Field communication

Laurent Avorio Expert in digital communication Endress+Hauser France

An introduction to the maintenance of fieldbus networks

The use of digital communication and fieldbus networks provides lots of advantages in terms of maintenance. Digital instrumentation can exchange simultaneously several data with PLCs and computers in both ways. Once the instruments have been installed, their parametrization can be performed remotely, from technical premises, a control room or at any point of the network with a laptop - which is nice in case of hazardous environments or difficult access. In case of troubleshooting, the diagnosis can also be performed in the same way, even at a long distance, thanks to gateways or modems. We have issued Guidelines for planning and commissioning for both Profibus and Foundation Fieldbus networks. For further details, please refer to BA 034S (Profibus) and to BA013S (Foundation Fieldbus). You can download these documents from our web site. As experts, we also offer training sessions, in classroom and on site. We would be glad to meet you and help you go one step further. See page Training in the section At your service. Contents Basics FAQ Zoom: hardware tools for the maintenance of fieldbus networks 94 96

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Basics

Helping you to maintain fieldbus networks

Endress+Hausers instrumentation is involved in networks that may combine: the HART protocol Profibus DP/PA architectures Foundation Fieldbus architectures

HART is a point to point protocol (see fig.1): a PC talks to a single instrument (or to several instruments via a multiplexer). Conversely, Foudation Fieldbus and Profibus fit for the data exchange to a programmable logic controller (PLC) or a process control system (PCS). Since Foudation Fieldbus and Profibus use the same electric signal and encoding - only the

protocol differs -, the low level maintenance is identical in both networks. Profibus DP/PA typical architecture (Fig. 2) The process is controlled by a process control system or a programmable logic controller (PLC). The control system or PLC serves as a Class 1 master. It uses the cyclic services to acquire measurements and

output control commands. The asset management program, e.g. FieldCare, serves as a Class 2 master. It uses the acyclic services and serves to parametrize the bus participants during installation and normal operation. The PROFIBUS DP system is used to handle the communication at the control level. Drives, remote I/Os etc. may all be found upon the bus. It is also possible to connect externally powered field devices to this level, e.g. the flowmeters Promass and Promag. PROFIBUS DP ensures that data are quickly exchanged, whereby in mixed PROFIBUS DP/PA systems the baudrate supported by the segment coupler is often the limiting factor.

PROFIBUS PA is used at field level. The segment coupler serves both as interface to the PROFIBUS-DP system and as power supply for the PROFIBUS PA field devices. Depending upon the type of segment coupler, the PROFIBUS PA segment can be installed in safe or hazardous areas. Foundation Fieldbus typical architecture (Fig. 3) The Foundation Fieldbus system architecture has been designed to promote interoperability between and among devices of different manufacturers. Since Foundation Fieldbus supports both a high speed and low speed (H1) network, two architectures exist. These provide the same basic functionality but differ in

PLC

PLC
e.g. PROFIBUS DP e.g. PROFIBUS DP Remote I/O 420 mA HART PLC + HART interface 420 mA HART HART Multidrop (up to 15 devices) Ethernet

420 mA HART

420 mA HART

Fig. 1: Typical HART architecture

Process operation and visualisation with P View Plant Asset Management with FieldCare Ethernet PROFIBUS master for acyclic communication PROFIBUS DP e.g. AS-Interface Devices from third-party vendors (Remote I/O, drives, pumps, etc.) PROFIBUS PA PROFIBUS master for cyclic process data communication (I/O)

Visualisation and Monitoring e.g. P View

Network engineering e.g. ControlCare Configurator

High Speed Ethernet Field Controller/ Gateway Field Controller

Safe Area Hazardous Area PROFIBUS PA

FOUNDATION Fieldbus H1

4x

4x

FOUNDATION Fieldbus H1

Fig. 2: typical architecture of a Profibus DP/PA network

Fig. 3: standard Foundation Fieldbus architecture

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the communication stack. The H1 layer is IEC 61158-2 based and the high speed layer uses High Speed Ethernet (HSE). Installation instructions Cabling and termination are at the origin of most reported problems. Cabling When installing a PROFIBUS network, particular attention must be paid to the cabling. This covers both choice of cabling, and the way in which the cables are laid in the plant. Thus by careful routing, e.g. avoidance of potential sources of intense electromagnetic interference, use of metal trays or separation of power and bus cables in the cable tray, a significant contribution can sometimes be made to the faultfree running of the bus. Note: never use Profibus DP cables for cabling PA devices and vice versa. Termination The start and end of every PROFIBUS PA segment must be fitted with a bus terminator. For non- hazardous areas, some T-boxes have an integrated terminating element that can be switched in when required. If this is not the case, a separate terminator must be used. The segment coupler at the beginning of the segment has a built in terminator. The terminator in the T-box at the end of the segment must be switched in, or a separate terminator must be used.

T-boxes with switchable terminators may not be used in explosion hazardous areas. The terminator requires the corresponding FISCO approval and is a separate unit. For a segment with a tree architecture, the bus ends at the device that is the furthest from the segment coupler. If the bus is extended by the use of a repeater, then the extension must also be terminated at both ends. The beginning and end of the PROFIBUS DP segment must also be terminated. The terminating resistors are already built into most of the connectors on the market and must only be switched in. Note: branch lines are allowed in Profibus PA segments but not in Profibus DP segments. Set-up Device Parametrization using FieldCare Asset Management FieldCare is Endress+Hausers FDT based Plant Asset Management Tool. It can configure all intelligent field devices in your plant and supports you in managing them. By using status information, it also provides a simple but effective means of checking their health. FieldCare supports Ethernet, HART, PROFIBUS, and in future FOUNDATION Fieldbus etc. FieldCare ensures that devices can be integrated and configured quickly and easily, with the transparency demanded by good manufacturing practice.

PLC FieldCare

Connection Commubox FXA195

Commubox FXA191/195

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Fig. 4: HART connection of a PC to a field device using Commubox FXA191/195

Operations and Maintenance HART devices As the HART signal modulates the 4-20 mA current, if the latter operates, the former should also operate. You just need to check the presence of the current with a multimeter. By using a Commubox FXA191/195 (see fig. 4), you should see the instrument from FieldCare, otherwise there is a problem with the cabling. Profibus network See diagnosis on next page.

Re-engineering When adding fieldbus networks to an existing installation, consider exchanging basic remote I/O devices with smart I/O devices thus allowing centralized access to HART devices. Also consider using the FXA720 gateway to link Profibus networks to Ethernet networks. Take care of the maximum output current supplied by the segment coupler when adding a new device otherwise the segment might fail.
Our Solutions teams can help you from the start of your revamping project. Please contact us.

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Off
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Diagnosis of Profibus networks

If you are facing a problem (be it during commissioning or be it a troubleshoting) with a device installed in a Profibus network: First search for addressing errors Then search for connection problems Then check the correct integration of the device in the system (how data are trasnferred to the PLC):

Do I use the correct GSD* file? Enable Set unit to bus at the device to ensure correct scaling Is the decoding correct at the PLC?
* The PROFIBUS system requires a description of the device parameters, e.g. output data, input data, data format and supported transmission rate, so that it can integrate the field devices into the bus system. These data are contained in a PROFIBUS device description file (GSD file) which is placed at the disposal of the PROFIBUS-DP master when the communication system is being commissioned. Device bitmaps, which appear as symbols in the network tree, can also be integrated. See Chapter 7-2 of BA034S

Frequently asked questions

HART protocol I have no communication to the device from the PC Ensure that the load resistance at the Commuboxs terminals equals 250 . If the loop is overloaded (due to the PLCs impedence or the presence of a recorder) the load resistance can be much higher thus reducing the signals intensity. Switch of the FIFO active setting. In order to do this proceed as follows: Windows NT Version 4.0: Using the menu START/SETTINGS/SYSTEM CONTROL/ CONNECTIONS select the menu point COM-Port. Switch off the FIFO active command off using the menu path SETTINGS/EXPANDED. Windows 2000: Select Advanced settings for COM1 from the START/ SETTINGS/SYSTEM CONTROL/SYSTEM/HARDWARE/ DEVICE MANAGER/CONNECTIONS (COM and LPT)/COMMUNICATION CONNECTION (COM1)/ CONNECTION SETTINGS/ADVANCED menu. Deactivate Use FIFO buffer. Windows XP: Select Port settings from connections Port (Com 1)/START/ SETTING/SYSTEM/HARDWARE/DEVICE MANAGER/ PORTS (COM and LPT)/COMMUNICATION PORT (COM1)/PORT SETTING/ADVANCED menu. Deactivate Use FIFO buffer. Also take care of the selected communication port: From Windows, START/CONTROL PANEL/SYSTEM/ HARDWARE/DEVICE MANAGER/PORTS From this window, use the port number that corresponds to the connected communication interface (FXA195 if you are using a HART modem). Check the minimum voltage required for your HART communicating transmitter(s); the voltage is related to the device. Commissioning of Profibus networks How can I assign an address to a device? With the exception of the analysis device Mypro, all Endress+Hauser devices have an address switch that allows hardware or software addressing. Software address changes can be made via the PROFIdtmDPV1 CommDTM of FieldCare, the DPV1-DDE server of Commuwin II or any other PROFIBUS operating tool. See also Chapter 6.6 of BA034S. Where is the device termination switch? PROFIBUS PA: There is no termination switch on the device itself. The bus is terminated by using a separate terminator or a Tpiece/junction box with a switchable terminating element PROFIBUS DP: Termination switches are located in the devices. We recommend the use of PROFIBUS connectors with integrated terminators (in cabinet). When a device is added to the bus, the segment fails. The segment coupler supplies a defined maximum output current to the segment. Every device requires a particular basic current (see Chapter 5.3 of BA034S). If the sum of the basic currents exceeds the output current of the coupler, the bus become unstable. Diagnosis: Measure the current consumption of the devices with an amperemeter. Remedy: Reduce the electrical load on the segment concerned, i.e. one or more devices must be disconnected. PROFIBUS-PA slave with address 2 cannot be found. If a Siemens DP/PA-link Type IM 153/157 is used, the internal address must be taken into consideration. On the PROFIBUS-PA side, the link has the fixed internal address 2. For this reason, the address 2 may not be assigned to any of the PROFIBUS PA slaves connected to the link. Two devices (slave or master) have the same address. Disconnect the slave with address 2 from the bus and check whether there are others on the bus with the same address (e.g. with FieldCare of Commuwin II). Readdress as appropriate. Check the settings of the PROFIBUS master as to whether the address 2 has been allocated twice. PLC planning on Profibus networks The measured value in Siemens S7 PLCs is always zero The function module SFC 14 must be used. The SFC 14 ensures that e.g. 5 bytes can be consistently loaded into the SPS. If the SFC 14 is not used, only 4 bytes can be consistently loaded into the Siemens S7. Newer versions of the S7 series can access the I/O buffer directly. The SFC 14 is no longer required. The measured value at the device display is not the same as that in the PLC. The parameters PV_SCALE and OUT_SCALE are not set correctly. OUT_SCALE_Min. = PV-Min. OUT_SCALE_Max. = PV-Max. Instructions on how to adjust the parameters PV_SCALE and OUT_SCALE in the function block can be taken from the device operating instructions. Note: we recommend to use FieldCare for this adjustment.

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No connection between the PLC and the PROFIBUS PA network. The bus parameters and baudrate were not set when the PLC was configured. The baudrate to be set depends upon the segment coupler used (Chapter 7-5 of BA034S). - Pepperl+Fuchs SK1: 93,75 kBit/s - Siemens: 45.45 kBit/s - PA-link (Siemens IM 153/157): freely selectable - Pepperl+Fuchs SK1: 93.75 kBit/s - Pepperl+Fuchs SK2 and SK3: freely selectable For Pepperl+Fuchs SK2 and SK3, the PROFIBUS PA GSD has not been converted The bus parameters require adjustment The polarity of the PROFIBUS-DP line is reversed (A and B)? PROFIBUS-DP bus not terminated? Both the beginning and the end of the bus must be terminated. Data transmission on Profibus networks How are data transferred to the PLC? The measured values are transmitted in 5 byte long data blocks. 4 bytes are used to transmit the measured value. The fifth byte contains standardised status information. Error codes for Endress+Hauser device faults, e.g. E 641, are not transmitted with the status. For limit switches, the information is transmitted in two bytes: Signal condition and status information. How can the PLC switch on the positive zero return of the Promag 53? Via the output word of the cyclic services. How can the totaliser of the Promag 53 / Promass 83 be reset? Via the output word of the cyclic services for the totaliser in question, see corresponding operating manual. How can I suppress a measured value in cyclic communication? By using the placeholder EMPTY_MODULE or FREE_PLACE during configuration. How can I write a value to the local display? By using the Display_Value model from the GSD (if supported). General note: You can refer to Chapters 7.2 and 7.3 of BA034S (Profibus) for more details.

FieldCare cannot open connection to the PROFIBUS PA devices FieldCare is a Class 2 master that allows the transmission of acyclic values. The PROFIBUS-DP baudrate to be set depends upon the segment coupler used. The connection to the devices cannot be opened. If the PLC and FieldCare are used in parallel, the bus parameters must be mutually compatible. The bus parameters must be identical for all connected masters. If FieldCare is used, the Token Rotation Time (TTR) calculated by the PLC configuration tool must be increased by 20 000 bit times and the corresponding value entered in the FieldCare Profibus configuration and in the PLC. The HSA parameter (Highest Station Address) must permit the FieldCare address. The HSA specifies the highest address permitted for active participants (masters) on the bus. Slaves can have a higher address. Is the FieldCare address free or is it being used by another device? Is the correct baudrate set? Have the drivers and cards been correctly installed? Is the green LED on the TAP of the Proficard or Profiboard lit? Is the GAP update to high (the result is longer waiting times)? A device does not appear in the live list. Device is not connected to segment. Address used twice. Device cannot be fully operated. The device version is not supported by FieldCare. An appropiate DTM is necessary. The default parameters of the PROFIBUS-PA profile are offered. A change of unit at the device has no effect on the value on the bus. If the measured value at the device display is to be the same as that transmitted to the PLC, the parameters PV_SCALE and OUT_ SCALE must be matched. - OUT_SCALE_MIN = PV_SCALE_MIN - OUT_SCALE_MAX = PV_SCALE_MAX See the device operating instructions.

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FieldCare

Field commuincation

Zoom: hardware tools for the maintenance of fieldbus networks

Commubox FXA191/FXA193 and USB HART interface

Commubox FXA191 is an intrinsically safe interface for Smart transmitters. It converts INTENSOR and HART protocols to RS-232 signals.

The Commubox FXA191 connects intrinsically safe Smart transmitters with INTENSOR or HART protocol to the serial port of a PC. This allows the transmitters to be remotely configured using for example the Endress+Hauser Commuwin II operating programme. The Commubox FXA 191 is powered over the serial port. If the computer, e.g. a notebook or laptop, is unable to supply enough power, the Commubox can be supplied with an external power pack.

The USB HART interface makes it possible to connect SMART transmitters with HART protocol to the USB port of a PC. The Commubox FXA193 connects all the Endress+Hauser transmitters with a service plug to the serial port of a PC. For example its easy to configure and service the PROline series flowmeters with the FieldTool software or the Micropilot M with ToF Tool / Fieldtool (see page 80). Main advantages: Simple connection of HART and INTENSOR transmitters to the serial port of a PC Intrinsically safe input (FXA191) Connection of HART transmitters to the USB port of a PC (USB HART interface) Connection of the Endress+Hauser transmitters to a PC by means of the Service plug in the connection housing of the instrument (FXA193)

Technical data Commubox FXA191 Power supply Either from RS232 port or external power pack (accessory) Electrical connection 9 pin DIN female connector for computer; 4 mm plug terminals for transmitter, polarity protected, supply (optional): clutch socket, 9VAC / VDC, polarity protected Intrinsic safety [EEX ia] IIC BVS 95.D.2060X for connection to intrinsically safe circuits EEx IIC with voltages up to 30V Operating range -20 C...+50 C Storage -40 C...85 C Humidity 0 %...95 % (no condensation) Dimensions Housing 143 x 60 x 30 mm with plastic housing for industrial use

Typical application of Commubox FXA191: HART connection to a Micropilot

How to order this tool: Refer to the price lists in the insert The Maintenance Store attached to this Maintenance Guide.

Typical application of Commubox FXA193: connection to the service plug in the connection housing of a Micropilot

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Fieldgate FXA520 - Modem for remote maintenance

Fieldgate FXA520 enables remote monitoring, diagnosis and configuration of connected HART field instruments (sensors/ actuators) by telephone lines (analogue), Ethernet TCP/IP or mobile communications (GSM). The measured data is webcompatible (http, html) and can therefore be displayed in your web browser without additional software. Fieldgate FXA520 has many possibilities from remote maintenance to inventory management (VMI).

GSM antenna on a solar panel

Main advantages Worldwide access to measuring points with HART protocol via the Internet Simple configuration with web browsers without additional software Visualisation of all sensor data Remote monitoring, diagnosis and configuration Uses standard Internet protocols (http, html)

Event message via e-mail and SMS Efficient employment of standby and maintenance staff The Fieldgate FXA520 has standard two channels for HART devices and two channels for analogue inputs 4...20 mA (use of multiplexers is possible up to 30 channels) DAT module for configuration data backup

Avoid on-site service operations by using remote monitoring, diagnosis and configuration:

How to order this tool: Refer to the price lists in the insert The Maintenance Store attached to this Maintenance Guide.

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