Integrated HART Protocol Device Networks for ControlLogix® Systems Practical Applications for Spectrum Controls Analog+HART

I/O

Introduction: Process networks come in many forms. They can be broke down into four basic categories, Enterprise, Control, Device, and Sensor. Enterprise networks are the highest level and typically encompass ERP, visualization, and maintenance activities. Control networks are the backbone of the PLC network. Chassis to chassis communication is accomplished using control networks. Device networks typically bridge devices to a master but can bridge device to device. Sensor networks are geared towards supporting discrete I/O operations. Control scenarios may be incorporated into the sensor and data sent back via the device network. Our focus will be HART device networks.

Key Focus Areas: • • • Overview of HART Protocol ControlLogix HART I/O Capabilities Benefits of integrated HART networks. Commissioning Efficient Documentation Simplified Device Configuration Operation Real-time diagnostics Regulatory Compliance (FDA, EPA…) Maintenance Automated Predictive Maintenance Audit Trail / Self Documentation

Integrated Device Networks for ControlLogix® Systems

Integrated Architecture:

Enterprise Client Applications

Engineering Asset Management Workstation RSLogix / Logix PAM / DMS/ RSView / RSMACC FieldCare

Visualization RSView or PanelView

Change Management & Maintenance

ENet

ControlLogix
Analog+HART I/O
ENet or CNet

HART Field Devices
Hand Calibrator

What is the integrated solution? It’s a combination of process networks. The needs of the industry have changed. Today, plants need to lower operating cost, maximize capital investments, improve plant operations and manage assets to remain competitive. Integrated architecture allows you to access HART transmitter data without being on the plant floor. It also allows you to share data across the enterprise. The integrated architecture allows you high levels of process control and more accurate predictive maintenance cycles. The integrated architecture is comprised of your existing HART field devices, MCCs and drives, Spectrum Controls HART I/O and ControlLogix hardware, and your Control and Maintenance Software.

Integrated Device Networks for ControlLogix® Systems

What is HART? HART (Highway Addressable Remote Transducer) originated by Rosemount in the late 1980s and became an open protocol in 1990. Designed to compliment traditional 4-20mA analog signaling, the HART Protocol supports two way digital communications for process measurement and control devices. Applications include remote process variable interrogation, cyclical access to process data, parameter setting and diagnostics

The most popular methods of acquiring HART data are the hand held communicator and the clipon serial modem. The data acquired by the hand held may be downloaded to a PC database or asset management tool. A direct connection via serial modem removes the user from the field. Either method is compatible with diagnostic software, but does not support real-time online communication.

Integrated Device Networks for ControlLogix® Systems

What data is available? Most smart transmitters are available with a HART protocol interface. The type of data available is dependent on the type of instrument. The most common data types are the process variable, a percent of range, a digital reflection of the analog mA signal or device status. These values are often mapped to the HART protocol PV (primary variable), SV (secondary variable), TV (tertiary variable), and FV (fourth variable). HART commands are categorized into three areas, general purpose, common practice and device specific. These commands are used to view and change device, configuration and status information For example, a mass flow meter has derived values that would normally be obtained using standard analog instruments. The PV would be the mass flow value, the SV could be the static pressure, the TV could be the temperature, and the FV could be the digital mA signal reflection. These mappings are device dependent and user selectable in most cases. Valves have position and cycle information allowing you to determine if the valve is functioning properly and when it is time to perform a maintenance cycle. This is just a small portion of data available from HART instruments.
Endress+Hauser Mass Flow Meter

• • • • • • • • •

PV: Mass Flow Rate SV: Totalizer 1 TV: Density FV: Temperature Volume Flow Std. Volume Flow Target Flow Carrier Flow Calculated Density

Read

Write

• Set Flow Units • Reset Totalizers • Set Zero & Full Scale Range • Change K Factor • Change Pipe Diameter • Set Flow Direction • Set “Low Flow Cutoff” •

• PV: Percent Travel • SV: Travel Setpoint • TV: Temperature • FV: Supply Pressure • Status Bytes
RAM Fail Pressure Sensor Fail Temperature Sensor Fail

Metso Control Valve

Read

Write

• Perform Diagnostic Tests • Set Zero & Span • Adjust For Mechanical Wear • Adjust Valve Sensitivity

HART also allows you to write data back to the instrument. You may want to make offset or span corrections, perform diagnostics or set scaling parameters. All of this communication is carried out over existing 4-20mA wiring using the HART digital signal. The HART Communication Foundation authors a standard which describes the command sets and allows manufacturers to author Device Descriptor (DD) files which highlight all of the common practice, general purpose and device specific parameters. The result is a highly standardized command set and reliable communications.

Integrated Device Networks for ControlLogix® Systems

Analog + HART I/O Module Overview The Spectrum Controls analog input and output modules with HART protocol function as standard I/Os within the ControlLogix system. Both modules support typical ControlLogix features including, insertion and removal under power, flash-upgradeable firmware, electronic keying and are non-slot dependent. Each channel can be configured for either current or voltage. HART can be enabled or disabled on any channel configured for current, allowing the user the flexibility of tailoring the system for the application. Both modules support the usual analog ranges including +/- 10 Vdc, 0 to 5 Vdc, 0 to 10 Vdc, 0 to 20mA, and 4 to 20 mA. The modules are configured by using Rockwell Software’s RSLogix 5000 programming software. The modules also provide standard analog features such as user calibration, scaling, process alarming and signal clamping. Both modules use Allen-Bradley terminal blocks (i.e. 1756-TBCH, 1756TBNH) allowing for pre-wired cables to be utilized thus minimizing the costs of installation.

Analog + HART Communications To better understand how HART data is retrieved from the modules you first need to understand how the modules communicate with the ControlLogix processor. HART modules communicate using two different messaging schemes connected and unconnected. Connected messages are messages that are periodically updated and maintained by the ControlLogix processor. The frequencies of the updates are adjustable and are defined by the user. Connected messages include data contained in the module’s input image, and in the case of the OF8H module, the output image. Unconnected messages are messages that are transmitted over the control network and are performed asynchronously from the normal processor scan. Unconnected messages include data contained in the module’s configuration image (i.e. Local:e:C), and CIP messages such as the HART Pass-Through message.

Integrated Device Networks for ControlLogix® Systems

Connected

• • • •

Analog data Module status HART Dynamic Variables HART device codes

Unconnected

• • •

Module Configuration Any CIP message HART Pass-Through

When a channel is configured for HART, the module will automatically search and establish a connection to any HART field device wired to the channel. Once the module establishes a connection it will begin to acquire HART data, including device specific codes (i.e. Manufacturer ID, serial number, etc.), the four dynamic variables, extended device status, slot variables (OF8H only), and any stored ASCII message descriptor that may be present. The HART data retrieved automatically by the module is then displayed in the input image and is accessible by ladder logic.

One of the many features of our HART modules is the ability to send and receive CIP messages. Both modules utilize a CIP command called HART pass-through. The pass-through command allows for any HART command to be passed by the module to the connected field device. The possible HART commands include all three types defined by the HART foundation, universal, common practice and device specific. With the ability to send any HART command, the user can access and change any parameter stored on the HART field device. This allows for maximum flexibility and reduces costs by limiting the need for expensive hand-held communicators and

Integrated Device Networks for ControlLogix® Systems

device configuration software. The pass-through command can be sent by a message instruction in the ladder program or by a piece of software that supports the Rockwell CIP protocol. For some HART installations the user may wish to implement some type of Plant Asset Management (PAM) software to better organize and maintain the HART devices in their system. Spectrum Controls has developed a piece of software that will make this process for the user as simple as possible. The software is called Connects. Connects can be interfaced with any PAM software that supports an RS485 hardware multiplexer. Connects works like a communication driver between the Spectrum HART modules and the PAM software. HART messages are captured from the PAM software and repackaged by Connects, using RSLinx, and then transmitted as CIP pass-through messages to the HART module. The HART module will then send the HART messages to the field device over the 4 to 20mA analog signal. This direct communication simplifies commissioning by eliminating the need for ladder logic to perform the communication.

Workstation
Device Management Application

+
10101010101

Spectrum Controls HART I/O Gateway

Rockwell Software RSLinx

+

Integrated Device Networks for ControlLogix® Systems

HART I/O HART I/O

The Big Picture The flexibility of the HART modules gives the user the ability to use them in a variety of ways. The modules can be used with PanelViews, SCADA packages or PAM software to monitor and change HART device parameters from anywhere on the plant floor. Using PAM software, the user can better manage plant operations by utilizing such features as trending, alarming, and device tracking. Our HART modules can also help eliminate field devices from the process by extracting more data from a single HART transmitter rather than using several standard analog transmitters to perform the same task.

Engineering Workstation RSLogix / Logix RSView / RSMACC

Asset Management PAM / DMS/ FieldCare

Visualization RSView or PanelView

Change Management & Maintenance

ENet

ENet or CNet

Analog and HART Data

Hand Calibrator

Integrated Device Networks for ControlLogix® Systems

Practical Applications for Integrated Device Networks The lifecycle of the system is greatly impacted by integrating HART device data into your control system. The major impact areas are: Commissioning Efficient Documentation Simplified Device Configuration Operation Real-time diagnostics Regulatory Compliance (FDA, EPA…) Maintenance Automated Predictive Maintenance Audit Trail / Self Documentation

Commissioning: Commissioning is impacted in a couple of ways. Initial device configuration becomes much more efficient as you no longer need to use the hand-held and sneaker net to configure all the devices. An added benefit is that you can develop a configuration template for each type of instrument and use that as the basis for future configurations. This makes for more consistent and less problematic startup. Another benefit is the ability to verify performance. This comes in several forms. You can verify loop integrity as well as validate instrument performance. In the case of a valve you can verify open and closed positions in relationship to the current loop values and make range adjustments as necessary. Configuration clients have tools specific to this purpose. Finally, documentation is drastically simplified. The reporting tools found in today’s configuration and asset management tools drastically simplify device and network documentation.

The software tool will dictate the level of your communications capability. A simple configuration tool such as the HART Communication Foundation Server will allow you to view common device parameters, set range, engineering unit, and calibration parameters. The tool will allow you to share this data with a business application allowing you to capture this data in an electronic form. More sophisticated Plant Asset Management tools such as Meriam DMS or Endress+Hauser Fieldcare also allow you to perform these operations as well as trend instrument behavior and provide the ability to clone and deploy instrument configurations when commissioning several of the same type of instrument.

Integrated Device Networks for ControlLogix® Systems

Operation: HART networks are typically viewed as an asset management tool, not an operational tool. In fact, most HART data is not time critical so network performance isn’t necessarily a factor. For example a valve would normally be controlled by an analog output. Without HART communication present there is no feedback within the system. With HART you can view the four basic HART variables, Percent Travel, Set Point, Temp and Supply Pressure, and use this data as a basis for feedback within the system. But what happens when it all goes wrong… A non-HART system still only shows the analog loop current. A HART enabled system can show status, electrical or mechanical failure diagnostics and wear patterns. All of this data can be monitored real-time to provide immediate diagnosis to the problem. Even with a handheld, the data may not be accessible if the sensor is in a hazardous area. All of this data may be displayed on the operator console by simply mapping the HART I/O controller tags back to your visualization software. Device specific parameters may require passthrough messaging but the I/O can easily accommodate and manage these requests. Another benefit is instrument cost reduction. A large integrator of pollution control sulfination systems has dramatically reduced the cost of their injector system. The system initially used three separate field transmitters and standard 4-20mA input signals to perform a mass flow measurement.

Using HART I/O allowed the integrator to remove the pressure and temperature transmitters from the system and use only the flow meter. The flow meter measures pressure and temperature, but this data was not available from the 4-20mA signal. Using HART allows full access to this data. The total cost reduction was approximately US$12,000 Another area for operational improvement is the use of HART data for its inherent accuracy. For instance, using HART-enabled mass flow meters that rely on the derived totalizer data as opposed to using data derived using secondary sensors. The mass flow meter provided 10% efficiency over other methods. This data was not previously available without HART communication.

Integrated Device Networks for ControlLogix® Systems

Maintenance with HART: Device Management and Plant Asset Management tools allow you a tremendous amount of functionality. The most obvious use is device management. Configuration during down cycles, historical maintenance records identifying problem sensors and regulatory documentation are dramatically simplified. Scheduling is based on instrument utilization. Instead of maintaining instrumentation over a specific calendar time you can now use cycle data. For instance, a valve can be interrogated to determine the number of cycles. If it has an MTBF of 200,000 cycles you can plan a more appropriate maintenance cycle where as previously you waited for a failure or performed unnecessary maintenance. Backup and recovery are also simplified as your system has a complete record of each device configuration and the network topology. Electronic download and recovery is far more efficient that using handhelds to regenerate a particular setup. Finally, trending and reliability data can help to make better decisions about the quality of the instrumentation being used and the performance of the system as a whole. Small changes can result in big payback.

Integrated Device Networks for ControlLogix® Systems

Conclusion: Integrated devices networks have progressed from expensive, high end implementations to scaleable, cost effective small to mid-range installations. Traditional issues such as noncompatible data interfaces and expensive hardware have been addressed. The efficiency of an integrated network can impact all aspects of the system performance and economy. The cost of implementation has been dramatically reduced. Integrated device networks for PLCs represent the beginning of the movement towards system wide diagnostic and asset management capability. Commissioning, Operation and Maintenance remain the key focus in operating and maintaining a cost effective operation.

References: Spectrum Controls, Inc. PO Box 5533 Bellevue, WA 98006 (425) 756-9481 spectrum@spectrumcontrols.com www.spectrumcontrols.com

Spectrum Controls, Inc. – www.spectrumcontrols.com ControlLogix® HART I/O and CONNECTS Communications Gateway Endress+Hauser – www.endress.com Field Care – Device Management Software, Field Instrumentation Meriam Process Technologies – www.meriam.com DMS, Device Management Software, Handheld HART Communicators HART Communication Foundation - www.hartcomm.org HART Server / Generic Client Configuration Software

Integrated Device Networks for ControlLogix® Systems

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