Electric actuators. with fieldbus interface. Information

Transcription

1 Electric actuators with fieldbus interface Information

2 Applications AUMA actuators are used wherever the flow through pipelines has to be controlled or regulated. They are the crucial link between the process control system and the valve. Fieldbus systems are increasingly used for communication in all industries. AUMA actuators come with the suitable interface for all common bus systems. Energy : Power plants : Air pollution control : District heating : Pipelines : Water works : Sewage treatment plants : Pumping stations : Dams : Chemical industry : Petrochemical industry : Pharmaceutical industry : Air conditioning : Ship building industry : Steel mills : Cement plants : Food industry 2

3 Contents General fieldbus information Structures in automation systems 4 Digital transmission 4 Advantages of fieldbus 5 Fieldbus cables/ installation 6 Transmission rate/ cable length 6 Device integration 7 Profibus DP Modbus RTU DeviceNet Foundation Fieldbus AUMA actuators with fieldbus interfaces Modular concept 16 Characteristics of AUMA fieldbus interfaces 17 Fieldbus connection non-explosion-proof actuators 18 Fieldbus connection explosion-proof actuators 19 SIMA master station SIMA: Fieldbus master and actuators from a single source 20 AUMA presales & after-sales AUMA technical fieldbus support 22 AUMA fieldbus service 22 Links & literature Solutions for a world in motion This brochure is intended for project engineers and purchasing managers who would like to use AUMA actuators with fieldbus interfaces. It offers an introduction to fieldbus technology, an overview of the fieldbus systems supported by AUMA and in particular the fieldbus-specific features of AUMA actuators. As early as the late 1980s, AUMA was actively involved in the development of the fieldbus standards. In 1993, the first AUMA actuator with fieldbus interface Profibus FMS was available. AUMA was one of the pioneers of fieldbus development for electric actuators. AUMA does not only want to provide a fieldbus interface: the features and functions defined by the corresponding fieldbus protocol should be used to the full for the benefit of valve automation. Further developments in fieldbus protocols are thoroughly checked for their potential usability in actuators and implemented accordingly. Due to AUMA s modular product range, any AUMA multi-turn, part-turn and linear actuator can be delivered with fieldbus interface. The process integration of almost any valve via fieldbus is possible. 3

4 General fieldbus information A fieldbus is an industrial communication system, connecting a variety of field devices such as transducers (sensors), MOVs and actuators (drives) with a control system. Fieldbus technology was developed in the 1980s to replace the parallel wiring of binary signals which was common at that time as well as analogue signal transmission by digital transmission technology. Today, many different fieldbus systems with different characteristics have become established on the market, e.g. Profibus, Interbus, ControlNet, or CAN. Since 1999, fieldbus systems worldwide have been standardised according to IEC Digital data communication for measurement and control Fieldbus for use in industrial control systems ). Structures in automation systems At least one control system and often several transducers and MOVs are required to control a system. If the control is to be performed electrically, the question is how the transducers and the MOVs should be connected to the control system. Two basic variants are possible: A separate signal channel is established from the control system to each transducer and each MOV (parallel wiring). The signal exchange between control system and several transducers and/ or MOVs is implemented via a common 2-wire cable (serial wiring). The higher the level of automation of a plant or machine, the larger the number of cables for parallel wiring due to the increased number of input and output points. Implementation, installation, commissioning and maintenance become time consuming. The demands placed on the cables are often high, e.g. special cables have to be used for the transmission of analogue values. Parallel wiring therefore becomes an essential cost and time factor in automation technology. In comparison, serial wiring on the field level using so called fieldbus systems have a considerable potential for simplification. The fieldbus replaces the parallel trunk groups by a single bus cable and connects all levels, from the field to the process control level. Whatever the automation device, e.g. programmable logic controls (PLC) from different manufacturers or computer-based controls, the fieldbus transmission medium links all components. The devices can be located anywhere in the field. Fieldbus therefore provides a powerful communication network for state-of-the-art modernisation concepts. Digital transmission Only digital information is transmitted in fieldbus systems. Analogue setpoints or measured values are converted into digital values before transmission via bus. The digital signals are generally less susceptible to interference than values subject to analogue transmission. Integral verification mechanisms additionally improve transmission security, e.g. by using checksums or acknowledging the receipt of information to the sender. 4

5 Advantages of fieldbus Parallel wiring: Multi-core cables for each device. This results in many input and output subassemblies within the control cabinet for connecting the field devices with the control system. Serial wiring fieldbus: A single 2-wire cable for all devices. The multitude of input and output subassemblies are replaced by a single fieldbus interface. Fieldbus systems have many advantages compared to parallel wiring: Reduced wiring saves time during planning and installation. Digitalisation of analogue values improves the protection against disturbance of signals. Cables, marshalling rack and dimensions of the control cabinet will be reduced. Reducing the components reduces the documentation at the same time. More information can be transferred using fewer wires. Self-diagnosis of the devices via fieldbus reduces downtimes and maintenance times (asset management). Digitally collected measurement values and digitally generated setpoints can be processed directly without further signal conversion. Open fieldbus systems standardise data transmission and device integration of different manufacturers the user is not restricted by the standards of the individual manufacturers. Expansions or changes can easily be performed guaranteeing flexibility and therefore security for the future. The following aspects have to be considered when implementing a fieldbus system. Qualified personnel required for installation and com- Special measuring and diagnostic equipment required. missioning. Increased price of components with fieldbus functions will be compensated by the potential savings of fieldbus systems. Slightly increased response times (can usually be ignored in process automation) 5

6 General fieldbus information Fieldbus cables/ installation Cable types Data transmission via fieldbus cannot be implemented on any cable. Cable types are specified for each fieldbus system. Due to the low data transmission rate, the requirements for Foundation Fieldbus are comparatively low; DeviceNet requires more complex cables as the bus specification requires a separate supply voltage within the same cable. Installation Data transmission on field bus systems are performed with low signal levels, e.g. +/ 5 V. The installation has to be performed thoroughly to ensure fault-free data transmission. This applies to screening, potential equalisation, observance of the max. permissible cable lengths, correct setting of the bus terminations and addresses of the field devices. Observing the installation guidelines ensures that all field devices on the bus can be smoothly commissioned. Transmission rate/ cable length Most fieldbus systems specify several data transmission rates which are indicated in kbit/s. Although it seems to be reasonable to select the highest data transmission rate, this is, however, at the expense of reduced cable length. The higher the transmission rate and the longer the cables, the higher the sensitivity and susceptibility to interference. For each plant, the ideal compromise between cable length and transmission rate has to be determined. Therefore, a lower transmission rate has to be selected for a sewage treatment plant with long distances than for applications where field devices are very close. Fibre optics As an alternative many fieldbus systems provide data transmission via fibre optic cables (FO). Longer distances can be covered than with the cable types described in the fieldbus specifications. An electric opto-coupler converts the fieldbus signal into an optical signal and vice versa (receiver). The number of repeaters or segments is limited. Furthermore repeaters are also used: km to implement drop lines. to create another bus segment if the maximum number of connectable devices per segment has been reached. Repeater/ Extender Generally speaking, repeaters or extenders are amplifiers which extend the cable length of a fieldbus segment. The section between the control system and the first repeater or between two repeaters is called a segment. m kbit/s Data transmission rate MBit/s 6

7 Device integration Commissioning Contrary to conventional wiring where different signals do not interfere with each other and do not require a chronological order, fieldbus devices have to adhere to strict organisation principles to ensure fault-free communication via the common data transmission medium. This can be achieved by determining the communication parameters. During commissioning the parameters for each device connected are determined in the master. During system start-up the parameters are sent to the field devices. The programming of the parameters is based on the electronic data sheets provided by the field device manufacturers, e.g. GSD (Generic Station Description) for Profibus DP. Commissioning example (Profibus DP) [1] The commissioning engineer requires the GSD files of all field devices involved which can be downloaded from the websites of the Profibus user organisation or of the device manufacturers, for example. GSD files contain information on the supported Profibus communication parameters of the devices such as the data transmission rates, data lengths [2] The commissioning engineer determines the communication parameters for all devices and stores them in the Profibus DP master, in our example a PLC with Profibus DP interface. [3] When switching on the master and/ or the field devices the determined communication parameters are matched with the field devices. Process data may then immediately be transmitted via the bus. During operation In addition to the central delimitation of communication parameters, field device configuration can be influenced online: the process behaviour, e.g. of an actuator, can be changed from the control room. The operating behaviour of the field devices can be optimised during operation without gaining access to the device. At the same time, diagnostic information is available, helping to optimise the device parameters with regards to an extended lifetime or enabling more efficient maintenance. The remote parameter setting is only possible if the fieldbus supports the corresponding services, i.e. acyclic DP-V1 services for Profibus DP. There are different concepts for the various fieldbus systems. [1] The device integrations such as EDD or DTM provided by the field device manufacturers are installed on the control and monitoring station within a standardised software environment. [2] From the control room, diagnostic data of the selected device can be read or parameters be changed. 7

8 Profibus DP Profibus FMS was developed from 1987 to 1989 within the framework of a co-operation project (industry, research institutes and the German federal office for research) and was translated into the DIN standard (the standardisation process was continued with the provisions of EN and IEC 61158). Further successive developments included Profibus DP, Profibus PA, Profibus DP-V1 and DP-V2, as well as ProfiNet. Topology The basic structure for Profibus DP topology is the line. Repeaters (R) can be used to implement drop lines to one or more field devices. Furthermore the repeaters can be used to connect different bus segments. Profibus systems can thereby be extended beyond the maximum cable length per segment. Control system Profibus DP Master (PLC) Development or notified certification body Concept/ communication principle Bus features Profibus Nutzer Organisation (PNO) Typically master-slave (for mono-master systems), additionally also master-master for multi-master systems. Use of request-response mechanisms for cyclic data transmission and DP-V1 services for acyclic data transmission. Applications Predominantly in machine and plant engineering as well as production automation. Due to the quick data transmission and the, in principle, simple and robust physical data transmission system (RS-485), Profibus DP can be used for various applications. Versions Profibus FMS, (FMS = Fieldbus Message Specification), the first Profibus version, is rarely used at the field level today. Profibus DP (DP = Decentral Periphery), often called Profibus DP-V0 today, cyclic data transmission for quick data exchange. Profibus DP-V1, introduction of special DP-V1 services for acyclic data transmission (programming and device diagnosis via Profibus). Profibus DP-V2, a generic term for further Profibus functions such as Isochron Mode (IsoM), Data Exchange Broadcast (DxB), time synchronisation (Time_Stamp), redundancy concept (redundancy) as well as upload and download. Profibus PA (PA = Process Automation), a version which has been specially adapted to the requirements of process engineering, among others, to make the bus intrinsically safe for the use in plants in potentially explosive atmospheres. ProfiNet, Profibus based on Ethernet technology. AUMA actuators currently support Profibus DP-V0 and DP-V1. Physical layer Maximum number of devices Typical number of devices RS-485, alternatively: FO 126 (125 field devices and a Profibus DP master), Without repeaters, a maximum of 32 devices per Profibus segment Depends on the plant; typically devices; for more devices, a second Profibus DP network is usually installed. 8

9 Field level with field devices Typical bus cycle time Data transmission rates of the bus Max. cable lengths without repeater Max. cable lengths with repeater Redundancy concepts Device integration/ remote programming of the slaves Fieldbus termination Bus features approx. 140 ms, for 30 actuators, the usually required process data (4 bytes input and 4 bytes output) and at kbit/s 9.6 kbit/s to 12 MBit/s Recommended baud rate: kbit/s (if required: also kbit/s). For these transmission rates, the maximum cable length is reached at considerable transmission speeds. AUMA devices support transmission rates up to 1.5 Mbit/s. max. 1,200 m (for baud rates exceeding kbit/s), 1,000 m at kbit/s 500 m at 500 kbit/s, 200 m at 1.5 MBit/s approx. 10 km (only applies to baud rates exceeding 500 kbit/s), approx. 4 km (at 500 kbit/s) approx. 2 km (at 1.5 MBit/s) The maximum cable length which can be implemented depends on the type and the number of repeaters. Usually, a maximum of 9 repeaters can be used in a Profibus DP system. Under the generic term of the Profibus DP-V2 services, there is a slave redundancy specification (2.212). This specification stipulates the behaviour of a redundant Profibus DP slave in detail. AUMA actuators are optionally equipped with a redundant Profibus DP interface. Today, many DCS still do not support redundancy or have their own redundancy concepts. Current redundant solutions have to be matched in the run-up to commissioning. Remote programming is done using the acyclic Profibus DP-V1 services. The device integration is implemented using an EDD (in combination with Simatic PDM in Siemens process control systems). using a DTM (in combination with an available FDT interface in the process control system) Both technologies are supported by AUMA. The RS-485 specification stipulates termination resistors at the beginning and at the end of each RS-485 segment. The resistor network has to be supplied with 5 V DC. On the master level, the supply voltage is provided by the master and on the field level by the field devices. AUMA products provide these fieldbus termination resistors and do not require external termination resistors. 9

10 Modbus RTU In 1979, Modbus was developed by Gould-Modicon (today Schneider Electric) and has turned into a de facto standard. Topology The basic structure for Modbus RTU topology is the line. Repeaters (R) can be used to implement drop lines to one or more field devices. Furthermore the repeaters can be used to connect different bus segments. Modbus systems can thereby be extended beyond the maximum cable length per segment. Control system Profibus DP Master (PLC) Development or notified certification body Concept/ communication principle Applications Bus features Modbus IDA Master-slave with query-response mechanisms for data exchange. For Modbus, there is no distinction between cyclic and acyclic data exchange; in both cases, the same mechanisms are used. There is only one master which is allowed to send messages without external request. The connected Modbus devices may acknowledge the received messages or send messages to the master on request of the latter. Predominantly in plant engineering where the real-time requirements on the response times are lower. Versions Modbus ASCII, each byte of a telegram is transmitted using two ASCII characters; suitable for applications with a low process data level Modbus RTU, each byte of a telegram contains 2 hexadecimal characters Modbus Plus, extended Modbus protocol (contains two additional protocol layers such as HDLC level, MAC level and LLC level) Modbus TCP/IP, Modbus based on Ethernet technology AUMA actuators support Modbus RTU. Physical layer Maximum number of devices Typical number of devices Typical bus cycle time RS-485, alternatively: FO 247 field devices and a Modbus RTU master Without repeaters, a maximum of 32 devices per Modbus segment Depends on the plant; typically devices; for more devices, a second Modbus network is usually installed. Approx. 850 ms, for 30 actuators, the usually required process data (3 input registers) and at 38.4 kbit/s 10

11 Field level with field devices Data transmission rates of the bus Max. cable lengths without repeater Max. cable lengths with repeater Redundancy concepts Device integration/ remote programming of the slaves Fieldbus termination Bus features 0.3 kbit/s to 38.4 kbit/s max. 1,200 m approx. 10 km The maximum cable length which can be implemented depends on the number of repeaters. This kind of cascadability depends on the repeater type; usually a maximum of 9 repeaters can be used in a Modbus system. There is no redundancy specification for Modbus RTU. AUMA actuators are optionally equipped with a redundant Modbus RTU interface. Today, may DCS still do not support redundancy or have their own redundancy concepts. Current redundant solutions have to be matched in the run-up to commissioning. Modbus has no special communication services for the transmission of parameters; available services are queried acyclically. Currently, there is no device integration specified for Modbus; this means that each parameter request as well as the corresponding parameter representation has to be programmed manually in the process control system. The RS-485 specification stipulates termination resistors at the beginning and at the end of each RS-485 segment. The resistor network has to be supplied with 5 V DC. On the master level, the supply voltage is provided by the master, on the field level by the field devices. AUMA products provide these fieldbus termination resistors and do not require external termination resistors. 11

12 DeviceNet DeviceNet was developed in 1993 by Allen-Bradley; the development of the CAN protocol by Bosch, which is the underlying protocol, started as early as Topology The basic structure for DeviceNet topology is the line; drop lines are explicitly permitted as long as the defined constraints are not exceeded. In case of DeviceNet, you often talk about a trunk line which is usually implemented with the thick cable. Thin cables are usually used for optional drop lines. When using extenders, DeviceNet systems can be extended beyond the maximum cable length per segment. Control system Profibus DP Master (PLC) Development or notified certification body Concept/ communication principle Applications Bus features Open DeviceNet Vendor Association (ODVA) DeviceNet is an object-oriented bus system operating according to the Producer-Consumer procedure. DeviceNet nodes can be client (master), server (slave) or both. Client and server can be producer, consumer or both. Each DeviceNet node can produce or consume data on the bus. This opens a large variety of possibilities for data transmission; however, a master-slave mechanism is usually applied for the process data. So-called Poll I/O Messages are used for cyclic data transmission, Explicit Messages for acyclic data transmission. DeviceNet devices are also called nodes in DeviceNet terminology. Machine and plant engineering as well as production automation Versions DeviceNet: DeviceNet consists of CIP on CAN (a protocol which uses CAN as physical layer and for data transmission). Ethernet/IP: Ethernet/IP consists of CIP on Ethernet (a protocol which uses Ethernet as physical layer and TCP/IP or UPD/IP for data transmission). AUMA actuators support the DeviceNet version. Physical layer Maximum number of devices Typical number of devices Typical bus cycle time Data transmission rates of the bus CAN, bidirectional data transmission, half-duplex. As a special feature, the DeviceNet cable contains an additional 24 V DC voltage which can be used to supply basic sensors, for example. 63 field devices and a DeviceNet scanner. In DeviceNet terminology, a scanner corresponds to the master. Depends on the plant; typically devices; for more devices, a second DeviceNet network is usually installed. approx. 230 ms for 30 actuators, the usually required process data (Process Input Data 1 and Process Output) and at 125 kbit/s 125 kbit/s; 250 kbit/s; 500 kbit/s Recommended baud rate: 125 kbit/s (for the maximum permissible cable length) 12

13 Field level with field devices Max. cable lengths without extender Max. cable lengths with extender Redundancy concepts Device integration/ remote programming of the slaves Fieldbus termination Bus features 500 m at 125 kbit/s 250 m at 250 kbit/s 100 m at 500 kbit/s approx. 1.5 km (at 125 kbit/s) approx. 750 m (at 250 kbit/s) approx. 300 m (at 500 kbit/s) The maximum cable length which can be implemented depends on the number of extenders, most manufacturers allow for 2 cascaded extenders within a DeviceNet network. Currently, there is no redundancy specification for DeviceNet. AUMA actuators can also be delivered with a redundant fieldbus interface. For DeviceNet, parameter data are read or written using acyclic Explicit Messages. The parameter structures in the device are laid down in the EDS file (Electronic Data Sheet). The EDS file has to be installed in the process control system so that the device data (e.g. parameters or operating data) can be read or modified from the control room using DeviceNet. The EDS file of the AUMATIC AUMA controls can be obtained from or For DeviceNet, a termination resistor of 121 Ohm is required at both ends of the trunk line. The resistor is simply connected to the CAN_H and the CAN_L wire. The termination does not have to be supplied. AUMA products provide this fieldbus termination resistor and do not require external termination resistors. 13

14 Foundation Fieldbus In 1994, after the WorldFIP and ISP organisations merged to form Fieldbus Foundation, the first Foundation Fieldbus specification was published. Distributed control system (DCS) Topology The basic structure for Foundation Fieldbus is the line. Star topologies and network structures are also allowed as long as the defined constraints are not exceeded. When using repeaters, Foundation Fieldbus systems can be extended beyond the maximum cable length per segment. Development or notified certification body Concept/ communication principle General information Fieldbus Foundation Foundation Fieldbus basically distinguishes between three different communication mechanisms: Publisher-Subscriber for cyclic process data transfer, Client-Server for diagnosis, parameter setting and configuration as well as report distribution for signalling alarms. There is no master; the data is directly exchanged between the field devices. The bus communication between the field devices is directly coordinated by the LAS (Link Active Scheduler). The LAS function is performed by one of the field devices for each segment. LAS capable field devices are called Link Masters, basic devices cannot perform the LAS function. Applications Chemical industry, petrochemical industry, power plants, pharmaceutical industry and food industry as well as paper industry and mining Versions FF-H1 based on IEC with a baud rate of kbit/s. This is the FF technology directly connected to the field devices. FF-HSE, based on Ethernet (100 MBit/s). The data is transferred via HSE both within the DCS as well as between the DCS and the linking devices. Generally speaking, a linking device can be considered as converter between the quick HSE and the slow H1 version. AUMA actuators support the FF-H1 version Physical layer Maximum number of devices Typical number of devices Typical bus cycle time For H1: IEC 61158, with kbit/s, bidirectional data transmission, half-duplex. Power supply and data transmission is performed on the same wires. Foundation Fieldbus devices with low-current consumption can be supplied via bus. 240 field devices including linking device. A maximum of 32 devices can be connected to a single Foundation Fieldbus segment. Usually 6 10 (max. of 12 14) per segment; mostly 4 H1 ports are available at a linking device, i.e. approx devices per linking device. Since FF is frequently used in large plants, often several linking devices are used. 500 ms - 2 s, depending on the number of devices 14

15 Field level with field devices Data transmission rates of the bus Max. cable lengths without repeater Max. cable lengths with repeater Redundancy concepts Device integration/ remote programming of the slaves Fieldbus termination General information kbit/s 1,900 m approx. 9.5 km The maximum cable length which can be implemented depends on the number of the repeaters. For FF, a maximum of 4 repeaters may be cascaded. For Foundation Fieldbus, the redundancy is only specified within the HSE (i.e. up to the linking devices). For the further H1 wiring to the field devices, there is no redundancy provided. By means of link master devices, some kind of implicit redundancy can be established for FF: if the LAS (link active scheduler) fails, another link master device can automatically take over the LAS function and can continue to co-ordinate the bus communication to the other devices. Client-server messages are used to program and configure Foundation Fieldbus devices via Foundation Fieldbus. All information required for these requests are stipulated in the device description of a Foundation Fieldbus field device which is imperatively required. All in all, the device description consists of three files (*.ffo, *.sym and *.cff). The device description has to be installed in the DCS so that the device data (e.g. parameters, operating data, or electronic name plate) can be read or modified from the control room using Foundation Fieldbus. The device description files of the AUMATIC AUMA controls can be obtained from or For Foundation Fieldbus, the termination consists of a resistor with an in series connected capacitor which is connected to the FF+ and FF wire at the beginning and the end of a main segment. The longest cable length within a Foundation Fieldbus network is called main segment. AUMA products provide these fieldbus termination resistors and do not require external termination resistors. 15

16 AUMA actuators with fieldbus interfaces Modular concept AUMA actuators can be combined with the fieldbus compatible AUMATIC actuator controls. Even when using different actuator types, i.e. multi-turn, part-turn and linear actuators, a uniform interface to the process control system is provided using the AUMATIC. This applies to both the hardware and the software and sets the stage for universal solutions in valve automation. Integral controls AUMATIC with fieldbus interface Explosion-proof versions Both AUMA actuators and the AUMATIC actuator controls are available in explosion-proof version. The devices conform to the classification II2G EEx de IIC T4/ II2G c IIC T4. Further literature For detailed information on AUMA actuators and AUMATIC controls refer to the brochures below. Actuator controls AUMATIC AC 01.1/ ACExC 01.1 Electric multi-turn actuators for open-close and modulating duty SA 07.1 SA 48.1 SAR 07.1 SAR 30.1 SAEx(C) 07.1 SAEx(C) 40.1 SARExC 07.1 SARExC 16.1 Multi-turn actuators SA/ SAR Part-turn actuators SG/ SGR or SG/ SGR Electric part-turn actuators for open-close and modulating duty SG 03.3 SG 04.3 SGR 03.3 SGR

17 Characteristics of AUMA fieldbus interfaces Fieldbus systems can only work reliably if they have been carefully installed and commissioned. The installation guidelines of the fieldbus organisations should therefore be observed in detail. If mistakes are made during installation this will often result in unstable communication. The field device manufacturer is often the first person contacted although the fault was caused somewhere else. The AUMA fieldbus interface is designed as to enable easy field bus connection and bus setting at the device. Smart bus termination Incorrectly set bus termination resistors impair the bus communication. The identification of bus terminations which have been activated by accident can be very time-consuming especially in the case of multiple bus terminations. With AUMA products, you just switch on the bus terminations. If a bus termination at an AUMA actuator has been activated by accident, the communication to all subsequent devices on the bus is interrupted. This so called smart bus termination automatically prevents multiple bus terminations and the communication remains stable. Advantages of AUMA fieldbus actuators Easy installation of the bus cables by means of plug-in connection Easy installation using a separate connection board Easy bus termination using the integral smart bus termination Quick commissioning in next to no time Redundancy concepts with two separate bus interfaces in a single AUMATIC Redundancy concepts with fieldbus interface and additional conventional control signals Configurable data interfaces for optimising the communication The bus communication will not be interrupted if the AUMA actuator is switched off or disconnected from the bus. Explosion-proof actuators contain a bus termination which has to be wired if the actuator is the last bus station. [1] [2] [3] [1] Removable lid [2] Fieldbus connection board for connecting the fieldbus cables [3] Fieldbus interface 17

18 AUMA actuators with fieldbus interfaces Fieldbus connection non-explosion-proof actuators The fieldbus connection and the connection of the power supply are located in separate sections. A plug/ socket connector establishes the electrical connection from the housing to the actuator. This plug-in feature is an asset during installation and maintenance. Depending on the fieldbus and the transmission mode, different modules are installed. Bus connection board The bus cables are wired to a separate connection board. The connection is easy to maintain: [1] Easy access to the connection board after removing the cover. Special terminals allow for easy connection of the bus cable. Bus communication is not interrupted if the actuator plug is removed (exception: fibre optics). Plug-in electrical connection for non-explosion-proof applications (ordering code SD) [1] Six conduit entries Fieldbus connection versions [2] [3] [2] Standard version [3] 2-channel version for the connection of a redundant fieldbus cable. [4] Version with protective equipment againt overvoltages (up to 4 kv) on the fieldbus. The 2-channel version is illustrated. [5] Version for connection to fibre optic cables. The versions shown in the illustration are suitable for connecting Profibus DP and Modbus RTU. Further versions are available for DeviceNet and Foundation Fieldbus. [4] [5] 18

19 Fieldbus connection explosion-proof actuators As for the non-explosion-proof actuators, the complete electrical connection both data cables and power supply cables is made in a separate plug-in connection. [1] If the actuator is the last device in the bus segment, the fieldbus termination integrated in the AUMATIC has to be wired accordingly. For this connection type, the bus communication also remains intact, even if the plug is disconnected (exception: FO). [a] [b] FO coupler If the data exchange is performed via fibre optic cables, an FO coupler is integrated in the connection housing for the connection of the fibre glass cables. [2] [c] [a] [3] [d] [a] [1] Plug/ socket connector with screw-type terminals standard (ordering code KP) [2] Plug/ socket connector with spring-type terminals option (ordering code KES) used with operating voltages exceeding 525 V and / or, if many terminals are required, e.g. due to redundancy, assignment of the sensor connections or connection of an external 24 V DC supply [3] Plug/ socket connector with FO coupler option (ordering code KES) for connecting fibre optic cables (Profibus DP or Modbus RTU) [a] All connections have six conduit entries [b] Screw-type terminals [c] Spring-type terminals [d] FO coupler 19

20 SIMA master station SIMA: Fieldbus master and actuators from a single source From the perspective of the field devices, the SIMA Configuration interface master station is used to set up an additional level below the actual DCS. This is recommended if: a protocol has to be converted, e.g. from Profibus DP to Ethernet. a physical conversion is required, e.g. from RS-485 to RS-232. a conversion from 1-channel to 2-channel operation (redundancy) is required. the process control system should not be burdened with diagnostic data and actuator parameters. SIMA simplifies the device integration of, in particular, AUMA actuators. SIMA uses open standardised fieldbus protocols enabling the integration of field devices of other manufacturers. Bus SIMA s advantages Only the SIMA master station has to be integrated in the higher level distributed control system as the only station. System data such as operating data or feedback signals from the AUMA actuators can be stored in the master station. As a standard computer, the SIMA master station comes with ports for connecting screen, mouse and keyboard. The SIMA software can be accessed via a Windows user interface. As an alternative, a laptop or computer can be connected via Ethernet. Standardised operation using a worldwide renowned operating concept. Further AUMA actuators can be added with hardly any effort. Online access via the World Wide Web by means of the integral web server. The SIMA operating data logging function enables the collection of information on the operation time, the number of starts, etc. of the slaves connected. The SIMA can be monitored and controlled from different locations within the plant. 20

21 Control system [2] [3] [1] [1] [2] [4] [4] [1] SIMA master station The SIMA is based on standardised industrial computer components and has been expanded by the required fieldbus interfaces. The entire hardware is integrated in a solid 19" industrial housing with EMC protection. The SIMA is available both with or without touchscreen. [2] Communication For the communication with field devices, SIMA supports the standardised fieldbus protocols such as Profibus DP or Modbus RTU. The cable types specified in the fieldbus standards are used as transmission medium. Up to 32 devices can be connected to a single bus segment; when using repeaters, up to 127 devices are possible. Communication with the decentralised control system is also performed according to above mentioned standards; in addition, Ethernet or customised RS-232 solutions can also be used. [3] Redundancy SIMA supports various redundancy concepts. Both redundancy to the AUMA field devices and/ or to the DCS and also SIMA master redundancy is possible. In case of loss of communication or master failure, automatic change-over to the redundant component will be performed. [4] AUMA actuators The SIMA is designed for the control of AUMA actuators. Since the communication is performed according to standardised fieldbus protocols such as Profibus DP or Modbus RTU, any field device conforming to these standards may be integrated. 21

22 AUMA presales & after-sales AUMA technical fieldbus support Despite the standardisation, implementing, installing and commissioning a fieldbus system is anything but trivial. Should any mistakes by made at this level, the problems caused by the delayed operation start and faults outweigh the obvious advantages of fieldbus technology. AUMA fieldbus service If the components involved are carefully selected at the planning stage, this enables a smooth system start at a later date. Since the beginning of the 1990s, AUMA has been engaged in the development of fieldbus technology. AUMA engineers in Germany and in the AUMA subsidiaries worldwide can rely on extensive experience an asset from which our customers can benefit when selecting the suitable device configuration. The crucial points for the configuration of the system are settled in direct contact with the project engineer. This includes for example transmission medium, redundancy or the projected process control system. Only after all these questions have been settled will a detailed plant configuration be determined. If one of the field devices does not work during commissioning, the field device manufacturer is the first person to contact. However, the failure is often not caused by the field device but by errors during installation or programming. Fieldbus sytems use low signal levels; the requirements on cables, shielding, correctly set terminators, etc. are consequently high. AUMA after-sales service AUMA has set up a worldwide service network which is unparalleled in valve automation. AUMA service technicians offer all kind of services with regards to actuators and have a sound knowledge of the surrounding infrastructure including fieldbus systems. AUMA commissioning service AUMA service technicians will adapt the actuator ideally to the chosen application. This includes setting the device parameters such as tripping torques or type of seating, but also configuring the bus address and the termination resistors and checking the connection of the fieldbus cable. AUMA fieldbus diagnostic service On request the AUMA service technician can perform a diagnostic check on the fieldbus cable or the data exchange on the bus if the AUMA actuator was excluded as the cause of failure. AUMA service technicians are well-equipped with diagnostic devices and monitoring equipment for the different fieldbus systems. Causes of faults can thereby quickly be determined and eliminated. 22

23 Links & literature Literature Profibus DP Manfred Popp: Hüthig Verlag, ISBN The New Rapid Way to Profibus DP Manfred Popp: can be obtained via Profibus Installation Recommendation for Cabling + Assembly, Download Profibus Installation Recommendation for Commissioning, Download Installation Guidelines for Profibus DP/ FMS Installation and wiring recommendations, Download Modbus Modicon Protocol:, Modbus over serial line specification and implementation guide DeviceNet, Rel. 2.0, Errata 5, March 31, 2002, Rel. 2.0, Errata 5, March 31, 2002 Grundlagen, Protokolle, Bausteine, Anwendungen, 3. aktualisierte Auflage, Hanser Verlag, ISBN Links On the websites of the various development organisations and notified bodies, you can find comprehensive information on the corresponding fieldbus system. Furthermore, the device integrations of the registered field devices, including AUMA actuators, are made available for download. These files can also be downloaded from the AUMA website : : : : Foundation Fieldbus, ( AG kbit/s Wiring and Installation Guide AG kbit/s Intrinsically Safe Systems Application Guide AG-165 Fieldbus Installation and Planning Guide AG-181 System Engineering Guidelines Fieldbus Inc. ( Fieldbus Technical Overview (Primer) Ian Verhappen, Augsto Pereira ISBN Jonas Berge ISBN

24 [1] Multi-turn actuators SA 07.1 SA 48.1 Torques from 10 to 32,000 Nm Output speeds from 4 to 180 rpm [2] Multi-turn actuators SA/ SAR with controls AUMATIC Torques from 10 to 1,000 Nm Output speeds from 4 to 180 rpm [3] Linear actuators SA/ LE Combination of multi-turn actuator SA with linear thrust unit LE Thrusts from 4 kn to 217 kn Strokes up to 500 mm Linear speeds from 20 to 360 mm/min [4] Part-turn actuators SG 05.1 SG 12.1 Torques from 100 to 1,200 Nm Operating times for 90 from 4 to 180 s [5] Part-turn actuators SA/ GS Combination of multi-turn actuator SA with part-turn gearbox GS Torques up to 360,000 Nm [6] Spur gearboxes GST 10.1 GST 40.1 Torques up to 16,000 Nm [7] Bevel gearboxes GK 10.2 GK 40.2 Torques up to 16,000 Nm [8] Worm gearboxes with base and lever GF 50.3 GF Torques up to 32,000 Nm AUMA Riester GmbH & Co. KG P.O.Box 1362 D Muellheim Tel Fax riester@auma.com [1] [2] [3] [4] [5] [6] [7] [8] Subject to change without notice. The product features and technical data provided do not express or imply any warranty. Y /002/en/1.06 For detailed information about AUMA products refer to the Internet: