Connecting Fieldbus power and knowledge Source Robby Bosgaerd (PEPPERL+FUCHS) https://ie-net.be/reg

1. PEPPERL+FUCHS 1
Robby Bosgaerd Key Account
Manager Pepperl-Fuchs
Connecting Fieldbus Power and
Knowledge
Robby Bosgaerd
®
PROCESS FIELD BUS

2. PEPPERL+FUCHS 2
<Proven fieldbus solutions
<Intrinsic safety experts
<Flexible configurations
<Reliable data transfer
®
PROCESS FIELD BUS

3. PEPPERL+FUCHS 3
<Standard Point-To-Point Intrinsic Safety Isolation
Barriers à PTP
<Remote I/O with Integrated Intrinsic Safety
Barriers à PTB
<Intrinsically Safe Remote I/O à PTB
<Intrinsically Safe Fieldbus à BTB
Available Technologies
Hybrid Field I/O Solutions

4. PEPPERL+FUCHS 4
P
Standard Point-to-point
• Many specialty barriers
• Huge field product selection
• Good technology for small
facilities
• Easy to use
• Suitable for critical loops and
shutdown circuits
• Simple upgrades
• Control room or field
installation
• No validation issues
Controller
Hazardous Area
Zone 0/1
Zone 2

5. PEPPERL+FUCHS 5
Controller
Remote I/O with IS barriers
à Point-To-Bus
• Standard field circuits
• Huge field product selection
• Mid-range complexity for
most facilities
• Similar to standard remote
I/O
• Reduced installation cost
• Low ownership cost
Hazardous Area
Zone 0/1
Zone 2
Profibus DPE, Modbus,
Modbus Plus,
ContolNet, Ethernet

6. PEPPERL+FUCHS 6
Intrinsically Safe Remote I/O
à Point-To-Bus
• Huge field product
selection
• Mid-range complexity for
many facilities
• Superior technological
solution
• Similar to standard remote
I/O
• Low installation cost
• High functionality
Controller
Hazardous Area Zone 1
Zone 0/1

7. PEPPERL+FUCHS 7
• Upper range technology for
many facilities
• Superior technologic
solution
• Low installation cost
• High functionality
Intrinsically Safe Fieldbus
à Bus-To-Bus
Controller
Hazardous Area
Zone 0/1
Profibus PA,
Foundation
Fieldbus H1,
AS-Interface
Profibus DPE,
Foundation Fieldbus H1

8. PEPPERL+FUCHS 8
Robby Bosgaerd Key Account
Manager Pepperl-Fuchs
Fieldbus History
PEPPERL+FUCHS
®
PROCESS FIELD BUS

9. PEPPERL+FUCHS 9
Profibus-
Master
Siemens S7 ET200
Gateway 1
Profibus-DP/ASi
Gateway n
Profibus-DP/ASi
Batch-Controller
...
ASi-EX
2E/A
...
ASi-EX
4E
...
ASi-EX
2E/A
...
ASi-EX
2E/A
...
...
...
process
Factory Automation As-i bus

10. PEPPERL+FUCHS 10
Side look to
Factory Automation
P2P
Remote I/O
1990
BUS
Remote I/O
P2P
2010

11. PEPPERL+FUCHS 11
Estimation for
Process Industry
P2P
Remote I/O
2000
BUS
Remote I/O
P2P
2010

12. PEPPERL+FUCHS 12
Why Fieldbus was not yet fully used in Process Automation?
<Not all field devices are already available with
integrated fieldbus interface.
<The limited power on an intrinsically safe
fieldbus limits the number of field devices to a
theoretical quantity of 10 which in practice are
very often less than 5 devices.
<Several low value field sensors will not justify
the fieldbus integration at all.
<Approach from vendors came from Factory
Automation = reduced wiring cost

13. PEPPERL+FUCHS 13
Available System
< Different systems
§ PROFIBUS-FMS
§ PROFIBUS DP (V1)
§ PROFIBUS PA
< Different physics
§ RS 485
§ Fibre optic
§ IEC 61158-2
< Different Systems
§ H1 Bus
§ H2 Bus (Fast Ethernet/High
Speed Ethernet)
< Different physics
§ IEC 61158-2 (H1)
• With power supply
• Without power supply
§ Fibre optic
§ Fast Ethernet (H2; HSE)
PROFIBUS FOUNDATION Fieldbus
Communication
Systems

14. PEPPERL+FUCHS 14
8
PROFIBUS Application Range
CNC
PC/VME
VME/PC
PLC PLS
Factory
level
Bus Cycle
Time
< 1000 ms
Cell-
level
Bus Cycle
Time
< 100 ms
Bus Cycle
Time
< 10 ms
Field-
level
Ethernet/TCP/IP Internet/Intranet
Work
station
Ethernet TCP/IP(Industrial Ethernet, PROFInet?
PROFIBUS DP
PROFIBUS PA or
PROFIBUS DP
AS-Interface
Communication Systems

15. PEPPERL+FUCHS 15
FOUNDATION Fieldbus Application Range
PC/VME
Operations
PLC
Factory
level
Cell-
level
Field-
level
Ethernet/TCP/IP Internet/Intranet
Work
station
Ethernet TCP/IP (HSE)
H1-Bus Non IS H1-Bus IS
Bridge
Maintenance
Management
Communication Systems

16. PEPPERL+FUCHS 16
Robby Bosgaerd Key Account
Manager Pepperl-Fuchs
Fieldbus Architecture
PEPPERL+FUCHS
®
PROCESS FIELD BUS

17. PEPPERL+FUCHS 17

18. PEPPERL+FUCHS 18
Real Line Topology
<If a field device must be replaced (e. g. depending on a
defect) the transmission cable must be interrupted.
Minimum
§ all field devices „right“ from the defective field device will
fail additional
§ all field devices „left“ from the defective field device will
continue the communication
<To avoid this, Junction Boxes are required
Power supply or segmentcoupler

19. PEPPERL+FUCHS 19
Line Topology with Spurs
<For this topology Junction Boxes are required
<Supported cable length = 1900 m
<Cable legth = legth of trunk + sum of all spurs
§ Spur legth < 120 m
<Example:
§ 10 spurs with 120 m each è max. trunk length = 700 m

20. PEPPERL+FUCHS 20
Structure of an Intrinsically Safe
Fieldbus System
<The max. number of participants depends on
§ Output current of the Power Repeater
§ Real current consumption of the participants
§ Voltage drop along the cable
§ Type of explosion protection model
• FISCO model
• Entity model
External
Fieldbus
terminator

21. PEPPERL+FUCHS 21
Difference between FISCO and Entity
Lcable
Ccable
FISCO model: Cable is a „distributed“ inductance and capacitance
Entity concept: Cable is a „concentrated“ inductance and capacitance
dR dL dL dL
dR dR
dC dC dC
Distributed reactances

22. PEPPERL+FUCHS 22
FISCO Model
Fieldbus Intrinsically Safe Concept
< Basics IEC 61158-2
< All participants, except the Power Repeater, works as a current
sink (passive)
< Only one active device per segment is allowed
< The values Ui, Ii and Pi of every field device must be higher than
the values U0, I0 and P0 of the Power Reeder (basics of intrinsic
safety)
< The values Ci and Li of every field device must be smaller or
equal than 5 nF bzw. 10 µH (negligible small; problem of
Developer!)
< The minimum supply current consumption per participant is 10
mA (typical value 12.8 V; 100 mA for EEx ia IIC)

23. PEPPERL+FUCHS 23
FISCO Model Preconditions
<The cable must have the following values
§ Resistance load per unit length R‘: 15 ... 150 W/km
§ Inductance load per unit length L‘: 0,4 ... 1 mH/km
§ Capacitance load per unit length C‘: 80 ... 200 nF/km
• C‘ = C‘ lead/lead + 0,5*C‘ lead/shield, if both leads are
working potential free (floating circuit)
• C‘ = C‘ lead/lead + C‘ lead/shield, if one of the leads is
connected to the shield
§ Max. cable length 1000 m for EEx ia IIC / 5000 m for
EEx ib (Theory, will be checked in the moment)
§ Max. spur cable length 30m (will be changed to 60m)
§ Fieldbus terminator
§ R = 90 ... 100 W
§ C = 0 ... 2,2 µF
PROFIBUS
DP/DPV1/PA

24. PEPPERL+FUCHS 24
Proof of Intrinsic Safety
<If you have to verify the Intrinsic Safety
§ Choose a Power Repeater in acc. to FISCO model
§ Choose only Field Devices in acc. to FISCO model
§ Choose a transmission cable in acc. to FISCO model
§ Verify
• UO (Power Repeater) < Ui (of every Field device)
• IO (Power Repeater) < Ii (of every Field device)
• PO (Power Repeater) < Pi (of every Field device)

25. PEPPERL+FUCHS 25
IS and Output Parameters
Repeaters
Concept U0 [V] I0 [mA] P0 [W] US [V] IS [mA] Cable Length[m] @
Entity 12,8 140 1.2 10.6 75 500
FISCO 15 207 1.93 12.6 110 750
non-I.S. -- -- -- 24 400 850
* @ IS, cable specification 18 AWG line type A, q=0,8mm2, 44W/km

26. PEPPERL+FUCHS 26

27. PEPPERL+FUCHS 27
Why Segment Protectors?
<What happens if there is a short on a trunk?
<The complete segment will fail
<Solution: Segment Protector
§ Segment Protectors do have a current limitation (45 mA)
at the spur output

28. PEPPERL+FUCHS 28
Segment Protectors
<To avoid problems in case of a short on a fieldbus
segment it is possible to use active Segment protectors
<If a Segment Protector is in use, a short at a spur has
no effect to the trunk
< A Segment Protectors
§ Causes an additional voltage drop (< 1.5 V)
§ Do have a current consumption (< 7 mA)

29. PEPPERL+FUCHS 29

30. PEPPERL+FUCHS 30
Problem with IS Applications
< Power Repeater with IS Interface limits the number of participants
per segment
§ to less than 10 field devices (FISCO model)
§ to less than 6 field devices (Entity concept)
< Intrinsic Safety limits the cable length
§ to less than 1000 m (FISCO model)
§ ??? depending on the available capacitances and inductances
< This requires a lot of Power Repeaters
Solution
< FieldBarrier

31. PEPPERL+FUCHS 31
FieldBarrier
Hazardous Area
EEx e wiring
EEx ia IIC
outputs
Standard Power
Repeater with
24 V; 400 mA

32. PEPPERL+FUCHS 32
Cable lenth per Spur
No. of
Participants
1
device
per
spur
2 devices
per spur
3 devices
per spur
4 devices
per spur
1 – 12 120 m 90 m 60 m 30 m
13 – 14 90 m 60 m 30 m 1 m
15 – 18 60 m 30 m 1 m 1 m
19 – 24 30 m 1 m 1 m 1 m
25 – 32 1 m 1 m 1 m 1 m
Based on cable type A
Functionality between No. of participants and spur length

33. PEPPERL+FUCHS 33
Types of cables
a = not specified

34. PEPPERL+FUCHS 34
Topology with Power Repeater
< A Power Repeater opens a new H1 segment
< Each segment can have
§ Cable length up to 1900 m
§ 32 participants (today no LAS can handle this amount of field
devices)
< Depending on the type of Power Repeater it is possible to open a
segment for hazardous area applications
Integrated
terminator

35. PEPPERL+FUCHS 35

36. PEPPERL+FUCHS 36
Power Conditioner
To non-powered H1 Host Ports 4A Redundant
Power Supplies
24 VDC
Fault Output Fault Output
24 VDC
Optional 24VDC
Power connection on
module if power feed
modules are not used!
1A powered H1 each
Field Devices

37. PEPPERL+FUCHS 37
FT
FT
H2 PROFIBUS DP 9,6kBit/s - 12MBit/s
20-35V
. . .
Up to
4x PA Master
20x PLM´s
Bridge
H1 IEC-61158-2
I.S.
H1 IEC61158-2
non I.S.
1...5 PLM
PA Master Channels
Div 2 /Zone 2
1...5 PLM
RLM
Architecture
Segmentcoupler 2nd. Generation
®
PROCESS FIELD BUS

38. PEPPERL+FUCHS 38
Advantages
<Up to 125 PROFIBUS PA devices connectable
<4 independent PROFIBUS PA Master integrated
§ up to 20 PROFIBUS PA Segments with up to 200
PROFIBUS PA slaves (Theory!!!, not addressable!!!)
§ „Adjustable“ PROFIBUS PA cycle time
<Variable mixture of IS and Non-IS power links

39. PEPPERL+FUCHS 39
Robby Bosgaerd Key Account
Manager Pepperl-Fuchs
What about discrete I/O?
PEPPERL+FUCHS
®
PROCESS FIELD BUS

40. PEPPERL+FUCHS 40
Remote
I/O
Price Device
Price Bus Connection
100%
50%
0%
Analog
Valve
Diff. Presure
Transm
itter
Tem
perature
Transm
itter
On/Off Valve
On/Off Valve with
zone 2 Rem
ote I/O
On/Off Valve with
Zone ! Rem
ote I/O
Therm
ocouple
PT100
Proxim
ity Sensor
Mechanical Contact
Economical justification
to use a fieldbus connection

41. PEPPERL+FUCHS 41
Valve Coupler
Field Process Interface, FPI
Features:
<4-Channel solenoid driver
<Two discrete inputs per output channel for valve position
<IP65, -20 ºC…+70 ºC
<Zone 1 / Division 1 mounting, EEx ia IIC T4
<Bus powered 23 mA current consumption
<Must be used with Low powered valves 6 V / 1.5 mA
Advantages:
<Cost effective solution, turns standard valves into”SMART”
valves for preventive maintenance
<Gets more valves on the Fieldbus
<Can be used with inductive sensors and mechanical contacts
<Easy to install
<Wide range of diagnostic and maintenance functions:
lead breakage, short circuit, counter,travel time and breaktime.
®
PROCESS FIELD BUS

42. PEPPERL+FUCHS 42
Robby Bosgaerd Key Account
Manager Pepperl-Fuchs
Fieldbus Topologies
Junction Box Junction Box
Junction Box
Power Supply
/ Segment coupler

43. PEPPERL+FUCHS 43
Robby Bosgaerd Key Account
Manager Pepperl-Fuchs
Junction Box Junction Box
Junction Box
Power Supply
/ segment coupler
Segment
Protector
FieldBarrier
Fieldbus Topologies

44. PEPPERL+FUCHS 44
Robby Bosgaerd Key Account
Manager Pepperl-Fuchs
Junction Box
Power Supply
/ segment coupler
Fieldbus
Process
Interfaces
FieldBarrier
Segment
Protector
Fieldbus Topologies

45. PEPPERL+FUCHS 45
FieldBarrier +
Valve Coupler
Zone 1
Zone 0
Red. Power Supply
To H1 Host
EEx e

46. PEPPERL+FUCHS 46
Werner Setzwein
BASF AG:
Savings on DCS investment
with RI/O and Fieldbus
100 %
75 %
62,5%
Conventional Remote I/O Fieldbus

47. PEPPERL+FUCHS 47
Surge Protection
SP
SP
SP
SP
SP
SP
SP
SP
SP
SP
SP
SP
Possibility 1: Highest degree of protection

48. PEPPERL+FUCHS 48
Surge Protection
<The truth will be anywhere in between, depending on
§ Real topology
§ Philosophy of the customer
§ ...
Possibility 2: Lowest degree of protection
SP
SP
SP
SP

49. PEPPERL+FUCHS 49
FieldConnex in Operation
FieldConnex
System
< FieldBarrier Topology and pneumatic valve coupling – ready to be
connected

50. PEPPERL+FUCHS 50
Marketing
Tools
System Catalogue cover

51. PEPPERL+FUCHS 51
EEx nL
<EEx nL is a „simplified“ version of intrinsic safety
(L= energy limitted)
<A simplified proof of intrinsic safety is required
Segment Protector
(preliminary)
Field Device
UO = 33 V < Ui
IO = 45 mA < Ii
PO = 1.485 W < Pi

52. PEPPERL+FUCHS 52
Problem
< To fulfil the EEx nL requirements it is mandatory to have a voltage
limitation in accordance with EN 50021 EEx nL!!!
§ Declaration of Manufacturer or Declaration of Conformity is
required.
< Perhaps you it can be used by you?
Category 3
(Zone 2)
UO = 33 V
IO = 45 mA
Ui = 24 V
Ii = 75 mA

53. PEPPERL+FUCHS 53
FNICO Concept
<IEC 60079-27 Electrical apparatus for explosive
atmospheres – Part 27: Fieldbus intrinsically safe
concept (FISCO) and Fieldbus non-incendive concept
(FNICO).
<Will be adopted in 2004
<Differentiation
§ FNICO è Category 3 (Zone 2) applications in EEx nL
§ FISCO è Category 1 and 2 (Zone 0 and 1) applications
in EEx i
Fieldbus Non-Incendive COncept

54. PEPPERL+FUCHS 54
Preconditions of FNICO
+ Basics IEC 61158-2
+ All participants, except the Power Repeater works as a
current sink (passive)
+ Only one active device per segment is allowed
+ The values Ui, Ii and Pi of every field device must be higher
than the values U0, I0 and P0 of the Power Repeater (basics
of intrinsic safety)
+ The values Ci and Li of every field device must be smaller or
equal than 5 nF bzw. 20 µH (negligible small; problem of the
developers!)
+ The current consumption from te fieldbus cable must be for
each field > 10 mA.

55. PEPPERL+FUCHS 55
FNICO Model Preconditions
< The cable must have the following values
§ Resistance load per unit length R‘: 15 ... 150 W/km
§ Inductance load per unit length L‘:0,4 ... 1 mH/km
§ Capacitance load per unit length C‘: 45 ... 200 nF/km
• C‘ = C‘ lead/lead + 0,5*C‘ lead/shield, if both leads are working
potential free (floating circuit)
• C‘ = C‘ lead/lead + C‘ lead/shield, if one of the leads is connected
to the shield
< Max. cable length 1000 m for EEx ia and 5000 m for EEx ib
<Max. spur cable length 60 m per spur
§ This will also be changed in the FISCO model
< Fieldbus terminator
§ R = 90 ... 100 W
§ C = 0 ... 2,2 µF

56. PEPPERL+FUCHS 56
FNICO Model
+ If the preconditions, described in the previous sheets,
are matched, the proof of Eex nL will be reduced to
U0 < Ui
I0 (in acc. with ignition curve) < Ii (in acc. with ignition curve)
P0 < Pi
„Power Supply“ Field device

57. PEPPERL+FUCHS 57
Robby Bosgaerd Key Account
Manager Pepperl-Fuchs
Connecting Fieldbus Power and
Knowledge
Robby Bosgaerd
®
PROCESS FIELD BUS