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Agenda
Presentacin Introduccin: Conceptos Bsicos Diseo de la Capa Fsica Seguridad Intrnseca Seleccin de Componentes de Capa Fsica
Agenda
Presentacin Introduccin: Conceptos Bsicos Diseo de la Capa Fsica Seguridad Intrnseca Seleccin de Componentes de Capa Fsica
Redes Industriales
Una primera clasificacin, segn sus capacidades:
Buses de Control o Controlbuses: (HSE high-speed ethernet, ControlNet, Etc.) Buses de Dispositivos o Devicebuses (DeviceNet, Profibus DP, SDS, Interbus-S, Etc.) Buses de Campo o Fieldbuses (Foundation Fieldbus, Profibus PA, WorldFIP, Etc.) Buses de Sensores o Sensorbuses (CAN, ASi, Seriplex, LonWorks, Etc.)
Jerarqua de Redes
Fieldbus: Definicin
Qu es una Red de Campo?
Un medio compartido: Solucin de comunicacin digital para intercambiar datos entre sistemas de automatizacin y dispositivos de campo Columna vertebral de un sistema Sistema de comunicacin en tiempo real basado en el modelo ISO/OSI Concepto Global Sistema de dispositivos de campo y/o dispositivos de control que utilizan un medio fsico comn para intercambiar datos
Resea Histrica
1940s
Instrumentacin Neumtica
1970s
Electrnica Analgica
1980s
Electrnica Digital
2000s
Redes de Campo
Organizaciones
HART
HART stands for:
Highway Addressable Remote Transducer
HART
HART is not considered a fieldbus. The reason is the connections of the devices are on a point-to-point basis. HART was born during the time of 4-20mA signals for the purpose of retrieving status information about the device and for configuration purposes.
What is HART?
HART is a digital signal that is superimposed on an analog current signal. Uses frequency shift keying to transmit 1s and 0s 1200 Hz represents a 1 and 2200 Hz represents a 0 Requires 230 ohms minimum loop impedance
FSK
PA
DP
Where/Why is it used?
DP
High speed batch type remote I/O Fast update times Wire savings compared to point-to-point
PA
True process fieldbus for continuous applications Supports intrinsic safety Wire savings compared to point-to-point
FOUNDATION Fieldbus
What is it? Digital replacement of 4-20 mA process signals Simultaneous power and signal on two wires Supports intrinsic safety Based on ISA/IEC Physical Layer, uses 61158-2 standard (same as Profibus PA) Introduces control in the field
Ethernet/TCP/IP
Management
Work station
Internet/Intranet
PC/VME
Celllevel
Operations
Bridge
PLC
Fieldlevel
H1-Bus Non IS
H1-Bus IS
User Layer
Provides Standard Function Blocks. Consistent definition of data for integrated and seamless distribution of functions in field devices from different suppliers. Provides Time Critical Scheduling of function blocks.
PHYSICAL LAYER
USER LAYER
COMMUNICATION STACK
Provides Device Descriptions which allows the host system to operate the device without custom programming.
Architecture and terminology consistent with the IEC TC65 WG7 Function Block - Part 1 CDV
Block Model
Device Device Management
Function Block
Block header
Resource Block describes characteristics of device Transducer Block(s) represent local connections for physical I/O Function Block(s) provide the control and I/O behavior of the device
Function Blocks
Function Block Field Device
Inputs
Outputs
Consistent, easy, blockoriented configuration of functions Distribution and execution of functions in field devices from different manufacturers in an integrated, seamless manner Consistent definition of information that will be communicated and functions that will be distributed Avoids custom interfaces and cumbersome mapping
FT
I/P
Fieldbus
AO 110
Discrete Input Block - DI Discrete Output Block - DO Analog input Block - AI Analog Output Block - AO PID, PI, I Controller Block - PID P, PD Controller Block - PD Control Selector Block - CS Manual Loader Block - ML Bias/Gain Station Block - BG Ratio Station Block - RA
Advantage of DDL
Device Descriptions allow operation of devices from different suppliers on the same Fieldbus with only one version of the host human interface program.
Device Descriptions
Device from Supplier A
Fieldbus
Comparison
FOUNDATION Fieldbus and PROFIBUS PA are most alike. What would make someone decide one over the other? Whether or not they want control in the field
Control room
Less I/O, Less Space Required Uses one I/O module for up to 32 devices
Fieldbus Savings
Fieldbus market is growing exponentially The technology has passed the inovators stage and is currently in the early adopters stage Everybody in the process industry is at least considering Fieldbus technology for new installations
Agenda
Presentacin Introduccin: Conceptos Bsicos Diseo de la Capa Fsica Seguridad Intrnseca Seleccin de Componentes de Capa Fsica
Physical Layer
The physical layer is where the messages from the communication stack are transferred to physical bus signals. The IEC and ISA defines all aspects of th physical layer for Profibus PA fieldbus. This specification includes:
Cable type (AWG, attenuation, impedance, etc.) Transmission rate (31.25k bps) Allowed topologies (bus, tree, chicken-foot) Number of devices (32 max)
Topologies
Topology - defines how individual nodes are physically connected to the network
Common Topologies
Line
Star
Ring
Topologies
Daisy chaining is NOT recommended Tree/Chicken Foot or star is most common
Star
H1 Specifications
Standards: Participants: Practice: Medium access: Transm.rate/ Cable length Telegram: Data check: Signal levels: Type of cable: IEC 61158-2 (Physics)/IEC ISA SP 50 32 without / 240 with repeater not more than 16 logical nodes (or 64 Function blocks for FF) Bus arbitration, Token passing 31.25 kBd 1900m w/o repeaters max. 251 Byte data per telegram CRC, Hd = 4 + 9 mA (IEC 61158-2) Twisted shielded pair
Ohms Law
The transmitting device delivers +/- 10mA at 31.25kbps into a 50 ohm equivalent load to create a 1V peak-to-peak signal modulated on top of the DC supply.
Current * Resistance = Voltage 10mA * 50 ohms = 0.5Vpeak (1Vpp)
1/100 ohms + 1/100 ohms = 1/R 2/100 ohms = 1/R -------- R = 50 ohms
Manchester II Coding
Manchester II Coding, voltage modulation measured at 50 Ohm (measured between signal leads)
Bits:
Supply voltage + signal amplitude
Supply voltage
1 Bit
T T
D
100 1 F
Terminators are required, one at each end Terminators match line impedance to minimise reflections & distortions No more than 2 terminators may be used
Effects of Termination
Transmit level 0.75Vpp to 1Vpp @ 50 Ohm In case when transmitting signal is between 1Vpp and 2Vpp one or more terminators are missing Recommended values for transmit level are as follows:
Transmit level peak-to-peak > 1V 0.7V 1V 0.3V 0.7V < 0.3V Transmit level peak > 0.5V 0.35V 0.5V 0.15V 0.35V < 0.15V Wire condition Missing terminator good e.g. 3 terminators 3 or more terminators
Troubleshooting Manual
Troubleshooting Manual
Connections
Segment Trunk Home Run
Control System
Fieldbus Cable
Type A: screened twisted pair
1900m typically 0.8mm2 (AWG18) 44/km loop, 100 nominal sometimes 1.5mm2 24/km loop
1 12 13 14 15 18 19 24 25 32
90 m (60 m) 60 m (30 m) 30 m (1 m) 1m 1m
60 m (30 m) 30 m (1 m) 1m 1m 1m
30 m (1 m) 1m 1m 1m 1m
Usage of Repeaters
In case where a segment needs to be longer than 1900m or the segment needs to be more densely populated with devices, the specification permits the use of a signal repeater No more than 4 repeaters between any two devices Conceptually, we can have a network lenght of 9500 m Each segment in this network would require its own power supply and terminators Each one of these segments could support up to 32 devices
Current/device = 20mA (typical) Maximum capacity = 17 devices * Beware of device inrush current
Grounding
Grounding
Hard Grounding
Safe area Power Repeater Hazardous area Field device or Junction box Equipotential bonding
Requirements for equi potential bonding The equipotential bonding must reach the requirements of the EN 50020 and EN 60079-14 (e. g. resisitive load < 1 , installation requirements, ...)
Capacitive Grounding
Safe area Hazardous area Field device or Junction box Equipotential bonding Power Repeater
Reqiurements for the capacitance for IS applications Capacitance C < 10 nF Solid dielectric medium Isolation voltage > 1500 V
Exercise
24 VDC
20..35 VDC
18 instruments with 20mA each These devices need at least 9V to operate Cable is type A = 44Ohms per km What is the maximum spur length? What would be the maximum achievable trunk length?
110 VAC
Safe area
+ 24V
360 mA
Ze
20 mA
Zi
9V -
Ls max = 60m, due to 18 instruments Rs = 44 Ohms/Km * 0.06 Km = 2.64 Ohms 24 V = .36 A * Rt + .02 A * 2.64 Ohms + 9 V Rt = 41.52 Ohms Lt = 41.52 Ohms/44 Ohms/Km = 943 mts
Agenda
Presentacin Introduccin: Conceptos Bsicos Diseo de la Capa Fsica Seguridad Intrnseca Seleccin de Componentes de Capa Fsica
El tringulo de Explosin
Los tres deben estar presentes para que se produzca la ignicin. Este concepto es el fundamento de los mtodos de proteccin. Elimine uno y tendr una operacin segura.
(Trmica o Elctrica)
ENERGA
Ex
OXIDANTE
(Aire) (Gas, Vapor o Partculas)
COMBUSTIBLE
Mtodos de Proteccin Se debe alcanzar un nivel de riesgo aceptable utilizando alguno de estos mtodos de proteccin estndar
ENERGIA
Concepto
Una ilustracin de seguridad intrnseca.
A. Circuito en rea clasificada B. Energa capaz de producir ignicin C. Agregamos barrera D. Energa insuficiente para causar ignicin
Mtodos de Proteccin
Principio: PREVENCION
Isc/Io
Seguridad intrnseca i
Div. 1,2 / Zonas 0,1,2
R V
L C
Voc/Uo
CARACTERISTICAS Tcnica de limitacin de voltaje, corriente y energa almacenada por debajo de los niveles mnimos de ignicin
DESVENTAJAS VENTAJAS No es aplicable a No requiere cables equipos de alto conespeciales sumo de potencia Seguro para personal Requiere ms trabajo No requiere permisos de ingeniera y en caliente documentacin Aplicable a todas las reas - Div.1/2 y Zonas 0,1,2
Proteccin
Principio: PREVENCION
Isc/Io
Seguridad intrnseca i
Div. 1,2 / Zonas 0,1,2
R V
L C
Voc/Uo
Mayor nivel de seguridad sostenible en el tiempo Menor costo de adquisicin e instalacin que explosion-proof Mantenimiento en caliente (nico mtodo que lo permite) No requiere cajas/conduits/sellos explosion-proof Aplicable a todas las Clases, Divisiones y Grupos Mtodo doblemente tolerante a fallas Opciones de cableado ms flexibles, facilitando expansiones Aceptado internacionalmente
Proteccin
Principio: PREVENCION
Isc/Io
Seguridad intrnseca i
Div. 1,2 / Zonas 0,1,2
R V
L C
Voc/Uo
nicamente para dispositivos de bajo consumo Considerado errneamente complejo Requiere atencin a la ingeniera
Mtodos de Proteccin
Principio: CONTENCION
Joint Width Gap
Explosion-proof o flame-proof d
Div.1,2 / Zonas 1,2
CARACTERISTICAS El encapsulado debe soportar la presin de la explosin interna y debe ser diseada para enfriar la llama antes de que llegue al medio ambiente exterior
DESVENTAJAS Altos costos en cajas, sellos y conduit No es posible trabajar con los equipos energizados Errores de instalacin y mantenimiento son peligrosos! No es aplicable a todas las reas
Ejemplo
Explosion-proof o flame-proof d
Div.1,2 / Zonas 1,2
Mtodos de Proteccin
Principio: PREVENCION
Non-Incendive n
Div. 2 / ZonA 2
OR
CARACTERISTICAS Seguro en condiciones normales de operacin y basado en la correcta ingeniera del producto
DESVENTAJAS Se basa en probabilidades No acepta mantenimiento en vivo Los mtodos de instalacin son crticos
Ejemplo
Non-Incendive n
Div. 2 / Zone 2
Curva de Ignicin
Concentracin Volumtrica (%)
GAS
CLASIFICACION L.E.L. U.E.L. M.I.E. Group (%) (%) (J) 5 2 2.7 4 15 9.5 34 75 320 180 60 20 D C B A
Curvas de Ignicin
Un circuito intrnsecamente seguro siempre operar por debajo del mnimo punto de ignicin, durante operacin norma o anormal, con un factor de seguridad de 50%. Las siguientes normas contienen las curvas de ignicin y los requerimientos de seguridad intrnseca de los equipos UL913 FM3610 CSA C22.2 No. 157 ISA 12.2.01 IEC 60079-11
Es realmente segura?
La seguridad intrnseca es el nico mtodo de proteccin basado en el concepto de prevencin.Las estadsticas demuestran que ofrece una probabilidad de causar explosiones inferior a 10 -18. Es ampliamente reconocido como el mtodo ms seguro disponible para reas explosivas. Esto lo valida el hecho de que es el nico mtodo aprobado para Zona 0.
HECHOS: Dentro de las cajas explosion-proof se producen explosiones. Seguridad intrnseca limita la energa, de modo que la explosin nunca llegue a ocurrir.
Es realmente segura?
La seguridad intrnseca ofrece varias ventajas. En instalaciones nuevas es significativamente ms efectiva en costo que explosionproof. Sin embargo, en muchas situaciones los ahorros de costo son proporcionalmente comparables a la resistencia al cambio Bajo igualdad de condiciones las empresas debieran optar por el mtodo ms seguro
HECHOS: Una pequea fisura o un tornillo no instalado en una caja explosion-proof significativamente reduce/invalida su desempeo seguro. Si se escogen adecuadamente los componentes, la seguridad intrnseca no se degrada en el tiempo.
Es realmente segura?
HECHO: La apertura de una caja explosion-proof requiere de un permiso de trabajo en caliente, dado que los componentes internos pueder producir la ignicin del medio. Con seguridad intrnseca no se requiern permisos de trabajo en caliente, dado que la electrnica no es capaz de producir la ignicin.
HECHO: El producto bsico relacionado a la construccin bajo explosion-proof ha permanecido inalterable por ms de 25 aos. Grande, voluminoso y pesado. Los equipos de seguridad intrnseca han evolucionado y adaptado nuevas tecnologas. Las demandas de bajo consumo han incrementado el foco en seguridad intrnseca durante los ltimos 10 aos. Liviano, confiable y high-tech.
Associated Apparatus
Dispositivo Asociado
Ejemplos: suiches, termocuplas, diodos emisores de luz (LEDs), conectores, sensores termoresistivos (RTDs), potencimetros, etc..
Voc
Corrient e de falla
HAZARDOUS AREA
Intrinsically Safe Apparatus Fault Zener Diode Barrier Fault current path
SAFE AREA
Safe Area Apparatus
Distribution System
Ground conductor for Intrinsic Safety Barriers <1 Reference Ground System
=
Main Transformer
Comparacin
Producto Barrera Zener Ventajas
Menor costo inicial Fcil de usar Ms compacta
Desventajas
Procedimiento de aterramiento Agregan impedancia al lazo Corriente de fuga Pruebas ms difciles
Barrera Galvnica
Ms fcil de seleccionar No requiere aterramiento IS Aislamiento Reduccin de ruido Independiente de la carga Mayor voltaje de salida
Resumen
Las barreras de seguridad intrnseca limitan la energa hacia el rea clasificada. Las barreras operan en forma segura bajo diferentes escenarios de falla Se disean para operar muy por debajo de los lmites de ignicin. Cada barrera normalmente posee un conjunto de parmetros que definen los circuitos elctricos que se extienden hacia el rea clasificadas: Parmetros de Entidad.
Voc Isc Ca Po
Mximo voltaje a circuito abiero Mxima corriente de cortocircuito Mxima capacitancia permisible Mxima transferencia de potencia
Aprobacin de Entidades
Consiste en una evaluacin en la cual la seguridad intrnseca del sistema es garantizada en base a la comparacin de parmetros elctricos.
Aparato de Seguridad Intrnseca Aparato Asociado Cable de Interconexin Parmetros del Cable Ccable Lcable 60pF/ft 0.2 H/ft
Comparacin de Entidad
Vmax Voc Imax Isc Pi Po Ci +Ccable Ca Li +Lcable La
Reglas bsicas
I) Los instrumentos de campo deben ser aptos para instalacin en el rea clasificada respectiva. V) Los cables y terminales I.S. deben ser separados de los no-I.S. y claramente indentificados.
II) Los parmetros de seguridad de las barreras deben coincidir con las de los instrumentos. III) Los parmetros de los cables (L y C) deben ser tomados en cuenta para la evaluacin de seguridad del sistema. IV) Las barreras zener requieren de conexiones a tierra dedicadas, la cual debe estar aislada de otras tierras y conectada a la malla en un slo punto. La resistencia del conector de tierra debe ser menor a 1 .
VI) Los conductores de S.I. deben poseer aislamiento. Las pantallas (si existen) tambin deben ser aisladas y puestas a tierra en un slo punto. VII) Los equipos de sala de control no deben ser alimentados ni deben ser capaces de generar ms de 250 V. IX) Un documento descriptivo debe contener toda la informacin relevante para poder auditar la seguridad del sistema.
Power Supply
Cables
Junction Box
Segment Protector
FieldBarrier
Term.
Field Devices
Field Devices
Field Devices
Field Devices
Field Devices
Field Devices
Zona 2 Clase I/Div2 High power Trunk: Spurs I.S. -Hasta 30V/500mA -Simplex o redundante -Mayor confiabilidad -Cables ms largos -Mximo nmero de dispositivos de campo -Autodiagnstico Clase I/Div 1 -Topologa uniforme
Field Devices Proteccin contra cortocircuitos Aislamiento
Proteccin en el campo: -Spurs protegidos contra cortocircuitos -Salidas de S.I. mantenimiento en caliente -Aislamiento galvnico entre el trunk y spurs -Proteccin contra punto nico de falla -Diferentes estilos
Field Devices Field Devices Field Devices Field Devices
Field Devices
High power Trunk: Spurs I.S. -Hastao 30V/500mA -Simplex o redundante -Mayor confiabilidad -Cables ms largos -Mximo nmero de dispositivos Zone 1 de campo -Autodiagnstico -Topologa uniforme
Field Devices
Aislamiento
Proteccin en el campo: -Spurs protegidos contra cortocircuitos -Salidas de S.I. mantenimiento en caliente -Aislamiento galvnico entre el trunk y spurs -Proteccin contra punto nico de falla -Diferentes estilos
Field Devices Field Devices Field Devices Field Devices
Field Devices
Instalaciones FISCO
Summary
PEPPERL+FUCHS
Training Seminar
Agenda
Presentacin Introduccin: Conceptos Bsicos Diseo de la Capa Fsica Seguridad Intrnseca Seleccin de Componentes de Capa Fsica
www.fieldconnex.info
Cables
Junction Boxes
Segment Protectors
FieldBarrier
Term.
Field Devices
Field Devices
Field Devices
Field Devices
For 1 or 2 or 4 Fieldbus segments Redundant or simplex Motherboard concept, passive components CREST Cross talk, Resonance Suppression Technology Fault output via Diagnostic Module Host connection via System Cable (customized solutions) Optional Trunk / Shield Termination Complies with new Foundation FF-831 test specification
Page 112
Diagnostic Module
4 Trunks
4 Trunks
Physical Layer : - Equipment used today: Voltmeter, Oscilloscope, - Reactive Maintenance only
Intermittent communications Can lead to an signal unbalance Intermittent Noise on the bus The effects on signal quality
Internally modified
Electro-magnetic interference
Wrong termination
Cable degradation
Page 120
The Pepperl + Fuchs Advanced Manage the Physical Layer Diagnostics Modules:
Page 122
Detailed online physical layer diag. such as: - Ground fault and jitter detection - Cable polarity detection - Base line and alarm set points - Load and noise monitoring - Built-in Fieldbus signal display (oscilloscope) Upgradeable from basic diagnostic module RS-485/EtherNet communication Great tool for start up validation, commissioning, online monitoring, preventive maintenance and troubleshooting!
Multimeter
Handheld Tester
Handheld Communicator
Oscilloscope
Requires shutdown
Fully supported
RS 485 Ethernet a very cost effective solution & allows for Remote Access
No additional communication bandwidth on the H1 bus Eliminate the chance a troubleshooting connection possibly causing a short Access to extremely detailed diagnostic information available through the Fieldbus Oscilloscope Easily integrated alarm data in to OPC
USB interface
Fieldbus interface
Bulk Power
Page 127
Page 129
Page 130
Actual Installation
Actual Diagnostics
Snapshot Explorer
Print out
Diagnostic Module
Diagnostic Link
Method:
High energy on the Trunk Ex nL: Energy limitation at each Spur via Segment Protector
Ex nA Ex nL Live working on field devices permitted without gas clearance
Non-incendive equipment
Power Supply
Non-Incendive Fieldbus
Associated Nonincendive Field Wiring Apparatus
Voc
Vout
Div.2 wiring method for high power trunk per NEC: -PLTC or ITC cable/wire tray -Armored cable or conduit
Segment Protector
OK to do Live maintenance!
The max. spur length per Fieldbus spec for type A cable is 120m. Therefore for practical purposes the L and C evaluation can be neglected due to the very short cable length on the spurs. Field Devices
Vmax
Reliable Operation
Replace or add field devices during normal operation Plug-in terminals with retaining screws LEDs indicate status Test points at trunk and spur
Advantages
Easy to use and install Excellent protection for your fieldbus Installations
Engineered Solution includes GRP Enclosure Fieldbus components Terminations system Wiring Diagram Parts List
Features: 4 short circuit, current limited IS outputs Connects 4 IS (Entity or FISCO) field devices Galva. isolation between non-IS trunk and IS spurs 40 mA per spur (typically 1 device) 120 m (393 ft) max. spur length Built-in selectable terminator Div.2/Zone 1 mountable IP 67 (Type 4X), salt water resistant housing or DIN rail/cabinet mountable version
FieldBarrier
Advantage: Field mountable Built in IS Barrier Creates isolated spurs for a secure network Provides Class I Div.1 outputs
Valve Coupler
Discrete I/O
Features: 4 channel on/off valve coupler For retrofitting standard valves for FF Bus powered Must be used with low power solenoids Can be used with mechanical contacts Field mountable (Division 1) Superior diagnostic
Advantage: Uses less Function Blocks than FF valves - gets more valves on H1 Cost effective solution to convert standard valves into Smart valves for Preventive maintenance.
Remote I/O
Surge Protection
Features: Fieldbus surge protection barriers For general purpose and IS applications Two part construction: DIN-rail mountable base module Removable protection module Optional: special base module, which allows for change of protection module
without signal interruption Advantage: Compact, space saving footprint (12mm wide) Affordable and reliable surge protection for Fieldbus installations
Cordsets/Ext. Cables
Features: 2,5,10 m or custom length Mini (7/8) or Micro (M12) connector styles Stainless steel or Epoxy coated, coupling nuts Extension cables and Cordsets Black connectors with orange/blue cable Type A Fieldbus cable
Advantage: Easy to install Fieldbus wiring concept Plug & Play Eliminates wiring errors For IS and non-IS applications Cost effective.
Terminators
Features: Terminates the H1 fieldbus Din-rail mountable Screw-in version for field device For IS and non-IS applications
Every Fieldbus installation needs terminators Cost effective solution to terminate H1 bus Easy to install.
Advantage:
Segment Checker
Assists Engineers in segment design, current consumption and cable length calculations www.segmentchecker.com
SUMMARY
Cables
Junction Boxes
Segment Protectors
FieldBarrier
Term.
Field Devices
Field Devices
Field Devices
Field Devices
GRACIAS