Basics of PROFIBUS / PROFIBUS PA en laatste updates

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1 De PROFINE, PROFIBUS & IO-Link dag Basics of PROFIBUS / PROFIBUS PA en laatste updates 2013 Jaap Westeneng Product Manager Asset Management

2 wo echnologies, One Organization Process Fieldbus More than 40 million installed devices. About 5.4 million in the process industry. he German PROFIBUS user organization (PNO) is an RPA and a permanent PI Support Center (PISC) (Karlsruhe, Deutschland): administers global activities PROFINE: 4.3 million installed devices, end of 2012

3 echnical Milestones 2010 First certified PA Profile 3.02 device 2008 Specification PROFIBUS PA Profile First PROFIBUS Coupler with embedded physical layer diagnostics 2005 I+M Function implemented for PROFIBUS PA 2004 PROFINE IO based on Real-ime & synchronized real-time 2002 PROFIBUS DP-V2 and PROFINE part of IEC 61158/IEC 61784; 10 profiles available 2001 Presentation of the Ethernet-based PROFINE (CBA) ,000 PROFIBUS devices in process automation 1999 PROFIsafe Profile for safety technology, PROFIdrive Profile for variable-speed drives 1998 PROFIBUS PA Profile for process automation 1996 PROFIBUS becomes European Standard EN st application in process automation (PA) 1993 PROFIBUS DP becomes DIN (Part 3) 1991 PROFIBUS becomes DIN (Part 1 and 2)

4 Product Spectrum Industrial PCs Frequency converters Ident systems Remote I/O Image processing Drives Displays Pressure sensors Encoder DCS PLC Scada ransmitters emperature sensors Flow meters Ranging sensors HMI Analyzers Light lattices Barcode scanners More than 5,000 products overall from more than 250 manufacturers

5 Development of Digital Communication Analog transmission of process value Analog transmission of process value and parameters Digital transmission of process value A/D HAR- Modem DP D/A D/A C C C C ma ma with HAR 1987 PROFIBUS DPV0 1991

6 Development of Digital Communication Digital transmission of process value and parameters Integration of fieldbus devices into Plant Asset Management Integration of Industrial Ethernet into automation environment PAM PAM PAM PAM DP DP PROFINE ProfiNet/PA PROFINE/ PA PA PA PA 1997 PROFIBUS DPV1 extension PROFIBUS PA, Profile 2.0 International Standardization Profile 3.0X 2000 PROFINE / PROFINE IO 2004

7 What is a fieldbus? he fundamental task of a fieldbus is to exchange information: In digital form With less wiring (unlike point-to-point connections ) with a group of participants (hence bus ) In a reliable way In real time

8 Communication layers (OSI model) Specific application profiles Layer 7 PA Devices PROFIdrive Encoder etc. SEMI RIO for PA Weighing & Dosing Common application profiles PROFIsafe imestamp Redundancy HAR on PROFIBUS Layer 3-6 Layer 2 Layer 1 Not in use Communication technology PROFIBUS DP (DP -V0, -V1, -V2) ransmission technology (RS-485 / Fiber optics / MBP, MBP-IS) MBP = Manchester Bus Powered

9 Architecture PROFIBUS DP/PA PLC/DCS Commissioning tool PROFIBUS DP Segment coupler PROFIBUS PA

10 Comparison PROFIBUS DP/PA Application PROFIBUS DP Decentralized Peripheral PROFIBUS PA Process Automation Protocol Common DP protocol: fast cyclic process data transmission acyclic services to access device parameters two defined master classes Physics RS kbit/s MBP kbit/s MBP = Manchester encoding, Bus powered

11 PROFIBUS DP PLC/DCS Commissioning tool PROFIBUS DP PROFIBUS DP based on line topology

12 PROFIBUS DP PLC/DCS Commissioning tool PROFIBUS DP PROFIBUS DP based on line topology

13 PROFIBUS DP / Extension repeater Segment 1 31 Devices + 1 Rep repeater Segment 2 30 Devices + 2 Rep Segment 3 30 Devices + 2 Rep

14 PROFIBUS DP PLC/DCS Commissioning tool PROFIBUS DP PROFIBUS DP based on star topology

15 Facts: physical transmission via RS wire cable, shielded 5V differential voltage signal Max m line length per segment (depending on transmission rate) Max. 5 segments connected via repeater (depending on product type) Max. 126 addresses possible Max. 32 nodes per segment Alternatively fiber optic cable No reverse-connect protection A separate power supply is necessary for each device!

16 PROFIBUS DP maximum line length ransmission Rate (kbit/s) Max Segment Length (m) , 6000, he values refer to Cable ype A with the following properties: Impedance Ω Capacity < 30 pf/m Loop resistance 110 Ω/km Wire diameter 0.64 mm Core cross-section > 0.34 mm 2

17 PROFIBUS PA PLC/DCS Commissioning tool PROFIBUS DP Segment coupler PROFIBUS PA

18 Facts: PROFIBUS PA Remote power supply and communication in 2-wire technology (optional intrinsically safe) Integrated reverse-connect protection possible (e.g. E+H) Fixed transmission rate of kbit/s Up to 32 participants per segment (up to 10 for Ex-ia IIC applications) Line length up to 1900 m (Ex-ia IIC up to 1000 m)

19 PROFIBUS PA / opology PROFIBUS DP RS 485 PROFIBUS PA MBP Max m U BUS = 24 V I BUS = < 500 ma PROFIBUS DP RS 485 PROFIBUS PA MBP-IS Max m U BUS = 13.5 V I BUS = < 110 ma for ia / ib IIC

20 PROFIBUS PA / opology PROFIBUS DP (RS 485) Max. total length 1900 meter (all spurs+trunk) runk line Spur PROFIBUS PA hese lengths are rules of thumb. Longer is very often possible. Amount of devices per Segement 1 Device per Spure 2 Devices per Spure 3 Devices per Spure m 1 m 1 m 1 m m 1 m 1 m 1 m m 30 m 1 m 1 m m 60 m 30 m 1 m m 90 m 60 m 30 m 4 Devices per Spure

21 PROFIBUS PA / topology PROFIBUS DP (RS 485) Line construction with spur runk line Spur PROFIBUS PA Ex-ia II C Max. total length 1000 meter (all spurs +trunk) No. of nodes 1-10 Max. spur length (each) 60 m

22 PROFIBUS PA / topology PROFIBUS DP (RS 485) Line construction with spur runk line Spur Multibarrier PROFIBUS PA Multibarrier Ex-ia II C Max. total length 1900 meter (all spurs +trunk) No. of nodes 16 Max. spur length (each) 120 m

23 Protocol conversion Segment Couplers PROFIBUS DP RS 485 DP PA PROFIBUS PA MBP Segment Coupler Asynchronous format NRZ coding 1 Byte 11 Bit (1 start + 8 Bit + 1 Stop + 1 Parity) Bitrate variable 9.6 Kbit/s to 12 Mbit/s Synchronous format Manchester Coding 1 Byte = 8 Bit Fixed bitrate = Kbit/s

24 SIEMENS DP/PA Link IM (IM 157 old version) 1..5 DP/PA Coupler(s)

25 SIEMENS DP/PA Coupler Qualities wo variants of the DP/PA coupler: Ex and Non-Ex Converts the signals from DP (RS 485) to PA (MBP) ransparent for master and slave Fixed transmission rate of KBit/s on DP side Contains termination on PA side with on/off switch Powers the PA field devices

26 SIEMENS DP/PA Link Qualities he LINK contains at least one IM153-2HF (former IM157)module and one DP/PA coupler he IM153 module contains a DP Slave and a PA Master subsystem the Link acts for the DP Master as a normal DP Slave device the Coupler acts for the PA Slaves as the master device max. I/O range sum for all PA devices: 244 Byte Input Byte Output Address range on PROFIBUS-DP between Address range for slaves on PROFIBUS-PA side from Up to 5 DP/PA couplers can be connected to one IM157 module ransmission rate 9.6 kbit/s to 12 Mbit/s

27 Pepperl+Fuchs SK3 PROFIBUS Power Hub Coupling of PROFIBUS DP with PA PROFIBUS DP: kbps 12 Mbps Automatic transmission rate detection Cyclical data interchange over buffer ransparent PROFIBUS PA: Independent cycle One bus master per segment, very fast No configuration required Advanced Diagnostics (More information in the chapter diagnostics )

28 Pepperl+Fuchs Compact PROFIBUS Power Hub Gateway for PROFIBUS DP/PA kbps 12 Mbps ransparent Needs no configuration wo independent fieldbus segments Motherboard design

29 PROCENEC Combricks

30 PROFIBUS PA Profile 3.01 Market Requirements Device Integration Fast Parameter ransmission Version Handling Up/ Download Solution Profile V Safety Device diagnostics Device identification PROFIsafe for PA Condensed Status I&M Functions Amendments Standard field devices for process automation Separate document (Consistent with PROFIsafe) Profile V /5 Profile V

31 Different Views of Diagnostics Asset Management Process Control

32 Different Views of Diagnostics Asset Management Status signals according to NE107 Failure Maintenance request Check Out of Specification Process Control PLC Interface BAD UNCERAIN GOOD Diagnostic Event

33 Condensed Status & Diagnostic Messages Maintenance Required Failure Functional Check Out of Specification Host Application, e.g. Process Control, Maintenance, Condition Monitoring PROFIBUS Field Devices Detailed Diagnostic Events

34 Configurable Mapping Mapping of device diagnostics to the process application must be configurable e.g. echo lost OK DIAG_EVEN_ SWICH Failure Echo Lost Default Example: Maintenanc e required Check Out of Specification

35 PROFIBUS PA Profile 3.02 Market Requirements Device Integration Fast Parameter ransmission Version Handling Up/ Download Solution Profile V Safety Device diagnostics Device identification PROFIsafe for PA Condensed Status I&M Functions Amendments Standard field devices for process automation Separate document (Consistent with PROFIsafe) Profile V /5 Profile V

36 Most important improvement by PA Profile 3.02 Automatic Ident Number Adaptation (used by cyclic communication) Easy handling of device exchange during plant runtime No GSD file exchange necessary No plant shutdown because of required PLC download Old.gsd New.gsd Replacement device. New type, different Ident. number

37 Device Integration Ease: Ident Number Adaptation Automatic overtaking of roles from former device versions Assignment Device ype Ident Number Process Control System Ident Number 1547 GSD Ident Number Adaptation , 1547 Ident Number Default:1547 Additional: 9700 Device Replacement Ident Number Default: 1591, Additional: 1547, 9700

38 PA Profile GSD vs. manufacturer-specific GSD PA Profile 3.x devices are compatible with the: Manufacturer-specific GSD and the PROFILE GSD! he device can either operate with the manufacturer-specific GSD or with the PROFILE GSD. PROFILE either or manufac. GSD Using the PROFILE GSD, functionalities may remain unused!

39 PA Profile / Manufacturer-Specific GSD Every PROFIBUS device receives a unique IDEN_NUMBER. IDEN_NUMBER in the device and of the GSD must be the same. IDEN_NUMBER issued by the PROFIBUS User Organization (PNO). If a field device is selected to work as a Profile device, it must be set by an acyclic tool to Profile Mode. Once a device is set to Profile Mode, it automatically changes its Ident_Number from manufacturer-specific to the corresponding Profile Ident_Number. EH3_152D PA PA gsd

40 Automatic Ident Number detection function Example: M84

41

42 Which is the right fieldbus? Requirements of a fieldbus system used in industry: Open and standardized Robust Ease of installation and commissioning High degree of freedom in installation Exchange and connection of new devices during operation Can be used in hazardous areas (Ex) Fulfills real-time requirements Reliability..

43 Benefits of a fieldbus conventional Digital Control System (DCS) I/O module PROFIBUS Digital Control System (DCS) Master / bus coupler Ex [i] marshalling rack Ex [i] cabinet marshalling rack junction box One single cable connection elements

44 User benefits and cost savings What additional benefits are there for the user? Are there cost savings with PROFIBUS PA in Purchasing Engineering Installation Maintenance? For the modernization, extension or revamping of process plants??

45 User benefits No scaling necessary Conventional Fieldbus 5bar 5bar 3bar 20mA bar 0bar 4mA 0bar Full resolution of process value over the entire physical measuring range e.g. Pressure membrane 0-5 bar

46 User benefits Higher precision of process value Conventional Fieldbus 11.53mA (= 5.5 meter) Process Value meter

47 User benefits Multivariable devices Conventional Fieldbus One PV per outlet or cable e.g. Density Several PVs over the bus Density emp. Flow Counter

48 User benefits Parameterization of field devices via PROFIBUS from operator station Conventional Fieldbus Parameterization from the control room Parameterization in the field on the device

49 User benefits Diagnostic data Bidirectional communication (device PLC/DCS) Predictive maintenance Customized diagnostic Devices offer substitute process value if device fails Failure Maintenance request Check Out of Specification Empty pipe detection Sensor drift Dirty pipe, please clean Maintenance needed...

50 Cost savings: Maintenance Costs Plant and Life Cycle Management

51 Cost savings: Purchasing costs Reduction of I/O modules (purchasing costs) No more marshaling racks (purchasing costs) Only one Ex-barrier per bus segment (purchasing costs) Fewer switching cabinets (purchasing costs) Fewer space for switching cabinets (purchasing costs) PLC/DCS PC PROFIBUS DP Coupler/ Link PROFIBUS PA

52 Balancing benefits and additional investments Additional Investments: Slightly higher field device costs Configuration of the PROFIBUS system in the PLC/DCS configuration tool Build up know-how about the technology, training! (wiring, functionality ) Specific tools for maintenance and inspection Additional investments Benefits cost savings

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