1 Profibus Technology

PROFIBUS Technology

© 2008 - 2010 Copyright Smar

PROFIBUS Family

EN 50170 Volum 2 and DIN 19245 Part 1 to 4

Process Automation

PROFIBUS-DP

PROFIBUS-FMS

PROFIBUS-PA

fast

universal

Application oriented

- plug and play - efficient and cost effective

- large variety of applications - multi-master communication

- powering over the bus (option) - intrinsic safety (option)

Device Profiles

Automation for General Purposes

Application Profiles

Factory Automation

Transparent Communication Factory level

Ethernet/TCP/IP Router /

Plant Backbone

Firewall Bus Cycle Time < 1000 ms

CNC

Cell Level Bus Cycle Time < 100 ms

Field Level Bus CycleTime < 10 ms

ETHERNET VME/PC

PLC

DCS

PROFIBUS-DP

PROFIBUS-PA

Products application range Controllers

Drives

Converters AC

PLC /NC /RC VME , PC

Converters DC I/O Decentralized I/O Binary I/O Analogical Module PID

DCS

Net Components Repeaters Optical Fibers

Tools Configuration Bus Monitor Engineering

Gateways AS-Interface Proprietary Networks

Cables

Timers Counters Systems Iden

Valves Pneumatic Magnetic

MMI HMIs Text Displays

Instrumentation Level Flow Pressure Temperature

PROFIBUS – Network Topologies Optical Fiber

DP/PA link

DP/PA link

OLM

OLM

OLM

Repeater

Infrared

Barrier+ Repeater

ILM

PROFIBUS PA

ILM

DP/PA link

– Network topologies: • • • • •

redundant ring line star Eex / Not-Eex

Architecture Industrial Ethernet / Fast Ethernet

Controller

H2 Level T PROFIBUS DP Slaves DP/PA link

PROFIBUS PA Barrier + Repeater

H1 Level

– PROFIBUS offers with the same communication protocol the levels H1 and H2 – PROFIBUS DP is the high speedy H2 bus level – PROFIBUS PA is the process H1 bus level

PROFIBUS-DP •

Excellent to substitute large amounts of wire between PLC/ DCS/ PC e E/S

•

Very fast, DP transmits 1 kByte of input and output data up to 2ms

•

Powerful tools reduce the configuration and maintenance efforts

•

Supported by main PLCs and DCSs manufacturers

•

Many kind of product, namely, PLC, DCS, PC, I/O remote, Drives, smart MCCs, Valves, Encoders

•

Cyclic and acyclic communication

•

Mono and multi master communication

•

Up to 244 bytes of input and output per station

DP Characteristics • The DP communication is permanent and cyclic • The data to be transmitted are configured during the configuration (optimized data exchange) • Only one master can write the output (safety) • Data can be read by controllers and by the Class 2 masters • Acyclic data exchange via DPV1 functions • Alarms recognition • It is a very fast fieldbus system (uo to 12 MBaud) • Up to 244 bytes of data for inputs and 244 bytes for outputs per network node

Distances and speeds in PROFIBUS DP Baude Rate(kbit/s)

9.6

19.2

93.75

187.5

500

1500

12000

Distance/ Segment (m)

1200

1200

1200

1000

400

200

100

Note: Distances based on transmission speed for type A cable in RS485

Fiber Type

Properties

Glass – Multimode

Media distance, 2 to 3 km

Glass – Monomode

Long distances, > 15 km

Synthetic

Long distances, > 80 km

PCS/HCS

Short distances, < 500m

Optical Fiber properties

Open Configuration PROFIBUS Configuration Tool (Class 2 Master)

PLC / DCS / PC (Class 1 Master)

Device Data Base Files GSD-file

PROFIBUS - DP

Field device

M Transmitter I/O

Sensor

Drive

Field device

PROFIBUS: Benefits – Costs reduction

$

$

– Flexibility – Reliability and Technology oriented to the Future – Wide solution – Interoperability and Multiple vendors Open standard !

Why to choose a fieldbus system? • • • •

Proprietary solution independence Supplier independence Costs reduction Productivity increase due to: – – – –

Short cycle time Flexible Architecture Easy expansion Standardized

What does a fieldbus system have to offer? • • • • • • • •

Determinism Flexibility Interoperability Capex reduction (installation, startup, services) Reliable and safe Easy to use Wide solution (many applications) Open standard

Market Situation • More than 1400 members worldwide • More than 20 millions installed nodes with success • More than 5 millions sold nodes in the last 3 year • More than 2800 products and more than 2000 suppliers • More than 750 new products in the last 3 years

High application demand • Attends to the chemical industries and process techonologies requirements (recommendation NAMUR-NE-74) – Intrinsic Safety – Bus powered • For sensors and actuators via H1 channel

– Standardized device profile – Interoperability

• Usability certification for PROFIBUS in control applications by NAMUR

PROFIBUS technology is reliable and tested in plants in real conditions. • PROFIBUS is operating in several plants and applications worldwide since 1989. • Up to now there are more than 500.000 plants in operation. • In the last 5 years more than 1000 PROFIBUS PA installations were made in the chemical and process industry. • More than 300.000 PROFIBUS PA devices in operation.

Reliability

PROFIBUS is part of open standard IEC 61158

Costs reduction

$

$

PLC

Terminal blocks

Terminal block

PROFIBUS Terminal block

Barrier

I/O

Future oriented technology

…because PROFIBUS is deterministic …beacuse diagnostic methods and failure detection are native to the system …because PROFIBUS International ensures quality through test laboratories …because dedicated and detailed tests & certification procedures are available and established  …more than 20 millions nodes PROFIBUS techonology installed and more than 1000 PROFIBUS PA technology plants  …stable standard, however not static

Total covered solutions available  PROFIBUS DP/PA  Same communication protocol in all segments  Total transparency between segments  The solutions attend critical applications

 Wide application coverage: (ex. Inverters, I/O remotes, field instrumentation, smart CCMs, substation relay...)

DP/PA Advantages  Benefits combination  For manufacture and process  Integration with legacy technologies  Short execution time

( HART, AS-I, etc)

Wide Solution Acyclic configuration: ProfibusView, PDM, CommuWin II, FieldCare, Pactware

Class 1 and 2 Master

Integrated Operation Center

PROFIBUS-DP max 12 Mbit/s DP/AS-i link 20

DP/PA Link

AS-I bus

PROFIBUS-PA 31.25 kbit/s 4-20mA Integration

Krohne

Krohne

TT303 LD303 FY303

Smar

LD301 WEG

Micromaster

On/Off Valves AS-i P+F devices

FTD/DTM Technology

• DTM – Device Type Manager – Software component (DLL, OCX) that contains all device functions

• FDT – Field Device Tool – Application for Windows that manages DTMs.

FTD/DTM Technology

• Use of a single software environment to integrate products from different manufacturers and protocols. • Tipically a Windows application known as FDT Frame Application ou FDT Container.

FTD/DTM Technology FDT Container or FDT Frame Application is the configurator,in other words, the software that allows the device access through its driver (DTM).

FDT Container

HART

FTD/DTM Technology Benefits  Full connection to any plant automation and supervision system  Easy to learn and to use  Open to all communication protocols  Reduced costs in development, operation, system maintenance and training  Competitiviness between system manufacturers  Open technology, free distributed standard, it doesn´t need proprietary components, as the DD technology that is dependent on interpreters that are closed.

FTD/DTM FDT/DTM Integration

Proprietary

Protocol

The manufacturer provides the DTM with the equipment

New equipment? Install the respective DTM provided by the manufacturer

DTM’s integrate to the FDT application and communicate in a standardized way

Total access in a single tool – FDT Container

FTD/DTM Technology Plug&Play Concept New printer installation

New Device installation

FTD/DTM Technology Plug&Play Concept FDT Container programa Plug & Play

DTM

Device Type Manager

FTD/DTM Technology DD Integration (Device Description)

DTM

Device Description (DDL, EDDL, HDDL...)

ARCHITECTURE

Profibus PA smart positioner

DTM ACTR

DTM COMM

FDT FRAME APPLICATION

Screen: FieldCare

Device: Pressure Transmitter

FDT FRAME APPLICATION

Screen: FieldCare

Device: Pressure Transmitter

Integration in PROFIBUS systems

PROFIBUS network elements Couplers

Class 1 Master PROFIBUS PLC / DCS / PC PROFIBUS-DP 45.45 kbit/s ou 93.75 kbit/s SK2 12Mbit/s COUPLER DP/PA

24V

COUPLER DP/PA

24 V PROFIBUS-PA 31.25 kbit/s

PROFIBUS-PA 31.25 kbit/s

Slaves

PROFIBUS network elements Links

Class 1 Master PROFIBUS PLC / DCS / PC PROFIBUS-DP up to 12Mbit/s

DP/PA Link + Couplers

DP/PA Link + Couplers

24 V

24 V

PROFIBUS-PA 31.25 kbit/s

PROFIBUS-PA 31.25 kbit/s

Max. 5 DP/PA Couplers per link IM157 Max. 32 equipment per link IM157 – Ex ia * Max. 64 equipment per link IM157 - Non-Ex *

Slaves (*) depends on the device current consumption and the number of occupied slots/device

PROFIBUS System Address Couplers

Master

1

PLC / DCS / PC PROFIBUS-DP 45.45 kbit/s or 93.75 kbit/s

PROFIBUS DP

24V

24V COUPLER DP/PA

PROFIBUS-PA 31.25 kbit/s

2

Slaves

3

4

PROFIBUS System Address Links

Masters PLC / DCS / PC

1 PROFIBUS DP

2

24V

PROFIBUS-PA 31.25 kbit/s

3

24V

1

DP/PA LINK COUPLER

1 Max. 5 DP/PA Couplers per link IM157

Slaves

2

PROFIBUS-DP Up to 12 Mbit/s

3

2

Max. 35 devices per link IM157 - Ex Max. 64 devices per link IM157 - Non-Ex

What we need in a PROFIBUS-PA network ? • PROFIBUS-DP Communication card in the computer (Class 2 Master) • Configuration and field device diagnostic PROFIBUS-PA software (ProfibusView(Smar), Simatic PDM, Commuwin II, FieldCare, Pactware,) • DP/PA Coupler or DP/PA Link + Coupler • Programmable Logical Controller, DCS or PC as Class 1 Master

•Network terminators • Field Devices (transmitter, valve positioners, etc) PROFIBUS-PA

Integration between PROFIBUS-PA and PROFIBUS-DP segments • GSD (device master data) file: txt file with hardware and software review details, PA equipment bus timing and cyclic data exchange information. It must have one for each equipment.

• DD (Device Description) for Simatic PDM : ddl file with a description of all functional blocks and methods (calibration)

parameters and optional menus. • DTMs (Device Type Manager) for FDT systems: FieldCare, Pactware, Smar Studio302

Profibus PA instrument GSD file #Profibus_DP GSD_Revision = 2 Vendor_Name = "SMAR" Model_Name= "LD303" Revision= "1.0" Ident_Number= 0x0895 Protocol_Ident= 0 Station_Type= 0 Bitmap_Device = "Src0895n" FMS_supp= 0 Hardware_Release= "3.0" Software_Release= "1.17" 31.25_supp= 1 45.45_supp= 1 93.75_supp= 1 187.5_supp= 1 MaxTsdr_31.25= 100 MaxTsdr_45.45= 250 MaxTsdr_93.75= 1000 MaxTsdr_187.5= 1000 Redundancy= 0 Repeater_Ctrl_Sig= 0 24V_Pins= 0 Freeze_Mode_supp= 0 Sync_Mode_supp= 0 Auto_Baud_supp= 0 Set_Slave_Add_supp= 1

Min_Slave_Intervall= 250 Modular_Station= 1 Max_Module= 2 Max_Input_Len= 10 Max_Output_Len= 2 Max_Data_Len= 12 Max_Diag_Data_Len= 14 Slave_Family= 12 User_Prm_Data_Len= 0 ; ;Modules for Analog Input Module = "Analog Input (short) " 0x94 EndModule Module = "Analog Input (long) " 0x42, 0x84, 0x08, 0x05 EndModule ; ;Module for Totalizer Module = "Total " 0x41, 0x84, 0x85 EndModule Module = "Total_Settot " 0xC1, 0x80, 0x84, 0x85 EndModule Module = "Total_Settot_Modetot " 0xC1, 0x81,0x84, 0x85 EndModule ; ;Empty module Module = "EMPTY_MODULE" 0x00 EndModule

Profibus PA instrument GSD file #Profibus_DP GSD_Revision = 2 Vendor_Name = "SMAR" Model_Name= ”FY303" Revision= "1.0" Ident_Number= 0x0897 Protocol_Ident= 0 Station_Type= 0 Bitmap_Device = "Src0897n" FMS_supp= 0 Hardware_Release= "3.0" Software_Release= "1.17" 31.25_supp= 1 45.45_supp= 1 93.75_supp= 1 187.5_supp= 1 MaxTsdr_31.25= 100 MaxTsdr_45.45= 250 MaxTsdr_93.75= 1000 MaxTsdr_187.5= 1000 Redundancy= 0 Repeater_Ctrl_Sig= 0 24V_Pins= 0 Freeze_Mode_supp= 0 Sync_Mode_supp= 0 Auto_Baud_supp= 0 Set_Slave_Add_supp= 1 Min_Slave_Intervall= 250 Modular_Station= 1 Max_Module= 1 Max_Input_Len= 15 Max_Output_Len= 10 Max_Data_Len= 25 Max_Diag_Data_Len= 14 Slave_Family= 12 User_Prm_Data_Len= 0

; ;Modules for Analog Output Block ; Module = "eSP ” 0x82, 0x84, 0x08, 0x05 EndModule ; Module = " SP ” 0xA4 EndModule ; Module = "eSP + RB + POS_D " 0xC6, 0x84, 0x86, 0x08, 0x05, 0x08, 0x05, 0x05, 0x05 EndModule ; Module = "eSP + CHECKBACK " 0xC3, 0x84, 0x82, 0x08, 0x05, 0x0A EndModule ; Module = "eSP + RB + POS_D + CB " 0xC7, 0x84, 0x89, 0x08, 0x05, 0x08, 0x05, 0x05, 0x05, 0x0A EndModule ; Module = "eRCAS_IN + RCAS_OUT " 0xC4, 0x84, 0x84, 0x08, 0x05, 0x08, 0x05 EndModule ; Module = " RCAS_IN + RCAS_OUT " 0xB4 EndModule ; Module = "eRCAS_IN + RCAS_OUT + CB ” 0xC5, 0x84, 0x87, 0x08, 0x05, 0x08, 0x05, 0x0A EndModule ; Module = "eSP+RB+RCASIN+RCASOUT+POS_D+CB" 0xCB,0x89,0x8E,0x08,0x05,0x08,0x05,0x08,0x05,0x08,0x05,0x05,0x05,0x0A EndModule

Profibus PA instrument EDDL file

/* Example file using Electronic Device Description (EDD) */ /* Important: This file serves as an example only, it is not normative */ /* File name: example.edd */ /* 3.1. The Identification */ MANUFACTURER 42, DEVICE_TYPE 42, DEVICE_REVISION 1, DD_REVISION 1 VARIABLE local_variable { LABEL "Local Variable"; HELP "Help"; CLASS LOCAL; TYPE FLOAT { DEFAULT_VALUE 30; MIN_VALUE 10; MAX_VALUE 200; SCALING_FACTOR 200; EDIT_FORMAT "5d"; DISPLAY_FORMAT "5d"; } HANDLING READ & WRITE; VALIDITY TRUE; } BLOCK BlockIdentifier1 { TYPE PHYSICAL; NUMBER 1; } VARIABLE local_variable_1 { LABEL "Local Variable 1"; CLASS LOCAL; TYPE FLOAT {

DEFAULT_VALUE 20; MIN_VALUE 10; MAX_VALUE 200; } POST_EDIT_ACTIONS { postscale_variable } HANDLING READ & WRITE; } METHOD postscale_variable { LABEL "Local Method"; DEFINITION { float f; int i; f = fvar_value(local_variable_1); i = (f / 5) + 0.5; f = i * 5; assign_float(local_variable_1, f); } } COMMAND read_command { SLOT 1; INDEX 2; OPERATION READ; TRANSACTION { REQUEST { }

PROFIBUS PA field device Block Model • You can find simple or multivariable devices, in which there are multiple sensors, transducer blocks and blocks • For simulation, the AI and AO blocks have the simulate parameter where the user can simulate values and ensure the integration and communication integrity.

Physical Block

Sensor

Transducer Block

Function Block Analogue Input

Measured value = input value Process value = output value

PROFIBUS - PA

Device Management

Transducer Blocks • Blocks dedicated that interface hardware (sensors and actuators) via internal channel with AI and AO blocks • allow values to be sent or read by class 1 Master

Function Blocks Function Blocks

Analog Input

Totalisator

Analog Output

Discrete Input

Counter

Discrete Output

PID-Control

Nicht Bestandteil des Profils Bestandteil des Profils

• Function blocks are standard interfaces (normally, 4 bytes for the measure value and 1 byte for status) that will be cyclic exchanged with class 1 master. • They can offer basic functionality (characterization, scales, etc)

Analog Input Block

Analog Output Block

Totalizer Block

PROFIBUS PA device profile (DD)

Status Process Value

Cyclic and acyclic DP services

Calibration zone

PA-Profile

damping Alarms, Limit Indicators Alarm summary

Acyclic DP service

(for instance: for pression transmitter)

TAG

Specific parameters for each manufacturer

DD Acyclic DP service

Measured values and measurement status

Measured variable IEEE Floating Point Format (4 Byte) Status Byte

Measurement e parameters and variables

Cyclic communication

00 . . . . . .= bad 01 . . . . . .= uncertain 10 . . . . . .= good ....

= Sub status

. . . . . . 00 = Limits o.k. . . . . . . 01 = low limit . . . . . . 10 = high limit

Status bytes

• PROFIBUS PA gives process variable high resolution. • Process variables possess a status byte. • The status byte evaluation permits the measurement validation and can be used as online diagnostic.

Measuremente status (quality) • The status byte is divided in 3 logical parts

7

6

Quality

5

4

3

Sub-status

2

1

0

Limit

For example: – “Good Non Cascade IFS” – used in the AO in a FailSafe situation. – “Uncertain Simulate Value” – used each time the block goes to Man.

Measurement Status – diagnostic online decodification

Block Diagram: PROFIBUS PA x 4-20 mA instrument PROFIBUS DP PA Generic Device

Sensor

A D

µP

DP/PA-Link

PAInterface

PROFIBUS PA

PROFIBUS DP Remote I/O

4-20mA Generic Device

D A

µP D

4 to 20 mA

D A

A

Block Diagram: PROFIBUS PA x 4-20 mA instrument • PROFIBUS PA provides

– digital process variable in floating point format – one status byte for each process variable – cycle times < 20 ms per transmitter (1 variable) – complete access of all parameters via class 2 master

• 4 to 20 mA requires a D/A and A/D converters that: – Demands the commitment between the resolution and the conversion time, excluding the error due to this conversion. – requires a perfect coupling between the equipment range and the host system for a resolution optimization – Susceptible to noises and DC/AC devices, increasing drifts – without diagnostics, without information from other parameters, etc

Multivariable bidirectional communication

PROFIBUS DP DP/PA-Link

PROFIBUS PA Concentration/ Density Transmitter

• Manydevices can measure more than one measurement, can receive and send values to controllers (PLC / DCS / PC): •

Concentration (Brix),

•

Density (Kg/m3),

• Temperature (C)

Multivariable bidirectional communication PROFIBUS DP Remote I/O

4 to 20 mA

• Flow transmitter (4-20mA) • total flow with reset input for flow counter • total flow forward with reset input for flow counter • total flow reverse with reset input for flow counter • temperature • ultrasonic sound velocity • damping of ultrasonic sound amplitude

Cyclic online diagnostic in PROFIBUS PA instruments and via class 2 master

Temperature Transmitter Sensor

PROFIBUS DP

DP/PA-Link PROFIBUS PA

Sensor failure

PROFIBUS DP

Remote I/O > 20 mA or < 4 mA

• Online diagnostics are cyclically exchanged with class 1 master allowing the instantaneous failure detection.

• In the 4-20mA a failure can be detected if the current exceed the 4-20mA zone, however the user can’t distinguish between a sensor failure and any other failure.

Cyclic online diagnostic in PROFIBUS PA intruments

PROFIBUS DP Valve positioner DP/PA-Link PROFIBUS PA

Air deficiency

• A valve positioner can not reach a specific position due to air deficiency or if there is a problem • Online diagnostic via Profibus PA allows to create an alarm indicating the failure and thus an easy correction action can be taken.

PROFIBUS DP

Remote I/O

4 to 20 mA

• In the 4-20mA positioner failure only can be recognized with additional alarm switches.

E.G. FY303 - Smar Positioner Functional Diagram, its parameters and diagnostics –

Functional Blocks and Fail Safe

• Safety condition that the function block assume when its algorithm detects a failure situation. (After the failure is normalized, the block returns to the normal operation).

• Both input and output blocks handle with FailSafe procedure.

• The failure sitution are detected by different ways in input and output blocks.

Functional Blocks and Fail Safe • Input Blocks: The failure situation occurs when the transducer send a “Bad” status. (For instance, “bad sensor”) • Output Blocks: The failure situation can occur due to: • Communication fail with RCAS_IN for a time greater than FSAFE_TIME

• Communication fail with SP for a time greater than FSAFE_TIME • “Good (C) IFS” status in the RCAS_IN input when the target mode is RCAS.

• “Good (NC) IFS” status in the SP input when the target mode is AUTO.

Functional Blocks and Fail Safe • The actions to be taken in Fail Safe conditions are set in the FSAFE_TYPE parameter (in the AI and AO), and can be : •To use a preset value (FSAFE_VALUE). Status = “Uncertain Substitute value” •To use the last valid value (LUV). Status= “ Uncertain LUV”or “Uncertain Initial Value” •To use the bad value (AI), or to use certain value in the parameter ACTUATOR_ACTION of Trd (AO). Status is the same as the input.

• In the totalizer, the actions are guided by FAIL_TOT, and can be: • Hold (stop the totalizer) • Memory(totalize with the last good value) • Run (totalize with the bad value)

Function Blocks and Fail Safe Sensor Failure AI Bad – Sensor Failure IFS – Initiate Fail safe

PID Good Cascate FSA Active Fail safe Good Cascade IFS Initiate Fail safe

AO

Fail Safe Value: 50% Fail Safe Time: 3 s

E.G. IF303 - Smar 4-20mA Converter to Profibus PA PHY BLOCK

3 TRD BLOCK

3 AI BLOCK

3 TOT BLOCK

IF303 DSP BLOCK

Technical Support For questions & technical support consult us at: [email protected]