PROFIBUS Design Good Practices 2011

PROFIBUS Design and Good Practices
Agenda PROFIBUS Family Communication Medias Topologies Cable length Devices Rules Installation Rules
Introduction PROFIBUS-DP PROFIBUS-PA Installations and Best practise
Troubleshooting Training
PROFIBUS Family
3
Agenda PROFIBUS Family Communication Medias Topologies Cable length Devices Rules Installation Rules Troubleshooting Training
2 3 4 5 6 7 8 31 3 4 2 1 1
DCS
ERP MES Ethernet backbone
PROFIBUS PA
PROFIBUS DP PROFIBUS PA
6 7 8 31
PA coupler PA link
Author / Title of the presentation
PROFIBUS-DP/PA
Specification by 13 industrial firms and 5 university institutes 1988 German DIN Standard 19245 1996 European Fieldbus Standard EN 50170 2000 International Standard IEC 61158
Profile PROFIBUS-DP (high speed)
IEC 61158 communication RS485 physic or fiber optic max. 12 MBaud IEC 61158 communication
Profile PROFIBUS-PA current supply over bus IEC 61158-2 physic 31,25 KBaud
PROFIBUS - Transmission Technologies

Controller
Agenda PROFIBUS Family

PROFIBUS DP
> 10km FO RS485 Fiber optic RS485
Per PROFIBUS DP Master system max. 125 DP slaves OLMs (Optical Link Module) for wide distances with high EMC stability Electrical networks can be extended by means of repeaters (segments)
max. 32 DP slaves per
Coupler RS485iS
Communication Medias Topologies Cable length Devices Rules Installation Rules Troubleshooting Training
Repeater 1,200 m
segment
RS485iS DP/PA 1.900 m Non-Ex 1.000 m 1.000 m
RS485iS couplers for intrinsically safe PROFIBUS DP in EX areas PROFIBUS PA for direct connection of field devices with power supply via bus
PROFIBUS PA (MBP IS)
PROFIBUS - Functional levels

Functional Levels DP-V2 extension: Peer Slave Communication (Publisher / Subscriber) Isochron Mode (Equidistance) Clock Synchronization & Time Stamps HARTon DP PROFIdrive Redundancy
Cyclic Data Exchange between PLC and Slave Devices GSD Configuration Diagnosis
> 90%
Time
DP-V0
field decice
DP-V1 extension: Acyclic Data Exchange between PC or PLC and Slave Devices Integration within Engineering: EDD and FDT Portable PLC Software Function Blocks (IEC 61131-3) Fail-Safe Communication (PROFIsafe) Alarms
PROFIBUS - Master - Slave

Master (class 1)
Central control Cyclical data exchange with the slaves Acyclical data exchange with the slaves Active with a high priority
Master (class 2)
Engineering tool for commissioning and parameter settings of the slaves Acyclical data exchange with the slaves Active with a low priority
SPS
Master (class 1)
Master (class 2)
PROFIBUS Bus slaves (passive)
PROFIBUS DP/PA - Deterministic communication
Deterministic communication according Master/Slave principle:

Parameterized time behaviour of the bus and defined reaction times of the slaves are permanently guaranteed!
Master class 1 Master class 2
cyclic
acyclic acyclic
cyclic
1 t
2
PROFIBUS DP
Read measured values, write manipulated variables
Read/write parameters and measured values of a slave
PROFIBUS PA
Slave 1
Slave 2
Configuration of the bus (GSD file)
Bus master (Class 1 Master) needs the technical data of the attached field device.
The GSD file describes the general and device specific communication characteristic of a PROFIBUS device: sheet
Supported transmission rates Length of the transferred I/O data Type of the field device (compact slave, modular slave)
ion urat nfig s - Co Bu
PROFIBUS Configurator
SPS
PROFIBUS
PROFIBUS Family - Principle

11
To create hierarchy in the network, PROFIBUS defines 2 types of stations: active (masters) and passive (slaves).
master
0 1 0 1 0
commands
0 1 0 1 0
slave
responses
network
At least 1 master is mandatory. PROFIBUS networks allow multiple masters. In total 127 stations can be addressed (masters + slaves).
Communication Medias
12
PROFIBUS Supports 3 transmission media

Coupler Coupler
RS 485 2-wire CU-cable for general purposes
Fiber Optic Highest EMC protection and wide distances
MBP-IS 2-wire CU-cable with the option for power over the bus and Ex-protection
Fiber optic cable
Total Overview of the Technology

13
Agenda
Identification Systems Identification Systems
PA Devices PA Devices
V2.0 and V3.0 V2.0 and V3.0
Encoder Encoder
SEMI SEMI
Topologies Cable length Devices Rules Installation Rules Troubleshooting Training

Comm. App. Profiles I
Common Application Profiles (optional): Common Application Profiles (optional):
PROFIsafe, Time Stamp, Redundancy, etc. PROFIsafe, Time Stamp, Redundancy, etc.
IEC 61158/61784
Descriptions (GSD, EDD) Descriptions (GSD, EDD) Tools (DTM, Configurators) Tools (DTM, Configurators)
PROFIBUS DP
Fiber Fiber Optics: Optics:
Glass Multi Mode Glass Multi Mode Glass Single Mode Glass Single Mode PCF // Plastic Fiber PCF Plastic Fiber
FDL + DPV0...V2
Physical Layer
RS 485 RS 485 RS 485-IS RS 485-IS
NRZ NRZ Intrinsic Safety Intrinsic Safety
MBP MBP MBP-LP MBP-LP MBP-IS MBP-IS
Manchester Bus Powered Manchester Bus Powered Low Power Low Power Intrinsic Safety Intrinsic Safety
Integration Technologies
App. Profiles II
PROFIdrive PROFIdrive
RIO for PA RIO for PA
Weighing & Dosage Weighing & Dosage
PROFIBUS Family
PROFIBUS DP Topologies - General

14
PROFIBUS communicates over a two wire bus structure.

T
listen, taking over and answering
sending listen
0 1 0 1 0
1 43
117
T
5
listen listen
Devices are addressed through a network address (0..126). Devices are coupled in parallel to the bus. Devices can be hot swapped and position does not matter. Each segment is terminated at both end with an active termination Spurs should be avoided as length is very limited
PROFIBUS DP Topologies - Repeaters

15
Single Repeaters
Agenda PROFIBUS Family
PROFIBUS Hubs
Segment 1
Stations
Backbone
Segment 2
Stations Segment 1 Segment 2
Benefit: Isolate part of your network from EMC/Noise
PROFIBUS DP Topologies Fiber Optic

16
Classic Topology
Agenda PROFIBUS Family Communication Medias
Coupler
Ring Topology
Fiber optic cable

Coupler

Coupler Coupler Coupler Coupler
Fiber optic cable
Benefits: Long distances and EMC/Noise isolation
PROFIBUS DP Topologies - Wireless

17
Connect your slaves through wireless couplers

Wireless gateway Wireless gateway
Wireless gateway
Wireless gateway
Segment
Wireless DP Device
Wireless PN Device
PROFIBUS DP Topologies - Redundancy

18
RS 485 RS 485
glasvezel coupler glasvezel coupler
RS 485
RS 485
coupler
RS 485
coupler
RS 485
RS 485
1.0
Transmission speed (baudrate)

19
PROFIBUS offers the user the possibility to choose from 10 transmission speeds (RS 485).
9,6 19,2 45,45 93,75 9,6 19,2 45,45 93,75 187,5 500 1500 3000 6000 12000 kbps 187,5 500 1500 3000 6000 12000 kbps
Remarks: The transmission speed determines the maximum cable length and vice versa. The transmission speed has to be set identically at all the masters on the same bus. Most slaves detect the baudrate automatically. Because of economic and technical reasons some products do not support all transmission speeds. Some older products do not support 45,45 kbps.
2.1
PROFIBUS DP Cable Length

20
Baudrate vs Cable Length

Baudrate (kbit/s) Segment length (m) Segment length (feet) 9.6 19.2 45.45 93.75 187.5 500 1500 3000 6000 12000
1200
1200
1200
1200
1000
400
200
100
100
100
3940
3940
3940
3940
3280
1310
656
328
328
328
3 baudrate transitions in which the cable 3 baudrate transitions in which the cable length reduces with more than 50 %. length reduces with more than 50 %.
These lengths are defined for 1 segment with 32 bus loads!
2.1
Device Rules - Network

21
PROFIBUS Address Map

0 1..2 3..125 126 127
Service-, diagnosis- and programming tool Masters (class 1) Slaves (total 123 or 124) Address for: Set Slave Address Broadcast address
Most configuration tools block address 0 and 126 for slaves. Address 126 is a default address for slaves with software address settings. Address 127 is a broadcast address (only visible with a busmonitor). Maximum 124 DP slaves per bus!!!!!!!
2.0
Device Rules - DP Segments

22
Maximum 32 loads per RS485 segments

Max 30 Stations
Max 31 Stations
Segment 1
Segment 2
Devices that generate new segments:

Repeaters Fiber Optic Couplers Wireless gateways
After these devices, PROFIBUS segment rules are the same.
PROFIBUS-PA Network layout

Layer Model (ISO Standard since 1983)
Agenda PROFIBUS Family Communication Medias

PROFIBUS DP
Controller (Master)
7
Remote IO
Application Presentation Session Transport Network Data Link
DPV0 .. 2

IEC 61158-2 Manchester Bus Powered (MPB)
I IB + 9mA IB IB - 9mA t 1 0 1 1
6 5 4 3 2 1
Link
FDL Physical MBP
Gert
PROFIBUS PA
PROFIBUS PA Topologies - Overview

25
24 V
+
DCS/PLC
PROFIBUS DP
Junction Box
DP/PA-Link
Segment PROFIBUS PA
PROFIBUS PA Topologies - Redundancy

26
Coupler Redundancy
Bus termination Automatic bus termination
PROFIBUS DP
Coupler-Redundancy
M
DP/PA-coupler, redundant (M = master)
IM 153, redundant
AFS
Active Field Splitter PROFIBUS PA
PA Ring Redundancy
PROFIBUS DP
Coupler-Redundancy
M
DP/PA-coupler, redundant (M = Master) AFD
Media redundancy based on a ring topology

AFD Active Field Distributor
IM 153, redundant
PROFIBUS PA AFD AFD
Higher availability with Redundancy
Short-circuit or wire break on trunk line
DP/PA Link
M
Field Device Coupler, redundant (M = master)
PROFIBUS PA
PA Junction Box
Junction Box
Automatic bus termination
Automatic Termination
Automatic bus termination enables unique online changeability
Agenda PROFIBUS Family Communication Medias Topologies
Bus termination Automatic bus termination
FF Link
Add new devices Enhance line Enhance ring
Cable length Devices Rules Installation Rules Troubleshooting Training
PROFIBUS PA
AFD
AFD
AFD
AFD
AFD
There is no need to reserve spare ports of the AFDs !
Installation rules
30
Grounding & Shielding

PROFIBUS is digital communication, not 4-20mA Ground at both end Ungrounded shield has no effect
Installation rules
31
Power Lines
Digital communication is sensitive to power lines Watch out for cable runs in trays Respect distances for air separation
Power line too close
Power line are removed
Installation rules
32
Some examples with Power Lines

Installation rules
33
Proper wiring and component selection

Wiring and cable termination is critical Wrong component selection leads to bad installation Take environment in account (humidity, sunlight)
Troubleshooting
34
Recognizing bad installations

You cannot use the multimeter, this is digital comm. Specific tools are required
Cable Tester
Oscilloscope Analyzer
Find wiring errors such as short circuit Identify missing termination and EMC Capture error messages and find the source of your system shutdown Cost and time saving by using the right tools!
Troubleshooting - Oscilloscope
35
Good signal
Missing termination
Troubleshooting - Analyzer
36
Capture all PROFIBUS messages

Useful for random errors Shows underlying conditions Device diagnostic
Training
37
Certified Training by PROFIBUS International

Benefits
Avoid basic errors that cost time and money Quality assurance for design and commissioning Faster project delivery Better installation, longer operation
Various courses available

PROFIBUS Certified Engineer PROFIBUS Certified PA Module PROFIBUS Certified Installer PROFINET Certified Engineer
Certified by
38
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PROFIBUS Design Good Practices 2011

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PROFIBUS Design Good Practices 2011

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PROFIBUS Design and Good Practices

Introduction PROFIBUS-DP PROFIBUS-PA Installations and Best practise

ERP MES Ethernet backbone

Profile PROFIBUS-DP (high speed)

PROFIBUS - Transmission Technologies

Agenda PROFIBUS Family

RS485iS DP/PA 1.900 m Non-Ex 1.000 m 1.000 m

PROFIBUS PA (MBP IS)

PROFIBUS - Functional levels

PROFIBUS - Master - Slave

PROFIBUS Bus slaves (passive)

PROFIBUS DP/PA - Deterministic communication

Deterministic communication according Master/Slave principle:

Read measured values, write manipulated variables

Read/write parameters and measured values of a slave

Configuration of the bus (GSD file)

Introduction PROFIBUS-DP PROFIBUS-PA Installations and Best practise

PROFIBUS Family - Principle

PROFIBUS Supports 3 transmission media

RS 485 2-wire CU-cable for general purposes

Fiber Optic Highest EMC protection and wide distances

Fiber optic cable

Total Overview of the Technology

Identification Systems Identification Systems

V2.0 and V3.0 V2.0 and V3.0

Topologies Cable length Devices Rules Installation Rules Troubleshooting Training

Common Application Profiles (optional): Common Application Profiles (optional):

RS 485 RS 485 RS 485-IS RS 485-IS

NRZ NRZ Intrinsic Safety Intrinsic Safety

MBP MBP MBP-LP MBP-LP MBP-IS MBP-IS

RIO for PA RIO for PA

Weighing & Dosage Weighing & Dosage

PROFIBUS DP Topologies - General

PROFIBUS communicates over a two wire bus structure.

listen, taking over and answering

PROFIBUS DP Topologies - Repeaters

Topologies Cable length Devices Rules Installation Rules Troubleshooting Training

Stations Segment 1 Segment 2

Benefit: Isolate part of your network from EMC/Noise

PROFIBUS DP Topologies Fiber Optic

Fiber optic cable

Topologies Cable length Devices Rules Installation Rules Troubleshooting Training

Fiber optic cable

Benefits: Long distances and EMC/Noise isolation

PROFIBUS DP Topologies - Wireless

Connect your slaves through wireless couplers

PROFIBUS DP Topologies - Redundancy

Transmission speed (baudrate)

PROFIBUS DP Cable Length

Baudrate vs Cable Length

These lengths are defined for 1 segment with 32 bus loads!

Device Rules - Network

PROFIBUS Address Map

0 1..2 3..125 126 127

Device Rules - DP Segments

Maximum 32 loads per RS485 segments

Devices that generate new segments:

After these devices, PROFIBUS segment rules are the same.

Introduction PROFIBUS-DP PROFIBUS-PA Installations and Best practise

PROFIBUS-PA Network layout

Agenda PROFIBUS Family Communication Medias

Application Presentation Session Transport Network Data Link

Topologies Cable length Devices Rules Installation Rules Troubleshooting Training

FDL Physical MBP