Foundation Fieldbus Training Book PDF

Foundation Fieldbus
Technical Training
Ryan Kelly
Chevron Energy Technology Company (ETC)
June 2008
© Chevron 2005
1
Welcome & Introductions
Ryan Kelly
Instrumentation & Controls Engineer
Chevron ETC – Process Automation Unit
ryan.kelly@chevron.com
Vincent Palughi
Snr Instrumentation & Controls Engineer
Chevron ETC – Process Automation Unit
vpalughi@chevron.com
© Chevron 2005 ETC-PA: Foundation Fieldbus Training 2
2
Welcome & Introductions
Please tell us about yourself:
Name
Role on the project
Experience (if any) with Foundation Fieldbus or

other types of smart instrumentation
Your expectations of the course – what you hope

to learn from it
3
Safety Moment – Hazardous Areas
The Fire Triangle
4
Area Classification (NEC Article 500.5 / API RP 500)
Class I - flammable gases, flammable liquid–

produced vapors, or combustible liquid–produced
vapors
Class II – combustible dust
Class III - easily ignitible fibers or materials

producing combustible flyings
For full text of the standard, please see NEC Article 500.5
5
Class I, Division 1 is a location in which ignitible

concentrations of flammable gases, flammable liquid–
produced vapors, or combustible liquid–produced vapors
can exist
under normal operating conditions, or
frequently because of repair or maintenance operations

or because of leakage, or
due to breakdown or faulty operation of equipment or

processes that might also cause simultaneous failure of
electrical equipment in such a way as to directly cause
the electrical equipment to become a source of ignition.
6
Class I, Division 2 is a location in which volatile
flammable gases, flammable liquid–produced vapors, or
combustible liquid–produced vapors are handled,
processed, or used, but in which the liquids, vapors, or
gases will
normally be confined within closed containers or closed
systems from which they can escape only in case of
accidental rupture or breakdown of such containers or
systems or in case of abnormal operation of equipment,
or
normally prevented by positive mechanical ventilation
and which might become hazardous through failure or
abnormal operation of the ventilating equipment, or
the area is adjacent to a Class I, Division 1 location
7
Protection Techniques (NEC Article 500.7)
Explosion-proof Equipment (XP) - Class I, Div 1&2
“Explosion-proof" means that the enclosure is capable of containing an internal

explosion without allowing flames or hot gasses to escape and trigger an
explosion in the surrounding atmosphere. It does not indicate that the product
is capable of withstanding an external explosion.
8
Intrinisically Safe Equipment (IS) - Class I, Div

1&2
"Intrinsically safe" devices produce or consume electrical power at levels below

what is required to cause an ignition in a hazardous area. The electrical energy
going to the device is limited, and the devices are incapable of storing enough
energy to create a spark when disconnected.
9
Non-Incendive Equipment (NI) - Class I, Div 2
“Non-Incendive” equipment works on the same principle as Intrinsically Safe,

that is by limiting the amount of energy going to and stored in a device. The
difference is that Non-Incendive is only permitted for use in Division 2 areas,
and as such has a reduced safety factor which allows more energy to the field
devices (but still not enough to create a spark).
10
Purged and Pressurized – Class I, Div 1&2
Hermetically Sealed – Class I, Div 2
Combustible Gas Detection – Class I, Div 1&2
Oil Immersed – Class I, Div 1
Used more in electrical systems than instrumentation
The above techniques are more commonly used for electrical equipment than
instrumentation.
11
Agenda – Day 1
Introduction to Foundation Fieldbus

z History, Basics, Benefits
Fieldbus System Components

z Power, Devices, Wiring
Key Fieldbus Concepts

z Tags/Addresses, Blocks, DDs
R00#1 Segment Design and Specifications
Fieldbus and Yokogawa Centum CS3000

z Hardware, Software, HMI example
12
Agenda – Day 2
Yokogawa Plant Resource Manager (PRM)

z Device configuration and troubleshooting
Foundation Fieldbus Commissioning

z Segment and Loop Checks
Maintenance of Fieldbus Systems

z Physical Layer diagnostics (inc. P+F modules)
z Device troubleshooting
z Adding/removing/replacing devices
z Fieldbus device calibration
13
Introduction to Foundation Fieldbus
Image Source:
http://www.fieldbus.org/index.php?option=com_content&task=view&id=45&Ite
mid=195
14
What is Foundation Fieldbus?
From equipment up
More vendors, to user interface
interoperable
“Foundation Fieldbus is an open, nonproprietary

architecture that provides a communications protocol
for control and instrumentation systems in which
each device has its' own "intelligence" and
communicates via an all-digital, serial, two-way
communications system.”
More functionality
More accurate
(no 4-20mA)
Definition from
http://www.fieldbus.org/index.php?option=com_content&task=view&id=23&Ite
mid=308
15
History of Foundation Fieldbus
Development of proprietary digital bus protocols during
the 1980s
Formation of the Fieldbus Foundation in 1994 to

develop an industry standard
Focused on development of open and interoperable

standards with input from suppliers and users
Future development includes DD enhancements and

safety systems
1995 1998 2001 2002 2003 2008

FF Standards First registered FF HSE First major First Chevron 1,000,000 devices
first introduced FF devices linking devices FF plant FF installations 12,000 systems
Currently for use in process control systems only, not safety systems.
Shell Deer Park was the first major plant to use Foundation Fieldbus.
Foundation Fieldbus Standards:

ANSI/ISA 50.02 (USA)
IEC 61158 (World)
CENELEC EN 50170 (Europe)
16
The Fieldbus Foundation
Non-profit consortium formed by members of

various supplier and user organizations
Develops and administers the standards for

Foundation Fieldbus which are open and non-
proprietary
Provides reference material such as user guides

and engineering guides.
Useful website as a resource

for Fieldbus information
z http://www.fieldbus.org/
Examples of Chevron participation:

•Deon Rae’s contribution to the Fieldbus Engineering Guideline and standard
development
•Vincent Palughi’s participation in groups developing device coupler test and
wiring standards
17
Industry Acceptance
Users:
z Major oil & gas companies
z Other industries – manufacturing, pharmaceutical
z Over 12,000 systems and 1 million devices*
z 68% of projects are selecting FF
Examples of Chevron installations:

z El Segundo blending & shipping, California
z Al Jubail petrochemical plant, Saudi Arabia
z SJVBU tank farm, California
z TGPP and TL platforms, Angola offshore

(*) Data from ARC report
Examples of Chevron projects using FF:

•Takula Gas Processing Platform (TGPP) – Angola offshore
•Tombua Landana Production Platform (TL) – Angola offshore
•Cabinda Gas Plant (CGP) – Angola onshore
•Escravos Gas To Liquids plant (EGTL) – Nigeria onshore
•R00#1 SLC VGO unit – Salt Lake City, Utah
•R00#1 Pascagoula Crude 2 unit upgrade – Pascagoula, Mississippi
•R00#1 Burnaby – Burnaby, Canada
18
Industry Acceptance
Suppliers – Control Systems & Field Devices
Suppliers – Power Supplies & Connecting

Equipment
Emerson – includes Fisher, Rosemount, Micro Motion, etc.
19
Comparison with Analog Systems
Fieldbus uses a digital signal (1s and 0s) rather than
reading analog values (milliamps)
Digital data provides an actual measurement value

(e.g. 80 psi) rather than an analog value that has to
be interpreted (e.g. 12 mA)
Digital signal
Actual waveform
Reading analog values requires correct setup of scaling at either end of the
control loop.
20
Fieldbus devices are also bus-powered (9-30 VDC)
Fieldbus uses a bus topology rather than requiring a

pair of wires to every device
Host Host
Marshalling Marshalling
Device Coupler
Field Devices
Field Devices
Bus-powered means that the device obtains power and communicates on the
same pair of wires (i.e. 2-wire device).
The above examples show field devices with Intrinsic Safety (IS) barriers –
these may or may not be required depending on equipment location and the
facility’s choice of hazardous area protection.
21
Smarter field devices
z Setup of inputs in the device (range, units, etc.)
z Built-in device diagnostics (e.g. impulse line plugging)
z Additional functionality (mathematical functions, PID)
H1
Image Source: Fieldbus 101 Presentation (Dale Perry, Emerson)
22
Comparison with HART
HART uses analog 4-20mA for process values and

superimposes a digital signal on top
Devices have some parameters built into them,

but not to the level and functionality of FF
Devices are polled by the controller (on demand)

rather than transmitting autonomously
Much slower data rate (FF is >25 times faster)
FF is not approved for safety systems, so HART is

generally used
Fieldbus for Safety Instrumented Systems (FF-SIS) is currently undergoing

development and testing.
23
FF Topology
Host Interface
(DCS I/O card)
Spur Cables
Power
Conditioner
T
Trunk Cable
T
Surge Protector Device
Coupler
T = Terminator
Field Devices
Key components in an FF segment:

•Host interface (I/O card)
•Power Conditioner
•Device Coupler (Brick)
•Field Devices
•Terminators (one at each end)
•Trunk and Spur wiring
•Surge Protectors
24
FF Design Limits
Up to 32 devices per segment

z Usually up to 12 devices connected
z Also depends on power available
Up to 1900m (6200ft) total field wiring

z Includes total of both trunk & spurs
z Individual spurs up to 120m (390ft) long
z Should be individual shielded twisted pair (STP)
Requires 9-32 VDC at field device

z Consider voltage drop on long segments
The R00#1 segment design will be covered later.

Devices called “repeaters” can be used to extend the network length and
increase the number of devices. However the facility design is usually such that
repeaters are not required, and they are generally not used in Chevron
installations.
25
FF Protocol
Communications protocol includes:
Physical layer (H1)

z 31.25 kbit/s digital signal
z 9-32 VDC bus powered
Data link layer

z Defines what the bits/bytes mean
z Specifications for messages (packets)
User layer
z Function blocks
z Virtual Communication Relationships (VCRs)

26
FF Benefits
Digital protocol
z No analog conversion, includes digital error correction,
less susceptible to noise
Bi-directional communication between host & device
More data is available from the field device

z PV status, health/diagnostics, extra PVs, asset mgmt.
More powerful field devices

z Special function blocks, alarming, output scaling,
mathematical functions
More power at field devices enables additional

functionality (HART/analog were limited to <4mA)
Mathematical Functions – Integrator/totalizer, Signal Characterizer, Arithmetic
27
FF Benefits
Fully digital communications from the sensor to the
control system without D/A conversion
D/A conversion reduces accuracy and the electronics are more susceptible to
current drift over time than fully digital electronics. This is the main reason that
analog and HART instrumentation require more frequent field calibration than
FF devices. For example, the EJX pressure transmitter guarantees error < 0.1%
of URL for 10 years.
Image Source: http://www.yokogawa.com/fld/3D/EJX/p03.html
28
FF Benefits
Less field wiring/terminations and more physical layer
diagnostics available
Faster field commissioning (no field/bench calibration,

configure multiple devices simultaneously)
Many projects are seeing a lower total lifecycle cost
Open standards
Devices tested and approved
Interoperability required
Lower total lifecycle cost is contributed to by saving in commissioning time and

additional info/diagnostics that can alert to device problems and avoid
downtime.
The Fieldbus Foundation check mark shown indicates that a device has passed
the Foundation’s testing
29
Fieldbus System Components
Image Source: Fieldbus Book – A Tutorial (Yokogawa Corporation)
30
FF Components – Host Interface Card
Yokogawa CS3000 DCS
ALF111 Card
Redundant I/O cards

mounted in the Field
Control Station
Interface between the

control system and field
devices
4 segments per card
Special cable (AKB336)

between card and power
conditioner
31
FF Components – Power Conditioner
MTL-Relcom
F880 hub w/F801 modules
Special power hub for
Yokogawa connectors
8 segments per hub
Supplies power to field
devices (24 VDC)
Special power supplies
required for FF
Redundant power
conditioner modules
F809f Diagnostic module in
the center
Built-in terminator
Redundant modules are hot swappable

Dual 24 VDC feeds from bulk power supply
The F809f diagnostic module is actually a fieldbus device on the segment
(either segment 1 or 8). It can also be connected to an external segment.
32
FF Components – Surge Protector
Pepperl+Fuchs
DB-LB w/ DP-LBF-1.34
Installed on all trunks in

the marshalling panel
Surge protection is required

on all pairs due to potential
voltage surge coupling from
the affected wire to any
adjacent wiring in the tray.
DB-LB base allows removal

of the protection module
without interruption of the
signal
Surge protection devices are also available that can be placed at the instrument
end (not part of the R00#1 spec)
33
FF Components – Div 2 Device Coupler
Moore Hawke
Trunksafe TG20W (12-spur)
Connects trunk to field

spurs
Installed in field junction

box rated for Div 2
Built-in auto terminator
Short-circuit protection
Spurs are classified

Div 2 Non-Incendive
The bottom two connectors on the device coupler are for trunk connections only
(only one is used). The others are for the spurs to devices and contain energy
limiting circuitry. The device coupler must be connected in accordance with its
control drawing (TG200-FM)
34
FF Components – Div 1 Device Coupler
Turck
MBD49-T415/Ex (4-spur)
Connects trunk to field

spurs
Complete with enclosure

rated for Div 2
Switchable terminator
Short-circuit protection
Spurs are classified

Div 1 Intrinsically Safe
Also known as a
“Multibarrier”
Switchable terminator enables a second multibarrier to be connected on the

segment. The terminator should only be switched on in the final multibarrier on
the segment so that there are exactly 2 terminators per segment (the other is
in the power conditioner).
The bottom two connectors on the device coupler are for trunk connections
only. The others are for the spurs to devices and contain energy limiting
circuitry. The device coupler must be connected in accordance with its control
drawing (IS-2.502)
35
FF Components – Field Devices
Pressure: Yokogawa EJX
Temp: Yokogawa YTA
Valve: Fisher DVC6000f
Vortex: Yokogawa DY
Radar: Vegaflex 62
Look the same as 4-

20mA and HART devices
but NOT interchangeable
Contains special FF
microprocessor
FF tick of compliance
Can be polarity sensitive
All devices will have + and – terminals – some devices require correct polarity
while some are able to operate correctly if the polarity is reversed. The best
solution is to assume all devices are polarity sensitive and always connect the
devices according to the polarity indicated on the terminals. + to brown, - to
blue.
Models used for R00#1 specified in:

YR-PAS-DSP-201 Instrumentation Design
YR-PAS-DSP-214 Yokogawa Instrumentation
36
FF Components – Wiring
Trunks: 16AWG (1.5mm2)
Spurs: 18AWG (1mm2)
Similar to analog
instrument wiring
Two pair with shield
z Jacket : orange
z Positive : brown
z Negative : blue
Turck Minifast
connectors are used
for field devices
(hand tighten only!)
16AWG trunk wire was selected to eliminate the need for volt drop calculations.
Trunk wire is generally run in multipair (8 pair) cables.
For the Turck Minifast connectors, ensure you hand tighten only, don’t use a
wrench!
Field wiring has a drain wire which is used to connect the shield to instrument
ground at the control room end.
37
FF Components – Terminators
Resistor and capacitor in
series.
Two required on a
segment, one at each
end of the trunk
z Power Conditioner
z Device Coupler
Stops reflections of the

digital signal at each end
Any number of
terminators other than 2
causes signal problems
< 2 terminators results in signal reflections

> 2 terminators attenuates the fieldbus signal
38
FF System Grounding
Similar to analog instrument grounding:
Connect the shield to instrument ground at one point only
(where the trunk cable enters the marshalling cabinet)
Ensure that only the signal wires (+ and -) are connected to
the field device
Signal wires should NEVER be grounded or allowed to come
into contact with the shield.
More than one ground point on a segment creates ground loops which can
introduce noise onto the network.
39
FF Hazardous Areas
The R00#1 project requires the ability to connect

and disconnect Fieldbus devices in hazardous
locations under power
This requires Fieldbus spurs to be classified either:

z Class I Division 2 Non-Incendive
z Class I Division 1 Intrinsically Safe
IMPORTANT
Fieldbus trunk cables are NOT rated
for live connection/disconnection and
must be de-engergized first
The guiding industry standards for hazardous areas are:

Divisions (Non-Incendive): NEC Article 500, API RP 500, ANSI/ISA-12.12.01 /
FM 3611
Zones (Energy Limited): NEC Article 505, API RP 505, IEC 60079-15
40
FF Hazardous Areas: Division 2
Equipment rating requirements (FM/IEC)
Field devices
z Non-Incendive (NI)
Device couplers (associated apparatus)

z Non-Incendive (NI) and
z Non-Incendive Associated Apparatus (ANI)
Length of spur cable ≤ 120 meters (393 ft)
This does NOT meet the requirements for Division

1 areas (which requires the device coupler contain
an approved Intrinsically Safe barrier)
Generally most equipment will have equivalent ratings for both NEC and IEC
standards. Always view the actual approval certificate/drawing, since some
manufacturers may say the approval is “in progress” which can take a while.
41
Power
Conditioner
Spur Cables
T
Junction Box
T
Surge Protector
Device Coupler
(NI & ANI)
Not Div 2 Field Devices

Rated (NI)
Remember, only the spurs can be disconnected under power. Fieldbus trunk
cables are NOT rated for live connection/disconnection and must be de-
engergized first.
Refer to the FF Hazardous Area Verification Drawings document for further
information
Higher rated equipment (e.g. intrinsically safe devices) can be used in this
configuration, but will still only be allowed for used in Division 2 areas.
42
Equipment rating requirements (FM/IEC)
Field devices
z Intrinsically Safe (IS)
Device couplers (associated apparatus)

z Non-Incendive (NI) and
z Intrinsically Safe Associated Apparatus (AIS)
Length of spur cable ≤ 120 meters (393 ft)
Device couplers can NOT be placed in Division 1

areas
Generally most equipment will have equivalent ratings for both NEC and IEC
standards. Always view the actual approval certificate/drawing, since some
manufacturers may say the approval is “in progress” which can take a while.
43
Power
Conditioner
Spur Cables
T
Device Coupler
(NI & AIS)
Surge T
Protector
Not Rated Div 2 Div 1 Field Devices

(IS)
Remember, only the spurs can be disconnected under power. Fieldbus trunk
cables are NOT rated for live connection/disconnection and must be de-
engergized first.
Refer to the FF Hazardous Area Verification Drawings document for further
information
44
Key Fieldbus Concepts
45
FF Concepts – Tags & Addresses
Each device on the segment (host cards,

instruments, valves, handheld communicators) has a
tag, address and Device ID.
Tags for identification of an instrument by the DCS

z PT101 – pressure transmitter
z CV101 – control valve
Addresses for managing segment communications

z Between 10 and 255
Device IDs are unique serial numbers, e.g.

z 5945430005S0010968
Tags and addresses can be assigned by engineering software and field

communicators.
Device IDs are fixed and cannot be changed. Needs to be updated if devices are
replaced
46
FF Concepts – Address Range
0-15 Reserved Addresses (do not use)
16-247 Permanent Addresses

z Host system card and permanent field devices
248-251 Default Addresses

z Used by system and assigned to unconfigured field
devices
252-255 Temporary Addresses

z Used by tools such as handheld configurators and
diagnostics tools
See: FF address range.xls
Similar to IP addresses on computers

Refer to FF address range spreadsheet for decimal to hexadecimal conversion
47
FF Concepts – LAS
Link Active Scheduler (LAS) – the device on the

segment that controls communications
z Without a LAS there is no segment communication
z The LAS is the host interface card (ALF111)
z Redundant ALF111 card is the backup LAS
Two “device types”

z Basic Device (does not have LAS capability)
z Link Master (can become LAS)
Link Master capable devices can also become the LAS, but the R00#1 fieldbus
design specification dictates that the LAS shall be the primary ALF111 card and
the backup LAS shall be the redundant ALF111 card.
48
FF Concepts – Blocks
There are three types of blocks in a FF field device –

Resource, Transducer and Function.
Resource Block (RB)

z Device Name
z DD Information
z Manufacturer
z Serial Number
z Only one per device
The user application layer is based on blocks which perform different application
functions
49
Transducer Block (TB)

z Transmitter range
z Measurement setup
z Calibration data
z Sensor type
z Can be more than one per device (e.g. one for

sensor measurement and one for an LCD display)
z Unique for each device (specified by the

manufacturer)
50
Function Blocks
z Provide input, output and control functions
z Can communicate to the control system and

between each other
z Executed every scan period
z Many different types (input, output, PID,

mathematical function)
z Multiple function blocks in a device
z Function blocks are always identical (standardized

by the Fieldbus Foundation)
Common types of function blocks and their abbreviations:

Analog Input (AI)
Analog Output (AO)
Discrete Input (DI)
Discrete Output (DO)
PID Control Block (PID)
Signal Characterizer (SC)
Integrator/Totalizer (IT)
Input Selector (IS)
Multiple Analog Input (MAI)
Multiple Analog Output (MAO)
51
FF Concepts – Block Modes
Each block has a mode (MODE_BLK) that determines

its response to inputs or user action.
AUTO (Automatic) – Normal operation
MAN (Manual) – Manual operation
CAS (Cascade) – Set by another function block
O/S (Out of Service) - When downloading or

configuring blocks they may be temporarily
unavailable.
Remember the difference between “Target” and

“Actual” block modes.
Each block has three categories:

•Actual – mode that the block is currently in (if not equal to target, then there
is a problem in the device)
•Target – desired mode as set by the user
•Allowed – modes that the block is permitted to be in
If you set the “target” mode and the “actual” does not change to match, then
there may be a problem in the device preventing it from moving to the “target”
mode.
52
FF Concepts - Parameters
The data inside each
block is organized into
parameters.
Each parameter has a

name, format and value.
Allowable formats with

examples
z String: “PT101”
z Bit: “1” or “0”
z Integer: “243”
z Floating: “25.6234”
Similar to the way HART uses parameters inside the field device to store
information.
Each Parameter can have several Elements, which are individual pieces of data
that make up a parameters (e.g. range, units, decimal point)
The allowable format will depend on what the parameter is used for. Examples
of different types of parameters:
•String: TAG_NAME
•Bit: CHANNEL
•Integer: ADDRESS
•Floating: AI1_OUT
53
FF Concepts – Resource Block
Parameter Explanation Example

MODE_BLK Actual/Target/Permitted block modes AUTO
BLOCK_ERR Error code associated with the block 15 (O/S)
MANUFAC_ID ID number of the device manufacturer 0x00594543
DEV_TYPE Model number of the device 0X000C

DEV_REV Revision number of the device 2
DD_REV Revision number of DD file 1
The above example shows the Resource Block

parameters in a Yokogawa EJX pressure transmitter,
device revision 2 and DD revision 1.
Anytime that “0x” is seen in front of a number, it means that it is in

hexadecimal format.
54
FF Concepts – Transducer Block

PRIMARY_VALUE_T Type of measurement represented by the 107 (DP)
YPE primary value (recommended to keep as
default)
PRIMARY_VALUE_ High and Low range limit values and -100 to 100 kPa
RANGE engineering units of primary value
(generally set at factory)
PRIMARY_VALUE_F Damping time constant for the primary 2
TIME value (in seconds)
SENSOR_RANGE High and Low range limit values and -328 to 2192
engineering units of the sensor (e.g. deg F
thermocouple or RTD)
CAL_POINT_HI Highest calibrated value 1000
SENSOR_CONNEC Type of RTD or thermocouple connected Pt100
TION (for temp. transmitters)
XD_ERROR Error code in the transducer 22 (I/O failure)
Examples of important parameters in a sensor transducer block. The

parameters will vary considerably depending on the type of device (e.g.
pressure transmitter, temperature transmitter).
Valve positioners have a different set of parameters – it is generally
recommended to use the Setup Wizard in ValveLink to set these up.
55
FF Concepts – Analog Input Block

OUT Output from the AI block 72.34 kPa
CHANNEL Logical hardware channel that is connected 1 (Primary
to this I/O block Value)
L_TYPE Selects if value from the transducer is Direct
output as is (direct), with scaling (indirect)
or with square root function (indirect sqrt)
XD_SCALE High/Low scale values and engineering 0-100 kPa
units from transducer
OUT_SCALE High/Low scale values and engineering 0-100 %
units for output (used for indirect output,
e.g. level or flow)
Important parameters – remember that the AI block is the same for every
fieldbus device, regardless of instrument type or manufacturer.
56
FF Concepts – Analog Output Block

CAS_IN Remote setpoint value from the controller 50 %
block (PID)
SP Setpoint of the AO block (Equals CAS_IN in 50 %
cascade and tracks valve position in
manual)
OUT The AO block output and status – limited by 46 %
allowed rate of change
READBACK Actual valve position 42 %
BKCAL_OUT Back calculation provided to BKCAL_IN of 42 %
the controller (PID). This provides
bumpless transfer on mode changes and
windup protection in the upstream block.
XD_SCALE High/Low scale values and engineering 0-100 %
units from transducer
Important parameters – remember that the AO block is the same for every
fieldbus device, regardless of instrument type or manufacturer.
57
FF Concepts – VCRs
Virtual Communication
Relationships (VCRs) are
the links between function
blocks which enable data to
be exchanged.
The type of communication

is known as
“Publisher/Subscriber”.
Devices always transmit

information rather than only
doing so when polled.
Difference between publisher/subscriber and master/slave.

Can be one-to-many communications if PVs are required by more than one
device.
58
FF Concepts - Macrocycle
Cycle of communications between devices
Executed once per scan period (e.g. 1 second)
Controlled by the LAS
Two types of communications
Scheduled – communication between function

blocks that occur at the same time every cycle
(each FB has an execution time)
Unscheduled – asynchronous communication (e.g.

configuration, downloads) that are executed after
the scheduled communications.
Scheduled communications are for control data – occur at the same time every
macrocycle (deterministic).
Unscheduled communications are non-critical and will occur when spare time is
available (like ethernet).
59
FF Concepts - Macrocycle
It is required that the macrocycle contains at least 30%

unscheduled time (i.e. the cycle time for schedule
communications should not exceed 700 msec)
60
FF Concepts - DDs
Device Descriptors (DDs) are files that describe the

functionality of a device so that other devices and
control systems can interface with it correctly.
The revision of the DD file on the host computer

must match the DD revision in the device.
Updated DD files are available from the Fieldbus

Foundation or vendor’s websites:
z http://www.fieldbus.org/index.php?option=com_mtree&Itemid=324
z http://www.yokogawa.com/fbs/fbs-download2-en.htm
Similar to the way that a computer uses drivers so it knows how to interface
with hardware such as printers.
Recommend getting updated DD files from the host’s website (Yokogawa)
because they have undergone the HIST (Host Interoperability Systems Test)
Copies of DD files are stored in the following locations:

•CS3000 project database on the engineering workstation
•PRM Server
•PRM Field Communication Server (if on a different machine)
61
FF Concepts - CFFs
Capabilities files (CFF - Common File Format) describe the
functionality of the devices to enable engineering and
configuration of the devices.
DD = Device revision number
RR = DD revision number
FF = Capabilities file revision number
Device Descriptor (DD)

DDRR.ffo / DDRR.sym
Capabilities File (CFF)

DDRRFF.cff
DDs and CFFs will be located under a directory for the supplier and then device
type.
•Yokogawa = 594543
•Fisher = 005100
•Rosemount = 001151
62
FF Concepts - Interoperability
All devices must be tested to get approval from

the Fieldbus Foundation (check mark)
Control systems perform the Host Interoperability

Systems Test (HIST) based on the Foundation’s
guidelines. Lists of devices that have undergone
the HIST are available on the vendor’s website
z http://www.yokogawa.com/fbs/Interoperability/fbs-hist-en.htm
63
R00#1 FF Segment Design
The defining document for R00#1 is the FOUNDATION Fieldbus Segment
Design (YR-PAS-DSP-203) which is an addendum to the CVX standard
ICM-DU-5161
Key requirements:
Redundant ALF111 modules (which is also the backup LAS)
16AWG (1.5 mm2) segment trunk wiring with orange jacket
Maximum of 12 devices for Div 2 segments
z Last 2 spurs reserved for owner use (spare)
z Maximum of 10 devices connected during system design
Maximum of 8 devices for Div 1 segments

z Last 2 spurs reserved for owner use (spare)
z Maximum of 6 devices connected during system design
A maximum of three control valves are permitted on a segment

during system design (On-Off actuated valves are not considered
control valves)
This presents a summary of the key requirements in the R00#1 project

segment design.
Devices should NOT be daisy-chained, but this introduces more connections
onto the trunk and hence additional points of failure.
64
R00#1 FF Segment Design
Only one device shall be connected to a device coupler spur
Device spur wiring shall not exceed 120 meters (393 ft)
Segment trunk wiring plus all device spurs shall not exceed a
cumulative length of 1660 meters (5446 ft)
Control segments shall have a 1 second macrocycle with a

minimum of 30% spare (unscheduled) time
All control functions shall reside within the Process Control

System (PCS) and not in the field device
Multi-variable transmitters (i.e., compensated flow

transmitter) may use only one variable for control
The aim is to build in reliability, expandability and make it easier

to perform maintenance.
For segment wiring length limit of 1660 meters:

a. 1900 meters is the maximum length for a FF segment per FF Guidelines AG-
181.
b. The two owner reserved spurs may be up to 120 meters each for a reserved
length of 240 meters
65
R00#1 Segment Topology
Device Coupler
Junction Box
Multipair JB
Power Marshalling
Conditioner Panel
Devices
Figure 8 from ICM-DU-5161 Foundation Fieldbus Segment Design
66
R00#1 Device Coupler Junction Boxes
One Device Coupler
Device Coupler
Wiring Diagram
Four Device Couplers
YR-PAS-DWG-203 (One Brick JB Schematic)

YR-PAS-DWG-204 (Four Brick JB Schematic)
67
Fieldbus and Yokogawa Centum CS3000
68
FF and Yokogawa Centum CS3000
System Hardware:
Field Control Station (FCS)
Fieldbus I/O Card (ALF-111)
Special cables to FF Power Conditioner (AKB336)
69
System Software – System View
Main system “explorer”
Used for overall project configuration
Add ALF111 I/O cards to controllers
Launches other builders:

z Fieldbus Builder
z Control Drawing Builder
Generally used by control system engineers. For further learning, recommend

the Yokogawa-run CS3000 engineering course.
70
System View - Screenshot
FCS0101 > Node 1 > Slot 1 > Segment 1
71
System Software – Fieldbus Builder
Interface for fieldbus data in the project database
Add/remove and configure devices
Set up device tags and addresses
Download parameters and control logic to the

field devices
Download
Upload
Project Database Field Device
Generally used by control system engineers. For further learning, recommend

the Yokogawa-run CS3000 fieldbus course.
72
Fieldbus Builder - Screenshot
Device
Blocks
Linked blocks (i.e. those that are in the control drawing builder and used for
process control) are indicated with a star (*)
73
Fieldbus Builder – Parameter Edit
74
System Software – Device Panel
Interface for fieldbus data in the field devices
View live devices connected to segment
Change tag, address and other parameters in

connected field devices
Equalize parameters between the project

database and the field device
75
Device Panel - Screenshot
Address Tag
Devices in
engineering
database
“Live List”
Devices currently
attached to segment
76
Faceplate for the device AI PVI AO
(e.g. TL-TIT-7935B)
Viewing block mode
Viewing error status (e.g. feedback
IOP, OOP, CNF) from PID
output
Faceplate for the indicator or

PID (e.g. TL-TI-7935B)
Setting alarm ranges
Setting calibration mode
77
Alarms occur on the banner and alarm screen in a similar
way to analog devices
Process alarms (e.g. low, high) will occur with the

indicator or PID tag
Device errors (e.g. IOP, OOP, CNF) will occur with the
device tag
Live demonstration if possible
78
Yokogawa Plant Resource Manager
79
Plant Resource Manager (PRM)
PRM is Yokogawa’s plant asset management

application. It can be used for:
Setting up and modifying field devices
Management of field device configuration
Diagnostic alarms and troubleshooting
Launching specialized plug-in applications
Instrument calibration and recording
It is used for both Fieldbus and HART devices.
80
PRM – Network View
Segment
Device Status
Green = Device Ok
Red = Device Error
Yellow ! = Unacknowledged Alarm
Network view displays all the fieldbus devices and which segment they are
connected to.
Plant view can be configured to group the devices based on geographic area,
unit number, equipment number.
81
Plant Resource Manager (PRM)
Key functions used in PRM:
Device Status – indicates if a device is OK
Device Viewer – more detail on errors
Maintenance History – alarm/event history
DD Menu (Methods) – use to perform tasks such
as device setup and calibration
Parameter Manager – save/restore parameters
Plug-Ins – launches specialized applications
Explained in more detail in the ‘Maintenance’ section

The DD menu (methods) is similar to the device menus on a Rosemount

275/375 communicator.
82
PRM – Device Viewer
Cause of Alarm
Alarm Code
Current
Parameters
Red = Alarm
Yellow = Warning
Green = Ok
Mandatory – alarms which must be fixed to return the device to normal

operation (device status will be red until fixed)
Optional – alarms which may not affect the operation of a device (doesn’t affect
device status)
The trend tab allows you to trend the values in the parameter list.
83
PRM – Maintenance Alarm
•Problem
•Cause
•Action
84
PRM – DD Menu
e.g. Configuring
temperature sensor type
DD menu maps are normally available in the device’s user manual.
The problem with using PRM for configuration is that these changes are not
reflected in the engineering database (Fieldbus Builder).
85
PRM – Parameter Manager
Current Saved
Saving device parameters in PRM:

Select the desired device on the left and click on the “Parameter” tab
Select the desired block tag (resource, transducer or function blocks)
The column on the left displays the current parameters in the device – click
“Update” to refresh
The column on the right displays historical parameters – right-click and select
“Save All Parameters”
The arrow in the middle is used to change a device’s parameters back to a
saved configuration – click “Set” to execute
86
Yokogawa Fieldmate
Fieldmate is a device configuration tool that connects

to a live segment and has many of the functions of
PRM in a portable format.
Can be used for: Can’t be used for:
Segment LAS Plug-ins (e.g. ValveLink)
Device Viewer
DD Menu
Parameter save
HART (with modem)
Fieldmate can be installed in a Panasonic Toughbook that is rated for Class 1,

Div 2 hazardous areas (e.g. TB-19 or TB-30). However these are only rated for
use in hazardous areas when it is inside the supplied leather case and all port
flaps are closed. The only way to make a connection to a device in a hazardous
area is to use a bluetooth HART modem (no such bluetooth or wireless device
exists for fieldbus). If you need to connect locally to a fieldbus device, then the
375 field communicator can be used as it is Class 1, Div 1 rated.
87
Yokogawa Fieldmate
DCS ALF111 card(s) are

at the top of the list
Device Status
Green = Device Ok
Yellow = Error (optional)
Red = Error (mandatory)
Right-click on a device top open the various tools:

•Tag/Address assignment
•Device Viewer
•DD Menu
•Parameter Manager
•DTM
88
FDT/DTM Technology
FDT = Field Device Tool
z (the program that runs DTMs)
DTM = Device Type Manager

z (the file for each type of device)
Standardizes the interface between control system

and the field device.
Makes it easier to view the device parameters and
perform maintenance and configuration functions.
DTMs exist for both Foundation Fieldbus and HART
devices.
Chevron is a participating member of the FDT group.
89
FDT/DTM Technology
Parameter Manager DTM

Text Based More visual
DD language Intuitive naming
Harder to navigate Easier functions
Example of the difference between looking at a device through DD parameter

view, and through a device’s DTM.
DDs use more complicated parameter names, DTMs have a better description of
what they are.
DTMs use graphics and alarm colors to better convey the device’s status to the
user.
Commonly used functions (e.g. changing a block mode) are easily accessible
from the first screen in a DTM.
DTMs are supported in PRM v3.02 and Fieldmate v1.03
90
Fisher ValveLink
ValveLink software is a tool for Fisher valve

positioners (e.g. DVC6000)
Launched from the “Plug-In” menu in PRM
Valve and positioner configuration management
Displays current status and troubleshooting info.
Setup wizard and travel calibration
Valve partial stroke testing
Step response and valve signature analysis
Used for both Fieldbus and HART devices
91
Fisher ValveLink
Select the device in PRM and click on the “Plug-In” tab. Double click on “Fisher
ValveLink” to launch the application.
92
Fisher ValveLink - Status
Red tabs
indicate errors
Live data
from device
Click “Start Monitoring” to obtain valve information, then end and “Save
Dataset” to record the values.
93
Fisher ValveLink – Total Scan
Example of a Valve Signature obtained through the ValveLink “Total Scan”

function which can be used to identify and diagnose valve problems. ValveLink
can also run a step response as a performance test for the valve.
94
Foundation Fieldbus Commissioning
95
FF Commissioning
Commissioning Foundation Fieldbus devices typically

consists of three main steps:
Physical Inspection – check of field device

installation, instrument air lines, etc.
Segment Check (unique to fieldbus) – checks the

physical layer components and performs initial
segment configuration.
Loop Check - checking of control loops in a similar

way to analog instrumentation.
96
FF Segment Check
Segment Check
Tag/Address
Assignment
(Device Panel)
Cable/Network
Test
(F809f module)
Segment Config./
Download
(inc. PRM save)
Sign-off Segment
Check Sheet
Segment Check (unique to fieldbus) – checks the physical layer components

and performs initial segment configuration.
97
FF Loop Check
Loop Check
Check Inputs
(AI/DI blocks)
Check Outputs
(AO/DO blocks)
Check PID Blocks
Sign-off Loop
Check Sheet
Loop Check - checking of control loops in a similar way to analog

instrumentation (check instruments read correct values and final control
element action is correct)
98
Maintenance of Fieldbus Systems
99
Maintenance of FF Systems
Typical maintenance tasks in a Fieldbus system:
Fieldbus Physical layer troubleshooting
Fieldbus device troubleshooting
Replacing fieldbus devices
Adding/removing fieldbus devices
Calibrating fieldbus devices
Other potential problems
100
Physical Layer Maintenance
Examples of physical layer problems that can occur:
Damage of field wiring or devices (mechanical damage,

water damage)
Accidental shorts or grounding
Faulty components
Improper termination of segments
Noise from Electromagnetic Interference (EMI)
Degradation of device electronics over time
Use physical layer diagnostic devices for troubleshooting
These should generally not be a problem if proper installation and maintenance

procedures are followed.
101
Expected segment measurements:
Measurement Resistance Capacitance

Positive to Negative > 50 kΩ 0.8 to 1.2 μF*
Positive to Shield > 20 MΩ < 300 nF
Negative to Shield > 20 MΩ < 300 nF
Positive to Ground > 20 MΩ < 300 nF
Negative to Ground > 20 MΩ < 300 nF
Shield to Ground > 20 MΩ < 300 nF
These values come from the Fieldbus Foundation System Engineering

Guidelines.
(*) Note that these measurements are taken from the control system end with
the trunk cable disconnected from the power conditioner (so that there is only
one terminator present on the segment). The capacitance between positive and
negative signal wires may be less that stated if active terminators are used in
the device coupler.
102
Tools for physical layer
troubleshooting:
F809f diagnostic
modules on power
conditioners (fixed)
FBT-6 handheld
diagnostic tool (portable)
Multimeter for
measuring resistance
and capacitance
103
Physical Layer Maintenance: FBT-6
Portable diagnostics unit:
• Connect FBT-6 at device

coupler or device
• Should read “ALL

MEASUREMENTS OK”
• If not, errors will be

displayed
• Press “FUNC” to view

other segment
diagnostics
• Scroll to save menu and

hold “SEL” to save
The FBT-6 comes with a USB cable and software for exporting measured data to
a PC as an excel .csv file.
104
Physical Layer Maintenance: FBT-6
Connect the FBT-6 to a laptop and launch the FBT-6
Assistant software.
Click “Transfer Reports from FBT-6” to transfer the

reports to the laptop.
By default they will be saved with the report slot

number - rename the files with the segment number
for easy identification.
Need to remember which slot the measurements were saved into
105
Physical Layer Maintenance: F809f
Fixed on the power hub, F809F
continuously monitors all

8 segments
Communicates through
the fieldbus segment
(selectable on module)
The F809f is actually a
fieldbus device on the
segment (with a tag and
an address)
Diagnostic
measurements are made
available as parameters
in transducer blocks
The F809f can be configured to communicate on segment 1 or 8 of the power

hub by the “comb” on the corner of the module (flip it over to change between
segments). The “comb” can also be removed so that the F809f can be
connected to an external segment.
Image Source: MTL - F809F Integration for Yokogawa (MTL)
106
HIS PRM Client
Fieldbus power supply

system Segment 1 of 8
Field junction box
H1 Fieldbus
Basic failure
alarms
Controller I/O (ALF111) On-line
Diagnostic Module
The diagnostic measurements in the F809f are read by a fieldbus tool such as
PRM that can look at the individual parameters in the module’s transducer
blocks.
There is a dry contact on the power hub to indicate failure of either of the
redundant power conditioner modules. This should be connected to a discrete
input (DI) card.
Image Source: MTL - F809F Integration for Yokogawa (MTL)
107
The F809f modules have a number of features to

assist with maintenance activities:
Segment measurement
Diagnostics and alarm logging
Historical data viewing and export
Oscilloscope for viewing waveforms
Automated commissioning function
See: MTL - F809F User Manual.pdf
108
F809f: Fieldbus Block Structure
Resource Block
System Transducer Block
Segment
Transducer Blocks
Alarm DI Block
F809f on System Alarm DI Block
Fieldbus seg.
Segment Alarm
DI Blocks
RESRC: Resource block, defines the physical resources of the device including
type of measurement, memory, etc.
DITB_S: System transducer block (SysTB), allows the user to view system and
self-test alarms together with the system power feed voltages and temperature.
DITB_1 – DITB_8: Segment transducer blocks (SegTB), provide all the
measured parameters and associated alarms for each fieldbus segment and its
devices.
DIFB_1: Alarm DI block, set to 1 if any of the System Alarm, Segment / Device
Alarm or Self Test Fault Alarm bits is set.
DIFB_2: System alarm DI block, set to 1 if any System Alarm and Self Test
Fault Alarm bits are set.
DIFB_3 – DIFB_10: Segment alarm DI blocks, set to 1 if any of the Segment
/ Device Alarm bits is set for the respective segment.
109
F809f: Device Alarm
•Problem
•Cause
•Action
Maintenance alarms for the diagnostics module are logged the same way as
field devices. Note that in general, the recommended actions are not
particularly useful, so it is recommended to look at the segment transducer
block parameters to determine the cause of the alarm.
110
F809f: System Transducer Block
Current Saved
The above example shows the system transducer block parameters when the
secondary power feed to the power hub is disconnected. Note the
SYSTEM_ALARMS parameter shows the description “Power feed B voltage low
alert” – use this parameter to determine the cause of the alarm. Looking at the
parameters that have changed since last save (highlighted in yellow) we can
see that the secondary power feed voltage decreased from 27.8V to 0.1V,
indicating it has either been disconnected or the bulk power supply is faulty.
111
F809f: Segment Transducer Block
Current Saved
The screenshot above shows typical segment parameters viewed in the

segment transducer block, including:
•Segment Voltage
•Average and Peak Noise (The peak is recorded over the previous hour, and
may be caused by connecting/disconnecting devices. In general, average noise
is a more useful measurement and is the one specified in the Fieldbus
Foundation System Engineering Guidelines)
•Lowest device signal level
•Retransmissions
112
F809f: Segment Transducer Block
Current Saved
The screenshot above shows typical device parameters viewed in the segment
transducer block, including:
•Device address
•Device tag (This has to be entered manually and is stored in volatile memory,
so it will be lost if power fails. It is recommended to save all parameters to the
PRM database so the tags can be reloaded into the module in the event of a
power failure.)
•Device signal level
•Device retransmissions
•Device jitter
113
F809f: Know Issues
The hardwired contact on the power hub is the only indicator
of primary or secondary power module failure (contacts are
closed when normal, and open when there is a fault). This
contact should be wired to a DI card in the DCS to provide an
alarm if there is a problem.
The Alarm DI Block should be configured in a DCS control

drawing to provide a path for the F809F diagnostic module
system alarm on an operator station. This will change to 1 on
all F809f diagnostic alarms.
For segments containing F809f modules, a manual change

had to be made to the NM folder in the common section of
Fieldbus Builder. The maximum response delay setting should
be changed from 4 to 5 in the NM folder.
For detailed instructions on how to make the change of maximum response

delay setting, see SLR VGO SYSTEMS INTEGRATION FAT.doc in the supplied
flash drive.
114
F809f: Forthcoming DTM Interface
This screenshot is from a prototype DTM (Device Type Manager) which will
make it easier to view the diagnostic measurements and perform
troubleshooting. It will also have the ability to generate a commissioning report
115
Device Troubleshooting
Examples of device problems that can occur:
Incorrect setup of a device
Block left out of service
Alarms requesting maintenance
Out of range alarm
Problems with temperature sensor connection
Problems with instrument air supply
Advanced diagnostics (e.g. impulse line plugging)
Use PRM Device Viewer or DTM for troubleshooting

116
Device Troubleshooting
Example of a “Device Status” screen on a DTM for the YTA temperature

transmitter. The alarm indicates that there is a problem with Sensor 1 (either
faulty or not connected).
117
375 Field Communicator
The 375 is a field
communicator for both FF
and HART devices
Change tags & addresses
View & write parameters
Link Master capability
View device alarms
Basic physical layer

diagnostics (voltage,
signal level)
Intrinsically Safe for use

in hazardous areas
118
Replacing Fieldbus Devices
1.Decommission device to be replaced (Device Panel)
2.Install and connect new device
3.Assign correct tag & address (Device Panel)
4.Download configuration (Fieldbus Builder)
5.Check for correct operation (call up faceplate)
6.Commission for use
It is important to check that all the blocks go to

normal operating mode (typically AUTO) and
communications are re-established.
Remember that Foundation Fieldbus devices are INTEROPERABLE (different

devices work together) but not INTERCHANGEABLE (cannot replace a device
with one of a different type). You need to use the exact same manufacturer,
model and DD revision when replacing devices. If a different device is required
to be used, then some minor re-engineering is required in Fieldbus Builder.
119
Adding Fieldbus Devices
1. Add new device into engineering database

(Fieldbus Builder)
2. Configure control drawing and device parameters

(Control Drawing Builder)
3. Install and connect new device
4. Assign correct tag & address (Device Panel)
5. Download configuration (Fieldbus Builder)
6. Loop check for correct operation
7. Commission for use
8. Device plug & play in PRM

Suggest following steps of the project’s fieldbus commissioning procedure
120
Removing Fieldbus Devices
1.Decommission device to be removed
2.Disconnect and remove device
3.Remove device tag from engineering database and

control drawings
Decommissioning the device in Device Panel will

remove it’s tag and address so it is ready to be
installed in a different location.
121
Fieldbus Device Calibration
With analog devices, calibration compensates for

inaccuracies in two parts of the device:
Sensor or actuator
Digital/Analog conversion
Fieldbus devices have no analog communications

signal, eliminating that source of error.
The sensor or actuator can still develop an error over

time (although this is very low in modern devices) so
calibration may still be required.
With an analog device, such as a transmitter, the output is scaled so that the
expected operating range uses the entire 16 mA of a 4-20 mA signal. This
minimizes the effect of error in both the transmitter analog output and the host
analog input. However, it's common to see errors resulting from a mismatch
between the scaling of the field device and the host.
With digital fieldbus devices, output scaling isn't required — so there's no such
mismatch. Fieldbus does require that the unit of measure be the same in both
the device transducer block and the function blocks.
http://www.yokogawa.com/fld/3D/EJX/p03.html
122
Fieldbus Device Calibration
1. Add calibration record in PRM and enter settings
2. Open up Calibration method in DD Menu or DTM

(PRM/Fieldmate)
3. Record the “As Found” results on calibration record
4. Follow instructions from the manual or calibration

wizard to calibrate the transmitter using a suitable
reference source (it will first ask you to set the
transducer block to O/S mode)
5. Record the “As Left” results on the calibration record
6. Return block mode to normal operation (AUTO)
7. Check device status returns to good and the PV reads

correctly
Calibration of a fieldbus device is similar to that of a smart (HART) transmitter.

A number of tools can perform this function:
•Yokogawa PRM
•Yokogawa Fieldmate
•375 Communicator
123
Calibration Data in PRM
Add new calibration record
124
Set up calibration
The input/output values are set based on the individual device’s range settings.
125
Calibration with DD Menu - YTA
O/S
Start by setting CAL_STATE

to “Calibration Exec”
Follow the steps in the Yokogawa YTA manual to calibrate the transmitter –
start by setting CAL_STATE to “Calibration Exec”.
126
Calibration with DD Menu - EJX
Click on “Pressure
Calibration” and follow the
O/S
steps to calibrate
The Yokogawa EJX has a “Calibration Wizard” that helps automate the
calibration steps.
127
Calibration with DTM - EJX
Use the “Sensor Calibration

Wizard” and follow steps
The Yokogawa EJX has a “Calibration Wizard” that helps automate the
calibration steps.
128
Record calibration results
“Input” is the simulated value from the reference source (such as a pressure
pump, temperature element simulator or Fluke 744 calibrator).
“Output” is the value measured by the transmitter – suggest using Device
Viewer to read the current value.
Remember, a calibration is only as accurate as the reference source! Use a high

accuracy calibrator or send the device out to be factory/bench calibrated.
129
Calibration Data in PRM – Fluke 744
The Fluke 744 is capable of HART communication only. The only calibrator
currently available that supports Fieldbus is the Beamex MC5 (a plug-in for the
MC5 does not exist yet, but is under consideration/development)
Create a new entry in the “Calibration Data” tab and select “Fluke 74X” as the
Calibrator. Add details as appropriate into the Fluke 74X tab at the bottom of
the screen.
130
Calibration Data in PRM – Fluke 744
Then click “Detect” and

“Download” to load
calibration data to the
Fluke 744. Perform
calibration and then
Upload the results
First click “Add

Group” to add
the instrument
tags to be
calibrated.
Go to the PRM menu: Option > Cal. Data > Download
131
Troubleshooting DD/CFF files
These files need to be in the following locations:
z On the engineering station in:
C:\CS3000\eng\BKProject\TOMBUA\Fieldbus\CFDDFILE\
z In the PRM server and Field Communication Server in:
C:\PRM\DD
DD/CFF problems – occasionally a new type of device might not work or

behave unexpectedly.
z Check device has FF tick and passed the Host Interoperability System Test
z Contact the manufacturer for any known issues
z Try connecting the device on a segment of it’s own
z Try using a previous revision of the DD files
Sometimes capabilities files (CFF) have several options for the same
device – e.g. linkmaster capability, PID blocks, advanced diagnostics.
Check that you have selected the right option for a particular device.
132
FF Tools Summary
Changing tags & addresses 375
Device Panel
Downloading to devices
Fieldbus Builder
FBT-6
Troubleshooting physical layer
Troubleshooting devices 375
Calibrating devices 744
Note that for calibrating devices, the Fluke 744 is required as a reference
source (for temperature and pressure) while PRM to write calibration data to the
device and record the results.
133
Key Resources
Check out the “References” folder on your flash drive:
FF Web Links
Fieldbus Foundation - System Engineering Guidelines
Fieldbus Foundation - Wiring and Installation Guide
Yokogawa - Fieldbus Book
Yokogawa - Fieldbus Technical Information
Relcom - Fieldbus Wiring Guide
MTL - Fieldbus Physical Layer Troubleshooting Guide
Pepperl+Fuchs - FF Troubleshooting Manual
134
The end of the theory…
… now for the practice
135
R00#1 Foundation Fieldbus Training Exercises
Exercise 1 – Using Device Panel & Fieldbus Builder
Part 1 – Assigning Tags & Addresses (Device Panel)
Part 2 – Downloading To Devices (Fieldbus Builder)
Exercise 2 – Using Fieldmate
Exercise 3 – Using Plant Resource Manager (PRM)
Exercise 4 – Physical Layer Diagnostics
Part 1 – Using the Relcom FBT-6 handheld tool
Part 2 – Using the MTL F809f diagnostics module
136
Exercise 1 – Using Device Panel & Fieldbus Builder
Part 1 – Assigning Tags & Addresses (Device Panel)
This step provides an introduction to Device Panel, a software package that is part of CS3000
and used to view and set up fieldbus devices. In this exercise, you will learn how to set the tag
and address of fieldbus devices.
1. From System View, open the Device Panel application by selecting the segment and clicking
in the menu: Tools > Fieldbus > Display Device Information
2. The Device Panel screen is split, with the devices in the project database shown on the left,
and the actual devices connected to the segment shown on the right (known as the live list).
3. Locate the following items on the Device Panel screen:
a. Tag Name
b. Address
c. Device ID
d. Device Revision information
4. If device tags and addresses have not been assigned, the system will assign temporary
addresses in the range 248-251 (0xF8-0xFB). Note that only 4 unconfigured devices can be
displayed at a time. If the desired device does not appear on the live list, then the devices will
need to be connected to the segment (and the addresses assigned) one at a time.
Device ID
5. Identify the instrument tag and matching Device ID as shown on the instrument’s
commissioning tag.
6. Locate the instrument on the live list with the desired Device ID, right click and select “Tag
Assignment”. De-select “Assign Automatically” and input the instrument tag and address that
matches the values in the database on the left.
137
Matching
7. Repeat steps 5 & 6 for every device on the segment.

8. Click on the [+] next to the devices to explore the devices and their block structure.
Part 2 – Downloading To Devices (Fieldbus Builder)
This step provides an introduction to Fieldbus, a software package that is part of CS3000 and
used for engineering and downloading of configuration to fieldbus devices. In this exercise, you
will learn how to download configuration to as segment and check that it is working.
1. From System View, locate the segment and double-click on it to open Fieldbus Builder.
2. This screen shows the devices configured in the engineering database (same as the left part
of the screen in Device Panel). Locate the following items on the Fieldbus Builder screen:
a. Tag Name
b. Address
c. Device ID
e. Polled address range for the segment (this setting dictates which addresses the
ALF111 looks for – if this range doesn’t include a device it will be invisible!)
3. Select the ALF111 card and select: File > Download (ensure all boxes are ticked)
138
4. Confirm that there are no errors and verify that all the devices were downloaded successfully
by checking that the “Device ID” column has been filled in for each tag. If there are any
errors, view the “Message” window at the bottom of the screen for details and rectify the
problem.
Device IDs
No Errors
5. From Fieldbus Builder, open the Device Panel application by selecting the segment and
clicking in the menu: Tools > Display Device Information
6. If any of the devices have a yellow lightning bolt icon next to them, then they have not been
equalized successfully. Sometimes parameters such as software revision are not
successfully imported to the database by Fieldbus Builder so this has to be corrected
manually.
7. Double-click on the device to launch the “Device Information Display” and perform the
following steps:
a. Click on “Update” to show the current parameters.
139
b. Select “Equalization Mode” and “Difference” to see the parameters that are not yet
equalized.
c. Tick “Equalization of block parameters is executed”
d. Select “Equalization” and execute.

e. Select “Update” and check that the parameters are now equalized
f. Close the equalization window and check that the yellow lightning bolt next to the
device icon has disappeared.
8. Right-click on each device and select “Commission”. This will remove the commissioning tag
icon from each device. The Device Panel should now look as shown below, with no question
mark or lightning bolt icons.
9. Close Device Panel and return to Fieldbus Builder.

10. From a HIS, open the faceplate for each instrument on the segment to ensure it is working
correctly (click the “NAME” button and type the instrument tag). The status should be NR
140
(normal) with no errors (note that since the instrument is not yet in service, the faceplate may
display a LL or HH alarm – this should be normal depending on the alarm settings). The
faceplate should NOT display an IOP (input open), OOP (output open), CNF (connection fail)
or O/S (block out of service) status. Faceplates for input blocks (AI/DI) should be in AUT and
output blocks (AO/DO) should be in CAS.
11. Experiment with the instrument by making the following changes and observing the effect it
has on the instrument faceplate (and associated indicator or PID faceplate):
a. Change the process value (e.g. test pump on a pressure transmitter)
b. Change the process value outside of alarm limits (PL/PH)
c. Change the process value outside of range limits (LL/HH)
d. Disconnect the device and then reconnect it
e. Disconnect the temperature element (temperature transmitters only)
141
Exercise 2 – Using Fieldmate
This exercise provides an introduction to Fieldmate, a portable software tool that is used to
configure fieldbus devices. In this exercise, you will learn how to connect Fieldmate to a segment
and set the tag and address of fieldbus devices, and troubleshoot using Device Viewer.
1. Open the NI-FBUS Interface Configuration utility from the start menu:
Start > National Instruments > NI-FBUS > Utilities > Interface Configuration Utility
2. Select each port and click edit to configure only the first port with the following settings:
When there is no other LAS on the segment (i.e. no ALF111 card connected) and you want
Fieldmate to become the LAS:
• Device Address: 0x10
• Device Type: Link Master Device
• Usage: NI-FBUS
When another LAS is already connected to the segment:

• Device Address: Visitor
• Device Type: Basic Device
• Usage: NI-FBUS
3. Connect one port of the NI-FBUS card to the segment to a spare device coupler terminal.
4. Start up the Yokogawa Fieldmate application and select “FF-H1” as the default scan
segment. Click “Ok” to start up NI-FBUS Communications Manager which will pop up the
following window once it has started successfully.
5. Ensure the “Segment Viewer” tab and “Foundation Fieldbus” are selected on the left panel.
The actual devices connected to the segment are shown on the right (known as the live list).
Note that there is no panel on the left showing the devices in the engineering database – this
feature is only available in Device Panel on an engineering workstation.
142
Device ID
Live List
6. Locate the following items on the Fieldmate screen:

a. Tag Name
b. Address
c. Device ID
7. If device tags and addresses have not been assigned, the system will assign temporary
addresses in the range 248-251 (0xF8-0xFB). Note that only 4 unconfigured devices can be
displayed at a time. If the desired device does not appear on the live list, then the devices will
need to be connected to the segment (and the addresses assigned) one at a time.
8. Identify the instrument tag and matching Device ID as shown on the instrument’s
commissioning tag.
9. In Fieldmate, locate the instrument on the live list with the desired Device ID, right click and
select “Tag/Address Assignment”. Input the instrument tag and address that matches the
values in the project database print-out generated from Fieldbus Builder and click “Set”.
143
Matching
Fieldbus
Builder
print-out
10. Repeat steps 8 & 9 for every device on the segment.

11. Check the Device Status for all devices on the segment (the colored oval next to the device
icon). The Device Status should be good (green) for every device on the segment.
Device
Status
12. Right-click on the device and select “Device Viewer” to see more detailed status of the
device.
13. Since the devices have not yet been configured by the DCS, Device Viewer may see some
errors such as “AI FB not scheduled”. This is expected and can be ignored as it will be
resolved once the instruments are connected to the DCS and downloaded.
144
has on Device Viewer (Right-click on the instrument and select “DD Menu” or “Assigned
DTM” to launch the application used to make these changes)
a. Change the block mode of AI1 to out of service (O/S)
b. Click on the “Trend Information” tab to observe trended parameters
DD Menu Screen DTM Screen
145
Exercise 3 – Using Plant Resource Manager (PRM)
This exercise provides an introduction to PRM, the application used for management of
Foundation Fieldbus and HART instrumentation. It shows how to set up PRM for a segment and
introduces its device troubleshooting tools.
1. Open up the PRM application select the “Network” tab.

2. Under “Foundation Fieldbus” locate the segment, right-click on it and select “Plug & Play” to
automatically recognize the devices connected to the segment.
.
3. Check the Device Status for all devices on the segment (the colored oval next to the device
icon). The Device Status should be good (green) for every device on the segment.
146
Device
Status
has on Device Viewer (Right-click on the instrument and select “DD Menu” or “Assigned
DTM” to launch the application used to make these changes)
a. Change the block mode of AI1 to out of service (O/S)
b. Click on the “Trend Information” tab to observe trended parameters
DD Menu Screen DTM Screen
5. Click on the “History” then “Maintenance” tab of the device to view the alarm generated –
read the message regarding problem, cause and action. Right-click on the alarm and select
“Acknowledge” – enter a reason and you should see the yellow exclamation point icon
disappear from the device.
147
6. Right-click on the device and select “Device Viewer” to launch. The following screenshot
shows an example of a device viewer warning that states “AI1 FB is in O/S mode”. This
means that the analog input block is out of service, so the process value is not being
transmitted to the control system.
7. Fix the problem using DD Menu or the DTM and observe the device return to normal.
8. Right click on the segment and select “Save All Parameters”. Type ‘Commissioning’ into the
“Reason” box, tick the “Read details from the field devices” box and select ok. This will save
the current set of parameters in the device.
148
9. In the following steps you will compare previously saved parameters to the current
parameters read from the device:
a. Select a device on the segment and click on the “Parameter” tab
b. Select the desired block tag (resource, transducer or function blocks)
c. The column on the left displays the current parameters in the device – click “Update”
to read in current parameters from the device
d. The arrow in the middle is used to change a device’s parameters back to a saved
configuration – click “Set” to execute
Current Saved
149
Exercise 4 – Physical Layer Diagnostics
Part 1 – Using the Relcom FBT-6 handheld tool
The FBT-6 is a handheld fieldbus monitor that can detect physical layer problems on the
segment. It is bus-powered and rated for use in hazardous areas. This exercise will show you
how to use the FBT-6 to check a segment and identify common problems.
1. Connect the FBT-6 Fieldbus Monitor to the segment at the device coupler and wait for it to
check (approximately 20 seconds). The FBT-6 should display “ALL MEASUREMENTS OK” if
there are no problems. Press the “FUNC” button to scroll through the various measurements
for the segment.
2. With the FBT-6 still connected, introduce the following faults onto the segment and observe
the reading on the FBT-6 to see whether the changes are identified.
a. Disconnect a device and then reconnect it
b. Place a short between the shield wire and one of the signal wires
c. Switch off the terminator at the power supply end
3. Press “FUNC” to scroll through to the save function. Hold down the “SEL” button to save the
segment measurements into one of the empty slots (there are 8 slots available). Make sure
the number of the slot is noted on the check sheet as this will be needed for the next step.
150
4. Connect the FBT-6 to a laptop and launch the FBT-6 Assistant software. Click “Transfer
Reports from FBT-6” to transfer the reports to the laptop. By default they will be saved with
the report slot number - rename the files with the segment number for easy identification.
Part 2 – Using the MTL F809f diagnostics module
The MTL F809f is a physical layer diagnostics module that mounts on the segment power hub for
continuous monitoring. This exercise will show you how to use the module to check a segment
and identify common problems.
1. Open up the PRM application select the “Network” tab.

2. Under “Foundation Fieldbus” locate the segment and select the F809f module.
151
3. Click on the “Parameter” tab, then right-click on <Show actual parameter> and select
“Parameter Manager”. This will enable you to read the current parameters in the F809f.
152
4. The parameters in the F809f display the measured values from the segment, and any active
alarms that are present. Read through the parameters for the two types of transducer blocks
to see what the current status is (TB01 is the system transducer block, and TB02-TB09 are
the segment transducer blocks). Consult the F809f user manual on your flash drive if you are
not sure what a parameter means.
5. Generate a print-out of the current parameter values – this can be useful as a commissioning
report to document the measurements taken.
6. Right-click on the F809f module and select “Save all parameters” to save all the current
parameters in the device to the PRM database. In Parameter Manager you will then be able
to view the saved values alongside current measurements taken from the segment.
7. Introduce the following faults onto the segment and observe the measurements by updating
the current parameters in Parameter manager. Compare these to the saved parameters in
the previous step to see whether the changes are identified.
a. Unplug the secondary 24VDC power connector from the power hub
b. Place a short between the shield wire and one of the signal wires
c. Switch off the terminator at the power supply end
153
Current Saved
8. Click on the “History” then “Maintenance” tabs of the device to view the alarms generated,
and read the message regarding problem, cause and action. Right-click on the alarm and
select “Acknowledge” then enter a reason. You should see the yellow exclamation point icon
disappear from the device.
154

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Foundation Fieldbus

© Chevron 2005 ETC-PA: Foundation Fieldbus Training 2

Please tell us about yourself:

 Role on the project

 Experience (if any) with Foundation Fieldbus or

 Your expectations of the course – what you hope

© Chevron 2005 ETC-PA: Foundation Fieldbus Training 3

© Chevron 2005 ETC-PA: Foundation Fieldbus Training 4

The Fire Triangle

Area Classification (NEC Article 500.5 / API RP 500)

 Class I - flammable gases, flammable liquid–

 Class II – combustible dust

 Class III - easily ignitible fibers or materials

© Chevron 2005 ETC-PA: Foundation Fieldbus Training 5

Class I, Division 1 is a location in which ignitible

 under normal operating conditions, or

 frequently because of repair or maintenance operations

 due to breakdown or faulty operation of equipment or

© Chevron 2005 ETC-PA: Foundation Fieldbus Training 6

Protection Techniques (NEC Article 500.7)

 Explosion-proof Equipment (XP) - Class I, Div 1&2

© Chevron 2005 ETC-PA: Foundation Fieldbus Training 8

“Explosion-proof" means that the enclosure is capable of containing an internal

Protection Techniques (NEC Article 500.7)

 Intrinisically Safe Equipment (IS) - Class I, Div

© Chevron 2005 ETC-PA: Foundation Fieldbus Training 9

"Intrinsically safe" devices produce or consume electrical power at levels below

Protection Techniques (NEC Article 500.7)

 Non-Incendive Equipment (NI) - Class I, Div 2

© Chevron 2005 ETC-PA: Foundation Fieldbus Training 10

“Non-Incendive” equipment works on the same principle as Intrinsically Safe,

Protection Techniques (NEC Article 500.7)

 Purged and Pressurized – Class I, Div 1&2

 Hermetically Sealed – Class I, Div 2

 Combustible Gas Detection – Class I, Div 1&2

 Oil Immersed – Class I, Div 1

Used more in electrical systems than instrumentation

© Chevron 2005 ETC-PA: Foundation Fieldbus Training 11

 Introduction to Foundation Fieldbus

 Fieldbus System Components

 Key Fieldbus Concepts

 R00#1 Segment Design and Specifications

 Fieldbus and Yokogawa Centum CS3000

© Chevron 2005 ETC-PA: Foundation Fieldbus Training 12

 Yokogawa Plant Resource Manager (PRM)

 Foundation Fieldbus Commissioning

 Maintenance of Fieldbus Systems

z Fieldbus device calibration

© Chevron 2005 ETC-PA: Foundation Fieldbus Training 13

© Chevron 2005 ETC-PA: Foundation Fieldbus Training 14

“Foundation Fieldbus is an open, nonproprietary

© Chevron 2005 ETC-PA: Foundation Fieldbus Training 15

 Formation of the Fieldbus Foundation in 1994 to

 Focused on development of open and interoperable

 Future development includes DD enhancements and

1995 1998 2001 2002 2003 2008

© Chevron 2005 ETC-PA: Foundation Fieldbus Training 16

Foundation Fieldbus Standards:

 Non-profit consortium formed by members of

 Develops and administers the standards for

 Provides reference material such as user guides

 Useful website as a resource

© Chevron 2005 ETC-PA: Foundation Fieldbus Training 17

Role on the project

Experience (if any) with Foundation Fieldbus or

Your expectations of the course – what you hope

Class I - flammable gases, flammable liquid–

Class II – combustible dust

Class III - easily ignitible fibers or materials

under normal operating conditions, or

frequently because of repair or maintenance operations

due to breakdown or faulty operation of equipment or

Explosion-proof Equipment (XP) - Class I, Div 1&2

Intrinisically Safe Equipment (IS) - Class I, Div

Non-Incendive Equipment (NI) - Class I, Div 2

Purged and Pressurized – Class I, Div 1&2

Hermetically Sealed – Class I, Div 2

Combustible Gas Detection – Class I, Div 1&2

Oil Immersed – Class I, Div 1

Introduction to Foundation Fieldbus

Fieldbus System Components

Key Fieldbus Concepts

R00#1 Segment Design and Specifications

Fieldbus and Yokogawa Centum CS3000

Yokogawa Plant Resource Manager (PRM)

Foundation Fieldbus Commissioning

Maintenance of Fieldbus Systems

Formation of the Fieldbus Foundation in 1994 to

Focused on development of open and interoperable

Future development includes DD enhancements and

Non-profit consortium formed by members of

Develops and administers the standards for

Provides reference material such as user guides

Useful website as a resource

Examples of Chevron installations:

Suppliers – Control Systems & Field Devices

Suppliers – Power Supplies & Connecting

Digital data provides an actual measurement value

Fieldbus uses a bus topology rather than requiring a

HART uses analog 4-20mA for process values and

Devices have some parameters built into them,

Devices are polled by the controller (on demand)

Much slower data rate (FF is >25 times faster)

FF is not approved for safety systems, so HART is

Up to 32 devices per segment

Up to 1900m (6200ft) total field wiring

Requires 9-32 VDC at field device

Physical layer (H1)

Data link layer

Bi-directional communication between host & device

More data is available from the field device

More powerful field devices

More power at field devices enables additional

Faster field commissioning (no field/bench calibration,

Many projects are seeing a lower total lifecycle cost

Devices tested and approved

Redundant I/O cards

Interface between the

4 segments per card

Special cable (AKB336)

Installed on all trunks in

Surge protection is required

DB-LB base allows removal

Connects trunk to field