Industrial Automation

Unit 2

Instrumentation Standard
Protocols
Syllabus
• Instrumentation Standard Protocols: Definition of protocol, Introduction to Open
System Interconnection (OSI) model
• Communication standard (RS232, RS485), Modbus (ASCII/RTU)
• Introduction to third party interface, concept of OPC (Object linking and
embedding for Process Control)
• HART Protocol: Introduction, frame structure, programming, implementation
examples, benefits, advantages and limitation.
• Foundation Fieldbus H1: Introduction, frame structure, programming,
implementation examples, benefits, advantages and limitation.
• Comparison of HART, Foundation Fieldbus, Devicenet, Profibus, Controlnet,
Industrial Ethernet

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Communication
• Communications methods can be applied to transfer larger amounts of
information to and from a controller. With this method, digital and analog I/O
statuses, along with text and numerical data, can be transferred.
• There are many different methods of communication based input and output
protocols. Many of the communication techniques described below have been
adapted to allow remotely mounted devices and I/O blocks to be distributed to
various locations on a machine or within a system and to be controlled from a
central point.
• Often the remotely mounted I/O points can be semiautonomous in controlling
their local stations, with only periodic communication to the central controller.
• Devices and controllers are linked together to form a communications network. A
network may be as simple as two devices talking to one another or a multilayered
scheme with hundreds or even millions of devices on it (as with the Internet).
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Communication Protocol
• Communication protocols are formal descriptions of digital message formats
and rules. They are required to exchange messages in or between computing
systems. Communication protocols are important in telecommunications
systems and other systems because they create consistency and universality for
the sending and receiving of messages.
• Communications protocols can cover authentication, error detection and
correction, and signaling. They can also describe the syntax, semantics, and
synchronization of analog and digital communications.
• Communications protocols are implemented in hardware and software. There
are thousands of communications protocols that are used everywhere in
analog and digital communications. Computer networks cannot exist without
them.

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 The Open Systems Interconnection (OSI) Model
• The open systems interconnection (OSI)
model is a conceptual model created by
the International Organization for
Standardization which enables diverse
communication systems to
communicate using standard protocols.
In plain English, the OSI provides a
standard for different computer systems
to be able to communicate with each
other.
• The OSI Model can be seen as a
universal language for computer
networking. It’s based on the concept of
splitting up a communication system
into seven abstract layers, each one
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stacked upon the last.
 The OSI Model (Cont.)
• Although the modern Internet doesn’t strictly follow the OSI Model (it more closely follows
the simpler Internet protocol suite), the OSI Model is still very useful for troubleshooting
network problems. Whether it’s one person who can’t get their laptop on the Internet, or a
web site being down for thousands of users, the OSI Model can help to break down the
problem and isolate the source of the trouble. If the problem can be narrowed down to one
specific layer of the model, a lot of unnecessary work can be avoided.

Layer Layer Name Diagrammatic Representation

No.

7 This is the only layer that directly interacts with data from
the user. Software applications like web browsers and
email clients rely on the application layer to initiate
communications. But it should be made clear that client
software applications are not part of the application layer;
rather the application layer is responsible for the
protocols and data manipulation that the software relies
on to present meaningful data to the user. Application
layer protocols include HTTP as well as SMTP (Simple 66
Mail Transfer Protocol is one of the protocols that
enables email communications).
RS232
In telecommunications, RS-232 or Recommended
Standard 232[1] is a standard originally introduced in 1960
for serial communication transmission of data. It formally
defines signals connecting between a DTE (data terminal
equipment) such as a computer terminal, and a DCE (data
circuit-terminating equipment or data communication
equipment), such as a modem. The standard defines the
electrical characteristics and timing of signals, the
meaning of signals, and the physical size and pinout of
connectors. The current version of the standard is TIA-
232-F Interface Between Data Terminal Equipment and
Data Circuit-Terminating Equipment Employing Serial
Binary Data Interchange, issued in 1997. The RS-232
standard had been commonly used in computer serial
ports and is still widely used in industrial communication
devices.
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A serial port complying with the RS-232 standard was once a standard
feature of many types of computers. Personal computers used them for
connections not only to modems, but also to printers, computer mice, data
storage, uninterruptible power supplies, and other peripheral devices.
Compared with later interfaces such as RS-422, RS-485 and Ethernet, RS-
232 has lower transmission speed, shorter maximum cable length, larger
voltage swing, larger standard connectors, no multipoint capability and
limited multidrop capability. In modern personal computers, USB has
displaced RS-232 from most of its peripheral interface roles. Few computers
come equipped with RS-232 ports, so one must use either an external USB-
to-RS-232 converter or an internal expansion card with one or more serial
ports to connect to RS-232 peripherals. Nevertheless, thanks to their
simplicity and past ubiquity, RS-232 interfaces are still used—particularly in
industrial machines, networking equipment, and scientific instruments
where a short-range, point-to-point, low-speed wired data connection is
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fully adequate.
RS485
RS-485, also known as TIA-485(-A) or EIA-485, is a
standard defining the electrical characteristics of
drivers and receivers for use in serial
communications systems. Electrical signaling
is balanced, and multipoint systems are supported.
The standard is jointly published by
the Telecommunications Industry
Association and Electronic Industries
Alliance (TIA/EIA). Digital communications networks
implementing the standard can be used effectively
over long distances and in electrically noisy
environments. Multiple receivers may be connected
to such a network in a linear, multidrop bus. These
characteristics make RS-485 useful in industrial
control systems and similar applications. 99
MODBUS
▪ Modbus is a serial communication protocol developed by the Modicon
corporation in 1979. It was originally designed to be used with the company’s
programmable logic controllers (PLCs). Modbus is an open protocol that
supports serial devices that use the RS232/RS485/RS422 protocols. Its
simplicity and the fact that manufacturers can incorporate it into their products
at no charge has helped it become the most popular method of connecting
industrial electronic devices.
▪ There are two main styles of transmission that are used when employing the
Modbus protocol. They are Modbus RTU and Modbus ASCII. This article is
meant to be an advanced Modbus ASCII tutorial. We will start with an overview
of Modbus that is pertinent to both the ASCII and RTU implementations of the
protocol.
▪ Modbus addresses the issue of sending information between electronic devices
over serial lines. The protocol is implemented in an architecture that follows
the master/slave model. The Modbus master is in charge of requesting
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information from the other devices. There is one Modbus master in a standard 10
Modbus Network.
The master requests information from the slave devices, which can number up to 247. Each
slave device is identified by a slave address of between 1 and 247. The process by which the
master queries the slave and receives information returned from the slave is what is meant
by Modbus communication. In addition to requesting information from the slave, the master
device can also write to the slave device’s internal registers.
Serial data is exchanged between devices in bitstreams where each bit is a voltage. Binary
data is exchanged with a 1 being denoted by a negative voltage and a zero is represented by a
positive voltage.
The Modbus protocol defines function codes and the encoding scheme for transferring data
as either single points (1-bit, coils) or as 16-bit data registers. Data packets are encapsulated
according to the transmission method in use. The Modbus protocol uses four distinct tables to
store data in the slave devices. There are two coils which store discrete on or off values and
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two registers which store numerical values. In the case of Modbus ASCII, messages are passed
using the ASCII character set, making them more easily readable by human eyes.
HART Protocol
▪ the HART (Highway Addressable Remote Transducer) Protocol is the global
standard for sending and receiving digital information across analog wires
between smart devices and control or monitoring system or Handheld
communicators.
▪ More specifically, HART is a bi-directional communication protocol that
provides data access between intelligent field instruments and host systems
(DCS/PLC or Handheld Communicator). A host can be any software
application from technician’s hand-held device or laptop to a plant’s process
control, asset management, safety or other system using any control
platform.

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HART Protocol
• HART technology is easy to use and very reliable when used for commissioning and calibration of
smart devices as well as for continuous online diagnostics.
• There are several reasons to have a host communicate with smart devices. These include:
• Device Configuration or re-configuration
• Device Diagnostics
• Device Troubleshooting
• Reading the additional measurement values provided by the device
• Device Health and Status
• Much more
• Years of success using these benefits explain why HART technology is the largest of all
communication protocols, installed in more than 30 million devices worldwide.
• If you’ve ever used a land-line telephone and noticed the Caller ID display to take note of who is
calling, you already know half of what the HART Protocol does—it tells “who” is calling. In an
industrial automation network “who” is a microprocessor-based smart field device. In addition to
letting such smart field devices “phone home,” HART Communication lets a host system send data to
the smart instrument. 13
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HART Protocol
▪ HART emerged in the late1980s based on the same technology that brought Caller ID
to analog telephony. It has undergone continued development, up to and including
automation products now shipping with built-in WirelessHART Communication.

▪ Working
▪ “HART” is an acronym for Highway Addressable Remote Transducer. The HART Protocol
makes use of the Bell 202 Frequency Shift Keying (FSK) standard to superimpose digital
communication signals at a low level on top of the 4-20mA.

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HART Networks
▪ HART devices can operate in one of two
network configurations—point-topoint or
multidrop.
Point to Point
▪ In point-to-point mode, the traditional 4–
20 mA signal is used to communicate one
process variable, while additional process
variables, configuration parameters, and
other device data are transferred digitally The HART Protocol provides for up to two
using the HART protocol (Figure 2). The masters (primary and secondary). This
4–20 mA analog signal is not affected by allows secondary masters such as
the HART signal and can be used for handheld communicators to be used
control in the normal way. The HART without interfering with communications
communication digital signal gives access to/from the primary master, i.e.
to secondary variables and other data control/monitoring system.
that can be used for operations,
commissioning, maintenance, and 15
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diagnostic purposes.
HART Protocol
Multi-Drop Configuration:
▪ There is also an optional “burst”
communication mode where a single slave
device can continuously broadcast a
standard HART reply message. Higher
update rates are possible with this optional
burst communication mode and use is
normally restricted to point-to-point
configuration.
▪ The multidrop mode of operation requires
only a single pair of wires and, if applicable,
safety barriers and an auxiliary power
supply for up to 15 field devices. All process
values are transmitted digitally. In
multidrop mode, all field device polling
addresses are >0, and the current through
each device is fixed to a minimum value
(typically 4 mA). 16
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HART Communication Modes
▪ Master Slave Mode
▪ HART is a master-slave communication protocol, which means that during normal
operation, each slave (field device) communication is initiated by a master
communication device. Two masters can connect to each HART loop. The primary
master is generally a distributed control system (DCS), programmable logic controller
(PLC), or a personal computer (PC). The secondary master can be a handheld
terminal or another PC. Slave devices include transmitters, actuators, and controllers
that respond to commands from the primary or secondary master
▪ Burst Mode
▪ Some HART devices support the optional burst communication mode. 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). The master receives the message at
the higher rate until it instructs the slave to stop bursting.
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HART Benefits
▪ HART technology can help you:
• Leverage the capabilities of a full set of intelligent device data for operational
improvements.
• Gain early warnings to variances in device, product or process performance.
• Speed the troubleshooting time between the identification and resolution of
problems.
• Continuously validate the integrity of loops and control/automation system
strategies.
• Increase asset productivity and system availability.
▪ Increase Plant Availability
• Integrate devices and systems for detection of previously undetectable problems.
• Detect device and/or process connection problems real time.
• Minimize the impact of deviations by gaining new, early warnings. 18
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• Avoid the high cost of unscheduled shutdowns or process disruptions.
HART Benefits
Reduce Maintenance Costs
• Quickly verify and validate control loop and device configuration.
• Use remote diagnostics to reduce unnecessary field checks.
• Capture performance trend data for predictive maintenance diagnostics.
• Reduce spares inventory and device management costs.
Improve regulatory compliance
• Enable automated record keeping of compliance data.
• Facilitates automated safety shutdown testing.
• Raise SIL/safety integrity level with advanced diagnostics.
• Take advantage of intelligent multivariable devices for more thorough, accurate reporting.
The standard features of HART technology range from simple compatibility with existing 4-20mA
analog networks to a broad product selection:
• Compatibility with standard 4-20mA wiring
• Simultaneous transmission of digital data
• Simplicity through intuitive menu-driven interfaces
• Risk reduction through a highly accurate and robust protocol
• Ease of implementation for maximum “up-front” cost effectiveness
• Broad product selection, with compatible devices and software applications from most
process automation providers 19
• Platform independence for full interoperability in multi-vendor environments
HART Benefits
▪ The HART Protocol was developed in the late 1980’s and transferred to the HART Foundation in the
early 1990’s. Since then it has been updated several times. When the protocol is updated, it is
updated in a way that ensures backward compatibility with previous versions. The current version
of the HART Protocol is revision 7.3. The “7” denotes the major revision level and the “3” denotes
the minor revision level.
▪ The HART Protocol implements layers 1,2, 3, 4 and 7 of the Open System Interconnection (OSI) 7-
layer protocol model:
▪ The HART Physical Layer is based on the Bell 202 standard, using frequency shift keying (FSK) to
communicate at 1200 bps. The signal frequencies representing bit values of 0 and 1 are 2200 and
1200Hz respectively. This signal is superimposed at a low level on the 4-to-20mA analog
measurement signal without causing any interference with the analog signal.
▪ The HART Data Link Layer defines a master-slave protocol – in normal use, a field device only
replies when it is spoken to. There can be two masters, for example, a control system as a primary
master and a handheld HART communicator as a secodary master. Timing rules define when each
master may initiate a communication transaction. Up to 15 or more slave devices can be
connected to a single multidrop cable pair.
▪ The Network Layer provides routing, end-to-end security, and transport services. It manages 20
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“sessions” for end-to-end communication with correspondent devices.
HART Benefits
▪ The Transport Layer: The Data-Link Layer ensures communications are successfully
propagated from one device to another. The Transport Layer can be used to ensure end-
end communication is successful.
▪ The Application Layer defines the commands, responses, data types and status reporting
supported by the Protocol. In the Application Layer, the public commands of the protocol
are divided into four major groups:
▪ Universal Commands – provide functions which must be implemented in all field devices
▪ Common Practice Commands – provide functions common to many, but not all field devices
▪ Device Specific Commands – provide functions that are unique to a particular field device
and are specified by the device manufacturer
▪ Device Family Commands – provide a set of standardized functions for instruments with
particular measurement types, allowing full generic access without using device-specific
commands.

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 HART Applications
▪ The power of the HART protocol is evident
in the control diagram of Below Figure.
This innovative application uses the
inherent feature of the HART protocol
that both 4-20 mA analog and digital
communication signals are transmitted
simultaneously over the same wiring.
▪ In this application, the HART-compatible
transmitter has an internal PID control
capability. The device is configured such
that the 4-20 mA loop current is
proportional to the control output of the
PID algorithm executing in the device (not
the measured variable as in most The control loop executes entirely in the field between the
transmitter applications). Since the 4-20 transmitter (with PID) and the control valve. The control
mA loop current is regulated by the PID action is continuous as the traditional 4-20 mA analog signal
control output, it is used to drive the valve drives the valve. HART digital communication links the
position directly. operator with the control loop to change set point, and read
the primary variable, or valve position output. Substantial
savings are possible in applications where this innovative 22
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control architecture is appropriate.