant media. Redundant transmitters are
either on the same wires, or on different segments.
Valve and piping redundancy
Like transmitter redundancy, valve redundancy in a fieldbus environment is implemented

basically the same way as in a traditional, analog environment. The theory is the same: two
valves are more reliable than one. And the issues are the same: how much redundancy do I
really need?
Best case/downside. The most reliable redundancy scheme would put redundant valves
installed in parallel piping in the process. But double the valves and piping, and you double the
installation cost.
So if redundancy in a fieldbus world isn't any cheaper than in the analog world, where's the
advantage?
Information makes the difference. The advantage is in the information a fieldbus valve
instrument provides.
Valves are mechanical devices subject to harsh process environments and wear of moving
parts and are thus points of maintenance and potential failure in the process loop.
Because an analog valve controller (or redundant valve pair with analog controllers) has no way
of determining valve health, it may fail without warning.

Emerson's DVC 5000 fieldbus Digital Valve Controller (and thus a redundant
valve pair with such controllers) has the intelligence to diagnose its own health.
It can predictively and proactively indicate if it's having health problems so you
can deal with them before they result in a failure.
Fewer failures, lower maintenance cost, less lost production. There's the advantage
Control redundancy
Typical DCS and PLC control system failures can affect a large number of loops. The loss of
control, and possible equipment failure or plant shutdown, can carry an extremely high price.
The traditional method of avoiding such problems involves duplicating parts of the host control
system. This redundancy means potentially a lot of extra equipment — input and output cards,
terminations, power, controllers, etc. — at a lot of extra cost.
As you learned earlier in this course, control in the field allows the control function to continue
even if the host system fails – potentially reducing the need for costly redundant host
components.
It is worth noting, however, that when the host is lost, the operator can no longer see what's
happening or control it manually from the operator console. Data will also not be available to
alarm and event logs and historians. Also, the PID block in a host may offer features (such as
autotuning) not available in the device's PID function block. And although regulatory control is
maintained in the field devices, host resident advanced control is lost until the host connection is
re-established.
You should therefore use this approach only where you can do without these capabilities until
the host is available again. Until then, the field device can maintain safe, effective, on-spec
control to prevent a process upset or unscheduled shutdown.
Host redundancy options
As explained earlier, control in the field will provide regulatory control in the event the host or
host connection is lost. But it won't provide operator visibility, host-based advanced control, or
alarm, alert, or historian data. To ensure these are available, host redundancy is needed.
Host redundancy philosophy. Many plants have standard practices for redundancy. These
frequently include redundant communications, operator interface, power, controllers, and I/O.
Specific implementations of redundancy depend on the requirements of the process.
FOUNDATION fieldbus redundancy should conform to these practices.
Redundant host H1 interface cards. Although the fieldbus specification does not require H1
interface card redundancy, a backup H1 card will allow the operator continued visual access to
the process should the primary H1 card fail. It will also provide process information needed for
functions such as validation or quality systems, plus uninterrupted advanced control. If your
plant or process requires these things, redundant H1 cards should be used.
Another common criterion is that redundant I/O is required if I/O modularity exceeds a certain
level -- for example, 8 points per card. If redundant H1 cards aren't available, plant practices
may require that the loading of an H1 segment be reduced to a level below the threshold
required for redundancy.
Finally, if no device on the segment is a link master, capable of taking over the function of link
active scheduler, redundant H1 interface cards may provide this capability.
Emerson now offers redundant H1 interface cards in the DeltaV system that serves
as the host system in a PlantWeb architecture. These cards can be removed and
replaced under power.
In addition, each H1 interface card has LAS capability, providing backup LAS in the interface
card.
Other redundancy options
In making the control system more reliable through redundancy, we've covered the major
elements of the control loop — transmitters, valves, and host control systems. Now let's take a
look at other areas of the automation architecture that can be redundant.
Custom redundancy block. This software option is a custom function block, residing in the
valve, designed specifically for redundancy. The valve function block passes an output from the
primary (host) PID to the valve's analog output. If the primary PID fails, the backup PID (in the
valve) sends its output to the valve's AO.
Redundant air and power. Since actuators, transmitters, valves, and control systems all
depend on air or electrical power to operate, making these sources redundant, or having a
reliable backup, will go a long way toward ensuring a safe plant.
FOUNDATION fieldbus power redundancy includes redundant, isolated bulk power, and
redundant power conditioners to the segment. This level of power redundancy provides reliable
power even if a power failure occurs.
Redundant media (wire). As mentioned previously, the wire in general is the most reliable part
of the control architecture. Adding a backup wire segment may make sense only if it is part of a
completely redundant process stream with redundant instruments, valves, process piping, and
host elements. This is implemented by having one set of valves and instruments on one
segment, and the second set on a second segment. Each device is connected to only one
segment and one set of physical media. In this case, a link must exist between the two
segments to ensure status information is continually exchanged.
Link active scheduler and backup LAS
Link Active Scheduler. In a host control system, the control strategy generally dictates the
execution of function blocks as well as communication between the blocks themselves. On a
fieldbus segment, this task is the responsibility of the Link Active Scheduler, or LAS.
As the name implies, the LAS actively schedules communication and function block execution
on the segment. If there is no LAS running on the segment, function block execution and
communication on the segment cease.
Because the LAS often resides in the host system, the most probable cause of an inactive LAS
is the loss of the host. A host-based LAS is also unavailable in the case of stand-alone loops,
where a host is used for configuration and then disconnected.
Backup Link Active Scheduler. A backup LAS, usually not residing in the host, coordinates
block execution and communication on the running segment when the primary LAS is lost or
unavailable.
A backup LAS should be used in a host-plus-control-in-the-field scenario so that control can be
maintained even after the host is lost.
If control is performed strictly in the host, that is, no control-in-the-field, then the loss of the host
means loss of control, even if a backup LAS is present. The exception occurs when the host has
redundant controllers and FOUNDATION fieldbus H1 interface cards, configured to take over
control if the primary components fail. In this case, the backup LAS would usually be in the host
system rather than a field device.
Regardless of where control resides, it's still important to make sure final control elements are
selected to fail to the proper failsafe positions if automatic control is lost.

Most fieldbus field devices from Emerson Process Management have backup
LAS capability, which can be used without affecting device performance.
Configuring a backup LAS in PlantWeb is as simple as checking a box at device

commissioning time.
Fieldbus 203
Intrinsic safety
• Overview
• Intrinsic safety models
• The ignition curve
• Designing an intrinsically safe segment
• Combining safe and hazardous areas
• Multiple barriers: One approach
• Multiple barriers: A better approach
• Maximum current draws
• Other intrinsic safety considerations
Overview
Is intrinsic safety handled the same way with fieldbus as with analog devices?
In the analog world, intrinsic safety is based on well-known practices.
• Each input and output has a dedicated barrier

• Intrinsically safe points and conventional points are on separate field wires.
In the fieldbus world, intrinsic safety brings some new practices -- and some new advantages.
• Several devices may be on a single barrier, and several barriers may be on a single
fieldbus segment
• Both intrinsically safe points and conventional points may coexist on the same segment
• Fieldbus intrinsic safety may be more flexible and more cost effective.
This course looks in more detail at how intrinsic safety works in a fieldbus-based architecture.
• What is the ignition point?
• What is the maximum current draw for an intrinsically safe barrier?
• How can multivariable devices reduce the number of barriers required?
Intrinsic safety models
Devices and barriers for intrinsically safe areas are designed so that the energy released by an
electrical fault is not enough to cause ignition, even in a single or double failure condition. The
ignition point is a function of power, determined by voltage and current.
How much current is allowed on an intrinsically safe segment -- as well as segment voltage,
choice of barriers, and device count on each barrier -- depends not only on the type of
hazardous atmosphere in which the devices are located, but also on which intrinsic safety
model you use.
For fieldbuses, there are two models:
• The Entity model assumes the electrical parameters that represent the
characteristics of the wire are all concentrated at the point of a fault. In this model,
the wire is considered a source of stored energy. This conservative approach leads
to a maximum DC current of 83 mA permitted in the wire and a maximum voltage of
18.4 V.
This model is well known and recognized worldwide.
• The Fieldbus Intrinsically Safe Concept or FISCO model considers the electrical
wiring parameters to be distributed along its entire length. This reduces the energy
available at a fault, resulting in a maximum current of 110 mA. This model permits
more devices on a wire pair in a hazardous area.
FISCO is not a worldwide standard. It is, however, a Euronorm and part of the
FOUNDATION fieldbus specifications (Physical Layer Profile).
Intrinsic safety barriers are certified on the basis of one model or the other. Field devices can be
certified for both.
Despite the differences between the two models, the basic concepts for designing an
intrinsically safe segment are similar. The remaining sections of this course describe those
concepts using the FISCO model.
The ignition curve
Each type of atmosphere requires a certain minimum power for ignition. The plot of the voltage
and current points that provide that power is called the ignition curve.
Because power is voltage times current, as voltage increases, the maximum amount of current
required for ignition decreases. And, conversely, as voltage decreases, the maximum amount of
current required for ignition increases.
In a segment using the FISCO model, the maximum current allowed is 110 mA in a Class IIC
environment. This means that the total current draw for ALL devices on this barrier is 110 mA.
Designing an intrinsically safe segment
To calculate how many devices a single barrier can support, you add the individual current
draws of each device — since each device type has a potentially different current draw.
For the FISCO model, as long as the total current draw is under 110 mA for gas groups A and
B, and under 235 mA for gas groups C and D, the segment on the hazardous side of a barrier is
intrinsically safe. You must also consider the electrical parameters of each device and be below
the amounts permitted for the hazardous area classification.
In the example shown in the diagram, a single barrier is placed on a segment between the
segment power conditioner and the field devices. There is a terminator in the safe area and in
the hazardous area.
Here are some example calculations to determine the number of field devices allowable in this
example. The current consumptions listed are for illustration purposes only and do not reflect
the actual current consumption of specific devices or device types:
Temperature monitoring.
If a temperature transmitter uses 16 mA of current, a maximum of six (6 x 16 = 96)
transmitters could be placed in a hazardous environment on a single barrier. For Class
IIB gases, the maximum current is 240 mA, allowing 15 devices per barrier.
Temperature and pressure compensated mass flow.

In this case, the temperature transmitter uses 16 mA, a pressure and DP transmitter
each use 20 mA, and a control valve uses 25 mA. All four of these devices could be
placed on the same barrier in a Class IIC hazardous environment (16+20+20+25=81).
Combining safe and hazardous areas
There may be occasions when it's desirable to have both safe and hazardous areas on the
same fieldbus segment. This isn't a problem as long as you follow the simple rules illustrated by
the example below.
In this example, there are n devices in the safe area and k devices in the hazardous area. The
maximum number of devices on a segment is 32. Experience demonstrates that up to 16
devices are acceptable. So k+n must be less than or equal to 32 or 16, depending on the type
of devices being used.
In addition, k must equal the total number of devices with a combined power consumption of
110 mA or less (remember the ignition curve) with FISCO safety barriers.
If more devices are desired in the hazardous area, you can use multiple segments, multiple
barriers on one segment, or devices with lower power consumption.
Multiple barriers: one approach
Since FOUNDATION fieldbus is a multi-drop bus, there can be multiple barriers on a segment
— each on a separate drop. However, if there are more than two barriers on a single segment,
galvanically isolated barriers must be used.
Standard isolating barriers tend to distort the fieldbus signal. If more than two barriers are used,
it is advisable to use a repeater type barrier. The repeater barrier corrects the signal back to its
original shape.
The diagram shows an example of a multiple-barrier configuration using repeating barriers for
one fieldbus segment. In the example, the process requires six temperature measurements, a
mass flow loop, a liquid flow loop, and a level loop.
As shown, one possible solution is to put each of the four processes on a separate barrier.
Notice in the diagram that there are ten terminators — two on each barrier in the hazardous
area, and two in the safe area. This is because with galvanic barriers the part of the segment in
the safe area, and each drop in the hazardous area, are considered separate electrical
segments. Each electrical segment must have a terminator at each end.
Each barrier powers the devices attached to it.
Note: Each of the four barriers also acts as a repeater. There is currently a limit of four repeater
barriers per segment.
From a software addressing and segment communications perspective, all fourteen devices are
on a single segment.
Although this is an acceptable configuration, it's not very cost efficient. In the next section, you'll
see how to substitute and rearrange devices on barriers to reduce the cost of the segment.
Multiple barriers: a better approach
The digital advantage. One of the advantages of FOUNDATION fieldbus devices is that, being
digital, they can have multiple parameters. As such, the previous example can be redesigned by
placing all six temperature measurements into a single 8-point temperature multiplexer — thus
reducing power consumption from 96 mA to 22mA.
Next, a 4-wire coriolis meter can be substituted for two pressure transmitters and one
temperature transmitter — again reducing power consumption, this time from 56 mA to 10 mA.
It's a good idea to have all components associated with a loop on a single barrier. So the new
design looks like:
• Barrier 1 - one 6-point temperature mux (22 mA), one liquid flow transmitter (20 mA),
and one valve (25 mA). The total current draw is a safe 67 mA.
• Barrier 2 - one 4-wire coriolis flow meter (10 mA), one level transmitter (20 mA), and two
valves (50 mA). The total current draw is 80 mA.
Careful selection of intrinsic safety devices can significantly reduce engineering time and
complexity, and component cost.
Maximum current draws
The maximum current draw for a segment depends in part on the physical-layer type of each
device. The Fieldbus Foundation classifies devices as one of two types depending on whether
they're self-powered or externally powered, and whether their current consumption is constant
or variable:
• Physical-layer device types 111 and 112 have a constant current draw while
transmitting and receiving.
• Physical-layer device types 121 and 122 have different current draws for receiving
(lower) and transmitting (higher).
The Foundation's list of registered devices (available on their website at www.fieldbus.org)

shows the physical-layer type for each device.
The maximum current draw for an entire segment is equal to the total current draw for all
devices on the segment that have a constant current draw, plus the transmitting current draw
for the device with the LARGEST incremental current draw while transmitting.
Other loads. In addition to current draws for installed devices, temporary current loads may be
imposed on the segment. These added loads may include the current draw for bus analyzers or
for configuration and maintenance tools.
These additional devices will tend to have their own power — but intrinsic safety requires that
these devices NOT inject power to the bus. To ensure this happens, any device MUST draw a
minimum of 8 mA from the segment while communicating. It's wise to leave 10 mA of extra
available current to allow for connection of temporary devices.
Other intrinsic safety considerations
Even equipment on the safe side of an intrinsically safe environment is subject to rules and
regulations.
One device can make the difference. One such rule is that no equipment supplying or
sourcing over 250 V RMS AC or DC power can be connected to any part of the safe segment.
In addition, the entire system on the hazardous side of a intrinsic safety barrier is certified at the
lowest certification category and gas group of any apparatus in the system. For example, if a
single piece of equipment on a category IIC segment is classified as IIB, then the entire system
is classified as IIB.
Power supplies. Different types of power supplies can be used for intrinsic safety.
• A type 133 power supply uses galvanic isolation. It provides a nominal 80 mA to the
hazardous area and can connect directly to devices in a hazardous area.
• A type 131 supply provides a nominal 400 mA for the segment. An intrinsic safety
barrier MUST be used between a type 131 power supply and the hazardous area.
Fieldbus 301
Network wiring fundamentals

• Overview
• A fieldbus advantage
• Basic segment design
• Wire types and segment lengths
• Total segment length
• Mixing wire types on a segment
• Spur length
Overview
What are the rules for wiring a fieldbus network?
Many aspects of a FOUNDATION fieldbus network are similar to a traditional analog control
network. You'll still need wire, power, field devices, I/O cards, and possibly intrinsic safety
barriers. There are a few new components, such as terminators. And there are differences in
how you put the pieces together. But different doesn't mean harder. In this case, different
means better.
This course focuses on wiring, which is the backbone of the fieldbus network — and one of the
most visible changes to the traditional system.
• Does existing plant wire need to be replaced to use FOUNDATION fieldbus?
• What's the difference between a branch layout and a tree layout?
• Can you mix wire types on a segment?

A fieldbus advantage
Wire isn't very expensive — if you're connecting a couple of instruments a few yards away.
But put in a few miles of wire to connect hundreds — or even thousands — of individual devices
across a plant, and you're talking about a major expense. Especially when you include the labor
required to install the wire, as well as conduits and cable trays. Not to mention documenting
every wire and connection, then keeping up with changes.
You get the picture.
These are the costs that FOUNDATION fieldbus and PlantWeb architecture are designed to
reduce.
• Digital communication enables several devices to share the same cable, vastly reducing
the total amount of wire required.
• FOUNDATION fieldbus H1 can work on standard plant wiring, so you can even use
wires that are already available.
• If you do need to add wiring, either for new construction or for a capacity increase,
available wiring and cable options make the job easier and the results more reliable.
And all of that translates into a lot less cost.
Basic segment design
Conventional analog installations have a dedicated pair of wires connecting each field device to
a host system. FOUNDATION fieldbus installations use a single twisted-pair cable — also called
a bus or trunk — to connect multiple devices. The cable, connected devices, and supporting
components are called a segment.
Devices connect to the fieldbus either individually or in groups. If they connect through individual
spurs branching off the main trunk, the result is called a branch layout or topology
A bus with spurs connected to the trunk in close groups is called a tree layout.
A single segment can have both branches and trees, as long as a few rules are followed for
total segment length, length of drops, total device count, and segment current draw.
Key segment limits Typical values
Maximum of 32 devices per 4 to 16 devices per segment

segment without a repeater
Maximum of 240 devices per

segment with a repeater
Each device must draw at least 15 to 25 mA power consumption for

8 mA from the segment a two-wire device
8.5 mA for a four-wire device
400 mA typical segment limit
Voltage range 9-32 Vdc 24 Vdc

Wire types and segment lengths
The length of a total fieldbus segment depends on the type of wire you're using.
For example, the maximum wire length is 1900 meters (6232 feet) if typical instrument grade
wire — individually shielded twisted pairs — is used. The maximum length drops to 200 meters
(656 feet) if you're using just two wires with no shield and not twisted.
The table below provides examples of wire types and allowable segment lengths.
Type Description Size Maximum length
Individual shielded, #18 AWG 1900 m

A
twisted pair (0.8 mm2) (6232 ft.)
Multiple-twisted-pair #22 AWG 1200 m
B
with overall shield (0.32 mm2) (3936 ft.)
Multiple-twisted-pair #26 AWG 400 m
C
without shield (0.13 mm2) (1312 ft.)
Two wires with no shield #16 AWG 200 m
D
and not twisted (1.25 mm2) (656 ft.)
Total length segment
Total segment length is determined by adding the length of all the sections of the segment. The
total segment length must be within the maximum allowed for the wire type(s) used.
The diagram provides an example.

The total segment length is the sum of the lengths of all the spurs (S1 through S7), plus the
length of the main cables, or trunks (T1 and T2). For type A wire, the total must be less than
1900 meters.
Mixing wire types on a segment
You can use different wire types on the same FOUNDATION fieldbus segment — as long as
you follow the rules about how much of each type can coexist on the segment.
To find the maximum length of each wire type on a segment, first calculate the following ratio for
each wire:
Length of individual wire

Max. length for wire type
(For maximum lengths for each wire type, see the previous topic, "Wire types and segment
length.")
Then add the ratios for all the individual wires in the segment. If the sum of the ratios is less
than 1.0 (or 100%), the wire combinations and lengths are acceptable.
Here's an example:
A segment has 2000 feet (610 meters) of type A shielded twisted pair wire and 400 feet (122
meters) of type D non-shielded, non-twisted pair. Is this combination acceptable?
2000 ft A = 0.32 400 ft D = 0.61

6232 ft max 656 ft max
0.32 + 0.61 = 0.93 or 93%
The sum of 0.93 or 93% is less than 1.0 or 100%. So this is an acceptable wire combination.
Spur length
The maximum length of a spur depends on
• the total number of devices on the spur, and

• the total number of devices on the segment
Total devices Devices per spur
on segment 1 2 3
1-12 120 m 90 m 60 m
13-14 90 m 60 m 30 m
15-18 60 m 30 m 1m
Note that a spur can have up to three devices.
For example, the diagram below shows a segment with a total of eight devices. Reading across
the "1-12" row in the table, that means the spurs with one device can each be 120 meters long,
the spur with two devices can be 90 meters, and the spur with three devices can be 60 meters.
Practical pointer
Some suppliers offer automated segment design tools that take all these rules into
consideration. These tools make FOUNDATION fieldbus segment design quick and easy.
©2002 Emerson Process Management. All rights reserved. View this and other courses online at www.PlantWebUniversity.com
Fieldbus 302
Network wiring options

• Overview
• Tree and branch topologies
• Conduit options: tree
• Conduit options: branch
• Combining conduit and armored cable
• Non-conduit options: tree
• Non-conduit options: branch
• Using existing wiring and junction boxes
Overview
How do I connect the pieces?
With FOUNDATION fieldbus you have a broad range of options for building a network that
meets your needs.
The choices you make depend on the location of each device, the amount of existing wiring you
want to use in the new network, and the wiring practices best suited for your plant or project.
This course outlines some of those choices.
• When is a branch layout a better choice than a tree layout?
• What are the advantages of pre-assembled cables and connectors?

• How can you convert wiring in an existing junction box from analog to fieldbus?
Tree and branch topologies
A fieldbus network should be designed with the location of the field devices in mind. That's
especially true in an existing plant with wiring, conduit, junction boxes, field devices, and related
equipment already installed.
Some devices will be located by themselves, others in groups. FOUNDATION fieldbus

accommodates both situations through branch and tree network layouts (also called
"topologies").
Branch. Like its namesake, a branch is a single "limb" or spur off the main trunk of a fieldbus
segment. A branch layout makes sense when the devices on a segment are geographically
separated from each other.
Tree. A tree layout (also called a "chicken foot") has a number of branches, or spurs, that
connect to the main trunk in one location. This layout works well when several devices are
located near each other.
Either of these network layouts can be used with wire in conduit or not, with a combination of
conduit and armored cable, and with existing wiring and junction boxes. The topics that follow
will examine each of these configurations in more detail.
Conduit options: tree
Many plants have existing wire in conduit. This setup can easily be used in a FOUNDATION
fieldbus network with either tree or branch layouts.
A tree layout connects several spurs to the main fieldbus trunk (also called a home-run cable)
at a single point. You can use standard shielded, twisted-pair wire for the home-run cable and
for the spurs that connect to the devices. Or you can use conduit for the home run cable and the
trunk, and armored exposed cable for the spurs.
The connection to the main cable is often made with a junction box or spur block. A spur block
takes in a segment and passes it out to other spur blocks or remote devices.
Another connection option is to use standard field terminal blocks. The style of terminal block
shown below — called a disconnect block — reduces the risk of a short circuit by eliminating the
need to physically unscrew a device in order to remove it from a segment.
Practical pointer
Establish standard practices such as "segment in at upper left" and "segment out at upper
right" for making connections at junction boxes, spur blocks, or terminal blocks.
Such conventions can help reduce wiring errors and simplify maintenance. For example, a
maintenance technician will know which terminals affect only a single device, and which
affect the rest of the segment.
Conduit options: branch
There are also several options for using conduit with a branch layout.
One option is called a condulet.
As the photo shows, a condulet is designed so that a segment comes into the box on one side
(the top side in this photo) and extends through the opposite side, if necessary. The branch line
to the device is attached on the third side.
In the example shown in this photo, conduit is used all the way to the field device.
Combining conduit and armored cable
You may want to use a combination of conduit and armored cable for your project -- either
because it's too expensive to run conduit to remote areas, or because you already have both
conduit and armored cable installed in the plant.
Whatever the reason, there are options for this combined approach, too.
The first photo shows one of these options. The unit -- which accepts either two devices, or a
single device and a terminator -- mounts on a standard conduit run like that shown in the
second photo. Then pre-assembled armored cable connects the unit to the field device.
Practical pointer
Pre-assembled cables and connectors may increase the cost of materials, but they usually
reduce overall project cost because they reduce the time and labor required for installation.
They also reduce costs by protecting against many types of maintenance errors. For
example, they provide short-circuit protection by eliminating exposed wires at the termination
points that could be accidentally shorted together or grounded.
However, pre-assembled cables must be ordered to length or assembled to length in the

field. It's sometimes difficult to order the correct lengths in advance, and assembly in the field
Non-conduit options: tree
Conduit is expensive — especially if you need a lot of it. So rather than installing miles of
conduit, many plants use cable trays or other ways of routing signal wires.
You can still use traditional junction boxes if you take this approach, but other options are also
available.
One option for use in a tree layout is a pre-assembled fieldbus junction box like the one in the
photo. The junction box — sometimes called a "brick" — combines a set of cable connectors
and interconnect wiring in a potted assembly suitable for mounting in a plant environment.
These junction boxes come with connectors for four to eight devices, plus connectors for
segment-in and segment-out. Each connector is labeled to help prevent incorrect assembly.
Caps protect unused connectors from the environment.
This type of junction box is typically mounted to a plant structural member close to the devices it
serves.
Practical pointer
Some junction boxes are available with short circuit protection. If there is a short circuit on a
spur, the short is isolated to just that spur, and therefore just one device. This reduces the
risk of a wiring problem affecting several devices.
When you're installing a fieldbus segment, avoid filling a junction box completely. Allow room
for growth by leaving at least one location open for either a fieldbus terminator or an
extension of the segment trunk.
Non-conduit options: branch
For non-conduit installations with a branch layout — where each device is attached to an
individual drop off the main trunk — a "T" connector offers low cost and easy installation.
The "T" connector has a segment-in and a segment-out connection, plus a connection for the
single spur or branch to the individual field device.
Like a fieldbus "brick," the "T" connector can be mounted on a plant structural member close to
the segment trunk. And, like the brick, it's made to withstand typical plant environments.
Using existing wiring and junction boxes
FOUNDATION fieldbus is designed to work with existing instrument-grade wires. With just a few
wiring changes to a junction box, you can convert point-to-point analog wiring to a
FOUNDATION fieldbus trunk with spurs.
As the diagram shows, the positive wires are jumpered together, as are the negative wires, on
the home run (or host) side of the junction box. The individual plus and minus terminals on the
field side connect to the spurs that run to groups of 1 to 3 devices per spur.
The photo shows a conventional junction box that has been converted to a FOUNDATION
fieldbus H1 junction box.
Practical pointer
Converting one or two of the twisted pairs in a multi-core cable from analog to FOUNDATION
fieldbus can substantially extend the capacity of installed wiring.
It's also significantly less expensive than pulling new cable, especially if conduit is used and
the conduit is at recommended capacity.
If you convert only part of a cable bundle from analog to fieldbus, clearly label the fieldbus
segments so anyone working with the cable in the future will know which is which.
Fieldbus 303
Segment hardware
• Overview
• Required and application-dependent components
• Power supply
• Power conditioners
• Terminators
• Repeaters
• Intrinsic safety barriers
Overview
What are the other pieces of a network?
The previous two courses focused on network wiring — first the fundamentals, then the options.
This course covers other pieces of the physical network.
• What hardware is required on a fieldbus segment?
• What is the primary purpose of a power conditioner in a fieldbus network?
• Why are terminators needed?

Required and application-dependent components
As the diagram shows, a typical FOUNDATION fieldbus segment consists of both required and
application-dependent hardware.
Fieldbus devices are intelligent nodes on the network, providing sensing, actuation, process
control, and diagnostic information. In this sense, a host system — usually a fieldbus
engineering tool or a control system such as a DCS, PLC, or PC — is one type of fieldbus
device.
The rest of the fieldbus network hardware links and supports these devices.
• The fieldbus power supply is normally a redundant, 24-volt bulk unit that provides
power for multiple fieldbus segments.
• The fieldbus power conditioner provides communication isolation between multiple
segments that are connected to a common power supply.
• Intrinsic safety barriers provide intrinsically safe power for one to six fieldbus devices.
• Terminators help provide a high quality communications signal and prevent signal
reflection on the bus.
• Connectors and junction boxes provide places to terminate field wiring on the
segment.
• A repeater electrically isolates one part of a segment from another. It also provides
longer distance communications and can increase the total segment device count.
The rest of this course describes these supporting hardware elements in more detail.
Power supply
Power is one of the areas in which FOUNDATION fieldbus is quite similar to conventional analog
networks.
For example, both device power and communications occur on the same two wires designed to
run at 9 to 32 VDC. And FOUNDATION fieldbus is fairly tolerant of power quality.
In general, FOUNDATION fieldbus power is
• Shared across many devices and segments

• Quite often redundant
• Multiplexed either through a separate power multiplexer or through multiplexers
integrated with the supplies.
• Listed as 9-32 volts floating (24 volts is most common)
Most existing analog bulk power supplies will work with FOUNDATION fieldbus and are good
sources for FOUNDATION fieldbus bulk power. Some plants like to have a UPS or battery
backup as one of the power sources.
The diagram below shows an example power source configuration for multiple segments.
Practical pointer
Make sure the voltage at the farthest point of the segments powered is at least 9 vdc when
the batteries are at their lowest expected operating voltage.
To ensure this, higher voltage is required at the power supply. Some plants have backup
batteries that float on a 24 vdc bus. These batteries take over if the AC/DC power supplies
are lost. A margin of several volts is recommended.

The Emerson field devices used in PlantWeb architecture are polarity insensitive.
This means the plus and minus wires can be reversed at a field device, and the
device and segment will both work normally. This simplifies segment checkout and
eliminates many wiring "mistakes."
Power conditioners
It's critical that communications on a segment not cross to other segments through the power
supplies. Power conditioners prevent this "cross-talk" between multiple segments using the
same power supply.
The power conditioner limits maximum segment power. A typical value is 400 mA.. If a typical
device draws 15-20 mA, a power conditioner could supply about 20 devices and still have some
reserve capacity.
Power conditioners also current-limit the segment, so that grounding of one segment won't
affect other segments attached to the same bulk power source.
Practical pointer
Cable shields can be grounded to the power conditioner. But make sure the shield doesn't
touch a field device housing; letting it do so can create a second grounding point and thus
cause a ground loop.
Also, FOUNDATION fieldbus signaling uses a balanced line to provide more robust
communications than a signal and ground. Balanced lines require that the individual signal
wires NOT be grounded.
Terminators
Terminators are simple resistor-capacitor circuits used to prevent problems like signal reflection
from the end of the wires. They're installed in pairs, with one terminator as close as practical to
each end of a fieldbus segment.
Fieldbus segments have been known to work with terminators incorrectly installed or missing,
but this situation dramatically increases the chances of segment problems.
Power conditioners frequently include a terminator, eliminating the need for a separate external
terminator on that end of the segment. However, terminators are usually NOT built into or
installed in field devices. That's because the segment could be left without proper termination if
the device that contains the terminator is removed from service.
Practical pointer
Put a terminator in the junction box that's closest to the far end of a segment. Even if there
are individual devices farther out, the junction box is usually close enough to the end of the
segment for the terminator to function properly.
Because terminators are very simple circuits, it's tempting to make your own. But homemade
units frequently fail in installation, checkout, or service. Whatever you saved by making the
terminators will be spent many times over fixing or retrofitting them.
Repeaters
Repeaters are optional components used either to extend the length of a fieldbus segment or to
increase the number of devices on a segment. They provide power and a clean communication
signal for the extended part of the segment.
A segment can have as many as four repeaters dividing the segment into five pieces.
Electrically, each piece acts as a separate segment -- but devices can communicate with each
other as though they were on the same segment, even if there are up to two repeaters between
the devices.
Although a fieldbus segment can have up to 32 devices without repeaters, H1 segments

typically don't have more than 12-16 devices even if repeaters are used.
Intrinsic safety barriers
FOUNDATION fieldbus was designed to support intrinsic safety — and to do so with more
flexibility and lower cost than traditional analog intrinsic safety.
In the analog world, each input and output has a dedicated barrier. But in the fieldbus world —
with its single cable supporting multiple devices — one barrier can serve several devices. That's
a tremendous saving in barrier and installation costs.
Depending on your needs, you have the option to put several barriers on a single fieldbus
segment. You can also have both intrinsically safe and conventional points on the same
segment.
Intrinsic safety requirements and practices are covered in more detail in Fieldbus 203.
Practical pointer
Although you can re-use existing analog wiring in a fieldbus network, DON'T use existing
analog barriers for FOUNDATION fieldbus. Existing barriers aren't certified for FOUNDATION
fieldbus and won't work in this application.
Here's another tip: You can achieve two goals at once by using FOUNDATION fieldbus
repeater barriers, which combine the functions of a repeater and an intrinsic safety barrier.
Fieldbus 401
Project engineering standards

• Overview
• Field device specifications
• Segment design practices
• P&IDs
• Loop sheets
• Segment design drawings
• Cable schedules
• Installation practices
• More on installation practices
• Project schedules
Overview
How is project engineering different with fieldbus?
Engineering standards help ensure everyone does things not just the same way, but the best
way for project success. That's especially important when using new technologies, like
FOUNDATION fieldbus, that not everyone is familiar with.
Even if your project timeline doesn't allow for formal adoption of new standards, you should
review your existing standards, determine what needs to be changed, and then document and
communicate those changes before the project begins. The time you invest will reduce the risk
of costly errors, rework, and "one-off" solutions.
Fortunately, engineering a fieldbus project isn't any harder than using traditional technology —
and in many areas it's substantially easier. The basics are generally the same, from
environmental specifications to hazardous area considerations to wiring types. What will change
most are standards related to field devices, which are now capable of far more than their analog
ancestors.
This course outlines how various aspects of project engineering are affected by FOUNDATION
fieldbus technology.
• Which project engineering standards will change as a result of adding fieldbus?
• What new information will be required on instrument specification sheets?
• What should be added to a P&ID to accommodate fieldbus?
Field device specifications
Because of the added functionality in fieldbus devices, their specifications are more
comprehensive than for analog devices. Spec sheets for fieldbus devices should incorporate
new fields for input and output, control, and diagnostic capabilities that didn't exist previously.
For example:
Input and output
• Function blocks, such as integrators for flow devices and characterizers for analytical
devices
• Multivariable input blocks — for example, allowing a flow device to also provide
temperature, density, and viscosity inputs
• Output blocks that include both the output value and the actual valve position
• Additional information used in diagnostics, such as temperature of the electronics.
Control
• Standard control function blocks in a device, such as PID

• Multiple function blocks in the same device, such as two PIDs for a cascade loop
• Link Active Scheduler/Backup LAS to maintain loop control without a host
• Configurable loop execution times.
Diagnostics
• Basic status information, such as sensor failure

• Health monitoring to detect problems such as impulse leg plugging, glass breakage, or
probe fouling
• Wear monitoring indicators such as valve cycles and total valve travel, and performance
diagnostics such as valve signature
• Statistical process monitoring
• Loop diagnostics.
In addition to function-block, control, and diagnostic requirements, other items to include in

fieldbus device specifications include
• Working voltage
• Maximum current draw from bus
• Block execution speeds
• Interoperability testing (ITK 4.1 or higher)
• Polarity sensitivity (if required by device)
• Capacity for instantiable function blocks
Segment design practices
In a fieldbus project, segment design replaces and greatly simplifies the traditional I/O
assignment task. Segment design standards set the segment-loading rules for your plant.
• Instead of assigning every signal to a specific I/O at the host and splitting inputs and
outputs to separate places, you design segments and bring all the devices, regardless of
input or output, into a single point for I/O assignment.
• The bus nature of fieldbus also gives you much more flexibility in adding to and
modifying device counts and types. As devices are added and changed during design, in
many cases I/O assignment is either unchanged or changed only to a very limited
extent.
• Finally, the need to marshall I/O points -- so different signal types and inputs and outputs
can be properly routed to a dedicated termination point -- is significantly reduced.
The documents you will need for segment design include
• P&IDs
• Instrument plans
• Host-system documentation showing configuration rules or restrictions.
Segment design standards set the segment-loading rules for your plant. Devices should be
grouped according to these rules and, of course, your specific process.
Both fieldbus and host-system constraints should be considered. As you are engineering a
project, an automated segment design tool can check fieldbus-related items such as number of
devices, power, and overall segment length. Vendor-specific segment design tools may also
cover host-system issues such as the maximum number and type of parameters.
Piping and Instrumentation Diagrams
There's currently no industry standard for showing fieldbus capabilities in P&IDs, although ISA
is working on one. In the meantime, your best option is to develop a company or plant standard.
This doesn't have to be a major effort. With the few simple changes to your existing standards,
your P&IDs can reflect both conventional and fieldbus devices.
Label all fieldbus devices. This can be done by simply placing a small "FF" beside each
fieldbus device.
You can also use a different line style for the connection between fieldbus devices.
Indicate where control resides, especially if it's in a field device. You can do this by placing a
small "FF" next to the PID or other function block. Then, to indicate where the control block
resides, place the function block symbol next to the field device that will execute control.
Label the Link Active Scheduler (LAS). If a specific loop requires a backup LAS, this should
also be indicated.
Label the loop execution time. Show the execution time (such as 250 ms or 500 ms) so
devices with appropriate control performance can be specified.
Loop sheets
Fieldbus changes what's shown on loop sheets — or can even eliminate the need for them. It
depends on what you choose to document on loop sheets.
For example, because point-to-point wiring is replaced by fieldbus segments, a loop sheet that
shows only point-to-point wiring can be replaced by a segment drawing. One segment drawing
typically shows four to six loops (as well as additional devices), substantially reducing drawing
time and costs.
If you've traditionally used loop sheets to document device ranging for analog signals, you no
longer need them to show that information. Fieldbus uses only digital signals.
If, on the other hand, you typically use loop sheets to show process diagrams or logic drawings,
you may want to retain a very simplified form of loop sheet that includes this information.
And with the added diagnostic capabilities of FOUNDATION fieldbus, you may also decide to
add loop-specific diagnostics to the loop sheet.
Segment design drawings
Use segment design drawings to document the topology, electrical characteristics, and
control properties of each segment:
1. Segment topology
• Segment and spur length

• Wire types (and pinouts on any pre-manufactured connectors)
• Locations and types of
° Junction boxes and connectors
° Power supplies and conditioners
° Barriers and terminators
° Guest devices like configuration tools and bus analyzers
• Additional segment physical capacity for connecting new devices or extending the
segment
2. Segment electrical characteristics
• Voltage and current draw, both per device (including guest devices) and for the overall
segment. This is especially important for long segments or those with intrinsic safety
requirements.
• Device polarity — or polarity insensitivity for devices that offer this feature.
3. Control properties
• Loop execution requirements and times are used to determine overall segment
communications loading.
Cable schedules
Your standards for cable schedules should address types of cables and cable numbering
conventions.
The type of cable used will depend on the planned segment length and, of course, plant
practices.
Single shielded, twisted pair wires inside an instrument cable, or small multi-conductor cables,
are often used for fieldbus wiring. You can use existing wire unless it's old or in poor condition.
Cable and wire numbering and labeling conventions will need to be changed in order to
differentiate between traditional point-to-point, single-device wire pairs, and a multi-drop digital
bus.
For example, in a traditional analog installation, a single wire pair has a single device tag. In the
fieldbus environment, that same wire pair acts as a digital bus connecting multiple devices, so it
should be labeled with a segment number or segment description.
Installation practices
As with so many other aspects of fieldbus projects, installation isn't any harder than with
traditional technologies. In fact, it's usually easier. But some things are different — and those
differences should be reflected in your standard installation practices.
Here are few examples:
Optimize your wiring. To reduce costs and labor, wire the home-run cable to a field junction
box close to the field devices. Then connect the devices using either of the following methods:
• Continue running individual wire pairs — through conduit if you want — from the trunk to
the individual devices
• Run quick-connect cables from the junction box to the individual devices. Quick-connect
cables cost more than twisted pair, but they install faster, produce fewer wiring errors,
and provide some short circuit protection.
Select time-saving devices. Devices with vendor-installed, quick-disconnect wire connectors

are faster and easier to connect and can reduce wiring errors.
More on installation practices
Observe device polarity. Because most fieldbus devices are polarity sensitive, crossing the
positive and the negative anywhere on a segment may cause individual devices or parts of the
segment to malfunction.
Although this won't happen with polarity-insensitive devices, observing the polarity of all devices
will reduce electrical installation problems.

All fieldbus devices from Emerson are polarity insensitive. They will function
regardless of the polarity of the wiring. This reduces design, installation,
commissioning, and troubleshooting by eliminating polarity considerations.
Anticipate device and segment changes. Define standard methods of attaching and removing
individual devices without shorting out the segment. For example, you might use quick-
disconnect cables, removable terminal blocks, and short-circuit-protected junction boxes.
Standard wiring practices can also help technicians avoid mistakes in connecting (or
disconnecting) devices and cables. For example, always have the segment enter a junction box
on terminals 1 and 2 and exit on terminals 3 and 4. If the segment doesn't continue beyond the
junction box, put the terminator on the same terminals where the segment would have left the
box.
Document everything. To ensure consistent installation and streamline maintenance later,

immediately update your standards and project records to reflect any changes made during
engineering and installation. The time and headaches you save may be your own.
Project schedules
With fieldbus you may spend more time doing up-front planning but less on installation,
checkout, and commissioning. In general, fieldbus will shorten your overall project schedule
and allow your plant to start up earlier. The profit from incremental production enabled by an
earlier startup can easily exceed the total project cost reduction..
The biggest schedule change is that field devices are specified earlier in the project.
That's because they're no longer single-function components at the end of individual 4-20 mA
wires. They're intelligent devices that provide new capabilities and work together on a digital
network.
For example, in a traditional project I/O assignment and instrument specification could proceed
in parallel. But with fieldbus, device attributes such as power, diagnostic requirements, and
multivariable capability can affect segment design -- which means you'll need to specify the
devices that go on a segment before segment design can be completed.
Similarly, on traditional projects with all control in the host system, instrument specification can
wait until system configuration is complete. If your fieldbus project includes control in the field,
instrument selection must be done much sooner to ensure they have the needed control
functionality.
One of the longest-duration tasks in a typical project is host configuration of control strategies,
operating displays, data historians, etc. How a vendor implements fieldbus in their host can
have a huge impact on both schedule and functionality.

With well over 1000 FOUNDATION fieldbus PlantWeb projects, in every
industry and every world area, Emerson has more FOUNDATION fieldbus
experience than anyone else.
This experience translates into bottom-line benefits for you. For example, we've consistently
implemented FOUNDATION fieldbus projects with shorter project schedules and lower total
installed costs than conventional analog projects.
The savings are so consistent and so real, we'll even guarantee them.
Fieldbus 402
Choosing a host system

• Overview
• Supplier experience
• Designed for fieldbus
• Access to validated device data
• Fieldbus redundancy options
• Interoperability testing
• Ease of commissioning and testing
• Predictive maintenance
• See what you're buying
Overview
Does it matter which host system I use?
Not all host systems deliver the same level of functionality — especially when it comes to taking
full advantage of fieldbus technology.
As you select a host system, you'll therefore want to consider how well it meets your needs in a
number of areas, including
• Collecting and easily disseminating FOUNDATION fieldbus information for more efficient
operations, precision control, and proactive maintenance
• Integrating field and supervisory control
• Surpassing the capabilities associated with traditional distributed control systems
This course covers these and other considerations that will guide your decision.
• Do fieldbus devices and host systems need separate configuration tools?
• How can a host system apply information about the status of the field signal?
• How can a host system reduce the effort required for device commissioning?
Supplier experience
When you buy a host system, you're not just getting a bunch of hardware and software. You're
also getting the benefit of the supplier's experience in similar applications.
Ask about their experience and run-time applying the host system in real, mission-critical
applications. In particular, look for fieldbus experience in your application. A proven track record
will help you avoid being part of the supplier's learning curve.
Also consider the breadth and depth of installations of each system around the globe. This is an
indication of the experience a supplier has in delivering host systems and services to make your
installation meet your expectations. Again, make a point of asking about the supplier's
experience implementing and supporting FOUNDATION fieldbus projects in your area.
Designed for fieldbus
The design of many host systems — especially those based on traditional distributed control
system architectures — can affect their ability to take full advantage of FOUNDATION fieldbus
and the information it provides.
Function block compatibility. For consistent control with minimum configuration, the same
fieldbus function block should be able to run in either the host system or the fieldbus device. If
not, extra effort is required to modify control strategies and tuning parameters to get similar
performance.
You may also have to map fieldbus block structures into legacy host structures to access
fieldbus data. Depending on the host architecture, the mapping can be extensive.
Matching operating modes. The mode of host control strategies should be identical to
FOUNDATION fieldbus standard modes, whether the block runs in the host controller or
fieldbus device. Mode mismatch between the host and the devices could result in inoperable
control with very little indication of the problem.
Single configuration environment. The host system should provide a common control-
strategy configuration tool that can assign execution of the function block to the host controller
or to the fieldbus device, or split execution between them.
Ideally, you should be able to configure a control strategy before determining whether it will run
in the host or the device. This capability optimizes your configuration investment.
Calibration from host. A well-integrated host system lets you calibrate fieldbus devices right
from the configuration environment on one of the host workstations. This integration reduces
engineering time and effort and avoids the need for separate, non-integrated software.
Another key designed-for-fieldbus capability — network-wide access to validated device data —

is covered in the next topic.
Access to validated device data
The FOUNDATION fieldbus standard provides for fieldbus devices to pass not only process
data to the host system, but also the status or "goodness" of that data. Having good, validated
data from the fieldbus device improves the validity of the control, and your ability to respond
correctly to abnormal or failure conditions.
A well-designed host system should incorporate this validated data in many areas:
In control strategies. Control strategies that recognize when data coming from a fieldbus
device is no longer good can take corrective actions — potentially avoiding process upsets and
dangerous conditions.
Propagating the status of the field signal to supervisory control strategies and to historical
storage also ensures that these decision support systems are using a true representation of the
plant.
In advanced control applications. To be effective, robust advanced control relies on a solid

foundation of accurate information. When applied in host systems that do not give the goodness
of the data, these controls are often decommissioned because they no longer work as initially
designed.
If a field device is delivering bad data, the host should recognize this and propagate the status
information to advanced control strategies such as Model Predictive or Neural Network Control
to mark those strategies as using bad or suspect data.
In operator displays/alarms. For conditions not handled by the control strategies, operators
can be notified of suspect data coming from a fieldbus device and take the proper actions to
avoid process upsets.
Fieldbus redundancy options

Make sure the host system you're considering offers the level of security your application
requires. Systems can provide redundancy in fieldbus segment communications scheduling, in
power supplied to the fieldbus segment, and in the interface between the segment and the host
system.
Segment communications scheduling. In addition to fieldbus devices that can provide

backup scheduling (link active scheduling or LAS) of communications, the H1 interface card to
the host system should be able to provide this backup scheduling.
Fieldbus segment power. A robust host system offers redundancy options in the power
supplied to the fieldbus segment. This redundancy is critical to eliminate single points of failure
for the fieldbus segment.
H1 interface card. Beyond just redundant communications scheduling and segment power,
redundant H1 interfaces to the host system provide the ability to maintain an operator window
into a running segment. The redundant pair of H1 cards should provide automatic and bumpless
switchover if a card fails.
Interoperability testing
Important considerations in selecting a host system are its interoperability with other suppliers'
fieldbus devices, and the supplier's commitment to testing devices as they become registered
with the Fieldbus Foundation to ensure smooth operation.
Available library of device descriptions. To understand the system's level of interoperability

with other suppliers' fieldbus devices, ask the supplier if they have a library of device
descriptions for devices that have already been tested for interoperability. Such a library allows
you to quickly build your control strategies around these devices.
Also ask the system supplier about their policy regarding device descriptions for new devices.
Do they provide them? Via the web? E-mail? Or do they expect you to rely on the device
manufacturers to provide device descriptions?
Stress testing. Evaluate the host system supplier's commitment to testing and adding new
devices. Will they stand behind third-party devices on their host?
Remember that the automation system now extends from the host into the field devices. The
system supplier should be able to show evidence of tests with third-party devices and that they
will assume responsibility for control regardless of where it occurs.
Ease of commissioning and testing

For each host system you consider, evaluate the engineering effort required to commission a
FOUNDATION fieldbus segment and its devices.
Auto sensing of devices. Host systems designed with the fieldbus standard in mind can
automatically identify new fieldbus devices as they are connected to a fieldbus segment.
Commissioning time is shortened if the host supports connecting an entire segment and auto-
recognizing all devices without the need to commission a device fully before connecting
additional devices.
Drag and drop commissioning. The effort required from the sensing of the device to using it in
control strategies can vary dramatically among host systems. Consider ones that provide
intuitive, "drag and drop" commissioning.
Auto-macrocycle generation/optimization. Some hosts make scheduling the underlying

fieldbus communications transparent to the user by automatically scheduling and optimizing the
communications based on the number and types of fieldbus devices on a segment.
Host systems that have this capability reduce the effort required and avoid the mistakes
associated with the complex calculations of bus schedules.
Simulation of field devices. For faster commissioning, look for host systems that can simulate
the fieldbus device so control strategies can be pre-tested before startup begins.
Device simulation also lets you perform operator training before startup, which increases the
efficiency of the operation earlier. In addition, FAT (Factory Acceptance Test) is accomplished
far more readily by simulation than with staging a complete set of field devices.
Rollback of device configuration. Plants continually work to improve operational efficiency.

This frequently involves some experimentation to determine the optimum settings to run the
plant. Sometimes these experiments are not successful, and it is necessary to return to previous
operating parameters. To ensure you can quickly return to more efficient state of operation, look
for a host system that can roll back the configuration of a fieldbus device to a known optimally
operating state.
Predictive maintenance
Host systems incorporating FOUNDATION fieldbus technology have varying levels of support to
deliver predictive maintenance capabilities to your operations.
Device health alerts. Advanced fieldbus devices have the capability to send alerts about their
health to the host system. Look for a host system that's designed to receive these messages
and has pre-engineered alarms, faceplates, and screens that recommend a course of action to
solve the problem.
Process health alerts. Some advanced fieldbus devices have the ability to spot process
problems around them, such as plugged sensing lines. Like device health alerts, this information
is immediately communicated to systems and applications that can solve the problem and avoid
downtime.
Detailed device diagnostics upon demand. Host systems that integrate asset management
as a core part of their architecture can provide detailed device diagnostic information from any
view station into the host.
Audit trail and event history. To satisfy regulatory requirements and provide a clear picture of
who changed what, when, and why, some host systems incorporate changes in fieldbus devices
in the host audit trail. This, combined with the standard host system audit trail data, provides the
integration of device and host information needed to speed up troubleshooting and avoid
process problems.
See what you’re buying
At some point in your evaluation process, take an actual hands-on look each of the host
systems you are considering.
Take a test drive. The engineers, operators, and maintenance personnel who will interact day-
to-day with the host system should actually engineer, build, commission, and operate examples
of each of the host systems under consideration. This will help them understand how each
system will perform, and determine each host's strong and weak points.
Talk to users. Users around the world have installed FOUNDATION fieldbus technology and
benchmarked the benefits they have received. Talk to people who have used the host systems
under consideration. Ask them what they've learned, and how well the system — and the
supplier — met their expectations for delivering the benefits of fieldbus.
Fieldbus 403
Control design
• Overview
• Plant philosophy
• It's more than PID
• Control modularity
• Field control location
• Potential exceptions
• Maintenance and purchasing considerations
Overview
Should I put control in the host system or in field devices?
One of the advantages of using FOUNDATION fieldbus is that you can choose where control
algorithms execute. You can put control in the host system, in intelligent field devices, or both.
It's really up to you.
Moving control to the field may give you higher reliability, lower costs, and better performance
than traditional host-based control. But the key is making the choice that best supports your
plant's needs. This course will help you make the right choice.
• Which is better, control in a valve or control in a transmitter?
• How does control location affect purchasing?
• How can control in the field increase reliability?

Plant philosophy
The decision on whether a transmitter, a valve, or a host system will control a specific loop can
affect process performance and reliability.
But what about the next loop? Will it require another "start-from-scratch" decision-making
process? And will every engineer on the project reach the same conclusion?
They can if you implement a consistent plant philosophy on where to put control. An engineering
standard would be even better.
A well-thought-out philosophy can guide decision-making — resulting in a smoother, faster

design process. It can also maximize fieldbus benefits and help minimize future maintenance
costs.
Your philosophy should be tailored to your plant. It can identify a preferred approach as well as
specific exceptions. It can even evolve to address new situations and lessons learned.
The rest of this course covers several of the issues that can shape your philosophy.

All Emerson fieldbus-based field devices and the DeltaV and Ovation systems
have the same algorithms for process control. This means the control action will
be the same regardless of where you place control.
It’s more than PID
Control is commonly equated with PID. But PID is only an algorithm that receives a signal input
from a measurement device and provides a calculated signal output to a final control element.
There's a lot of "control action" even before the PID algorithm receives the input signal —
including signal-conditioning functions such as
• Temperature, pressure, and differential pressure measurements to calculate mass flow

• Characterizer functions to linearize inputs
• Calculations to derive parameters such as density
• Integration for flow totalization.
It makes sense to put these pre-PID functions as close as possible to the actual measurement
— in other words, in the measurement device.
Why? If a calculation requires several inputs, processing them in the transmitter reduces links
and traffic on the fieldbus segment. Also, the blocks in each transmitter are typically chosen to
provide the specific type of signal conditioning required for that application.
Likewise, functions performed on the signal output after it leaves the PID algorithm are best
done as close as possible to the final control device that will actually implement the control
action — for example, a valve.
Of course, if the control function you need — such as advanced or supervisory control — isn't
available in a field device, then host-based control makes sense.

PlantWeb architecture provides a single configuration environment for
configuring control in the DeltaV or Ovation host and in FOUNDATION fieldbus
devices. The same configuration, documentation, simulation, and test and
debug tools work for both.
In fact, the same control configuration can be used anywhere — for control in the host, for
control in field devices, or for both. Simply assign the configuration to the appropriate
location, and go.
Control modularity
With control in the field, an entire control loop — including inputs, outputs, and control
algorithms — can operate in the devices on a fieldbus segment.
This allows a more modular approach than traditional host-based control. As your process
grows and you add more field devices, you're also adding control capacity.
With host-based control, on the other hand, extending control to new process areas can result in
increased loading on the same host controllers. The net result could be slower control in the
host.
This modularity can also give control in the field the edge in process reliability. Only field
devices, segment power, and wire continuity are required to maintain process control. If one or
more of these components fails, only that one segment is affected.
Host-based control requires the same components plus
• An input card, controller, and output card

• Intra-card communications for the host
• Power for the host
• Significantly more wiring
Many of these components are shared by a large number of loops, making the impact of a
single failure quite extensive. This is usually addressed with redundancy, which is a more
expensive option.
Field control location
Control in the transmitter and control in the valve both seem equally effective. But there are
other considerations that may make one location more appropriate.
For example, if a problem causes loss of automatic control, the operator's ability to manually
control the process can be affected by where the PID block was running, as well as by the host
system's capabilities.
1. If the PID is in the valve, and the transmitter fails: The operator assumes manual
control by placing the PID in manual mode and manipulating its output using the host's
loop faceplate display of the PID block. [The PID output is normally sent to an analog
output block which actually controls the valve position.]
2. If the PID is in the transmitter, and the transmitter fails: If access to the transmitter's
PID block is also lost, the operator must take manual control at the analog output block.
However, many host operator interfaces don't support direct access and control of the
output from an analog output block — it must be done from the PID. In this case, manual
control may not be available.
3. If the PID is in either the valve or transmitter, and the valve fails: Control of the PID
is meaningless since the final control element — the valve — will go to the failsafe
position and can no longer be manipulated.
If your host system doesn't support direct manipulation of the analog output block, as in the
second example, you may choose to put PID in the valve controller rather than the transmitter.

The DeltaV and Ovation operator interface used in PlantWeb allows the operator
to view and manipulate any function block. This means control can be anywhere --
the transmitter, the host, or the valve -- and the operator can still access and
manipulate the final control element.
Potential exceptions
Once you've defined a control location philosophy or standard, stick with it — unless there are
overriding considerations that require an exception.
Here are some examples.
Cascade loops may require an exception if you want to put PID in the valve. You can
• Place the outer-loop AI and PID, and the inner-loop AI, in transmitters.
• Place the inner-loop PID and AO in the valve.
Device capability and capacity. Remember that even interoperable devices may have
different capabilities and capacities.
• PID may be supported in a device from one vendor but not from another.
• A device may have its entire capacity used for calculations or other functions, so control
must be placed elsewhere.
Other functions may override the standard location for control. For example,
• A device may need PID capability to perform statistical process monitoring or other
device-resident diagnostics for control loops
• A device may require the PID block to use its autotuning capability.
Document all deviations — and whenever it makes sense, update your standard to deal with
similar situations in the future.
You can also reduce the need for deviations by standardizing on devices that meet your plant
requirements.
Maintenance and purchasing considerations
Where you decide to put control affects more than just operations. A consistent approach to this
decision also offers benefits in purchasing and maintenance.
Standardizing on a single location for the PID block simplifies instrument purchasing as well as
spare parts procurement, storage, and usage. That's because you'll need fewer types of
instruments to implement the project, and fewer types of spares.
For example, if you always put PID in the transmitter, you can buy every transmitter — originals
and spares — with PID capability. If you don't use a consistent approach, you'll need to stock
some transmitters with control capabilities and some without, and some valve controllers with
control and some without.
Your maintenance technicians will also appreciate a consistent approach. They'll know which
kind of replacement device or parts to take into the field, and whether the transmitter or
controller they're about to disconnect from the segment is likely to contain control functions.
Fieldbus 404
Segment design
• Overview
• Designing for loop criticality
• Mission-critical loops
• Highly important loops
• Normal-importance loops
• View-only or data acquisition loops
• Process modularity
• Multivariable devices
• Host system considerations
• Design resources
Overview
Which devices — and how many — go on each segment?
The answer to this question depends on the situation.
Using proven segment design tools and good installation practices, it's easy to design and
implement a highly reliable and functional fieldbus segment. However, loops and processes
differ in criticality and functional requirements.
This course covers how those factors may affect your segment design.
• Is there an optimum number of devices to put on a segment?
• Can fieldbus handle critical loops?
• What is process modularity?
Designing for loop criticality
Designing a fieldbus segment that's both reliable and easy to maintain depends to a large
degree on segmentation. This means putting common elements on the same fieldbus segment
and dissimilar elements on separate segments.
One of the most important criteria for segmentation is loop criticality: how much impact a loop
failure would have on the process or on the entire plant.
• With mission-critical loops, the loss of automatic control will result in a shutdown.
• In highly important loops, a loss of automatic control will require a near-superhuman
effort from the operator to sustain operations.
• For normal-importance loops, loss of automatic control or operator visibility could be
tolerated during normal mean-time-to-repair.
• Finally, loss of automatic control or the operator's ability to view a loop would not have
any detrimental affect on view-only or data acquisition loops.
Let's look at some design guidelines for loops at each of these four criticality levels.
Mission-critical loops
Initially, a mission-critical loop may be the only loop on a segment. That way problems with
another loop, such as accidentally shorting the segment during maintenance on the non-critical
loop, can't cause loss of the segment with the mission-critical loop. With time and experience,
you may discover that more loops can safely exist on this segment.
If two mission-critical loops are interacting or cascaded, you can put both on the same segment.
But if the process can be kept running with only one of the loops active, consider separate
segments.
Redundancy. On segments with mission-critical loops, it's a good idea to use redundant
segment infrastructure. That includes using redundant H1 interface cards and power supplies.
One of the devices on the loop should also have a backup LAS. (Don't use redundant
terminators on the same segment. Doing so can cause signal problems.)
If loops also include redundant field devices and process piping, put these redundant
components and loops on separate segments and bring the two segments into separate H1 field
interface cards.
Control in the field. Consider using control in the field for critical loops. As long as the segment
retains power (and one device has backup LAS), automatic control can be maintained in the
field devices even if the H1 interface card and all other host components are lost.
Remember that critical loops may have supervisory control, operator visibility, or regulatory
reporting requirements that require the host to be connected to the loop for the loop to remain
operational. Control in the field will not address these needs.
Non-fieldbus control. Although FOUNDATION fieldbus is quite capable of handling critical

loops, sometimes plant practices dictate that specific loops be controlled using other
technologies. That's okay — there's no harm in using both traditional and fieldbus technologies
on the same project. But as experience and confidence with fieldbus grows, you'll likely want to
use it more often for your critical loops.
Highly important loops
If a highly important loop loses automatic control, an operator will typically go to the loop's
physical location and operate the valve manually, receiving instructions by radio from the control
room.
Grouping and loading of such loops is therefore guided by how many loops an operator can
control this way, without control room visibility to the final control element.
Loops and devices. As a rule of thumb, two related loops will share a segment. You can also
put critical operator monitoring information on the same segment.
Consider six devices per segment as a maximum for these loops. The right number for your
plant will be determined by the nature of your process.
System interface. The number of highly important loops that should be brought into a single H1
field interface card depends on how many loops an operator can handle via manual control at
the valve — without visibility through the host system — if the card fails. If you have redundant
H1 cards, you may be able to bring in more loops on a segment.
Control in the field. If it's okay for a loop to operate in automatic control without operator
control, then control in the field can be a good idea for highly-important loops. Even if the H1
card and all other host components are lost, automatic control can continue as long as the
segment has power and one of the devices has backup LAS.
(That's why you shouldn't run power through the H1 card if removing the card would interrupt
power to the segment.)
Normal-importance loops
Although it's tempting to use higher loading on normal-importance loops, there are still practical
limits. Generally, no more than 4 to 6 normal-importance control loops, and 12 to 16 devices,
should be on a single segment.
These limits will help ensure a stable, reliable operation. Here's why:
Communication. As the total number of devices and loops increases, communication loading
also increases. If you have several very fast loops, the total amount of communication on the
segment might be more than the segment can reliably handle.
A properly optimized communication schedule can give devices plenty of time to communicate.
But automatic scheduling tools don't necessarily produce optimized schedules. If you use such
a tool, keep an eye on the total communication loading for each segment.
Power. Different devices take different amounts of power. Make sure the total current draw for
all devices on the segment is well within the capacity of the segment power supply — typically
about 400 mA.
View-only or data acquisition loops
These kinds of loops are generally not very fast, nor do they place a tremendous load on the
segment.
In general, for view-only or data acquisition applications, a segment can be loaded with sixteen
or more devices.
However, you still need to make sure that total current draw of all devices on a segment is well
within the power supply's capacity.
In some cases, the number of devices and blocks your host system can support will also be a
limiting factor.
Process modularity
It's generally a good idea to group devices, loops, and segments along process lines.
Besides providing structure for the design task, this modular approach offers both maintenance
and performance benefits.
Use separate segments for unrelated equipment units or process areas. That way,
maintenance of the devices or network for one unit — during a shutdown, for example — won't
affect the operation of other units.
Use separate segments for parallel process streams. That way one process stream can be
shut down while parallel streams remain online.
Put all devices for the same loop on the same segment. This includes closely integrated or
cascaded loops.
Although multi-segment loops will work, they increase maintenance complexity and the number
of components required to close the loop.
Timing of control execution and communications also becomes a bit less precise. For fast or
time critical loops, this can degrade performance.
Leave room for growth. You may decide to add more devices to a loop in the future. When
that happens, the extra capacity you build in now will help you keep all devices for the loop on
same segment.
Know your "comfort level." Traditional analog input or output cards typically have at least 8 to
16 points and are usually non-redundant. Since loop integrity of a FOUNDATION fieldbus
implementation is comparable to or better than a traditional analog solution, it's reasonable to
use similar risk levels for a first fieldbus implementation
Multivariable devices
Multivariable devices can make segment design easier and more cost-effective by letting you
acquire multiple measurements with a single instrument.
For example, one mass flow device may provide values for real-time mass flow, total mass flow,
process temperature, density, and viscosity. You get the functionality of five or six instruments
— without the maintenance and reliability issues that can come with adding that many devices
to your segment.
Cost is also much lower for a multivariable device than for multiple individual devices, especially
when you include the costs for design and for multiple process penetrations.
Capacity restrictions in some host systems may limit the number of multivariable devices you
can put on one segment. And if the inputs from a multivariable device are used in controlling
valves or other final control elements on more than one segment, it may be better to use
separate measurement devices on each segment.
Host system considerations
As explained in the previous course, different hosts provide different levels of support for
FOUNDATION fieldbus. Those differences can affect your segment design.
Capacity limits. All hosts have capacity limits of some sort. Some have limits on the total
number of devices for a segment. Some limit the number of devices or function blocks for an H1
interface card. Some even have a fixed capacity for parameters.
Keep those limits in mind as you design your segments.
Outages for repairs. Ideally, a failed system component, such as an H1 card, can be removed
under power, its replacement installed, and the configuration of the card downloaded
automatically — all without affecting segment power. This capability is available in some
fieldbus hosts shipping today.
There are host implementations, however, that require the H1 card, or even the entire controller
card cage, to be shut down for repair, affecting a large part of the process. And there are
instances where a partial download isn't possible. In this case, the entire card cage must be
downloaded.
In either of these circumstances, a failure generally requires a shutdown. Keep that in mind as
you plan how many segments— and which ones — will be connected to each H1 card. More
important, select a host that doesn't have these limitations.
Note that both of the issues covered here — capacity limits and repair time — are limitations of
some host systems and not FOUNDATION fieldbus. Careful host selection can minimize
Design resources
Designing a fieldbus segment isn't hard — but it is different. Here are some additional ways to
make your first project a success:
• Use design tools. A segment design tool can help prevent errors because much of the
work is automated and has already been debugged. You can find good tools from
fieldbus product vendors. Just call them or go to their web site to see what's available.
• Get training. The Fieldbus Foundation, Southern Alberta Institute of Technology (SAIT),
ISA, and various process-automation suppliers (including Emerson) offer classes
ranging from fieldbus basics to engineering design to commissioning. Learning from the
experts can help you avoid costly and unnecessary mistakes.
• Consult an experienced fieldbus solutions provider. Especially on your first project,
working with someone who's "been there" is probably the best way to rapidly absorb the
do's and don'ts of fieldbus segment design. Some fieldbus solutions providers have
experience on hundreds of projects — or more. They can bring you up to speed quickly.
• Contact the Fieldbus Foundation at www.fieldbus.org. The Foundation has a wealth
of information on all sorts of issues relating to fieldbus. Their mission includes educating
people like you on the best ways to implement fieldbus.
Fieldbus 501
Commissioning
• Overview
• Staging
• Pre-configured or not?
• Using pre-configured devices
• Using unconfigured devices
• Tagging devices
• Attaching devices
• Calibration and scaling
Overview
How is the commissioning process different with fieldbus?
Compared to traditional analog technology, FOUNDATION fieldbus reduces commissioning

time and cost. Reduced commissioning time can mean an earlier startup, and therefore more
revenue.
In the analog world, commissioning is done one device at a time by two technicians with walkie-
talkies and multimeters. With FOUNDATION fieldbus, an instrument technician can attach
several devices to a segment in the field, while an operator watches the devices appear on the
control-room display — completely functional and ready to go.
This course provides tips on commissioning FOUNDATION fieldbus devices.
• What are the steps associated with the commissioning of fieldbus devices?
• What is an unconfigured device?
• How can you shorten commissioning time?

When you work with Emerson Process Management on a PlantWeb
project, you get the benefits of an architecture designed specifically for
FOUNDATION fieldbus — and all we've learned in over 1000 fieldbus
projects.
This can make a real difference in commissioning. Although FOUNDATION fieldbus offers
the potential to reduce commissioning time and cost by up to 90%, the FOUNDATION
fieldbus specifications don't cover how devices are to be commissioned. Actual
commissioning practices and host-system capabilities differ from vendor to vendor. As a
result, time required to commission fieldbus devices may vary.
The commissioning practices described in this section are based on our experience with
PlantWeb. Commissioning cost and time savings of 75% to 90% are typical.
Although PlantWeb can use these commissioning practices, solutions based on other host
systems may not. Ask your vendor about commissioning practices, references, and
examples.
Staging
As automation architectures become easier to integrate and install, staging is becoming less
common. If this is your plant's first fieldbus project, however, staging a small fieldbus system (or
part of a larger one) in a lab or office gives everyone a chance to gain familiarity with the
technology.
For example, instrument technicians can practice connecting devices and verifying device
operation and configuration. You could even simulate potential error conditions such as missing
or extra terminators so the technicians can get used to viewing and correcting these problems.
Operators also benefit from early hands-on experience. At many plants, they're part of the team
that develops displays and control strategies. At a minimum, give them time during staging to
become familiar with the system and verify both the operator interface and control action.
If possible, use a host system to simulate control and operation so operators can start, stop,
and step through the control strategy and displays before startup, even without the field devices
connected to the host. This is especially valuable for sequencing operations.
Taking advantage of the opportunity to train operators and technicians during staging can help
save time — and avoid problems — during actual plant installation and startup. It will also speed
acceptance of the new equipment and software.

The simulation capability of PlantWeb's DeltaV and Ovation automation systems
lets you run control configurations in PCs without I/O or devices.
You can use this capability to configure and debug control strategies, and operators can
generate and train on operating displays before the actual controllers and devices are
installed.
Pre-configured or not?
For a first-time fieldbus project, or a project with a tight timeline, buying devices that are pre-
configured with specific plant parameters can save you valuable time. That's because the
physical and software capabilities are already set up. All you have to do is install and verify the
devices.
You'll spend a little more time specifying these pre-configured devices because configuration
parameters must be communicated at the time of purchase. This means device tags and
operating ranges must be known prior to delivery, which isn't the case with unconfigured
devices.
You may also want to order the devices earlier so each pre-configured device is available
when it's needed. And you'll have to be careful managing device inventory — even for identical
devices — since each may have a different configuration.
Despite the few disadvantages of pre-configured devices, many people choose to go this way
because of the time savings.
Using pre-configured devices
Each pre-configured device must be installed in the specific plant location it has been
configured for.
You'll also need to set up the control strategy to access the field device at a specific tag and/or
address.
The easiest way to do this is with a host system that allows configuration of a placeholder with
the correct device type and tag in the host database — without the actual device being
connected.
Commissioning the device should then be as simple as
• Attaching it electrically to the segment, which causes fieldbus to recognize it as an

uncommissioned device with a tag.
• Using the configuration software to "drag and drop" the newly connected device onto the
appropriate placeholder. This creates the link between the physical device in the plant
and the configuration in the database.
• Uploading the device internal data from the device to the host, and downloading the
control strategy from the host to the device.
This is the process for using pre-configured devices in PlantWeb. It really is that
easy!
Using un-configured devices
Unconfigured devices are configured during commissioning. To do this,
• Connect the appropriate devices to a fieldbus segment. The system will recognize them
as uncommissioned devices.
• In the configuration software, drag and drop each device onto the appropriate segment.
• Assign the tag for a specific process location to the appropriate device.
• Load the configuration into the device.

This is the process used for commissioning unconfigured devices in PlantWeb
architecture.
And because the PlantWeb configuration tool AMS Suite: Intelligent Device Manager
supports
Next: offline
Tagging configuration,
devices > you don't have to wait for the device to arrive at the plant to
prepare its configuration. You can do it as soon as the configuration tool is available.
Tagging devices
A typical segment may have several unconfigured devices of the same type. For example, you
may want to attach three similar valves to the same segment before returning to the control
room to commission them. It's vital that each physical device be given the correct tag and
configuration, and linked to the correct control strategy.
One way to manage this is to use a two-part instrument tag attached to the field device at the
factory.
The two-part tear-away tag has the device serial number printed on each part. When an
instrument technician attaches a device to a segment, he writes the plant tag on the removable
portion of the physical tag. Then he separates the tear-away portion to take back to the control
room.
When he gets there, he looks at the list of uncommissioned devices on the host operator
interface. The individual device serial numbers printed on the tear-away instrument tags he's
holding will be shown on the display. The technician now knows which devices are in specific
plant tag locations, and thus can correctly commission the devices.
Other methods may also work. This method has proven successful in a large number of
installations.
Attaching devices
When you attach a fieldbus device to a segment, it's recognized by the system but identified as
uncommissioned. Fieldbus allocates four addresses for uncommissioned devices, which means
you can attach and then commission four devices at a time. Some hosts don't support this,
requiring you to commission every device as it's attached.
For one person working alone, attaching and commissioning 16 devices therefore requires 4 to
16 trips to the field. Two people working together — one in the field and one in the control room
— still do the job four devices at a time, but without all the back-and-forth trips.
AMS Suite: Intelligent Device Manager software in DeltaV and Ovation allows you
to commission more devices at one time by reserving some of a segment's 32
operating addresses for uncommissioned devices.
Sixteen addresses are reserved for uncommissioned devices, and 16 addresses are used for
commissioned devices. This approach allows all the devices on a segment, up to 16, to be
attached at one time.
As a result, a technician can connect a large number of devices to many segments without
requiring that someone always be available in the control room to commission the devices as
they are attached.
Calibration and scaling
Calibration is often associated with analog devices. It's therefore sometimes assumed that
digital fieldbus devices don't need to be calibrated. Many do.
With analog devices, calibration compensates for inaccuracies in three parts of the device:
• Sensor or actuator
• Device electronics
• Analog communications signal.
Fieldbus devices have no analog communications signal, eliminating that source of error.
However, on many devices the sensor or actuator, and the device electronics, can have errors.
So calibration is still sometimes required.
With an analog device, such as a transmitter, the output is scaled so that the expected
operating range uses the entire 16 mA of a 4-20 mA signal. This minimizes the effect of error in
both the transmitter analog output and the host analog input. However, it's common to see
errors resulting from a mismatch between the scaling of the field device and the host.
With digital fieldbus devices, output scaling isn't required — so there's no such mismatch.
Fieldbus does require that the unit of measure be the same in both the device transducer block
and the function blocks.
Fieldbus 502
Checkout and troubleshooting

• Overview
• Wiring check
• Voltage check
• Signal check
• Signal waveforms
• Recognizing common errors
Overview
How can I make sure the network works as it should?
After installation is complete, the next step toward ensuring a successful startup is checkout and
(if necessary) troubleshooting the network. These procedures help eliminate potential network
communication problems.
Checkout generally includes testing both the wiring and the communication signal using
standard tools like a multimeter, capacitance meter, and scope meter.
This course provides guidelines for basic checkout procedures, including troubleshooting
common problems.
• What are the expected resistance and capacitance values for fieldbus wiring?
• Why might you need more than the minimum voltage on a segment?
• What's one way to determine the possible cause of a communication error?

Wiring check
This part of the process involves checking resistance and capacitance for
• Conductor to conductor
• Conductor to shield
• Conductor to ground
• Shield to ground
Before you begin, make sure all the parts of the segment are connected. That includes all
wiring, terminators, and field devices — but DON'T connect the segment power connector
during the wiring check.
With a multimeter, check the following resistance levels.
• + Signal to - signal 50 K ohms

• + Signal to shield >20 M ohms
• - Signal to shield >20 M ohms
• + Signal to instrument ground >20 M ohms
• - Signal to instrument ground >20 M ohms
• Shield to instrument ground >20 M ohms
You should also lift the shield from the ground and check the isolation between the shield and
the ground. The value should be greater than 20 M ohms.
Check capacitance wherever you have long wire runs or where fieldbus will be installed on old
wiring. Capacitance values should be
• + Signal to - signal ~1 µF
• + Signal to shield <300 nF
• - Signal to shield <300 nF
• + Signal to instrument ground <300 nF
• - Signal to instrument ground <300 nF
• Shield to instrument ground <300 nF
If everything checks out to be within these limits, then the basic wiring for your segment is good.
Voltage check
After ensuring the segment wiring checks out, next examine the segment power.
Remember that the power connector was disconnected for the wiring check. Re-attach it now
for the voltage check.
Check voltage at
• The power supply

• The H1 host interface card
• The individual field devices.
The voltage level between all the positive (+) and negative (-) signal wires must be between 9
and 32 Vdc.
Practical pointer
It's a good idea to make sure the lowest voltage on the segment is at least 1-2 Vdc higher
than the minimum 9 Vdc. This gives some buffer for low voltage conditions.
Generally, as the distance increases between devices on the segment and the power supply,
the voltage on the bus drops. Any device whose voltage varies significantly from other devices,
or any significant voltage drop that is not associated specifically with the distance to the power
supply, indicates a possible wiring problem.
If you anticipate a segment extending long distances beyond the current end point, then you
should either plan for a higher level of power at the current end point, or make provisions for a
powered repeater.
Signal check
Problems can arise when wiring isn't consistently set up according to the rules. For example, a
high rate of message retries, especially from a single device, indicates a potential wiring
problem.
Fortunately, signal checks can help you easily detect and diagnose situations like this.
Three error conditions account for most of the problems not detected by a resistance, voltage,
and capacitance check:
1. Not enough terminators on the segment.

For example, the type of power conditioner used may not have the terminator that's needed
for use in a fieldbus installation.
2. Too many terminators on the segment.

A terminator may have been added unnecessarily when one already existed as an optional
component in another device, such as a power conditioner. Or a segment may have been
extended without moving or removing the existing terminator.
3. Excessive trunk or spur length.
Excessive trunk or spur length can be caused by cable runs that are significantly longer than
the line-of-sight distance between the two ends of the segment. This can happen because
cable trays tend to follow a vertical / horizontal grid pattern and often change height. This
can make the actual length as much as double the perceived length.
Mixing wire types in a segment can also make your segment 'electrically' much longer than you
expect.
Some FOUNDATION fieldbus hosts provide communications statistics to help diagnose these
errors.
Signal waveforms
Fortunately, signals have easily recognizable signatures — or waveforms —- that you can use
to quickly identify the signal and any problems associated with it. A normal signature is shown
below.
A normal signal will have wave shapes that are well formed and are defined by
• A linear up-slope
• A well-defined wave top
• A linear down-slope
• A well-defined wave bottom
The up- and down-slopes will be symmetrical, and the top and bottom will be relatively flat and
free from spikes.
A good waveform will also have a nominal peak-to-peak voltage of 0.8 to 1.2 volts.
The signature in the illustration is well-formed and shows just more than 0.8 volts, so in this
case everything is fine.
Recognizing common errors
FOUNDATION fieldbus is very robust. Many segments can operate despite the presence of
waveform error conditions, but the overall reliability of the segment will be reduced. These
errors will commonly appear as an excess number of message retries.
Many of these errors can be diagnosed by using a scopemeter to check the communication
waveforms. Here are some of the errors you may see -- and what our experience has shown to
be the most common causes.
Missing terminator. If the waveform shows peak-to-peak signal strength to be twice as large
as the normal 0.8 to 1.2 volt, you may be missing a terminator on the segment.
There are two common reasons for missing terminators.
The first is that many fieldbus components such as power conditioners have built-in terminators
that can be switched in or out. Often a terminator that is intended to be switched in is in fact
switched out. This frequently happens after a repair or maintenance activity where the
component with the terminator is replaced.
The other common reason is that a segment is extended beyond its original end point. The
terminator at the old end point is removed, but the terminator is not installed at the new end
point.
Less common reasons include failing to terminate after an isolating safety barrier, or failing to
secure the terminator sufficiently and having it fall out.
Too many terminators. If the waveform peaks are shorter than normal, there may be extra
terminators somewhere on the segment.
This problem can occur when a technician doesn't realize that a fieldbus component such as a
power conditioner has a terminator in it, and adds another terminator.
It also happens when someone extends a segment, adds a terminator at the new segment end,
and forgets to remove the terminator at the old end location.
Excessive spur or segment length. A waveform with rounded peaks — rather than flat,
horizontal areas at the top and bottom — may indicate that a spur or segment is too long.
The most common causes of excessive length are
• using conduit and cable tray routes that are much longer than line of sight
• mixing wire types without considering the different maximum length specifications for
different wire types
• using wire that is very old and in poor condition.

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©2002 Emerson Process Management. All rights reserved. View this and other courses online at www.PlantWebUniversity.com.

Introduction to FOUNDATION fieldbus

• What is FOUNDATION fieldbus?

• The digital bus advantage

• Safe and effective process control

Why should I care about FOUNDATION fieldbus?

• Who controls FOUNDATION fieldbus technology?

• For what kind of application was FOUNDATION fieldbus originally designed?

What is FOUNDATION Fieldbus

FOUNDATION fieldbus is an all-digital, serial, two-way communications system that serves as

• H1 works at 31.25 Kbit/sec and generally connects to field devices. It provides

As a digital bus, FOUNDATION fieldbus doesn't have those limitations.

The PlantWeb advantage

FOUNDATION fieldbus is covered by standards from three major organizations:

How do you know it's interoperable? Instruments can earn "registered"

Host interoperability testing. Host systems undergo Foundation-supervised tests to

Fieldbus 201 covers interoperability in more detail.

Safe and efficient process control

• It can withstand the harsh and hazardous environment of process plants.

In short, it's designed to operate where your process does.

• The communications model

• Data link and application layers

• Link active scheduler

• Device address assignment

• Find tag service

• What kinds of information are transmitted using unscheduled communications?

• How does FOUNDATION fieldbus improve alarm and event time-stamping?

The communications model

The FOUNDATION fieldbus communications model has three parts:

• The physical layer

Data link and application layers

These scheduled (also called "cyclic") communications use a publisher/subscriber method.

• Configuration information sent to devices or a central database

FOUNDATION fieldbus supports a variety of data redundancy checks to avoid message-bit

The PlantWeb advantage

In a PlantWeb architecture, the DeltaV and Ovation systems read device

• Control strategies can be configured to modify their control action depending on

• Advanced Control strategies such as Model Predictive Control or Neural Network

• AMS Suite applications present the information to maintenance

Every device on a FOUNDATION fieldbus segment shares the same time.

Device address assignment

The PlantWeb advantage

• Multiple loops on the same segment

What makes each control action happen when it should?

FOUNDATION fieldbus solves this problem by executing control on a deterministic, real-time

This course summarizes how FOUNDATION fieldbus does this.

• What determines when a function block or communication action begins?

• How can you accommodate both fast and slow loops?

In FOUNDATION fieldbus, control-related communications and function blocks execute at

PlantWeb architecture makes loop scheduling a breeze. Scheduling is

Multiple loops on the same segment

• What is a resource block?

• What is a transducer block?

• What is a function block?

• FOUNDATION fieldbus function blocks

• Basic FOUNDATION fieldbus function blocks

• Advanced FOUNDATION fieldbus function blocks

• How do function blocks get into devices?

• Instantiating blocks into devices

What are fieldbus blocks? And what do they do for me?