Industrial

Communications
- by Rajeshkumar Modi

Rev. 0 – Oct 2014

 Evolution of Signal Transmission
Technology

Hybrid
Analog (Smart, Brain) Fieldbus (Profibus,
Pneumatic 4 -20 mA Foundation
3-15 psi Fieldbus,)

1940 1960 1980 2000

2
Instrumentation Signals

Pneumatic (1930’s)
 6 - 30 PSI
 3 - 15 PSI (ISA SP-50 Standard)

Electrical (analog)
 10 - 50 mA (1950’s)
 4 - 20 mA (ISA SP-50 Standard, 1975)

Electrical (hybrid)
 4 - 20 mA with superimposed digital signal

Electrical (digital)
 FOUNDATION Field bus (ISA SP-50 Standard, 1994)
 Profibus (1990)

3
4-20 mA Systems
Advantages:

OPEN, interoperable,
Broad range of equipment
Multiple suppliers
Standard control system interfaces
I/O
Standard support equipment

Shortcomings:

Limited information
4-20 mA - one variable, one direction
Point-to-point wiring

Traditional
Analog & Discrete
Instruments

4
HART

HART (Highway Addressable Remote Transducer) Communications

Protocol grew out as a practical way to bridge the analog/digital gap.

5
Communication Mode

Master-Slave mode which means that during normal operation, each slave
(field device) communication is initiated by a master communication
device.

Burst mode enables faster communication (3–4 data updates per second).
In burst mode, the master instructs the slave device to continuously
broadcast a standard HART reply message (e.g., the value of the process
variable).

6
Frequency Shift Keying

The HART communication protocol is based on the Bell 202 telephone

communication standard and operates using the frequency shift keying
(FSK) principle.

The digital signal is made up of two frequencies—1,200 Hz and 2,200 Hz

representing bits 1 and 0, respectively.

Sine waves of these two frequencies are superimposed on the direct

current (dc) analog signal cables to provide simultaneous analog and
digital communications.

7
Simultaneous Analog and Digital
Communication

8
Wiring and Installation

The installation practice for HART communicating devices is the same as

conventional 4-20mA instrumentation.

Individually shielded twisted pair cable, either in single-pair or multi-pair

varieties, is the recommended wiring practice.

Most installations are well within the 3,000 meter (10,000 ft) theoretical limit
for HART communication.

However, the electrical characteristics of the cable (mostly capacitance)

and the combination of connected device scan affect the maximum
allowable cable length of a HART network

9
Intrinsic Safety

 Intrinsic safety (IS) is a method of providing safe operation of electronic

process-control instrumentation in hazardous areas.

 IS devices (barriers / Isolators) are often used with traditional two-wire 4–

20 mA instruments to ensure an IS system in hazardous areas.

 Zener barriers use a high-quality safety ground connection to bypass

excess energy

 Isolators, which do not require a ground connection, repeat the analog

measurement signal across an isolated interface in the safe-side load
circuit

10
Control System Interfaces

 All HART-compatible control systems can read the digital primary

variable from a slave device (Transmitter).

 Gateways can be used to bring HART digital data into control systems
that do not support HART-capable I/O.

 Some systems support HART gateways with communication protocols

such as Modbus, PROFIBUS DP, or TCP/IP Ethernet.

11
HART Multiplexers

 HART-compatible multiplexers are ideal for users who want to interface

with a large number of HART devices.

 Using a multiplexer enables a supervisory computer to monitor

diagnostics and device status and read any additional process inputs
not provided by the 4–20mA signal.

12
Universal Handheld Communicator

 The 275 Universal HART Communicator is available from major

instrumentation suppliers around the globe and is supported by all major
HART Instrument Vendor.

 Using HART DDL, the communicator can fully communicate with and
configure any HART device for which it has a DD installed.

 If the communicator does not have the DD for a particular network

device installed, it can still communicate with that device using the
universal and common practice commands

13
PC Configuration Software

 Many instrument manufacturers, as well as some independent software

developers, offer HART communication software for PCs with capabilities
similar to and beyond those offered by a HART handheld communicator.

 The software packages listed in Table below are used for configuration
management, parameter tuning, and data acquisition with a HART device.

14
List of HART Softwares

15
Smart Instruments (HART)
Advantages:

 More information
 Proprietary or
Two-way communication of multiple Custom
variables
Interface
 Better accuracy, reliability
 Faster system commissioning
 Easier configuration, calibration maintenance,
and support

Tradeoffs: PLC
PLC
 Limited interoperability
 Lack control loop performance

Analyzer
Analyzer

Hybrid Instruments or Intelligent

Instruments with Custom
Interfaces

16
Fieldbus

 Fieldbus is the most advanced and scalable process automation

infrastructure. It is more than just a replacement for 4-20mA. It manages
data communication, plant assets and plant events, and it is Open and
standards-based.

 A Fieldbus is a serial digital bus optimized for response time and

predictable data transmission between field devices, sensors and
actuators

17
How is Fieldbus Different from 4-20mA
4-20mA fieldbus

P.S. P.S.

 Fieldbus devices are connected in parallel on the bus, which carries digital
data from/to all the devices on the bus
 Fieldbus devices provide almost unlimited information to all other devices
on the network
 Data have cyclical redundancy checking (CRC) to ensure receiving
devices use only good data
 A multi-drop fieldbus does not have the shortcoming of point-to-point
wiring

18
Terminology in Field Bus Systems

 H1: 31.25 Kbps AWG Range 1900* m

 H2: 1.0 Mbps AWG Range 750* m

 H3: 2.5 Mbps AWG Range 500* m

 HSE(High Speed Ethernet) : 100Mbps Peer to Peer Communication

support.

19
OSI Model

20
21
Fieldbus Communication

 The data transfer is via bi-directional Frames.

 The Pre-amble, start and end of a Frame are indicated by De-limiters in

the Frame.

 The delimiters use binary levels and edges. Other data use only binary
edges.

 The individual devices take over the bus based upon a priority assigned.

 This may be done by using a token passing procedure.

22
Physical Components in a Foundation
Fieldbus

23
Topology

24
Foundation Fieldbus Cable

 To get maximum performance from the network, use individually

shielded, twisted-pair cable designed especially for FF for all new
installations
 Twisted pair wire is used rather than a pair of parallel wires to reduce
external noise from getting onto the wires
 The shield over the twisted pairs further reduces susceptibility to noise
 Cables for FF installations should be labeled Type A (18 American Wire
Gauge)
 Multi-pair cables should have an additional overall shield

25
Cable length Calculation Limit

26
Trunk
 Use Type A (18 AWG) multi-pair, individually shielded cable for FF signals for all trunk
wiring
 Total Segment Length = Trunk + All Spurs
 Good design practice dictates providing a 20% spare pairs capacity all multi-pair FF
segment trunk cables, with a minimum of one spare pair.
 Typically, the trunk cable is a multi-pair cable if there is more than one segment in the
area or the segment in the area is to be loaded to maximum
 The maximum allowed length of an FF segment is 1900 m (6232 ft) Compute total
segment length by adding the length of the main trunk line and all the spurs that extend
from it

27
Spurs
 A spur is an H1 branch line connecting to the main trunk line
 The trunk is considered to be the main cable run and contains segment terminators at
each end.
 A spur can vary in length from 1 meter to 120 meters.
 When a short circuit protection wiring block is utilized, the segment design is limited to
one device per spur.
 The maximum spur length, that is, the length of the cable from the wiring block to the
H1 device, is 120 meters

28
Foundation Fieldbus Terminators

 Each fieldbus segment should have two terminators.

 The wiring between the two terminators is defined as the trunk.
 Terminators located in the field are installed in a junction box.
 A terminator is used to prevent a reflection at the ends of a fieldbus
cable.
 Noise on the line distorts the signal when:
• Signal travels on a cable and encounters a discontinuity (wire open or short) it
produces a reflection
• Portion of the signal that echoes from the discontinuity travels in the opposite
direction
 A fieldbus terminator consists of a 1mF capacitor in series with a 100
Ohm resistor

29
Foundation Fieldbus Segment design

 Based on Philosophy Table & Layout, Segment to be designed

 Preparing FF Segment Table and Validating segment in term of Voltage

loading using reputed validation software segment checker.

 Validating segment based on cycle time loading

 Optimizing the segment & Revise Layout

30
Segment Limits

 Factors that limit the number of devices per segment

 Bandwidth - approx. 50 messages/sec
 Power
• General Area - limited by power supply capacity
• Intrinsically Safe Area - IS barrier limits power to 600 mW

 Wire Size - high impedance wire reduces segment length and number of
devices
 Segment Capacity - 32 devices/segment; up to 240 devices total with
repeaters

31
Surge Protection Applied to Trunk and Spur

32
Concept

 Based on Area classification, Concept to be decided

– FISCO : As per IEC 60079-27, 1km/ 4 device/ 12.4V@ 120mA (Zone 1,IIC), 1.9
km/ 9 device/ 13.1@250 mA (Zone 2, IIB), Spur length 60 m

– FNICO : As per IEC 60079-27, 500 m/ 6 device/ 12.4V@180 mA (Zone 2,IIC),

500 m/ 8 device/ 13.1V@320 mA (Zone 2, IIB), Spur length 60 m

– High Power Trunk : As per ISA S 50.02 1700 m/ 12 Devices/ 24 V DC@

500mA (Zone 1 / 2), IS Device, IS Barrier, Exd Terminator, Exe Junction box,
etc.

33
FISCO (Fieldbus Intrinsically Safe Concept)

34
Boundary conditions for the application of
FISCO

 Only one power source permitted per segment

 All stations must be approved in accordance with FISCO

 The cable length must not exceed 1000 m (ignition protection class i,
category a)/ 1900 m (ignition protection class i, category b)

 The cable must satisfy the following values:

R´= 15 ... 150 Ω/km

L´= 0.4 .. 1mH/km

C´= 80 .. 200 nF/km

35
Foundation Fieldbus Engineering

 Decision on Technology : Conventional or Foundation Fieldbus/

Profibus / As-I Bus

 Concept : FISCO, FNICO, High Power Trunk

 Complying to International Standards IEC, AG standards, etc

 Process Design (Identifying loops, symbol)

 Identify Registered Instruments

 Control assignment

 Cable routing, Control room location based on above, Design basis / Std
Specifications for FF shall be prepared for the project

36
Termination Count
Field
Marsh Cab. I.S. I/O
Junction Box
FT-100 Barrier Assembly
+
-
1 1 + 1 + +
- - -
2 2 + 2 + +
3 3 - - -
FCV-100 + 3 + +
4 4 - - -
+ 5 5 + 4 + +
- - -
- 6 6 +
7 7 -
+
8 8 -
TT-100 9 9
+ 10 10
- 11 11
12 12

Conventional analog termination

PT-101
+ Marshalling done in Junction Box with Fieldbus termination (also included
- in conventional termination count)
Fieldbus so Marsh Cab is optional

37
Increased Information

 Instrument identification, location

 Status of PV
 Ambient conditions
 Diagnostics
 Configuration
 Instrument characteristics
 Calibration information: date, method, location, etc.

38
FF Diagnostics

 Shield short
• Easy to measure and understand
• Further measurements can identify location
 Signal level
• Minimum level is specified by Fieldbus specification
• Low or high levels on all devices suggests incorrect bus termination
• If only one device, suggests problem on single spur
 DC voltage
• Indicates correct function of power supply/conditioner
 Noise
• Maximum level is specified by Fieldbus specification
 Retransmissions
• Good measurement of physical layer health
• Re-tries can obscure faulty device or network

39
I/O Card Savings
Fieldbus

Conventional 4-20mA

40
Reduced Space Requirements

Conventional Cabinet Cable

 Wiring & Rack System
 Cable cost
 Junction box
 Cable Conduit
 Processing of cable
 Marshalling cabinets
 Barrier

Fieldbus System

Case of 350 I/O points

Courtesy of Emerson

41
Function Blocks
A location-independent model for distributed control

HMI

H1 Fieldbus

FT
FT
FC
FC
Process

AI-110 PID-110 AO-110

42
Advantages of Control in the Field

All function blocks control logic are implemented in the field devices

This control concept would be ideal as

• It minimizes communication traffic

• Control is not affected even in case of H1 card failure

• Host control system execution time and I/O scan rate does not affect

• This gives flexibility of adding more devices per H1 card and enable
future expansion without needing additional controllers.

43
Interoperability (DD)

44
Comparison
Conventional Technology Foundation Fieldbus
Technology
TOPOLOGY One to One Multi-drop

TRANSMISSION 4-20 mA DC Analog Only Digital

METHOD
TRANSMISSION One way Bi-directional
DIRECTION
SIGNAL TYPE Single Signal Multiplex signal
REMOTE SETUP OF Not possible Possible
FIELD DEVICE
SELF DIAGNOSTICS Information cannot be obtained Information can be
from field devices obtained through
separate maintenance
systems

45
Invensys Foxboro I/A FF Architecture

Two FF terminators FF power FF junction boxes /

conditioners MTL Megabox
I/A termination
Assembly / Barrier Board

I/A FBM228

24Vdc bulk power supply

Foundation Fieldbus field devices

46
Honeywell Experion PKS FF Architecture

47
Emerson Delta V FF Architecture

48
Emerson Delta V FF Components

49
PROFIBUS

 PROFIBUS (Process FieldBus) is an open, digital communication

system with a wide range of applications, particularly in the fields of
factory and process automation.
 PROFIBUS is suitable for both fast, time-critical applications and
complex communication tasks.

50
Profile

Physical Communication Application

Profiles Profiles Profiles

PA
Ethernet
Encoder
RS-485 TCP/IP
IEC 1158-2 FMS PROFIDrive
DP
Optical Fiber PROFISafe
PROFIBUS EN 50170

51
Types of Profibus

 Profibus FMS (Fieldbus Message Specification)

• General Purpose Automation

 Profibus DP (Decentralized Periphery)

• Factory Automation

 Profibus PA (Process Automation)

52
Profibus DP (Distributed Peripherals)
Master

PLC
PLC
DP - RS 485 - 9.6 kBit/s to 12 MBit/s

Slave Slave Slave Slave

53
Profibus DP (Distributed Peripherals)
 The objective of PROFIBUS DP is fast and effective communication on the
field level. It uses RS 485 (Voltage levels 0 and 5 V) or Fiber Optics. The
baudrate can be chosen from 9.6 kBit/s to 12 Mbit/s.

 The communication is build on the master/slave principle, with typically a PLC

or a PC as a master and several stations as slaves: Digtal I/O, Analogue I/O,
AC or DC drives, Magnetic or pneumatic valves, panels, etc.

 The DP stations must be assigned a unique address, a number (0 to 126).

One master can handle at most 126 slaves. Each station can send or receive
a maximum of 244 bytes.

 In RS 485, the network needs a repeater for every 32 stations. A repeater is

also needed if the cable distance is long (100m at 12 Mbit/s, 1200m at
9.6kBit/s). The total length of the network can not exceed 10 km.
54
Profibus DP – Example

PLC

Valve
Node
Operator Panel Modular I/O

55
Profibus PA
Process
Device
Manager

x
PROFIBUS-DP 9.6kBit/s  12 MBit/s H2

+ x
PROFIBUS-PA 31.25 kBit/s H1

Segment
Coupler / Link

56
Profibus PA

 The transmission technology used by PA is IEC 1158-2. The baud rate is

fixed: 31.25 Kbit/s , and the signal levels are 0 and 20 mA. Therefore it is
a need for a signal translator between the PA and the DP part of the
network. There are two kinds of such a translator : Coupler and Link.

 A Coupler does signal transmission only – Seen from the DP side, all
the PA instruments act like DP stations. The coupler is totally
transparent. If a coupler is used, the baudrate on the DP side will be
fixed.

 A Link is equipped with intelligence so that the DP network can run with
any of the H2 baudrates (9.6 kBit/s to 12 Mbit/s). The link has its own DP
address – and the PA stations are addresses under this.

57
PA - Example

Level Transmitter Flow Transmitter

DP/PA Coupler

DP

58
FMS : Fieldbus Message Specification

Master
PLS
PLC

FMS - RS 485 - 9.6 kBit/s to 12 MBit/s

Master Master Slave Slave

59
FMS - Example

SCADA PC with
CITECT and
PROFIBOARD

SIEMENS S300 PLC Moeller PLC

60
Modbus

 Modbus Protocol is a messaging structure created by Modicon to

connect PLCs to Programming tools.

 It is widely used to implement master slave communication between

Intelligent devices.

 Modbus is independent of the physical layer.

 It can be implemented using RS-232 , RS-485 or TCP/IP etc.

61
Modbus Serial line RS485

7 Application Modbus

6 Presentation

5 Session
Modbus Serial line RS485 is a low cost network using a master slave
medium access
4 Transport
with a transmission speed from 115 to 1200 Kbits/s
3 Network

2 Link Master - Slave

Physical RS485
1

62
Modbus TCP/IP

7 Application Modbus

6 Presentation
MODBUS TCP/IP uses TCP/IP and Ethernet 10 Mbit/s or 100 Mbits/s to
Session
5
carry the MODBUS messaging structure.
4 Transport

3 Network

CSMA / CD
2 Link ETHERNET V2 ou 802.3

1 Physical

63
Modbus ASCII & RTU Mode

Modbus protocol comes in two versions.

ASCII Transmission Mode:
 Each 8 bit data in a message is sent as 2 ASCII characters.
 ASCII mode allows time interval of up to 1 second for each character to
travel without any error.
RTU Transmission Mode:
 The main advantage of RTU mode is that it achieves higher throughput.
 Each 8 bit data in a message is sent as 2 hexadecimal characters.

64
Modbus Frame Structure
The Modbus frame structure is the same for requests (master to
slave messages) and responses (slave to master messages).

Modbus RTU

silence Address Function Data Checksum silence

Silence >= 3,5 characters

Modbus ASCII

: Address Function Data Checksum CR LF

0A Hex
3A Hex 0D Hex

65
Function Code Example

Code Function
01 (0x01) Read Coils
02 (0x02) Read Discrete Inputs
03 (0x03) Read Holding Registers
04 (0x04) Read Input Registers
05 (0x05) Write Single Coil
06 (0x06) Write Single Register
15 (0x0F) Write Multiple Coils
16 (0x10) Write Multiple Registers
23 (0x17) Read/Write Multiple
Registers
43 (0x2B) Read Device Identification

66
OPC
OPC (formerly: "OLE for Process Control", now: "Open Process Control") is an industry
standard set up by the OPC Foundation specifying the software interface (objects, methods) to a server
that collects data produced by field devices and programmable logic controllers.

interfaces application node

covered by the
OPC standard
(OPC client) servers

OPC OPC OPC

server server server
X Y

PLCs Brand X PLCs Brand Y

67
Before OPC
visualization
history
data base

MasterBus XWAY Profinet

MMS driver driver driver

ABB PLCs Télémécanique PLC Siemens PLC

68
After OPC
Operator Historian
application software is (Information
written independently from Manager)
the type of controller

the drivers still exist,

but the clients do not ABB Schneider Siemens
OPC server OPC server OPC server
see them anymore
MMS XWAY ProfiNet

ABB AC800M Télémécanique TSX Siemens S7

69
OPC Significance

 OPC is the greatest improvement in automation since IEC 61131.

 More than 150 vendors offer OPC servers to connect their PLCs, field
bus device, displays and visualization systems.

 OPC is also used for data exchange between applications and for
accessing databases

 OPC consists of three major components:

1. OPC - DA = Data Access (widespread, mature)
2. OPC - AE = Alarms and Events (not yet much used)
3. OPC - HDA = Historical Data Access (seldom used)

70
OPC DA for Data Access
 Process variables describe the plant's state, they are generated by the sensors or
calculated in the programmable logic controllers (PLCs).
 Process variables can be sent upon a change, on demand or when a given time elapsed.
The OPC DA (Data Access) specification addresses collecting Process Variables.
 The main clients of OPC DA are visualization and (soft-) control.

71
OPC AE for Alarms and Events

 determine
 OPC the exact
AE (Alarms and time of specifies how alarms and events are
Events)
change (time
subscribed, stamping)
under which conditions they are filtered and sent with their
associated messages.
 categorize by priorities
The main
 log clientsuse
for further of OPC AE are the Alarms and Event loggers.

 acknowledge alarms

72
HDA for Historical Data Access

 Historical Data are process states and events such as: process
variables, operator actions, recorded alarms that are stored as logs in a
long-term storage for later analysis.
 OPC HDA (Historical Data Access) specifies how historical data are
retrieved from the logs in the long-term storage, filtered and aggregated
(e.g. compute averages, peaks).
 The main client of OPC HDA are Trend Displays and Historians.

73
QUESTIONS?

74