FF – Physical Layer Components
Name
Chakravarthy Akella
Job Title
Dy. Manager S&S
Company Pepperl+Fuchs
Bangalore
Agenda
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Introduction
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FF Basics
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FF Zone1 and Zone2 Topologies
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System commissioning and maintenance
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© 1994 – 2011 Fieldbus Foundation
Conventional Instrumentation
4-20mA technique:
Factory
level
Ethernet/TCP/IP
Work
station
Management
Cell-
Internet/Intranet
PC/VME
Ethernet TCP/IP
level
Operations
Maintenance
Ex
Field-
level
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© 1994 – 2011 Fieldbus Foundation
Fieldbus Instrumentation
Factory
level
Ethernet/TCP/IP
Work
station
Internet/Intranet
PC/VME
Management
Celllevel
Ethernet TCP/IP
Operations
Maintenance
Fieldlevel
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Fieldbus
Fieldbus EX
© 1994 – 2011 Fieldbus Foundation
Expanded View of Process & Instruments
1. Self Diagnostics and communication capabilities of microprocessor based
fieldbus devices helps reduce downtime and improve plant safety.
2. Plant operation and Maintenance personnel can be notified and corrective
actions taken quickly and safely.
Control System Network
Analog Controller
PV
4-20mA
I/O Subsystem
Traditional 4-20mA View stops at I/O Subsystem
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Control System Network
Fieldbus Controller
PV , Mode , Variables , Alarm
Diagnostics , Etc
H1
Fieldbus Extends View to Field Instrument
© 1994 – 2011 Fieldbus Foundation
FF Design Guides
International Codes and Standards
International Electro technical Commission (IEC)
IEC 61158-1
Introductory Guide
IEC 61158-2
Physical Layer Specification and Service Definition
IEC 61158-3
Data Link Layer (DLL) Service Definition
IEC 61158-4
Data Link Layer (DLL) Protocol Specification
IEC 61158-5
Application Layer Service Specification
IEC 61158-6
Application Layer Protocol Specification
IEC 61158-7
System Management
IEC 61158-8
Conformance Testing
IEC 600079-11 (IEC 60079-27) Fieldbus Intrinsically Safe Concept (FISCO)
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© 1994 – 2011 Fieldbus Foundation
Foundation Fieldbus Design Guides
Foundation Fieldbus compliance Specification
www.fieldbus.org
FF-569
Host Interoperability Support Test
FF-831
Fieldbus Specification for Power Supplies and Conditioners
FF-844
Fieldbus Specification for Cable
FF 846-1.1 Fieldbus Device Couplers used at Zone2 and Zone1
AG 181
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System Engineering Guidelines (Rev 3.1)
© 1994 – 2011 Fieldbus Foundation
Fieldbus Physical Layer Design Guides
FF has the physical layer specification as per IEC 61158-2:
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Transmission rate of 31.25 kBit/s
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Total cable (Trunk + Spurs) distance of 1900m maximum
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Maximum spur length 120 m upto 12 devices
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Up to 32 devices per segment (Host + 31 field)
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Manchester II coding used to transmit data
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Data transmission by a ± 9mA modulation signal
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Minimum working voltage 9 Volts ( Range is 9-32V) and average current
consumption 20mA per device
© 1994 – 2011 Fieldbus Foundation
Output Cable Length
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No. of communication elements
Max. spur output cable length
1 – 12
120m
13 – 14
90m
15 – 18
60m
19 – 24
30m
25 – 32
1m
© 1994 – 2011 Fieldbus Foundation
Where is Exe protection required at the
Process Field
■Field
Enclosure mounted at Zone2, and Zone1
-Mechanical
Impact test
-IP
rating
-Material Grade
-Drop test
-Vibration test
■Any
Fieldbus cable system installed at Zone2, Zone1
- IS cables ( for operational reasons)
- non-IS cables
- Armor or conduit wiring are common practice
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© 1994 – 2011 Fieldbus Foundation
Application - Zone1 installations
Non-IS(EEx e)
– Trunk and spurs must be installed in increased safety EEx e
IS ( Limted Power and High Power)
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Limited power
– ENTITY and FISCO concepts
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High Power
– HPT
 Trunk has to be installed in increased safety
 Spurs are intrinsically safe
 Allows the use of Non IS Power Supplies and IS FieldBarrier
– HPT-IS
 Trunk and Spurs are IS
© 1994 – 2011 Fieldbus Foundation
Application Area - Zone 1 (EEx d)
Fieldbus
Power Hub
Segment Protector Ex me
Ex e
16..32V
230VAC
16..32V
Zone 1
Instruments
Ex d
Live Disconnect Switch
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© 1994 – 2011 Fieldbus Foundation
User Benefit : Design guidelines
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© 1994 – 2011 Fieldbus Foundation
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© 1994 – 2011 Fieldbus Foundation
IS Fieldbus
Refer AG 181-3.1
-Limited Power
-High Power
High power ( Exe + IS )
High Power IS
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© 1994 – 2011 Fieldbus Foundation
Application Area - Zone1 IS ENTITY
ENTITY FF
Power Supply
V = 10.5V
I = 70mA
Zone 0/1
230VAC
20..35V
9V
Trunk cable < 200m
23mA
ENTITY Device
Number of devices less than 2
No load sharing Redundancy at Power Supply
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© 1994 – 2011 Fieldbus Foundation
Application Area - Zone1 IS FISCO
FISCO FF Power V = 12.5V
Supply
I = 100mA(IIC)
I = 245mA (IIB)
Zone 0/1
230VAC
20..35V
9V
Trunk cable < 400m
23mA
FISCO Device
Number of devices less than 5
No load sharing Redundancy at Power Supply
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© 1994 – 2011 Fieldbus Foundation
Can FISCO/ENTITY power supply be Redundant?
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© 1994 – 2011 Fieldbus Foundation
Standby FISCO Concept
FISCO FF Power
Supply
Zone 0/1
A
B
9V
Trunk cable < 400m
23mA
Number of devices less than 5
FISCO Device
No load sharing Redundancy at Power Supply
Same limitations as per FISCO concept
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© 1994 – 2011 Fieldbus Foundation
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© 1994 – 2011 Fieldbus Foundation
Application Area - Zone1 IS - HPT
Exd Trunk live disconnect switch
FieldBarrier
Fieldbus
Power Hub
Zone 1
Ex e
Ex ia
(FISCO + Entity)
16..32V
Zone 0/1
230VAC
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16..32V
© 1994 – 2011 Fieldbus Foundation
Application Area - Zone1 IS HPT
High power trunk or FieldBarrier concept

Trunk is Ex e( increased safety) and Spurs intrinsically safe
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Spurs as per FISCO or Entity IS

Longest cable run possible 1900m(Trunk+Spurs) and 120m Spur
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No limitation of voltage and current on trunk
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Redundant power supplies possible
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Trunk could be live disconnect with approved Exd Switch
Hazardous area application with the least difficulties
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© 1994 – 2011 Fieldbus Foundation
DART Application : IS Fieldbus
The first step
Simplifying
validation
MAX power + FISCO
High Power Trunk Intrinsic Safety
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© 1994 – 2011 Fieldbus Foundation
Simple DART circuit
Ex ib IIC
Time to turn-off: 5…10 µs
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© 1994 – 2011 Fieldbus Foundation
Typical Spark – Physics
U
Initial
Phase
Critical Phase
IF
Spark voltage
di/dt
UF
Spark current
PF
Spark duration tF: 5 µs…2 ms
29
t
© 1994 – 2011 Fieldbus Foundation
U, I, P
Typical Spark – Turned Off by DART
Initial
Phase
Critical Phase
IF
UF
PF
t
Spark duration with DART tF ≤ 5 µs
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© 1994 – 2011 Fieldbus Foundation
DART High Power Intrinsic safety
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Provides 8…50 W, intrinsically safe
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Detects sparks as they occur
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Limits the energy during a fault
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Could be used at Conventional(50W) and Fieldbus(8W)
Applications
A completely intrinsically safe fieldbus segment in
gas groups IIB and IIC with real power redundancy and advanced
diagnostics.
The Intrinsically Safe High-Power Trunk
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© 1994 – 2011 Fieldbus Foundation
DART (HPT-IS) FIELDBUS STRUCTURE
DCS
Intrinsically Safe –
Trunk up to 1000m
22.5V
IS Segment Protector
Zone 1/ Zone2
Each Spur upto
120m
360mA
------Upto 16 IS devices
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© 1994 – 2011 Fieldbus Foundation
Fieldbus Design and validation
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
Factory Acceptance Tests
– Termination
– Communication
– Parameter measurements
– Segment operation – all typical segments
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Site Acceptance Tests
– Network validation
– Noise – Watch out for Frequency Drives
– Electrical characteristics
– Grounding and shielding
– System Functional Tests
– Cable check
– Device parameters measurements
– Signal patterns etc
© 1994 – 2011 Fieldbus Foundation
Commissioning until now
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Always on the critical path
Manual, step-by-step procedure
Labor intensive
Requires
– Screw driver
– Check sheet
– Pencil
– Multimeter - FF testers
– Oscilloscope
Connect one device at a time
Disconnect after testing
Test Report
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© 1994 – 2011 Fieldbus Foundation
Integrated and Portable Advanced Diagnostics
Stand Alone
Integrated at Fieldbus Supply
Portable Advanced Diagnostics
Advanced Diagnostics
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© 1994 – 2011 Fieldbus Foundation
Maintenance View
Network view
FF-Host
FF-Segment
Segment-specific status of the physical layer
ADM status view with PRM TAG
Alarm window view
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© 1994 – 2011 Fieldbus Foundation
Simple Commissioning Steps with ADM
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Verify address setting
Wire up devices in the right location
Check shielding
Activate communication
Use automated work procedures
– Testing
– Documentation
All devices at once
Wiring remains undisturbed!
Test
Report
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x
Commissioning Wizard
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© 1994 – 2011 Fieldbus Foundation
Commissioning Wizard
With Expert System Support
 Takes snapshot
 Identifies wiring erros
 Ensures compliance with
AG181 and IEC 61158-2
 Recommends limits for ADM messages
 Stores limits in non-volatile memory
Automatic Tag Readout
Creates baseline report:
 Snapshot of all measurements
 Complete documentation
Saves 80% of pre-commissioning time
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© 1994 – 2011 Fieldbus Foundation
Diagnostic Menu
Expert System delivers clear text
information for fast fault finding
1 Active messages
2 Actionable information with
solution guideance based on
expert system
3 History with timestamps
When the failure…
… occured
… disappeared
 Export function for external
analysis and storage
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1
3
2
2
© 1994 – 2011 Fieldbus Foundation
Online monitoring
Clean layout shows boundaries
 Displays measurement values
 Highlights violations with color coding:
 Issues diagnostic messages
Good value
Maintenance required
Out of specification
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© 1994 – 2011 Fieldbus Foundation
Online trending and history
Monitoring
 Reveals long term changes
 Exports into many formats
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© 1994 – 2011 Fieldbus Foundation
Built-in fieldbus oscilloscope
ADM provides expert tools
for fast fault finding
 For diagnosing complex scenarios
 For the fieldbus expert
 With fieldbus specific triggers
 Captures up to 10 shots in a row
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© 1994 – 2011 Fieldbus Foundation
Questions
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© 1994 – 2011 Fieldbus Foundation
THANK YOU
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© 1994 – 2011 Fieldbus Foundation