Field Bus

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Technical Information
TI 38K03A01-01E
Fieldbus Technical Information
Yokogawa Electric Corporation 2-9-32, Nakacho, Musashino-shi, Tokyo, 180-8750 Japan Tel.: 81-422-52-5634 Fax.: 81-422-52-9802
TI 38K03A01-01E Copyright Mar. 1998 3rd Edition Sep. 2002
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Introduction
Fieldbus is an innovative technology for creating field information networks, and is attracting much interest among users and manufacturers of process control systems. This manual describes how users can introduce Fieldbus into their process control systems, and also describes Yokogawas Fieldbus solutions and Yokogawas Plant Resource Manager (PRM) software package for managing plant assets in the field network era.
Structure of This Manual

This manual gives an overview of Yokogawas Fieldbus Solutions, and explains the benefits of adopting them. For the detail specifications for ordering, refer to the relevant General Specifications. For engineering, installation, operation, and maintenance of the Fieldbus system and products described in this manual, refer to the relevant Instruction Manuals. This manual consists of three parts. Part A outlines Fieldbus prescribed by the Fieldbus Foundation and Yokogawas Fieldbus-ready products, Part B explains Fieldbus engineering, installation, operation, and maintenance, and Part C outlines the Plant Resource Manager (PRM) software developed by Yokogawa. Part A consists of four sections. An overview of the functions and progress of international standardization of Fieldbus is given in Section A1, the features of Fieldbus in Section A2, Fieldbus-ready field devices in Section A3, and Yokogawas Fieldbus-ready systems in Section A4. Part B consists of five sections. Managing Fieldbus engineering is described in Section B1, design considerations in Section B2, construction considerations in Section B3, startup considerations in Section B4, and maintenance considerations in Section B5. Part C consists of four sections. An overview and glossary of Plant Resource Manager (PRM) are described in Section C1, the system configuration in Section C2, an overview of functions in Section C3, and the interface to the computerized maintenance management system in Section C4.
Media No. TI 38K03A01-01E (MO) 3rd Edition : Sep. 2002 (YK) All Rights Reserved Copyright 1998, Yokogawa Electric Corporation
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Target Readership for This Manual

This manual is mainly intended for: Managers who are planning to purchase a control system, Fieldbus, and Plant Resource Manager (PRM). Instrumentation, electricity, maintenance, and computer engineers who are evaluating process control systems, Fieldbus, and maintenance management systems for purchase or who will be in charge of installing these systems.
Trademarks
CENTUM is a registered trademark of Yokogawa Electric Corporation. Ethernet is a registered trademark of Xerox Corporation. Microsoft and Windows are registered trademarks or trademarks of Microsoft Corporation in the United States and/or other countries. FOUNDATION in FOUNDATION Fieldbus is a registered trademark of the Fieldbus Foundation. NI-FBUS Monitor is a registered trademark of National Instruments Corporation. HART is a registered trademark of the HART Communication Foundation. Oracle is a registered trademark of Oracle Corporation. MAXIMO is a registered trademark of MRO Software, Inc. Other product and company names may be registered trademarks of their respective companies (the TM or mark is not displayed).
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Fieldbus Technical Information Part A Overview of Fieldbus and Yokogawas Fieldbus-ready Products
TI 38K03A01-01E 3rd Edition
CONTENTS
A1. Progress of International Standardization of Fieldbus ....................... A1-1
A1.1 A1.2 A1.3 A1.4 What is Fieldbus? ......................................................................................... A1-1 Progress of Fieldbus Standardization ......................................................... A1-2 Fieldbus Standard Specifications ................................................................ A1-4 Yokogawas Efforts for Fieldbus Standardization ....................................... A1-5
A2.
Features of Fieldbus ............................................................................. A2-1

A2.1 A2.2 A2.3 A2.4 A2.5 A2.6 Comparison with Conventional Communication ........................................ A2-2 Reduced Wiring Cost .................................................................................... A2-4 Improved Transmission Accuracy ............................................................... A2-6 Enhanced Data Transmission ...................................................................... A2-8 Distributed Functions ................................................................................... A2-9 Interoperability ............................................................................................ A2-10
A3.
Fieldbus-ready Field Devices ............................................................... A3-1

A3.1 Changes in Transmitters .............................................................................. A3-3 A3.1.1 A3.1.2 A3.1.3 A3.2 A3.3 A3.4 Accuracy Improvement due to Digitalization .................................... A3-4 Multi-sensing Function Equipment .................................................. A3-6 Multifunction Equipment ................................................................. A3-7
Actuator ......................................................................................................... A3-8 Using Self-diagnostics Function................................................................ A3-10 Yokogawas Fieldbus-ready Field Devices Line-up .................................. A3-11
A4.
Yokogawas Fieldbus-ready Systems .................................................. A4-1

A4.1 Fieldbus Support in Yokogawas CENTUM Control Systems ..................... A4-1 A4.1.1 A4.1.2 A4.1.3 A4.1.4 A4.2 Fieldbus Support in FCS for FIO of CENTUM CS 3000 ................... A4-2 Fieldbus Support in FCS for RIO and Compact FCS of CENTUM CS 3000 ......................................................................... A4-4 Fieldbus Support in CENTUM CS 1000 .......................................... A4-6 Fieldbus Support in CENTUM CS ................................................... A4-8
Connection of FF Devices from Other Vendors to Yokogawas CENTUM Control Systems .................................................... A4-10
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<A1. Progress of International Standardization of Fieldbus>
A1-1
A1. Progress of International Standardization of Fieldbus

This section describes what is Fieldbus, the progress of standardization of Fieldbus, Fieldbus standard specifications, and Yokogawas efforts toward standardization of Fieldbus.
A1.1 What is Fieldbus?

The Fieldbus Foundation gives the following definition: Fieldbus is a digital, two-way, multidrop communication link among intelligent measurement and control devices. Fieldbus is gradually replacing 4 to 20 mA standard instrumentation signals used to transfer measurement and control data between control room and plant floor. It is one of several local area networks dedicated for industrial automation. Modern industries in the 21st century could not survive without information technologies and networks. From production line to enterprise level, digital communication supports all economic and social activities with powerful modern technologies. Fieldbus is one such technology and cannot be separated from others. Fieldbus is at the lowest level in the hierarchy and exchanges information with higher-level databases. IEC (International Electrotechnical Commission) prescribes the following seven definitions standardized by the standard organizations (shown by their trademarks) as international standards of Fieldbus: FOUNDATION Fieldbus and HSE ControlNet PROFIBUS and PROFInet P-NET WorldFIP INTERBUS SwiftNet FOUNDATION Fieldbus, which is one of the seven definitions, is a standard defined by the Fieldbus Foundation. Yokogawa, a member of the board of directors of the Fieldbus Foundation since its inception, has participated closely in developing the Fieldbus specifications. Unfortunately, the Fieldbus standards of IEC list the definitions of many standard organizations. In practice, all major makers and users are now participating in the Fieldbus Foundation, and many products based on the FOUNDATION Fieldbus specifications are developed and marketed. Yokogawa considers that FOUNDATION Fieldbus will be used as widely as the fieldbus for process control systems in industry. Yokogawas CENTUM CS 3000, CENTUM CS 1000, and CENTUM CS support FOUNDATION Fieldbus. FOUNDATION Fieldbus H1 (Low Speed Voltage Mode) is called FOUNDATION Fieldbus, Fieldbus, H1 Fieldbus, FF, or FF-H1 in this manual. The sophisticated communication functions of Fieldbus allow distributed control via Fieldbus devices and optimal control by interfacing with a field control station (FCS).
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A1.2 Progress of Fieldbus Standardization

The international standards of Fieldbus have been unified by IEC/TC65/SC65C WG6 (International Electrotechnical Commission/Technical Committee 65/Sub-Committee 65C/ Working Group 6), ISA (The International Society for Measurement & Control) SP50 Committee (which defined 4 to 20 mA analog signals as the standard electronic instrumentation signal), and the Fieldbus Foundation. Recently, the Fieldbus Foundation, a private organization formed to promote Fieldbus, is supporting the international unification of Fieldbus standards. Yokogawa, a member of the board of directors of the Fieldbus Foundation since its inception, is also promoting FOUNDATION Fieldbus worldwide.
Recognition as a Standardization Work Item

In 1984, the standardization concept for the next-generation digital communication protocol for field devices was first proposed to the IEC, which is to replace the 4 to 20 mA analog transmission. In 1985, IEC/TC65/SC65C recognized the digital communication protocol as a new standardization work item and named it Fieldbus. IEC/TC65/SC65C WG6, and the ISA SP50 Committee, which had already commenced discussions on Fieldbus standardization, consented to jointly standardize Fieldbus.
Establishment of the Fieldbus Foundation

The standardization of Fieldbus will have a great effect on industry. Many views were presented at the ISA SP50 Committee, delaying the standardization of Fieldbus. To make up for lost time and promote the production of Fieldbus, ISP (Interoperable Systems Project) was organized by Yokogawa, Fisher Control, Rosemount, and Siemens in August 1992. In February 1993, ISP became ISP Association. In March 1993, WorldFIP (Factory Instrumentation Protocol) was jointly created by Honeywell, A-B (Allen-Bradley), CEGELEC, Telemechanique, and several other companies. A consensus was then obtained amongst customers that Fieldbus should conform to the internationally unified standard. In September 1994, in accordance with this decision, the ISP Association and WorldFIP North America were combined to form the Fieldbus Foundation.
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Process of Standardization
IEC/TC65/SC65C WG6 and the ISA SP50 Committee started Fieldbus standardization. By establishing the Fieldbus Foundation, a structure has been built to develop internationally unified instrumentation specifications. The process of Fieldbus standardization is shown below.
WorldFIP North America
ISA SP50 Committee

ISP
The Fieldbus Foundation

FF-H1 standard is defined and published.
IEC
1984
1985
1990
1992.8
1993.3
1994.9
1996.8
1984 The standardization concept of digital communication protocol for field devices was proposed to IEC. 1985 In IEC/TC65/SC65C, the new standardization work item was recognized and named Fieldbus. 1990 The ISA SP50 Committee and IEC/TC65/SC65C/WG6 decided to collaborate on Fieldbus standardization. August, 1992 ISP was organized. March, 1993 WorldFIP was established. September, 1994 The ISP Association and WorldFIP North America were combined into The Fieldbus Foundation. Since then, The Fieldbus Foundation has developed the internationally unified instrumentation specifications. The Fieldbus standardization structure is configured by IEC, ISA, and The Fieldbus Foundation. August, 1996 Fieldbus Foundation defined and published FOUNDATION Fieldbus H1 standard (low speed voltage mode).
A010201E.EPS
Figure Process of Fieldbus Standardization
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A1.3 Fieldbus Standard Specifications

There are two kinds of Fieldbus physical layer specifications standardized by IEC61158-2 and ISA S50.02: low-speed and high-speed Fieldbus specifications. But the high-speed Fieldbus specification is not adopted and High Speed Ethernet (HSE) specification is added as additional type.
IEC/ISA Standard Specifications

The low-speed and high-speed Fieldbus specifications are standardized as shown in the tables below.
Table Fieldbus Specifications (Standard)
Item Positioning Low-Speed Fieldbus FF-H1 Field device integration High-speed Fieldbus FF-H2 Subsystem integration 1.0 Mbps (in 1 Mbps mode or high-speed current mode) 2.5 Mbps (in 2.5 Mbps mode) High-speed Fieldbus FF-HSE (High Speed Ethernet) Subsystem integration Data Server integration 100 Mbps
Transmission Speed
31.25 kbps
Number of Connectable Max. 32 devices/segment devices Cable Power supply to connected devices Intrinsic safety Redundancy Example of connected devices
*1:
Number of connectable devices Max. 32 devices/segment depend on the subsystem (Using repeaters increase the number of connectable devices.) integrated by FF-HSE. Twisted pair cable (shielded) Optical Fiber No No Enabled Multicomponent analyzer, PLC, remote I/O, etc.
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Twisted pair cable (shielded) Twisted pair cable (shielded) Optical Fiber Enabled Enabled No (*1) Transmitter, control valve, field multiplexer, etc. Enabled Enabled Enabled Multicomponent analyzer, PLC, remote I/O, etc.
Yokogawa has developed dual-redundant configuration of ALF111 Fieldbus Communication Module for FF-H1.
Table Type of Low-speed Fieldbus Cables and Transmissible Length

Type of cable Cable specifications Max. length of cable (reference value)
Type A: Individually-shielded twisted pair cable #18AWG (0.82 mm2) Type B: Overall-shielded twisted pair cable Type C: Unshielded twisted pair cable Type D: Overall-shielded non-twisted cable #22AWG (0.32 mm ) #26AWG (0.13 mm ) #16AWG (1.25 mm2)
2 2
1,900 m 1,200 m 400 m 200 m

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Note: Yokogawa recommends the use of Type A. Usage of Types B and D is restricted. Yokogawa does not recommend the use of Type C.
SEE ALSO
For the cable specifications, refer to Section B2 of Part B.
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A1.4 Yokogawas Efforts for Fieldbus Standardization

Yokogawa, a member of the board of directors of the Fieldbus Foundation, has played a leading role in the international standardization of Fieldbus standards.
Services for Fieldbus Support Devices

Yokogawa has worked hard to promote Fieldbus, and provided the following services to add value for customers:
Product Development
Yokogawa has developed and provided a variety of products that support Fieldbus, ranging from various field devices to an integrated production control system, CENTUM CS 3000.
Development of Field Device Management and Diagnostics Packages

Yokogawa has developed and provided field device management and diagnostics packages which support enhanced field information.
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<A2. Features of Fieldbus>
A2-1
A2. Features of Fieldbus

Fieldbus is a bidirectional digital communication protocol for field devices. Fieldbus technology drastically changes process control systems and is gradually replacing the standard 4 to 20 mA analog transmission that most current field devices employ. Fieldbus has the following features: Because multiple devices can be connected, and multivariables can be transmitted on a single cable, thus reducing the number of cables, wiring costs are reduced. A digital transmission protocol ensures accurate information processing and hence strict quality control. Multiplex communications allow other information as well as process variables (PVs) and manipulated variables (MVs) to be transmitted from field devices. Communication between field devices allows truly distributed control. Interoperability enables devices from different manufacturers to be combined. A broad choice of devices from any manufacturer permits flexible system construction. Instrumentation systems, electrical devices, FAs, BAs, OAs, and analyzers can be integrated. Some adjustments and inspections of field devices can be performed from the control room. The following sections explain the advantages of Fieldbus and the effect of Fieldbus on process control systems.
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A2.1 Comparison with Conventional Communication

The Fieldbus communication protocol is superior to analog transmissions and hybrid communications in information accuracy, transmission speed, and transmission amount. It also offers superiority to those transmissions and communications in functionality, including the ability to communicate between connected devices and to communicate bidirectionally.
Analog Transmission
An analog transmission is an information transmission technique using analog signals with a direct current of 4 to 20 mA. The topology, which is a one-to-one system, allows only one field device to be connected to a single cable. The transmission direction is one-way. Therefore, two different cables must be provided: one to acquire information from the field device, and the other to transmit control signals to the field device.
Hybrid Communication
A hybrid communication is a communication technique in which field device information is superimposed as digital signals on the conventional 4 to 20 mA analog signal. In addition to analog transmission capabilities, it is possible to remotely set up the field device range and zero-point adjustment. Also, maintenance information such as self-diagnostics of the field device can be obtained using a dedicated terminal. Hybrid communication protocols were developed independently by each manufacturer, and so devices from different manufacturers cannot communicate with each other. With the Yokogawa BRAIN system or the hybrid communication systems of other manufacturers, the self-diagnostics information cannot be exchanged between field devices from different manufacturers. A hybrid communication mainly supports 4 to 20 mA analog transmission, though it also allows digital data communication. The digital data communication speed through the hybrid communication is slower than that through the Fieldbus communication.
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Fieldbus Communication
The Fieldbus communication protocol, which is different from analog transmissions or hybrid communications, supports a perfect digital signal communication system. In addition, the Fieldbus communication supports bidirectional communication, thus allowing more types and a larger amount of data to be transmitted in comparison to analog transmission and hybrid communication. This communication removes the restriction which allows only one field device to be connected to a single cable in an analog transmission system. Multiple field devices can be connected to a single Fieldbus cable. Also, since this communication is internationally standardized, interoperability of field devices is guaranteed. Fieldbus solves the problems of hybrid communications, such as slow digital transmission speeds and lack of interoperability. A comparison between the conventional 4 to 20 mA analog transmission, hybrid communication, and Fieldbus communication protocols is shown below.
Table Comparison of Communication Protocols
Fieldbus
Topology Transmission method Multi-drop
Hybrid
One-to-one 4 to 20 mA DC analog signal + digital signal One-way (analog signal), bidirectional (digital signal) Partially multiplex signal Differs depending on manufacturers
Analog
One-to-one 4 to 20 mA DC analog signal
Digital signal
Transmission direction
Bidirectional
One-way
Type of signal Standard
Multiplex signal Standardized in 1996.
Single signal Standardized

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A2.2 Reduced Wiring Cost

The introduction of Fieldbus reduces wiring cost by means of multi-drop connections and multivariable transmission.
Multi-drop Connections
Connecting multiple field devices to a single cable is known as multi-drop connections, and the reduction in the number of cables has many advantages. An example of multi-drop connections is shown below.
Fieldbus Multi-drop connection
To the system
Field device
Field device
A020201E.EPS
Figure Multi-drop Connections
In a conventional analog transmission system, only one field device can be connected to a single cable that leads to a system. Multi-drop connections connect multiple field devices to a single cable, and so allow additional field devices to be connected to a cable which has already been laid. In the past, it was costly to connect multiple field devices. Using a Fieldbus communication system, it is possible to connect a large number of field devices to the Fieldbus because of low wiring cost by multi-drop connections. This expands the scale of process control systems and promotes a higher level of plant automation.
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Multivariable Detection and Transmission

Multivariable means multiple measured variables, and multivariable detection means that one field device can detect multiple measured variables, which is also called multi-sensing. A conventional analog transmission system requires one cable for each measured variable. Fieldbus supports multivariable transmission. Therefore, a field device can transmit all measured variables detected by the field device via a single cable. The difference in wiring a control valve between analog and Fieldbus communication systems is shown below.
Conventional Analog Transmission System Positioner control signal Lower limit signal Valve opening signal Upper limit signal Fieldbus Communication System Fieldbus Positioner control signal Lower limit signal Valve opening signal Upper limit signal
Positioner
Positioner
Control valve Number of cables Positioner control signal : 1 pair Valve opening signal : 1 pair Upper/lower limit signal : 2 pairs Total : 4 pairs
Control valve Number of cables Fieldbus : 1 pair
A020202E.EPS
Figure Difference in Detection and Transmission between Analog Transmission and Fieldbus Communication Systems
In the conventional analog transmission system, the control output signal to the positioner is usually transmitted. In a Fieldbus communication system, multiple pieces of information such as control signals, limit signals, and valve opening signals can all be detected and transmitted. Multivariable detection and transmission can be used for: Monitoring the condition of the steam heat tracing of differential pressure transmitters by ambient temperature information. Detecting clogging in impulse lines by static pressure information. Many other pieces of information will also be used to expand measurement and control capabilities.
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A2.3 Improved Transmission Accuracy

Fieldbus improves transmission accuracy by eliminating errors that occur during data transmission in the conventional analog transmission system.
Removing Error Factors

The following three factors cause errors in the conventional analog transmission system. D/A conversion in the field device Analog signal transmission A/D conversion in the system For example, if data is transmitted from a field device with a microprocessor in the conventional analog transmission system, an error may result during A/D and D/A data conversion. Fieldbus eliminates transmission errors and conversion errors during data transmission. The difference in transmission accuracy between the conventional analog transmission system and the Fieldbus communication system is shown below.
Conventional Analog Transmission System Error due to data conversion Sensor P D/A 4 to 20 mA analog signal A/D Error due to data conversion System PVs with transmission errors
Error due to analog signal transmission
Data transmission direction
Upgrade to Fieldbus
Fieldbus Communication System
Sensor
Modem
Digital signal
Modem
System
Data transmission direction
PVs without transmission errors
A020301E.EPS
Figure Difference in Transmission Accuracy between Analog Transmission and Fieldbus Communication Systems
Fieldbus transmits data using digital signals. Signal transmission errors rarely occur in digital signal transmission, unlike analog signal transmission. In addition, Fieldbus does not need A/D and D/A conversions because data is always transmitted digitally. Fieldbus removes these three error factors, improving transmission accuracy. System reliability also improves as a result of higher transmission accuracy, which allows stricter quality control and greater production efficiency.
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Making the Most of Field Device Accuracy

Improved data transmission means accurate transmission of data which is detected by field devices. Especially, digital field devices reduce transmission errors and conversion errors of digital signals detected by sensors. Therefore, a Fieldbus communication system can take advantage of the performance of high-accuracy field devices.
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A2.4 Enhanced Data Transmission

In a Fieldbus communication system, many pieces of field information as well as PVs and MVs can be exchanged between field devices. Fieldbus can transmit many kinds of data bidirectionally, so the system offers more advanced functionality than a conventional analog transmission system.
Various Types of Data Transmission

Fieldbus can transmit various types of data. The conventional analog transmission system cannot transmit data other than PVs and MVs. Although hybrid communication, an analog communication protocol with a digital data transmission function, allows various types of data transmission, the hybrid communication protocol has the following problems: The transmission speed is slow. Only one-to-one communication between a system and a field device is possible. Fieldbus solves the problems associated with hybrid communication. The transmission speed is fast. Multiple pairs of devices can simultaneously communicate among a system and field devices, and between field devices. Transmission of various types of data allows the following advanced functionalities. Since past maintenance information can be easily acquired, maintenance efficiency improves. Device management such as field device master file creation can be automated.
Bidirectional Communication
Fieldbus transmits multiplexed digital information. This enables the system to perform bidirectional communication, which is not possible with the conventional analog transmission system.
Data Exchange between Field Devices

Distribution of control to field devices is made possible by exchanging data between them.
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A2.5 Distributed Functions

The use of Fieldbus implements integrated control over the entire plant and autonomous distributed control.
Installing Advanced Functions in Field Devices

Fieldbus allows the exchange of field information used for control in addition to PVs and MVs. Field devices with a calculation function and other functions can thus be adjusted from a system. Although some functions such as correction computation have been installed in current field devices, various functions that use more information are expected to be included in future field devices. By doing this, a field device such as a positioner will be able to field-adjust valve control characteristics.
Distributing Functions to the Field

Depending on the requirements of the processes to be controlled, field devices are equipped with advanced functions that provide some control functionality that used to be provided by a system. Distribution of control to field devices will change system functions.
Functions of Field Devices and System

By increasing the functionality of field devices and distributing control functions, the functions will vary between field devices and system. For example, the user can install the PID function for each control object in a field device or a system. If the relation between loops is tight and they cover a wide range in a large-scale plant, the PID function will be generally installed in the system. Conversely, if the loops are relatively independent in a small-scale plant, the PID function may be installed in a field device. In an oil refinery or a petrochemical, for example, the PID function is closely related to complex control, advanced control, optimized control, and integrated control over the entire plant. Therefore, excluding some independent control loops, the PID function will be installed in the system.
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A2.6 Interoperability
Conventional hybrid communications can transmit digital signals, but information exchange between devices of different manufacturers is difficult because each device uses its manufacturers protocol. In Fieldbus communication, international standardization of the protocol ensures the Interoperability between FF devices including FF interface card in host system. FF devices allow digital data to be exchanged between devices from different manufacturers. Therefore, the freedom to configure the process control system increases since there is no need to choose one device manufacturer. The Fieldbus Foundation prescribes the interoperability test procedure called Interoperability Test (IT) to ensure the Interoperability for the FF devices, and the FF devices that passed the IT are registered to the Foundation, and published on the Fieldbus Foundations web site (http://www.fieldbus.org/). Yokogawa registered EJA series transmitter as the worlds first vendor. Fieldbus Foundation started the Host Interoperability Support Test (HIST) for host computer in September 2000. On September 14, 2000, Yokogawas CENTUM series were certified as the system able to execute the Host Interoperability Support Test (HIST), becoming the worlds first vendor to carry out the HIST. The HIST is to prove the interoperability between the host computer and devices. The various devices from different manufacturers has been tested by the CENTUM series with the HIST procedure, and the interoperability has been proved.
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A3. Fieldbus-ready Field Devices

When Fieldbus is introduced, the type and amount of transmissible information will drastically increase. Also, bidirectional communication of digital information can take place between a field device and a system, and between field devices. To make the most of communication improvements and to satisfy more advanced needs, big changes are taking place with field devices. This section explains the differences in field devices when Fieldbus is introduced in a communication system.
Difference between Analog Transmission and Fieldbus Communication Systems

The Fieldbus communication system transmits information differently from the conventional analog transmission system. It has the following capabilities: A large amount of information can be transmitted. There are many types of transmissible information, both control and non-control information. Digital information can be transmitted. Bidirectional communication is possible between a field device and a system. Bidirectional communication is possible between field devices. According to those differences, the information handled by field devices (field information) changes significantly. The differences between analog transmission and Fieldbus communication systems is shown below.
Conventional Analog Transmission System Fieldbus Communication System
Computer gateway Control station Controller Sequencer gateway Sequencer Remote I/O card, terminal board 4 to 20 mA analog communication cable One variable One way Multivariable Bidirectional Fieldbus
Control bus
Control valve
Field junction box
Bidirectional communication is possible between the control valve and flowmeters.
Flowmeter
Flowmeter
Control valve
A030001E.EPS
Figure Difference between Analog Transmission and Fieldbus Communication Systems

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Advanced Functionality of Field Devices

By making the most of Fieldbus communication system features, it is possible to have more advanced control over the system. As a result, more advanced functionality is required in field devices. For example, by transmitting self-diagnostics information from a field device to the system, with the appropriate timing, the system can control the field device according to its status and can predict a problem in the field device. Also, by exchanging data (PV, MV, etc.) between field devices, autonomously distributed control of multiple field devices will be possible. Once the main power to the process control systems was changed from air to electricity, new electric-powered field devices appeared on the market. Similarly, when process control systems are changing from analog transmission to Fieldbus communication, new field devices that support Fieldbus communication capabilities are appearing on the market. Field devices are primarily categorized into transmitters and actuators. Fieldbus will bring about changes in both components. The following sections describe what changes will occur in transmitters and actuators.
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A3.1 Changes in Transmitters

The Fieldbus communication system can transmit digital information in a single line. Therefore, the function of a transmitter is changing greatly. In a conventional analog transmission system, transmitters are primarily designed to transmit the PV value to be measured to the system. This is because the analog transmission system performs one-way communication, from a field device to a system, or vice versa. By using the Fieldbus communication system, the type and amount of information being transmitted through a single cable will increase drastically, and will be far greater than that of a conventional analog transmission system. In addition, bidirectional communication can be performed between a field device and a system, and between field devices. Since digital information can be transmitted to field devices without conversion, information will be much more reliable.
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A3.1.1 Accuracy Improvement due to Digitalization

Since the Fieldbus communication system transmits information digitally, it can transmit the measured data from a transmitter to the system with minimum error. Many transmitters with drastically higher accuracy come to market.
Improvement of Transmission Accuracy

A transmitter with the conventional analog transmission handled a PV value as a percentage (0 to 100 % relative value) of the measuring range, and transmitted this value to the system after converting to a 4 to 20 mA analog signal. The system converted the 4 to 20 mA analog signal that was transmitted to the digital signal in engineering unit, and used it. Errors occur during these signal conversion. In contrast, a transmitter with the Fieldbus communication handles a PV value in engineering units and transmits this value, without conversion, to the system as a digital signal. The system uses the digital signal as it was transmitted. The Fieldbus communication system does not require signal conversion, thereby eliminating conversion errors that occur during transmission of measured data. The Fieldbus communication system provides for higher data transmission accuracy compared to the analog transmission system. Using the example of the orifice flowmeter which uses a differential pressure transmitter, the difference in transmission accuracy between the analog transmission and Fieldbus communication systems is described below. In a conventional analog transmission system, the differential pressure generated at the orifice, proportional to the square of the flow rate, was measured by a differential pressure transmitter and transmitted to the system after converting to a 4 to 20 mA signal. If the differential pressure, P at the orifice is 2 kPa when the flow rate is 20 Nm3/h, the output signal of the differential pressure transmitter will be as shown in the table below. The analog transmission system generates an error when this output signal is converted to a digital signal in the system side. If the differential pressure is converted to a flow rate on the system side, the transmission error will be changed by the flow rate because this conversion is not linear as shown in Figure below.
Table Analog Signal Data
Output 4 mA 20 mA Differential pressure 0 kPa 2 kPa Flow rate 0 N m3/h 20 N m3/h
A030101E.EPS
Flow rate Differential pressure

A030102E.EPS
Figure Relationship between Differential Pressure and Flow Rate

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In contrast, the Fieldbus communication system transmits the flow signal in engineering units as a digital signal. Therefore, there is no error during transmission. In this example, the differential pressure generated by the orifice is calculated and converted to a flow rate by the microprocessor of the differential pressure transmitter. The flow signal in engineering unit is transmitted to the system as a digital signal without conversion.
Improvement of Transmitter Measuring Accuracy

If the transmission accuracy is improved by the Fieldbus communication, the improvement of transmitter measuring accuracy will be a factor in improving the accuracy of the entire process control system. To perform measurements at higher accuracy, field devices that employ a superior measurement principle will be widely used. For example, conventional mechanical flow meters and level meters will be replaced by electric flow meters and level meters that employ digital technology. Since the Fieldbus communication system transmits the measured data in engineering units, without dependence on measuring range, a transmitter with a wide measuring range will show the original measuring performance. The width of the measuring range is one of the most important factors in determining the quality of transmitters.
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A3.1.2 Multi-sensing Function Equipment

The function used to measure multiple variables with a single transmitter is known as the multi-sensing function. In a Fieldbus communication system, it is possible to transmit multiple pieces of information over a single cable. To make the most of this Fieldbus feature, users will demand transmitters equipped with a multi-sensing function. In a conventional analog transmission system, a transmission cable with a pair of wires is required to transmit one measured value. For example, a transmitter that can perform multiple measurements, such as the Coriolis flowmeter, requires multiple cables to transmit multiple measurement variables. The Fieldbus communication system allows the Coriolis flowmeter to transmit multiple measurement variables via a single cable. Transmitters that have been used to perform only one measurement are enhanced to perform the multi-sensing function using the Fieldbus communication system. For example, the differential pressure transmitter is able to measure process pressure, ambient temperature, etc., in addition to flow rate, which was the transmitters original function. If a temperature sensor for measuring the process temperature is combined with this differential pressure transmitter, all flow rate, pressure, and temperature variables necessary for process control will be measurable by the transmitter alone. Possible data that will be gained by multi-sensing function for the main transmitters are shown below. Differential pressure flowmeter: Magnetic flowmeter: Vortex flowmeter: Coriolis flowmeter: Differential pressure level meter: Ultrasonic level meter: Temperature transmitter: pH meter: Conductivity meter: Mass flow, volume flow, pressure, temperature Volume flow, conductivity, temperature Mass flow, volume flow, temperature, pressure Mass flow, volume flow, density, temperature Liquid level, density and specific gravity, tank internal pressure, temperature Liquid level, temperature Humidity, ambient temperature, vibration pH, temperature Conductivity, temperature
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A3.1.3 Multifunction Equipment

A Fieldbus communication system can transmit other information in addition to the PV value. To make the most of this feature, the transmitter is expected to calculate the multiple values and process them into the required information for control. A transmitter that incorporates multiple functions, such as the calculation function, is known as a multifunction transmitter. Multifunction transmitters increase for a Fieldbus communication system. The main function of transmitters used in a conventional analog transmission system is to measure a PV value at high-accuracy and transmit it. To do this, additional devices are used for converting the measured PV value into the information necessary for control. A multifunction transmitter can calculate the PV value in engineering units required by the user and transmit it to the system. If a multifunction transmitter is used in combination with the above multi-sensing function, it is possible to drastically simplify the process control system. For example, assume that there is a differential pressure transmitter which can multi-sense the flow rate, pressure, and temperature. If a calculation function is added to this differential pressure transmitter, it allows the transmitter to calculate the mass flow rate after temperature-pressure compensation using the measured flow rate, pressure, and temperature, and before executing transmission. To attain the above functions, a conventional analog transmission system would require three transmitters, one each for flow rate, pressure, and temperature, and an additional calculator for temperature-pressure compensation. A single multifunction transmitter with multi-sensing can process all of this. This will not only drastically reduce the instrumentation cost, but will also improve the reliability.
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A3.2 Actuator
Fieldbus is expected to offer many possibilities for actuators. This section explains, using a typical control valve actuator, the changes that are taking place in actuators.
Control Valve Changes

The progress brought about by Fieldbus communication will drastically change the role of the control valve. A control valve with a conventional analog transmission controls a valve using a positioner according to the MV value transmitted from the system. On the other hand, a control valve with Fieldbus communication does not only control the valve to a constant opening, but also returns the valve opening value back, with respect to the MV value, and outputs limit signals to the system. This will promise more stabilized control of the system without valve opening meter and limit switches separately. Also, this valve and its positioner are able to perform valve characteristic modifications, temperature compensations, etc., which were usually made by the system. This will make it possible to compensate for valve operation as close to the process state as possible, while monitoring the valve characteristics. If this positioner and valve are combined with a flowmeter, the feedback control of a control valve, which is currently handled by the system, will be handled by only the control valve. Features of control valves with the Fieldbus communication are summarized next.
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Features of Control Valves with the Fieldbus Communication

Improvement of valve controllability (detects stroke cycle, open-close time, etc. to predict clogging, sticking, leakage, etc.) Remote monitoring of control valves Modification and improvement of valve characteristics Stabilized control together with operability and complete closure of valves Improved valve stability Ease-to-operate adjustment and stabilization of valve characteristics Reduction of valve accessories The following figure shows the compensation curves of valve flow characteristics. By using the control valve with the Fieldbus communication, the following valve flow characteristics will be change easily. In addition, it is possible to adopt the customized characteristics.
Intrinsic flow characteristics (from ISA Hand Book of Control Valve)
en
k op
Quic
Sq
r ua
er
oo
n Li
ea
u Eq
al
c er
en
Hy
r pe
bo
lic
Flow rate Valve opening

A030201E.EPS
Figure Modification of Valve Flow Characteristics
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A3.3 Using Self-diagnostics Function

The Fieldbus communication system can predict a problem in a field device using the selfdiagnostics function.
Integration of Instrumentation and Self-diagnostics Functions

The conventional analog transmission system can handle only one signal on a single cable. The system handles the PV or MV value and the self-diagnostics information as completely different data, even if it is information from the same field device. The Fieldbus communication system can handle multiple signals on a single cable. The system can handle the PV or MV value and the self-diagnostics information in the same environment. Instrumentation and self-diagnostics will be performed under the same environment by integrating work in the field into a single network. This idea is far different from the conventional one which has separated instrumentation from self-diagnostics.
Problem Prediction Function

Since Fieldbus handles the measured values in engineering units, it allows the system to accurately measure slight changes in pressure and temperature, other than the PV value. This enables the system to detect the symptoms of problems that were difficult to predict. For example, suppose the system cannot judge whether the self-diagnostics result of a field device is abnormal or normal. The conventional analog transmission system can transmit a self-diagnostics result as either abnormal or normal. Therefore, if a result cannot be judged as being abnormal or normal, the system always handles it as abnormal for safety. If a minor abnormality is generated in field devices, a number of alarms will be displayed on the panel in the control room. However, if minor abnormalities in field devices are handled as normal to reduce alarms in the control room, the symptom of a major problem may not be detected. If a self-diagnostics result cannot be judged as abnormal or normal, Fieldbus communication system can transmit the status information to the system. In addition, Fieldbus communication system will be able to monitor the information which influences measurement and control, such as clogging, vibration, etc. The use of this information allows the system to chronologically analyze changes in field devices and predict their problems. Using the dedicated package software will make the maintenance work easier.
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A3.4 Yokogawas Fieldbus-ready Field Devices Lineup

Differential Pressure/Pressure Transmitter DPharp EJA Series (suffix code for output: F)
Function Block: Two (2) AI function blocks One (1) PID function block (option: /LC1) Link Master function (option: /LC1) Hazardous area certification for FM, CENELEC, CSA, or JIS is available. FISCO model for FM or CENELEC intrinsically safe is also available. (See GS 01C22T02-00E for the detail.)
Vortex Flowmeter YF100 (YEWFLO*E) (suffix code for output: F)

Function Block: One (1) AI function block One (1) PID function block (option: /LC1) Link Master function (option: /LC1) (See GS 01F02F04-00E for the detail.)
Magnetic Flowmeter ADMAG AE (with option code /FB)

Function Block: One (1) AI function block One (1) PID function block (option: /LC1) Link Master function (option: /LC1) Hazardous area certification for CENELEC ATEX is available. (See GS 01E07F01-00E for the detail.)
Temperature Transmitter YTA320 (suffix code for output: F)

Function Block: Four (4) AI function blocks One or two (1 or 2) PID function block(s) (option: /LC1 or /LC2) Link Master function: with one (1) PID function block (option: /LC1) with two (2) PID function blocks (option: /LC2) Hazardous area certification for FM, CENELEC, CSA, SAA, or JIS is available. FISCO model for CENELEC intrinsically safe is also available. (See GS 01C50T02-00E for the detail.)
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Advanced Valve Positioner YVP110

Function Block: One (1) AO function block Two (2) DI function block One (1) OS (Output Splitter) function block One (1) PID function block (option: /LC1) Link Master function (option: /LC1) Signature Function:(option: /BP) Hazardous area certification for FM, CENELEC, CSA, or JIS is available. FISCO model for FM or CENELEC intrinsically safe is also available. (See GS 21B04C01-01E for the detail.)
YVP Management Software <Model: YVP20S>

This software package offers a variety of functions to help users to easily set up and tune YVP110. This software needs National Instruments FBUS fieldbus communication interface card. (See GS 21B04C50-01E for the detail.)
Paperless Digital Recorder DAQSTATION (with option code /CF1)

Function Block: Link Master function (See GS 04L01A01-00E for the detail.) Eight (8) AI function block (1-channel each) One (1) MAO function block (8-channel)
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<A4. Yokogawas Fieldbus-ready Systems>
A4-1
A4. Yokogawas Fieldbus-ready Systems

The control system that uses Fieldbus communication handles more advanced information than the conventional analog transmission system. Information reception, display and record management are more important factors in control systems. This section describes the Yokogawa systems that support Fieldbus. The H1 Fieldbus Communication Protocol and H1 Fieldbus indicated in this section and Part B are the FOUNDATION Fieldbus H1 (Low Speed Voltage Mode) of the Fieldbus Foundation.
A4.1 Fieldbus Support in Yokogawas CENTUM Control Systems

The CENTUM CS 3000 Integrated Production Control System, CENTUM CS 1000 Production Control System, and CENTUM CS Integrated Production Control System support Fieldbus. This section describes a typical system configuration for each CENTUM Fieldbus system. These systems are connected to field devices via I/O modules which support 1-5 V DC/420 mA I/Os, thermocouple and resistance temperature detector inputs, digital I/O, and communication. The Fieldbus Communication Module can also be combined with such conventional analog I/O modules.
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A4.1.1 Fieldbus Support in FCS for FIO of CENTUM CS 3000

Fieldbus support in FCS for FIO of CENTUM CS 3000 is shown below. FCS for FIO can be connected via an ALF111 Fieldbus Communication Module installed in a node unit to FF transmitters and FF valve positioners.
Ethernet Operation and monitoring function Engineering function (system generation) Fieldbus tools: Engineering tool Device management tool V net
HIS
PRM
FCS FCU ESB bus EB401 SB401 (dual (dual redundant) redundant) Terminator Fieldbus power supply unit (optional) Local Node
H1 fieldbus segment Terminator (optional)
IS barrier or lightning arrester (optional)
ALF111 ALF111 (in service) (stand-by)
ER bus ACB41
H1 fieldbus segment Terminator (optional)
IS barrier or lightning arrester (optional)
ALF111 ALF111 (in service) (stand-by)
EB501 (dual redundant) Terminator Remote Node
Fieldbus power supply unit (optional)
HIS: PRM: FCS: FCU: SB401: EB401: EB501: ALF111: ACB41:
Human Interface station Plant Resource Manager Field control station Field control unit ESB-bus interface (in Local Node) ER-bus interface (in Local Node) ER-bus interface (in Remote Node) Foundation Fieldbus communication module I/O expansion cabinet for FIO
A040101E.EPS
Figure Fieldbus Support in FCS for FIO of CENTUM CS 3000
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ALF111 Fieldbus Communication Module Specifications

Number of ALF111s per FCS: Standard FCS control function: Enhanced FCS control function: Number of ALF111 ports: Max. 16 (*1) modules (8 pairs for a dualredundant configuration) per FCS Max. 32 (*2) modules (16 pairs for a dualredundant configuration) per FCS Max. 4 ports per ALF111 (One port is connected to one segment (*3).) Max. 32 units per segment (including an ALF111 as one unit)
Number of field devices per segment (*3): Number of FF faceplate blocks:
Max. 250 blocks for Standard FCS (generalpurpose database) Max. 600 blocks for Enhanced FCS (generalpurpose database) Dual-redundant configuration possible with two adjacent ALF111s in a node
ALF111 dual-redundant support:
Link active scheduler (LAS) function: Available Time master function: Available
The number of field devices per segment varies significantly depending on the cable length, power supply capacity, existence of a barrier, etc. For details, refer to Section B2.2 of Part B. Other Fieldbus specifications are in accordance with the specifications for the FOUNDATION Fieldbus.
*1: *2: *3: For the standard FCS control function, the maximum number of ALF111s may be two depending on the database type selected as the FCS database. For details, refer to GS, Control Function for Standard Field Control Station (for FIO) (GS 33Q03K30-31E). For the enhanced FCS control function, when remote node expanded is selected as the database type, the maximum number of ALF111s is 32. In the other database type, the maximum number of ALF111s is 16. For details, refer to GS, Control Function for Enhanced Field Control Station (for FIO) (GS 33Q03K31-31E). A segment is an engineering unit consisting of several Fieldbus devices and ALF111 port to be connected to one H1 Fieldbus.
SEE ALSO
For details of the ALF111 Fieldbus Communication Module, refer to GS 33Q03L60-31E.
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A4.1.2 Fieldbus Support in FCS for RIO and Compact FCS of CENTUM CS 3000
Fieldbus support in FCS for RIO and Compact FCS of CENTUM CS 3000 is shown below. FCS for RIO and Compact FCS can be connected via an ACF11 Fieldbus Communication Module installed in an I/O module nest to FF transmitters and FF valve positioners.
Ethernet Operation and monitoring function Engineering function (system generation) Fieldbus tools: Engineering tool Device management tool V net
LFCS
HIS
PRM
SFCS
RIO bus
NIU ACF11 External power supply (optional) Intrinsic safety barrier / arrester (optional)
ACF11
Fieldbus
Terminator
Coupler Terminator (optional)

HIS: PRM: LFCS: SFCS: RIO bus: NIU: ACF11: Human Interface Station Plant Resource Manager Standard FCS Compact FCS Remote I/O bus Node Interface Unit Fieldbus Communication Module
H1 Fieldbus Coupler
Field devices
A040102E.EPS
Figure Fieldbus Support in FCS for RIO and Compact FCS of CENTUM CS 3000
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ACF11 Fieldbus Communication Module Specifications of CENTUM CS 3000

The main specifications of the ACF11 Fieldbus Communication Module of CENTUM CS 3000 are shown below.
For LFCS (FCS for RIO)

Number of ACF11s per FCS: Number of ACF11s per AMN33 nest: Number of segments (*1) per ACF11: Number of field devices per segment (*1): Link active scheduler (LAS) function: Time master function: Fieldbus power supply: Max. 80 modules per FCS Max. two modules per nest Max. one segment Max. 32 units per segment (including an ACF11 as one unit) Available Available Available (supply current: max. 80 mA)
For SFCS (Compact FCS)

Number of ACF11s per FCS: Number of ACF11s per AMN33 nest: Number of segments (*1) per ACF11: Number of field devices per segment (*1): Link active scheduler (LAS) function: Time master function: Fieldbus power supply:
*1:
Max. 10 modules per FCS Max. two modules per nest Max. one segment Max. 32 units per segment (including an ACF11 as one unit) Available Available Available (supply current: max. 80 mA)
A segment is an engineering unit consisting of several Fieldbus devices and ACF11 to be connected to one H1 Fieldbus.
SEE ALSO
For details of the ACF11 Fieldbus Communication Module of CENTUM CS 3000, refer to GS 33Q03L5031E.
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A4.1.3 Fieldbus Support in CENTUM CS 1000

Fieldbus support in CENTUM CS 1000 is shown below. FCS can be connected via an ACF11 Fieldbus Communication Module installed in an I/O module nest to FF transmitters and FF valve positioners.
Ethernet Operation and monitoring function Engineering function (system generation) Fieldbus tools: Engineering tool Device management tool VL net PFCS
HIS
PRM
ACF11 External power supply (optional) Intrinsic safety barrier / arrester (optional)
Terminator
Coupler Terminator (optional)
H1 Fieldbus Coupler
HIS: PRM: PFCS: ACF11:
Human Interface Station Plant Resource Manager Control Station Fieldbus Communication Module
Field devices
A040103E.EPS
Figure Fieldbus Support in CENTUM CS 1000
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ACF11 Fieldbus Communication Module Specifications of CENTUM CS 1000

The main specifications of the ACF11 Fieldbus Communication Module of CENTUM CS 1000 are shown below. Number of ACF11s per FCS: Number of ACF11s per AMN33 nest: Number of segments (*1) per ACF11: Number of field devices per segment (*1): Link active scheduler (LAS) function: Time master function: Fieldbus power supply:
*1:
SEE ALSO
For details of the ACF11 Fieldbus Communication Module of CENTUM CS 1000, refer to GS 33S03L5031E.
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A4.1.4 Fieldbus Support in CENTUM CS

Fieldbus support in CENTUM CS is shown below. FCS can be connected via an ACF11 Fieldbus Communication Module installed in an I/O module nest to FF transmitter and FF valve positioners.
Operation and monitoring function System generation function PC EWS Fieldbus tools Engineering tool Device Management tool
ICS
Ethernet ACG V net

FCS
FCU
RIO bus NIU ACF11 External power supply (optional) Intrinsic safety barrier / arrester (optional) Terminator
Coupler Terminator (optional) ICS: ACG: FCS: FCU: RIO bus: NIU: ACF11: Information and Command Station Communication Gateway Unit Field Control Station Field Control Unit Remote I/O bus Node Interface Unit Fieldbus Communication Module
H1 Fieldbus Coupler
Field devices
A040104E.EPS
Figure Fieldbus Support in CENTUM CS
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ACF11 Fieldbus Communication Module Specifications of CENTUM CS

The main specifications of the ACF11 Fieldbus Communication Module of CENTUM CS are shown below. Number of ACF11s per FCS: Number of ACF11s per AMN33 nest: Number of segments (*1) per ACF11: Number of field devices per segment (*1): Link active scheduler (LAS) function: Time master function: Fieldbus power supply:
*1:
SEE ALSO
For details of the ACF11 Fieldbus Communication Module of CENTUM CS, refer to GS 33G6K40-01E.
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A4.2 Connection of FF Devices from Other Vendors to Yokogawas CENTUM Control Systems
FF devices from other vendors can be connected to CENTUM under the following conditions:
Use devices registered by the Fieldbus Foundation

The Fieldbus Foundation prescribes the interoperability test procedure called Interoperability Test (IT) to ensure interoperability between the FF devices. The FF devices that passed the IT are registered to the Foundation, and information about them is published on the Fieldbus Foundations web site (http://www.fieldbus.org/). The field devices from other vendors, which are registered to Fieldbus Foundation, can be connected to CENTUM. Yokogawa recommends to use the IT4.0 (or later version) registration devices including the Capabilities File and Device Description (DD) File. For the Fieldbus accessories (e.g. cables, external bus power supply units, barriers, and arresters), there is no system of registering to the Fieldbus Foundation; these accessories should be used according to the conditions provided by their vendors. Yokogawa informs users of field-proven Fieldbus accessories as recommended devices. Contact Yokogawa sales for the Fieldbus accessories if necessary.
Use devices as instructed

Use devices according to the conditions provided by their vendors. The vendors assume responsibility for the quality, performance and warranty of their field devices.
Test devices
A user who uses field devices from other vendors is responsible for testing them. Yokogawa, if required, will provide assessment information on connecting other vendors devices to CENTUM, to assist users in device selection.
Yokogawa supports only standard Fieldbus specifications, not manufacturer-specific extensions

Yokogawas systems support information and functions that meet the standard specifications prescribed by the Fieldbus Foundation. They may not support another manufacturers proprietary functions. The Fieldbus standardization facilitates operation and maintenance of field devices from different manufacturers. Yokogawa can meet a variety of user needs, including startup and maintenance work on process control systems including products (components) from other vendors, based on accumulated know-how about devices and their usage.
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<Int> <Ind> <Rev>
Toc B -1
Fieldbus Technical Information Part B Fieldbus Engineering

CONTENTS
B1. Managing Fieldbus Engineering .......................................................... B1-1
B1.1 B1.2 B1.3 Fieldbus Engineering Process ..................................................................... B1-1 Difference between Fieldbus and Analog Signal Process Control Systems ......................................................................................................... B1-4 Software Packages for Fieldbus .................................................................. B1-5
B2.
System Design Considerations ........................................................... B2-1

B2.1 B2.2 Considerations in Basic and Overall Design ............................................... B2-2 Detail Design Considerations ...................................................................... B2-3 B2.2.1 B2.2.2 B2.2.3 B2.2.4 Investigation of Number of Field Devices connected to an H1 Segment ............................................................................... B2-4 Selection of Fieldbus Cable and Wiring Method .............................. B2-5 Design of FF Device Grouping per Segment ................................... B2-8 Expansion and Modification of Existing System .............................. B2-8
B3.
System Construction Considerations ................................................. B3-1

B3.1 New Construction of Fieldbus Process Control System ............................ B3-1 B3.1.1 B3.1.2 B3.1.3 B3.1.4 B3.1.5 B3.1.6 B3.2 Mounting Terminators ..................................................................... B3-3 Mounting Couplers ......................................................................... B3-3 Cabling ........................................................................................... B3-4 Installing an Intrinsic Safety Barrier ................................................. B3-4 Handling the Shield Mesh ............................................................... B3-4 Connecting the Fieldbus Cable and Handling the Shield Mesh for Fieldbus Communication Module .................................................... B3-4
Reusing Existing Cables .............................................................................. B3-5
B4.
System Startup Considerations ........................................................... B4-1

B4.1 B4.2 B4.3 Tool Necessary for Startup ........................................................................... B4-1 Technologies and Expertise Necessary for Startup ................................... B4-2 Labor Savings in Startup Work .................................................................... B4-3
B5.
System Maintenance Considerations .................................................. B5-1

B5.1 B5.2 B5.3 B5.4 Daily Maintenance ......................................................................................... B5-1 Inspection and Maintenance ........................................................................ B5-2 Maintenance Management (Maintenance Plan, Device Management, Audit Trail) ..................................................................................................... B5-3 Evolution of Maintenance ............................................................................. B5-3
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<B1. Managing Fieldbus Engineering>
B1-1
B1. Managing Fieldbus Engineering

In a process control system that uses Fieldbus, the engineering process differs from that of a process control system that uses conventional analog signals. This section explains the engineering process in a process control system using the H1 (31.25 kbps) Fieldbus.
B1.1 Fieldbus Engineering Process

The engineering of a process control system that employs Fieldbus is divided into five steps: design, production, construction, startup, and maintenance. Each step has multiple task processes and each task process includes detailed task items. The example of engineering process for the process control system using Fieldbus technology is shown below.
START
Design
Basic design Overall design
Production System Hardware production
Detail design Field devices Production
Software production
Witness inspection Shipping
Witness inspection Shipping FF parameter confirmation Performed by contractor, system integrator or user.
Delivery Construction Acceptance inspection Installation work
Delivery Acceptance inspection Installation work
Unit startup Startup System startup Trial operation Maintenance Plant operation
Unit startup
Maintenance
B010101E.EPS
Figure Example of Engineering Process Using Fieldbus
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B1-2
Design
The specifications of the process control system are verified by completing the basic design, overall design, and detail design for the system. SEE ALSO
For detailed information about designing the process control system using Fieldbus, refer to Section B2, System Design Considerations.
Production
According to the specifications that are confirmed in the design process, the system and field devices are produced. Production work is completely performed by Yokogawa. No other work needs to be performed by the user.
Construction
The manufactured system and field devices are delivered to the users site. Then, according to the system layout that has been clarified in the design step, wiring such as Fieldbus cabling is installed. Acceptance inspection is performed for the field devices before installation. The process control system using Fieldbus needs to be closely inspected. The following items require especially close inspection. Parameter settings (PD tag names (*1), node addresses (*1)) required for Fieldbus communication Parameter settings specific to field devices After inspection, the system is installed in the control room, and field devices in the field. The system and field devices are connected to the Fieldbus.
*1: For PD tag name and node address, refer to Section C1.1 Glossary.
SEE ALSO
For detailed information about constructing a process control system using Fieldbus, refer to Section B3, System Construction Considerations.
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B1-3
Startup
In the startup step, unit startup, system startup and the trial operation are performed.
Startup (Unit and System)

The following checks are required. Unit identification for all field devices Confirmation of data input/output between system and field devices (The input/output definition on the system side must be completed by this time.) Adjustment of various control constants and parameters of FF devices by device management package on a system computer These parameters are for the built-in function blocks in field devices and for the function blocks managed by control function in a system computer.
Trial Operation
This includes adjustment of control parameters such as P, I, D constants of the built-in PID function blocks in FF devices. SEE ALSO
For detailed information about starting up the process control system using Fieldbus, refer to Section B4, System Startup Considerations.
Maintenance
During plant operation, the field device status is managed using a device management function which is supported by the Plant Asset Management (PAM) system such as Yokogawas Plant Resource Manager (PRM see Part C Overview of Plant Resource Manager) from the control room or maintenance room. Also, error generation is monitored using the self-diagnostics function of field devices if the field device has such a self-diagnostics function. With maintenance work, parameters can be confirmed by directly connecting field device management tools to field devices or by a field device management function on PAM system. The communication status can be checked by directly connecting the Fieldbus Monitor (*1) to Fieldbus. Some field devices may have a maintenance record function of their own. The maintenance record data on the field device is uploaded and managed them into the PAM system.
*1: Yokogawa recommends NI-FBUS Monitor Package from National Instruments Co. as Fieldbus Monitor. Contact National Instruments Co. (http://www.ni.com/).
SEE ALSO
For detailed information about maintaining the process control system using Fieldbus, refer to Section B5, System Maintenance Considerations.
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B1.2 Difference between Fieldbus and Analog Signal Process Control Systems
Process control systems using Fieldbus differ greatly from those using a conventional analog signal, in that the parameters for Fieldbus configuration definitions also need to be set.
Setting Parameters Specific to Field Devices

Various FF block parameters for field devices must be set up. The following main parameters for FF function block (FFB) must be set: Range parameters (XD_scale, OUT_scale and engineering unit for each scale) Compensation parameters (Direct, Indirect, Indirect Sqr Root) Input filter process parameters (PV_FTIME)
Setting Parameters for Fieldbus Communication and Its Functions

New parameters for Fieldbus communication and its functions have been added. The following main parameters must be set: PD tag name (*1) Node address (*1) FF function block definition Link information (connecting block, output parameter, etc.)
*1: For PD tag name and node address, refer to Section C1.1 Glossary.
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B1.3 Software Packages for Fieldbus

Yokogawa offers various packages that support engineering and maintenance for Fieldbus process control systems.
Fieldbus Package Types

Yokogawa offers the following types of packages for Fieldbus depending on the conditions of use. Fieldbus package type for desktop PC: Fieldbus engineering and maintenance packages for field devices in the central control room Fieldbus package type for portable PC: Field device maintenance package in the field site. An example of use of Fieldbus package types is shown below. In practice, these packages can be run on the same PC.
Ethernet
HIS HIS for builder (includes Fieldbus engineering function)
Plant Resource Manager (PRM)
V net
FCS
FF-H1 support tool (includes device management tool function and device tool function) Fieldbus monitor
H1 Fieldbus
Supply air Field device Remark Desktop type Fieldbus package
Field device
Portable type Fieldbus package

B010301E.EPS
Figure Example of Use of Fieldbus Package Types
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Fieldbus Engineering and Field Device Maintenance in Central Control Room

The Fieldbus package for desktop PC is designed for Fieldbus engineering and field device maintenance work in the central control room. Fieldbus engineering in integration with the system This package, which is added to conventional system configuration function, registers devices to Fieldbus segments and links FF function blocks. The Device Management Tool (DMT) or Plant Resource Manager (PRM) also executes remote parameter setting (tuning), and remote diagnosis of field devices. Parameter setting and tuning, and diagnosis for the field devices DMT or PRM executes remote parameter setting and diagnosis for field devices.
Field Device Maintenance in the Field

The Fieldbus package for portable PC is designed for tuning Fieldbus devices in the field. The FF-H1 support tool is installed in a portable PC (such as notebook PC), which is connected to Fieldbus to monitor the statuses of field devices. It is also used to tune parameters and check operation of field devices before actual plant operation.
TI 38K03A01-01E
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<B2. System Design Considerations>
B2-1
B2. System Design Considerations

When designing a process control system that uses the Fieldbus communication protocol, it is necessary to thoroughly understand the design considerations, including Fieldbus. This section describes the design considerations of a process control system that employs Fieldbus technology.
Importance of Process Control System Design

To design a process control system, the design procedure should follow these steps: Basic design Overall design for common specifications Detail design for individual components First perform the basic design, then the overall design for the specified system. If the basic and overall design have not been completed, inconsistencies with specifications may occur and require returning to an earlier step. The more sophisticated the process control system becomes, the more important the basic and overall design will be. During the detail design, the individual components to be designed are identified on the basis of the basic and overall design.
Designing Process Control Systems with Fieldbus Technology

In designing Fieldbus process control systems, more items need to be considered than for systems using conventional analog signals. However, this does not mean that it is difficult to design Fieldbus process control systems. Although Fieldbus-related items need to be added to the design items of conventional process control systems, a conventional design method can be used.
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B2.1 Considerations in Basic and Overall Design

During the basic design of a process control system that uses Fieldbus, it is necessary to properly consider the purpose of the system and its construction costs. Also, in the overall design, the process control system configuration and the integrating or grouping range and extent must be carefully considered.
Basic Design Considerations

During the basic design of a process control system that uses Fieldbus, the following must be taken into consideration. Purpose of the process control system Cost of system implementation (total estimation including the construction cost) Delivery period of the system implementation Safety concept Operation procedure Maintenance procedure
Overall Design Considerations

During the overall design of the process control system that uses Fieldbus, including common specifications, take the following into consideration. Configuration of the process control system (hardware and software configuration) Integrating or grouping range and scope Safety design and reliability design Measures under abnormal situations Interface design Future expansion
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B2.2 Detail Design Considerations

In detail design, the contents of the basic design and overall design are realized. This section describes major considerations in designing individual components. In detail design, the considerations for limit and restriction items depending on cable length, power supply capacity and so forth are also important. There are also many items to be considered other than those described here.
Integrating or Grouping Range and Scope

Integration of buses between the process control system and other systems Consistency of operation types between the process control system and other systems System integration through upper-level communication and lower-level communication Connectable number of field devices and their grouping Clarification of hardware and software configuration with system configuration drawings
Safety Design and Reliability Improving Design

Selecting devices and construction in hazardous area (power supply method for intrinsic safety devices) Assignment of Fieldbus I/O and conventional I/O for the system functionality For example, the emergency shutdown system should be assigned to the conventional analog control system. Selection of type of cables, field devices, and redundancy of FF power supply unit and Fieldbus interface module Fail-safe design, safety measurements using diagnostics technologies, and equipment diagnostics design Selection of noise resistant devices and wiring route to minimize noise (affected by high voltage or motors) Selection of fieldbus accessories such as FF power supply unit, terminator, barrier and arrester Design of a Link Master (LM) device with Link Active Scheduler (LAS) capability and backup LM devices with LAS capability.
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B2.2.1 Investigation of Number of Field Devices connected to an H1 Segment

The number of field devices that can be connected to an H1 segment is restricted by the power supply current capacity of the segment, macrocycle corresponding to the control period, and Fieldbus cable length. For details of the restriction by Fieldbus cable length, refer to Section B2.2.2, Selection of Fieldbus Cable and Wiring Method.
Restriction by Power Supply Current Capacity

The sum of the current consumption of field devices connected to one Fieldbus segment cannot exceed the current supply capacity of the power supply. In an intrinsic safety system, the sum of the current consumption of field devices connected to one Fieldbus segment can not exceed the current supply capacity of the power supply or limitation value of the safety barrier unit.
Restriction by Macrocycle Corresponding to Control Period

The number of field devices that can be connected to an H1 segment should be decided by the macrocycle corresponding to the control period. A macrocycle is the period of the control or measurement and the unit is 1/32 ms (1 sec = 32000 units). The scheduled control and communication on macrocycle is executed by the LM device with LAS capability.
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B2.2.2 Selection of Fieldbus Cable and Wiring Method

Data on several types of cables are given below for reference only. Yokogawa recommends using Type A cable. The Fieldbus cable specifications are important in Fieldbus system design. The voltage drop restrictions of Fieldbus should also be considered. Yokogawa investigates Fieldbus cable specifications in various aspects. Use the data described in this manual for reference only.
Consideration of Voltage Drop Restrictions

The voltage drop limits are set so that the minimum output voltage of the power supply, less the voltage drop in the cable resistance, is not less that the minimum operating voltage of the device, even considering the voltage fluctuation. Yokogawa recommends minimum 9.5 volts as operating voltage design.
Cable Type and its Resistance

The typical resistances per unit length of the various cable types that can be used for Fieldbus are shown below. The following resistance values are for reference only. For actual values, contact the cable manufacturer. Type A (individually shielded twisted-pair cable): Type B (multi-pair twisted-pair cable, with outer shield): Type D (multi-pair cable, no twist, with outer shield): 22 ohm/km 56 ohm/km 20 ohm/km
The following general formula is used to check whether the minimum supply voltage is secured. Minimum Power Supply Voltage (resistance per unit length cable length) device current minimum operating voltage This calculation must be performed for each Fieldbus device.
Selection of Wiring Cables

Consider noise, cost, flexibility, and explosion-proof.
Insulating Material of Twisted Pair Cable

The insulating material such as polyethylene is appropriate.
Selection of Bus Topology and Maximum Number of FF Devices per Segment

Consider the bus topology, such as serial link and tree link, and maximum number of devices per segment.
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Selection of Cable Type and Total Length

If using a twisted-pair cable for the main line, carefully consider the kind and total length of cabling. The total length of cabling for Fieldbus is as follows: Type A (Individually-shielded twisted pair cable) 1900 m Type B (Overall-shielded twisted pair cable) 1200 m Type D (Overall-shielded non-twisted cable) 200 m Some Type B cables attenuate signals largely. To secure sufficient signal amplitude, no more than 20 field devices must be connected with a maximum total cable length of 600 m, or no more than 10 field devices must be connected with a maximum total cable length of 1,200 m. When using Type D cables, up to two pairs of cables must be used for Fieldbus and each pair must be separated from each other to prevent interference. When using multi-core cables, do not send signals other than Fieldbus signals or analog signals (including hybrid communication) through the same cable.
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Number of Branch Cables and Total Length

In tree type wiring, carefully consider the total length of cabling in accordance with the number of spur (branch) cables (number of field devices to be connected). The typical maximum total lengths of spur cables shown in the IEC and ISA standard (*1) are given below. 1-12 field devices connected: 13-14 field devices connected: 15-18 field devices connected: 19-24 field devices connected: 25-32 field devices connected: 120 m 90 m 60 m 30 m 0m
The number of connected field devices may be restricted by power supplies, communication performance and other conditions. In principle, the total lengths of spur cables should be made less than the typical maximum lengths shown above. However, in some applications these maximum lengths are exceeded, so Yokogawa was requested to assess whether this is viable. Considering that those typical lengths shown in IEC and ISA standard are recommended ones, Yokogawa has assessed the lengths and obtained the following result. Assuming that Yokogawa CENTUM is used as Fieldbus host system, the spur cable lengths can be increased under the following conditions. Use of Fieldbus Type A cable Number of field devices connected to a segment: max. 16 devices (Yokogawa understands the number of devices per segment is actually 16 or less.) Maximum length of spur cable: Maximum total length of spur cable: Maximum length of trunk cable: 120 m 960 m 1900 m - total length of spur cable
There is no restriction on the number of junction boxes used to connect field devices via spur cables.
*1: The typical maximum total lengths of spur cables are shown in the standard IEC61158-2 and ISA - S50.02 Annex C (informative).
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B2.2.3 Design of FF Device Grouping per Segment

Assess the communication and control performance considering transmission speed, control period, communication period and number of communication items between field devices and system computer. Arrangement of information type and quantity (essential, expected, and convenient information) Future expansion (Consider the installation of spare wiring and devices.)
B2.2.4 Expansion and Modification of Existing System

Clarification of the purpose and extent of expansion, investigation of influence on the existing system, and merit of system construction Tentative feasibility study for introduction of Fieldbus Design of interface with existing devices (analog/digital conversion) Investigation of the usability of existing wiring TIP
Fieldbus is still being introduced. Therefore, in designing a process control system that uses Fieldbus, consider the following in addition to usual design considerations. Field operation records of each system and field device Effect to process control caused by a segment (bus) fail Specifications of wiring cables
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<B3. System Construction Considerations>
B3-1
B3. System Construction Considerations

When designing a process control system that uses Fieldbus, it is necessary to thoroughly understand construction considerations for Fieldbus. This section describes considerations in constructing a process control system that employs Fieldbus.
B3.1 New Construction of Fieldbus Process Control System

For wiring a process control system that uses Fieldbus, new construction examples of typical system wiring configurations serial link type and tree type are explained below.
Example of Serial Link Type Wiring

In serial link type wiring construction, the power supply and system are installed in the control room. A Fieldbus segment is installed from the Fieldbus Communication Module (ALF111 or ACF11), which is connected to the system, and goes out to a number of field devices. Various types of field device may be connected to this Fieldbus. A terminator is also connected to both ends of the segment. A terminator at the field side may be mounted at the end of a bus cable in the field junction box. An example of serial link type wiring is shown below.
FCU Field junction box ALF111 FCU Terminator Coupler NU External power supply Intrinsic safety barrier/arrester (optional) H1 Fieldbus
Terminator (optional)
Coupler
Intrinsic safety barrier: Required only if intrinsically safe construction is required. Arrester: Required for measure against lightning Required if the terminator is not installed in the ALF111. FCU: Field Control Unit NU: Node unit for FIO ALF111: Fieldbus communication module
Field device
B030101E.EPS
Figure Example of Serial Link Type Wiring
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Example of Tree Type Wiring

In tree type wiring construction, various types of field device are connected to Fieldbus segment via the field junction box. This wiring topology is applied generally. In this case, the length of brunch cable should be considered. A terminator at the field side is mounted on the end of a truck cable in the field junction box. SEE ALSO
The maximum length of cables in tree type wiring is the same as that in serial link type. For details, refer to Section B2.2.2, Selection of Fieldbus Cable and Wiring Method.
FCU ALF111
FCU Branch cable Field junction box NU Coupler Terminator
External power supply Intrinsic safety barrier/arrester (optional)
Terminator (optional)
H1 Fieldbus Coupler
Intrinsic safety barrier: Required only if intrinsically safe construction is required. Arrester: Required for measure against lightning Required if the terminator is not installed in the ALF111. FCU: Field Control Unit NU: Node unit for FIO ALF111: Fieldbus communication module
Field device
B030102E.EPS
Figure Example of Tree Type Wiring
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B3.1.1 Mounting Terminators

Terminators must always be mounted on both ends of a trunk cable. Various types of terminator such as a field device built-in type and a stand-alone type are marketed by different manufacturers. Install terminators in a pull box or a field junction box to improve resistance and prevent mechanical shock, or use the field device built-in type.
Fieldbus cable Conduit Field device side
Terminator
Field junction box
Shielded wire Run the wire through a field junction box and isolate it from the box. (Do not connect to the FG.)
Coupler Instrument room side

B030103E.EPS
Figure Mounting Terminator in Field Junction Box
B3.1.2 Mounting Couplers

Each field device is connected to Fieldbus via a coupler and branch cables. To prevent mechanical shock, a coupler is mounted inside a pull box or a field junction box.
Fieldbus main line cable Coupler
Conduit
Pull box Branch cable Branch cable

B030104E.EPS
Figure Mounting Couplers
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B3.1.3 Cabling
To protect the Fieldbus cable, use standard conduits. If the Fieldbus cable is stored in the cable rack or wiring duct, separate the cable as far from the other cable as possible, the same as when installing low-level signal cables. SEE ALSO
For more information, refer to Section 1.6, Cabling Requirements in CENTUM CS 3000 Installation Guide (TI 33Q01J10-01E).
B3.1.4 Installing an Intrinsic Safety Barrier

If intrinsically safe application is required, install an intrinsic safety barrier at the closest place to the field in the rack room. The cables in the non-hazardous area and hazardous area must be wired separately. Note that the intrinsic safety barrier attenuates signals. Recently new intrinsically safe products for Fieldbus are marketed, however, they are not introduced here.
B3.1.5 Handling the Shield Mesh

If using a shielded cable, consider the following when handling the shield mesh. Connection of shield mesh at the coupler Grounding location and number of grounds As a rule, the shielded Fieldbus cable must be grounded at one point in the building in the rack room.
B3.1.6 Connecting the Fieldbus Cable and Handling the Shield Mesh for Fieldbus Communication Module
For connecting the Fieldbus cables and handling the shield meshes for the ALF111 Fieldbus Communication Module, refer to Section 3.6.4 Inplementation and Cable Connection of Fieldbus Communication Module ALF111 in CENTUM CS 3000 Installation Guidance (TI 33Q01J10-01E) , or Section B3.5.4 in Input & Output Modules (IM 33YO6K01-01E). For connecting the Fieldbus cable and handling the shield mesh for the ACF11 Fieldbus Communication Module, refer to Section 3.7.9 Connecting the Fieldbus Cable and Handling the Shield Mesh for Fieldbus Communication Module ACF11 in CENTUM CS 3000 Installation Guidance (TI 33Q01J10-01E), or Section A4.3.3 in Input & Output Modules (IM 33YO6K01-01E).
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B3.2 Reusing Existing Cables

If the cables of the existing process control systems are reused, examine the existing cable to be reused for the Fieldbus digital communication. Also, check the existing cables for insulation deterioration and fatigue. Here, the reuse of existing cables is explained using a typical example of a process control system in an oil refinery plant or petrochemical plant. In an oil refinery or a petrochemical plant, the cables equivalent to the overall-shielded untwisted 2-core cable CVVS-1.25 mm2 have been installed since explosion-proof construction was required. Also, from the field junction box to the Fieldbus Communication Module (ALF111 or ACF11), the cables equivalent to the overall-shielded non-twisted multicore cable CVVS-1.25 mm2 have been installed. An example of existing cables in an oil refinery or a petrochemical plant is shown below.
FCU ALF111
FCU
NU Multi-core cable Field junction box
Cable equivalent to CVVS-1.25mm2-2C
Field device FCU: Field Control Unit NU: Node unit for FIO ALF111: Fieldbus communication module
Field device
B030201E.EPS
Figure Example of Fieldbus Segment Configuration Using Existing Wiring
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Reusing the Cables from Field Devices to Field Junction Box

Most of the existing cables (spur (branch) cables), from field devices to the field junction box, use the overall-shielded non-twisted 2-core cable CVVS-1.25 mm2. In this case the maximum cable length depends on the type of cable and the number of field devices connected. The following tables list the types of cables and specifications and the maximum length of spur (branch) cables according to the number of devices on the Fieldbus, respectively.
Table Types of Cables (Reference value)
Types of cables Type A (Individually shielded twisted pair cable) Type B (Overall-shielded twisted pair cable) Type D (Overall-shielded non-twisted cable) Cable size 0.82 mm2 0.32 mm 1.25 mm
2 2
Max. length of cable 1,900 m 1,200 m 200 m

B030202E.EPS
Table Maximum Length of Spur Cables (Reference value)

Number of devices on Fieldbus 1 to 12 13 to 14 15 to 18 19 to 24 25 to 32 Max. length (total) of branch cables 120 m 90 m 60 m 30 m 0m
B030202E.EPS
SEE ALSO
For cable types and spur (branch) cables, refer to Section B2.2.2, Selection of Fieldbus Cable and Wiring Method.
Reusing the Cables from Field Junction Box to Control Room

Most of the existing cables (trunk (main line) cables), from the field junction box to the control room (relay terminal board), use the overall-shielded non-twisted multi-core cable CVVS-1.25 mm2. Up to the maximum length of cable listed in the table, Types of Cables (Reference value) can be reused. This cable can be used for Fieldbus because noise interference due to cross talk is usually within the permissible range. If multiple types of cables are connected, the maximum length of each cable is shorter than that in the table, Types of Cables (Reference value).
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<B4. System Startup Considerations>
B4-1
B4. System Startup Considerations

Before starting up a Fieldbus control system, it is necessary to thoroughly understand all aspects concerning system startup. This section describes the tools and technologies required for starting up the Fieldbus system, and the differences in the startup processes between Fieldbus system and conventional analog system.
B4.1 Tool Necessary for Startup

For startup of a Fieldbus control system, use tools that are different from those of a conventional analog system. This section describes a variety of tools required to start up the system.
Instrument of Digital Signal Measurement

To start up Fieldbus control system, the instruments for digital signal measurement are required. These digital signal instruments are connected to field devices or Fieldbus interface modules, and which check digital signals. As digital measuring instruments, the digital multimeter, digital oscilloscope, and Fieldbus testers (*1) from Relcom Inc. are used to check related network communication items such as the current, volts, LAS status, number of connected devices, signal level and noise level etc.
*1: Yokogawa recommends Fieldbus Network Testers (FBT-3 etc.) from Relcom Inc. as Fieldbus testers. Contact Relcom Inc. (http://www.relcominc.com/).
Fieldbus Monitor
For starting up a process control system that uses the Fieldbus communication protocol, a Fieldbus Monitor (*1) is necessary for measuring signal data on the Fieldbus. The Fieldbus Monitor is equipped with a troubleshooting function which can track down the source of a communication problem between devices connected to segment.
*1: Yokogawa recommends NI-FBUS Monitor Package from National Instruments Co. as Fieldbus Monitor. Contact National Instruments Co. (http://www.ni.com/).
Field Device Maintenance Tool

For startup of a Fieldbus system, a field device maintenance tool for parameter setting (especially remote setup) to field devices is required. This maintenance tool is built into a desktop or portable PC.
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B4.2 Technologies and Expertise Necessary for Startup

To start up a Fieldbus control system, technologies and expertise that are different from those for a conventional analog system are required. This section describes the technologies and expertise required to start up a Fieldbus system.
Wiring Technology
Wiring is greatly changed by using Fieldbus. One of the main advantages of Fieldbus is that it minimizes wiring. However, greater care is required in the termination of communication cables. Since many signals are handled on a Fieldbus cable, wiring problems will greatly affect the system. It is therefore necessary to carefully check whether wiring complies with communication-cable and field-device specifications including communication transmission quality.
Technology for Field Devices

Although measuring methods (measuring principles) for pressure and flow rate are not different from that of a conventional transmitter, output signals from sensors are digitized, making field devices easier to handle. Remote maintenance by the field device maintenance tool saves labor in field device signal processing, such as operation checks, device adjustment, setting modifications, and data maintenance management.
Knowledge of System Software

Fieldbus is a communication system. Therefore, startup engineers must have knowledge about communication software setup, communication protocol, etc.
Knowledge of Application Software

In a Fieldbus control system, there are the following three control methods: All control is performed on the field device side, and only monitoring is performed on the system side. All control signals are transmitted to the system, and control is performed on the system side. A combination of the above two methods allows the best control for specific applications. These control methods promote distributed control more than conventional control systems where all control is performed on the system side. For example, by assigning simple control to field devices, the system can perform higher-level control (such as multivariable control and advanced control). Startup engineers must have knowledge about advanced control. Because of distributed control, a system will be closer to a control computer, therefore the startup engineers are also required to have knowledge about information processing in addition to conventional control and instrumentation.
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B4.3 Labor Savings in Startup Work

In the startup of a process control system that uses Fieldbus, labor savings can be achieved in some processes, unlike in a conventional analog system. This section describes the processes in which labor savings can be achieved.
Loop Check
Loop Check of Process Control System That Uses a Conventional Analog Signal
Usually two types of loop check were conducted: indoor loop check and total loop check. In the indoor loop check, the loop from the marshalling rack to the process control system is tested to check for incorrect indoor wiring and poor signal quality. In the total loop check, a loop check is performed to check for incorrect wiring and poor signal quality between a field device and the process control system. Troubleshooting in the total loop check is made easier by performing the indoor loop check. This procedure, however, requires many man-hours since these checks must be performed on all loops.
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Loop Check of Process Control System That Uses Fieldbus

In a loop check of a process control system that uses Fieldbus, man-hours can be saved in the following ways, as compared with a conventional system. There is no need to check twice, indoor loop check and total loop check, as described above. If Fieldbus is connected from field devices directly to the system, only the total loop check is required. In this total loop check, a digital signal oscillator can be connected to a field device to pass signals from the field device to Fieldbus. Since the check can be performed without disconnecting any wiring, a more reliable check will be ensured. High accuracy and high stability of transmitters are guaranteed thanks to digitization, and deterioration of accuracy in transmission need not be considered. If the operation of devices has been confirmed through the single unit test after the assembling or bench test, there is no need for actual environment tests by applying pressure or connecting a resistor with an equivalent temperature. For conventional analog devices, output signal checks of three or five points are necessary. However, the FF devices suffer no accuracy deterioration in transmission, so the output signal check need be performed at only one point if the instrument range is correct. In these ways, the time spent on loop checks can be reduced.
Past Operator station Future Operation station Field control device Computer
Control unit
C P U
Indoor loop check Total loop check
Control unit ALF111
FCU Total loop check
FCU
NU Marshalling rack
Marshalling rack Fieldbus
Field junction box
Field junction box Standard current /voltage generator Digital Multimeter
Field junction box
Digital signal generator
FCU: Field Control Unit NU: Node unit for FIO ALF111: Fieldbus communication module
B040301E.EPS
Figure Loop Check of Process Control System That Uses Fieldbus Communication
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Interlock Check
During the interlock check, various plant functions are checked. The functions to be checked include that for production itself in the plant, and that for maintaining plant safety, etc. To perform this check, not only is system software modification frequently required, but so are modifications to the relay board and other parts. In a conventional analog transmission system, actual wiring modifications and software modifications were required in about half of all cases. In a process control system using Fieldbus, interlock processing can be independently implemented on the field device side. By combining the interlock function of the system, this check can be performed by modifying software. Therefore, the cost and period required for modifying the conventional hardware will be eliminated.
Trial Operation
Control tuning parameters including the P, I, D constants of local Fieldbus PID function block are adjusted. The advanced diagnostic applications utilizing Fieldbus parameters also may be added at this phase. Since Yokogawa has an advanced operation package for start-up and shutdown, it will be used to reduce the time for start-up.
Range Free Devices

This system uses the actual digital measurement without regard to the percent of span or percent of full scale.
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<B5. System Maintenance Considerations>
B5-1
B5. System Maintenance Considerations

Since a process control system that uses Fieldbus is provided with numerous system maintenance functions that are superior to those of systems with an analog signal, labor savings and more efficient maintenance of field devices will be possible. This section explains the difference between the maintenance work of process control systems that use Fieldbus and that of conventional systems.
B5.1 Daily Maintenance

In a process control system that uses Fieldbus, daily maintenance can be performed more efficiently than in an analog control system.
Daily Field Inspection

In a process control system that uses a conventional analog signal, inspections of the field are made by operators at given times to check the operation status of field devices and to record changes in the installation environments. Daily inspection is performed to detect abnormal states and maintain stable operation of the system. In a process control system that uses Fieldbus, the type and amount of information to be acquired will increase drastically due to bidirectional digital communication and the multisensing function. This allows operators to perform remote monitoring and remote operation-status management from the control room, greatly reducing the operators daily inspection workload.
Maintenance during System Operation

In a process control system that uses conventional analog signals, daily maintenance work during system operation (such as check for zero-point of field devices, check for device status, and parameter adjustment) must be performed in the field. In a process control system that uses Fieldbus, maintenance work can be performed remotely from the control room. The daily maintenance information can be acquired in realtime using the self-diagnostics function and bidirectional digital communication function of field devices. Therefore, daily maintenance information will be effectively used to determine which items require maintenance during the inspection activity.
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B5.2 Inspection and Maintenance

In a process control system that uses Fieldbus, periodic inspection and maintenance will be performed more effectively than in a system that uses analog signals.
Function and Accuracy Check

Due to technological progress and the introduction of Fieldbus, which offers high accuracy, high stability, improved reliability, and improved maintenance of field devices, there are the following advantages.
Maintainability Improvement by Remote Operation

In a process control system that uses Fieldbus, range setup and zero adjustment of field devices can made remotely, thus improving maintainability. Also, device management work such as field device master file creation is automated.
Disassembly and Consumables Replacement

In a process control system that uses Fieldbus, instrumentation equipment can be maintained and replaced using CBM in addition to TBM, due to the improved device status monitoring function and diagnostics function.
Time-Based Maintenance (TBM)

This is a method for maintaining/replacing based upon all devices every periodic cycle, which is determined based on the shutdown cycle of a plant or a system, according to regulations and the service life of devices.
Condition-Based Maintenance (CBM)

This is a method for maintaining/replacing based upon individual devices according to the status of each device by monitoring the device status. It is also referred to as status monitoring maintenance. In conventional time-based maintenance, maintenance/replacement is usually performed in shorter cycles than the device life to avoid damage. Therefore, a device with no problem may be disassembled for maintenance or replaced. In a process control system that uses Fieldbus, sufficient maintenance/replacement is performed according to the status of each device. This reduces extra costs caused by too much maintenance being performed.
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B5.3 Maintenance Management (Maintenance Plan, Device Management, Audit Trail)

In a process control system that uses Fieldbus, device status information such as the PD tag name, serial number, internal parameters, maintenance record, and self-diagnostics results can be acquired in real-time from each field device. If that information is stored in the maintenance database of device management tools, it is possible to perform device management of all field devices and to continually monitor the status of field devices. This allows the users to perform preventive maintenance with respect to each field device status and to determine the periodic maintenance plan based on maintenance data.
B5.4 Evolution of Maintenance

With the introduction and acceptance of Fieldbus, a variety of maintenance support systems have been developed using Fieldbus features such as bidirectional digital communication, multi-sensing, multifunction, bidirectional communication between field devices, and interoperability. These systems have contributed to the productivity increases, safety improvements, and maintainability improvements expected by users. Yokogawa provides the Plant Resource Manager (PRM) software package, which is explained in Part C, for managing plant assets in the field network era.
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<Int> <Ind> <Rev>
Toc C -1
Fieldbus Technical Information Part C Overview of Plant Resource Manager (PRM)

CONTENTS
C1. Overview of Plant Resource Manager (PRM) ...................................... C1-1
C1.1 C1.2 C1.3 C1.4 Glossary ........................................................................................................ C1-2 PRM Software Configuration ........................................................................ C1-4 PRM Positioning ........................................................................................... C1-6 Devices Managed by PRM ............................................................................ C1-7
C2.
PRM System Configuration .................................................................. C2-1

C2.1 C2.2 System Configuration when Connecting FOUNDATION Fieldbus (FF-H1) ................................................................... C2-2 System Configuration when Connecting HART .......................................... C2-4
C3.
Overview of PRM Functions ................................................................. C3-1

C3.1 C3.2 PRM System Size .......................................................................................... C3-1 Overview of PRM Functions ......................................................................... C3-2 C3.2.1 C3.2.2 C3.2.3 C3.2.4 C3.2.5 C3.3 Device Navigator ............................................................................ C3-3 Maintenance Information Management ........................................... C3-5 Audit Trail Function ......................................................................... C3-5 Tuning and Diagnosis Functions ..................................................... C3-6 Utilities ............................................................................................ C3-7
PRM Supported Functions for Conventional, FF-H1 and HART Devices ............................................................................................... C3-8
C4.
Connection with Computerized Maintenance Management System (CMMS) .................................................................................... C4-1

C4.1 C4.2 Supported Functions Related to MAXIMO ................................................... C4-1 Role Sharing between PRM and CMMS ....................................................... C4-2
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<C1. Overview of Plant Resource Manager (PRM)>
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C1. Overview of Plant Resource Manager (PRM)

The Plant Asset Managemant (PAM) system, Plant Resource Manager (hereinafter referred as PRM) is used to manage field devices in real-time, and makes device maintenance more efficient and computerized. With the PRM function, it is possible to perform intelligent operations, such as remote access, device parameter management, and device diagnostics and tuning, for devices that have the field communication function including devices compatible with Fieldbus (FOUNDATION Fieldbus). PRM classifies and manages various device maintenance information such as inspection schedules, inspection memos, and configuration information of devices, and this information can then be used for versatile maintenance. PRM can also acquire operating information of devices in a field via the Fieldbus and system bus, which can then be used for maintaining the field devices. This helps reduce the maintenance cost and TCO (Total Cost of Ownership).
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C1.1 Glossary
In addition to standard terminology, the following terms are used in Part C.
Control Module
The smallest unit that can perform a function in a system, i.e., if broken down any further it will not be able to perform a function, is referred to as a control module. All control modules have unique serial numbers (device ID). Example: Valve positioner, differential pressure flow meter, electromagnetic flow meter, analyzer
Equipment Module
A device consisting of one or more control modules is referred to as an equipment module. Example: A valve main body and a valve positioner are two control modules, and the valve obtained by combining them is an equipment module.
Device ID
A device ID is an ID assigned to a physical device. It is sometimes called a manufacturing serial number. It is always assigned uniquely to a device. A device ID is determined uniquely when a device is manufactured and never changes until it is discarded. The device ID remains the same even if the device is removed, or placed again in a different position in a plant. Legacy devices and static devices are also required to be registered in the device list.
PD Tag Name (Physical Device Tag Name)

A PD tag name (or simply called a device tag) is a logical name assigned to an equipment module or control module, and is determined such that it corresponds to the function to which the equipment module or control module is assigned or which it implements. The device tag names described in plant design documents such as P&I (Piping and Instrument Diagram) correspond to these names. A device tag name is assigned according to the placement of an equipment module or control module in a plant. If the placement is changed, for instance when the equipment module or control module is replaced, the device tag name will also change.
Node address
The node address is specified by a unique address number within a segment.
Device with Field Communication Capability

This means the control module, which supports the communication scheme compliant with the FOUNDATION Fieldbus, HART and PROFIBUS standards.
Conventional Device
This means the control module (field device) of analog type such as 4 to 20 mA, 1 to 5 V, mV input/output. A conventional device does not have any digital communication functions device. Pneumatic control module may be also referred as a conventional device.
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Static Device
This means the static equipment without electric circuits or active elements. Example: Orifice, pressure gauge, heat exchanger
Plug & Play Function

The Plug & Play function automatically recognizes control modules having FF and HART communication functions that are connected to a field network, thus simplifying registration in the database.
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C1.2 PRM Software Configuration

PRM consists of the following three software products. An example of PRM software configuration is shown below.
PRM Server
Uses the popular, industrial-strength Oracle 8i database. Maintains a historical record of device parameters and maintenance records. Implements centralized management of device management information such as the device master (device profile), inspection record and schedule, and parts lists. Automatically acquires device events (e.g. alarms) in real-time, twenty-four hours per day, and saves them in the database. Thus the operating status of field devices can be monitored continuously.
PRM Client
User-friendly Windows-based operating environment, with Explorer-like Navigator for selecting a specific device. Uses bidirectional, all-digital field networks such as FOUNDATION Fieldbus. Performs automatic device recognition and registration (Plug & Play), monitors device status, displays device events (e.g. alarms), allows tuning of device parameters, and performs device diagnosis (DD menu). The display color of device icons changes depending on the device status. This provides an easy-to-understand overview of the device operating status. Allows not only devices with field communication capability but also conventional devices to be registered together for centralized device management. Allows third-party software, such as that of device vendors, to be used as PLUG-IN Applications in addition to Yokogawas product, Device Viewer (*1). PRM Client can execute a tuning tool or a diagnosis tool that is uniquely designed by the device vendor.
*1: PRM R2.03 or later supports Device Viewer. Device Viewer is a built-in PLUG-IN Application of PRM Client.
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Field Communications Server

The Field Communications Server consists of the field communication function and system bus (control bus) communication function. The system bus (control bus) communication function communicates with Fieldbus (field network).
Device master PRM server Maintenance information Parts list Related information Historical information Device setting information
Inspection memo Inspection schedule Audit trail of device parameters
PRM client (instrumentation and control)
PRM client (maintenance)
Field communication server
Parameter setting performed by operator
Input of inspection and control data
Online setting and acquisition of various parameters
Foundation Fieldbus Devices HART Devices

C010201E.EPS
Figure Example of PRM Software Configuration
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C1.3 PRM Positioning

This section explains the position of PRM in a plant system and the devices managed by PRM. The following figure shows the relationship between PRM and the Computerized Maintenance Management System (CMMS).
Enterprise Resource Planning (ERP)
Production management function
Computerized Maintenance Management System (CMMS)
Fieldbus PC tool DCS (plant operation function) Operation and monitoring Engineering functions
PRM (Plant Resource Manager)
Control functions Functions for field network support
Field network
Plant
C010301E.EPS
Figure PRM Positioning
Along with the Fieldbus engineering tools, PRM provides functions for supporting the field network (including functions for supporting field devices). While the purpose of the Fieldbus engineering tools is to build a Fieldbus system, the purpose of PRM is to maintain and manage the control module statuses (device statuses) and the parameters of the control modules (field devices) on the field network. Furthermore, while CMMS takes care of general management of the plant facilities, including asset management, PRM supports and manages the tasks of inspecting the control modules within the plant. TIP
The Computerized Maintenance Management System (CMMS) deals with the plant facilities (such as piping, electric devices, and control modules (field devices). The device management system, on the other hand, is concerned with the plants control modules (field devices) and provides software functions for supporting real-time management and inspection works of the control modules (field devices).
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C1.4 Devices Managed by PRM

PRM manages the following devices: Conventional devices Static devices Devices with field communication capability (FOUNDATION Fieldbus, PROFIBUS, HART and Modbus compliant devices) Note that it is possible to manage devices without fieldbus communication capability, conventional devices and static devices, as well as devices not connected to the system (spare devices in stock). However, only the offline functions are used for conventional devices and static devices that do not support field communication.
Devices Managed by PRM and Online Function Support

The table below lists managed devices and the availability of online function support by communication.
Table Devices Managed by PRM and Online Function Support
Devices Managed by PRM FF-H1 device HART device PROFIBUS device Modbus device Conventional device Static device Online Function Support Yes Yes No No No No
C010401E.EPS
Remark
FIO only
SEE ALSO
For PRM supported functions for conventional, FF-H1 and HART devices, refer to Section C3.3.
TIP
Online functions mean online tuning and diagnostic functions such as read/write of device parameters and automatic detection of devices.
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C2. PRM System Configuration

This section explains the system configuration in which PRM runs. SEE ALSO
For more information about PRM system configuration, refer to Plant Resource Manager (GS 33Y05Q10-31E). For PRM supported functions for conventional, FF-H1 and HART devices, refer to Section C3.3.
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C2.1 System Configuration when Connecting FOUNDATION Fieldbus (FF-H1)

A large-scale CENTUM CS 3000 and small-scale CENTUM CS 1000 system configuration when connecting FF-H1 are explained as follows.
Large-scale CENTUM CS 3000 System Configuration when Connecting FF-H1

The following figure shows a large-scale CENTUM CS 3000 system configuration when connecting FF-H1.
PC PRM Client (Oracle 8i) PC PRM Server (Oracle 8i) PC CMMS (MAXIMO) Ethernet HIS PC PRM Client (Oracle 8i) Field Communications Server
V net FCS FCU FCU FCS
ESB bus ALF111 ALF111 (in service) (stand-by) EB401 SB401 (dual (dual redundant) redundant) Local Node NIU
RIO bus
ACF11 I/O node Terminator
H1 Fieldbus Coupler Terminator
H1 Fieldbus Coupler
Field devices
HIS FCS FCU RIO bus NIU ACF11 SB401 EB401 ALF111
: Human Interface Station : Field Control Station : Field Control Unit Field devices : Remote I/O bus : Node Interface Unit : FOUNDATION Fieldbus Communication Module : ESB bus Interface (in Local Node) : ER bus Interface (in Local Node) : FOUNDATION Fieldbus Communication Module
C020101E.EPS
Figure Large-Scale CENTUM CS 3000 System Configuration when Connecting FF-H1
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Small-scale CENTUM CS 1000 System Configuration when Connecting FF-H1

The following figure shows a small-scale CENTUM CS 1000 system configuration when connecting FF-H1.
PC CMMS (MAXIMO) Ethernet HIS PC PRM Client (Oracle 8i) PRM Server (Oracle 8i) Field Communications Server VLnet
HIS FCS ACF11 : Human Interface Station : Field Control Station : FOUNDATION Fieldbus Communication Module
FCS
ACF11
Terminator
H1 Fieldbus
Coupler
Field devices
C020102E.EPS
Figure Small-Scale CENTUM CS 1000 System Configuration when Connecting FF-H1
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C2.2 System Configuration when Connecting HART

Two system configurations are available for managing HART devices: Vnet connection via HART Modules (FCS for FIO) Serial port connection via third-party vendor HART Multiplexer
Vnet Connection via HART Modules (CENTUM CS 3000 FCS for FIO)
The Field Communication Server communicates with HART devices via HART modules by using the on-demand communication functions of FCS.
PRM Client PRM Server PC CMMS (MAXIMO) Ethernet HIS/ENG PRM Client Field Communications Server
V net
FCS
ESB bus HART I/O module (in service) HART I/O module (stand-by)
Local Node HART devices
SB401: ESB bus interface (in Local Node) EB401: ER bus interface (in Local Node) EB501: ER bus interface (in Remote Node) SB401 (dual-redundant) EB401 (dual-redundant) ER bus
DEV1
DEV2
HART I/O module (in service) HART I/O module (stand-by)

Remote Node HART devices
DEV1
EB501 (dual-redundant)
DEV2
C020201E.EPS
Figure Vnet Connection via HART Modules (CENTUM CS 3000 FCS for FIO)
Note: The PRM server, PRM client, and field communication server can run on the same PC.
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Serial Port Connection via HART Multiplexer (CENTUM CS 3000 FCS for RIO)
PRM communicates with HART devices via the HART Multiplexer connected to the serial port of the PRM field communication server.
PRM Client PRM Server PC CMMS (MAXIMO) Ethernet PRM Client Field Communications Server *1: RS-232C/RS-485 converter HIS/ENG
(*1)
V net
RS Communication RS-485
FCS
HART Multiplexer (commercially available) RIO bus Slave No.2
Slave No.1
AAM11 AAM11
HART Devices DEV1 DEV2
Master
4-20 mA HART Digital Signals
C020202E.EPS
Figure Serial Port Connection via HART Multiplexer

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Serial Port Connection via HART Multiplexer (using P&F HART Multiplexer)
When using the P&F HART Multiplexer, the PRM system can be connected as follows without connecting the CENTUM system.
PRM Client PRM Server PRM Client PC CMMS (MAXIMO) Ethernet PRM Client Field Communications Server (*1) RS-485
*1: RS-232C/RS-485 converter
HART Multiplexer (Master No.1)
Directly connected to Master
HART Devices
HART Multiplexer (Slave No.1)
Connected to Slave
HART Multiplexer (Slave No.15)
C020203E.EPS
Figure Example of P&F HART Multiplexer Connection

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<C3. Overview of PRM Functions>
C3-1
C3. Overview of PRM Functions

This section describes the PRM system size and the functions that constitute PRM. SEE ALSO
For details of the PRM operating environment, refer to Plant Resource Manager (GS 33Y05Q10-31E).
C3.1 PRM System Size

This section explains the relationship between PRM and a CENTUM CS 3000/CENTUM CS 1000 project and system size supported by PRM.
Relationship between System and CENTUM CS 3000/CENTUM CS 1000 Project

One PRM database should be assigned to one CENTUM CS 3000 or CENTUM CS 1000 project. The PRM management unit and the plant operation range of a CENTUM CS 3000/ CENTUM CS 1000 project correspond one to one. PRM manages control modules (field devices) and equipment modules within the operation and monitoring range of a CENTUM CS 3000/CENTUM CS 1000 project. SEE ALSO
For a CENTUM CS 3000 project, refer to CENTUM CS 3000 System Overview (TI 33Q01B10-01E).
Number of Control Modules Managed by PRM

The number of devices subject to PRM control is determined by the purchased license. If the number of devices exceeds the licensed number, the exceeded part cannot be registered.
Table Number of Control Modules Managed by PRM
Option type Standard Option 1 Option 2
*1:
Number of control modules managed by PRM Max. 100 modules Max. 1000 modules Max. 3000 modules (*1)
C030101E.EPS
When the number of modules managed by PRM exceeds 3,000, contact Yokogawa sales.
Number of Users and Clients

The number of users and the number of clients who can use PRM are determined by the license purchased for Oracle. The number of users refers to the number of terminals that can be used at the same time and the number of clients refers to the number of terminals that can be installed.
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C3.2 Overview of PRM Functions

There are five groups of PRM plant asset management functions: device navigator, maintenance information management, audit trail, tuning and diagnosis, and utilities. The following figure shows a schematic view of the functions that constitute the PRM device management functions. This section describes an overview of these functions.
PRM Device navigation functions Plant View Network View Class View
Maintenance information management functions Device master
Audit trail functions Parameter audit trail
Tuning and diagnostic functions Parameter comparison
Utilities Browser
Inspection memo
Inspection memo audit trail
Tool DD Menu
Security
Inspection schedule
Operation audit trail
Tool Device Viewer
Export
Parts list
Device event message
Calibration
Self-documentation
Link to document
PLUG-IN Application
Online manual
C030201E.EPS
Figure Schematic View of PRM Functions
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C3.2.1 Device Navigator

The Device Navigator provides Plant View, Network View, and Class View. In hierarchical Explorer-like format, these views display the arrangement of devices in the plant, physical network configuration, and device type, respectively. Target devices can be selected and device management functions can be performed via these views.
Plant View
Displays the equipment which makes up the plant, and shows its place in the plant hierarchy, in hierarchical Explorer-like format. The equipment can be intuitively managed by plant organization based on P & I diagrams. Unused devices in the plant can be managed by putting them in the Spare folder, and devices that have failed or are under maintenance can be placed in the Off-Service (Out of Service) folder. An example of plant view is shown below.
Device Navigator 1 Plant Network Class
PLANT S SITE01 A AREA01 C CELL01 U UNIT01 E FI100 FI100 Spare 5945430003J0000369 (FI1004) 812703ER79873045 J8-123871234DF Off-Service
C030202E.EPS
Figure Plant View
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Network View
Displays the position of devices, related to the field network physical configuration, in an Explorer-like hierarchical view. The device icon next to the device name shows the operating status of the device: the color of the device icon changes if the device fails, so users have an immediate visual view of the operating status. An example of a network view is shown below.
PLANT Foundation Fieldbus BOILER-0101-10111-1 R302DME-0103-10113-1 DAQSTATION (Ready) EJA001 (Ready) FI1002 (Ready) YFL001 (Ready) YTA001 (Ready) YVP001 (Ready) HART MODBUS PROFIBUS
HART
C030203E.EPS
Figure Network View
Class View
Displays devices in an Explorer-like hierarchical view, grouped by supplier, model, and revision. For devices that have failed or are under maintenance, the status (e.g. spares) of devices of the same type can be checked at a glance. An example of a class view is shown below.
PLANT Foundation Fieldbus Yokogawa Electric M AE100 M DAQSTATION M EJA100A M YF100*E M YTA320 M YVP R R2.01 On-Service YVP001 Spare Off-Service C Flow Meter C Magnetic Flow Meter C Positioner C Pressure Transmitter C Recorder C Temperature Transmitter HART
HART
C030204E.EPS
Figure Class View
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C3.2.2 Maintenance Information Management

Manages the maintenance information of all devices.
Device Master
Manages an inventory of all devices. A list of all devices, or detailed information on each, can be displayed.
Inspection Memo
Reports and manages records of device inspection and malfunctions at the field. Moreover, maintenance personnel can save notes about how a failure was handled, as well as warnings or reminders about maintenance check items, in the historical record. This function can be used to manage not only device online work records but also device offline work records.
Inspection Schedule
Makes and manages inspection schedules (checking, tuning, calibration, etc.) for each device.
Parts List
A device may consist of several parts; the parts list displays the attributes of each part, and stock information. This enhances the efficiency of repair and parts replacement work.
Link to Document
This can display information such as configuration (e.g. P & ID and control drawings), instruction manuals, and pictures, as desired. This device-related information can be accessed and displayed using the tag name as a key.
C3.2.3 Audit Trail Function

This keeps a database containing an operation history for devices (parameter setting, parameter data saving, calibration history, inspection memo history), and historical device event messages. Database contents can be displayed in chronological order or by historical message type, in summary or detailed format. The operation records can be filtered by device ID or PD tag name, so the operation record for a specific device can be easily displayed.
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C3.2.4 Tuning and Diagnosis Functions

Support device online tuning and diagnostic functions.
Parameter Tuning and Comparison

Online device data can be displayed and device parameters can be set by this function. Current device data can be compared with stored device historical records, so device operating conditions can be switched easily and safely by comparing current and past values. The set data can be stored. The device data can be uploaded at any time, and stored in the database.
Tool
For FOUNDATION Fieldbus, display switching to DD Menu and Device Viewer can be supported. DD Menu: Using the Method of DD files provided by a vendor, diagnosis and tuning for devices can be performed. Its specifications are dependent on field devices. Device Viewer: Device Viewer is a PLUG-IN Application that displays the self-diagnosis result of FFH1 devices. In many cases, FF-H1 devices save vendors multi-parameters specified for devices errors. Device Viewer detects and displays errors in devices directly. Device Viewer displays not only the self-diagnosis result by reading parameters but also the data displayed on the FF-H1 devices LCD, such as error messages, in a user-friendly format. This allows operators to monitor the connected devices from DCS without viewing the LCD of field devices. SEE ALSO
For the FF-H1 devices supported by Device Viewer, refer to Plant Resource Manager (GS 33Y05G1031E).
Calibration
The standard calibration can be executed by using parameter tuning function and DD menu included in the tuning and diagnosis functions. In addition, original calibration tools, provided by a third party such as device vendors, can be registered as PLUG-IN Applications and executed from the Application menu.
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C3.2.5 Utilities
Consist of following functions.
Browser
Can search for devices using device attribute information such as device ID, device tag name, device tag comment, block name, or parameter value.
Security
During maintenance of field devices, restricts operation to specific user(s) or restricts the range of operations permitted, to prevent system troubles due to operator errors and to maintain system security. The user name and operation record of the logged-in operator are recorded in the operation history. The user group can be used to assign user privileges to groups of users (i.e. restrict rights) according to job function.
Export
Can output an operation history to a text file in CSV format.
Self-documentation
Automatically creates device documentation for management. Can collectively print out data stored in the database in report format. Device information is managed electronically, and can be printed out on demand. Information on each screen can be printed out as individual reports, so a report can be printed out after maintenance work to provide a maintenance work record, thus reducing the workload such as making reports.
PLUG-IN Applications
These are software packages provided by third-party device vendors which are built into the PRM software package. The PLUG-IN Application runs on the client PC and accesses field devices and the Oracle database in the PRM server via the PLUG-IN Application library.
Online Manual (R2.02 or later)

All instruction manuals are provided in PDF format on CD-ROM, and so can be viewed and printed on-demand.
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C3.3 PRM Supported Functions for Conventional, FFH1 and HART Devices
All functions can be performed for FOUNDATION Fieldbus devices, but there are some restrictions for HART devices. The following table shows the PRM supported functions for conventional, FF-H1 and HART devices.
Table PRM Supported Functions for Conventional, FF-H1 and HART Devices
Function Plant View Device Navigation Function Network View Class View Device Master Plug_&_Play Maintenance Information Management Functions Register from Host_File_Set Inspection Memo Inspection Schedule Parts List Link To Document Parameter History Inspection Memo History (*2) HART devices Detail part is different from other devices. Conventional Devices(*1) FF-H1 HART Specification Remarks
Audit Trail Management Function Operation History Device Event Message Parameter Tuning and Comparison Status Display Adjustment and Diagnosis Tool (*2)
Record the Start/Stop of only Menu Window
Take several ten seconds until this function is executed because of the performance of HART communications. Device Method and Device Viewer for Fieldbus. Menu and Offline Parameters for HART. The parameter information of HART devices can be acquired by Offline Parameters. The acquired data can be saved in each device in Text format.
Calibration Browse Function Security Other Functions Printing PLUG IN Application : Supported *1: *2: : Partly supported : Not applicale
C030301E.EPS
The conventional device includes the 4 to 20 mA analog devices and the static devices as a motor. Supported by R2.03 or later versions.
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C4. Connection with Computerized Maintenance Management System (CMMS)

The computerized maintenance management system (CMMS) evaluates the system status by analyzing a certain amount of data to ensure effective maintenance of the plant. By connecting PRM to CMMS, CMMS can acquire online information of devices from PRM, thus enabling more efficient maintenance. The CMMS which can be connected with PRM is MAXIMO from MRO Software, Inc. SEE ALSO
For detailed information about connection with CMMS, refer to Plant Resource Manager (GS 33Y05Q1031E).
C4.1 Supported Functions Related to MAXIMO

The following features are offered by connecting PRM to CMMS.
Device Master Synchronization (Offline)

Exports the contents of the Device Master in PRM to CMMS by using the synchronization tool of Device Master.
Mapping Equipment Hierarchy to Plant Hierarchy (Offline)

Establishes a mapping between the equipment hierarchy for CMMS and the plant hierarchy, then imports it to the PRM side.
Send Work Order (Online)

Sends Work Order from PRM to CMMS by calling up the Work Order Input Dialogue in the PRM side.
Progress Display (Online)

PRM can call up the Progress Display held by the client PC of CMMS.
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C4-2
C4.2 Role Sharing between PRM and CMMS

Overlapping of functions such as handling the same data occurs when the PRM and CMMS packages are connected. The following table shows which function is enabled when the two packages run. For detailed specifications, refer to the instruction manual of CMMS.
Table Role Sharing between PRM and CMMS
Function Plant Hierarchy/CMMS Structure Device Master Parameter Tuning and Comparison Tool/Method PLUG-IN Application Audit Trail Message Link to Document Security Printing Inspection Memo Inspection Schedule Parts List Work Order/Work Order Schedule Progress Display Resource Management Purchasing Management/ Budget Management N/A N/A N/A N/A : Function is enabled : Function exists but not used N/A: No function available
C040201E.EPS
PRM
CMMS
Description Map equipment hierarchy for CMMS to Plant Hierarchy of PRM. Device Master is stored in PRM. The contents of Device Master in PRM are exported to the CMMS.
N/A N/A N/A N/A "Link to Document" must be set in each package. A user accesses either PRM or the CMMS depending on the online document needed. Proper users are registered in both PRM and the CMMS to set security. Printing is available in both PRM and the CMMS. These functions are only available in the CMMS side. However, these are still enabled in PRM side to ensure the system flexibility and upper compatibility. These are unique function of the CMMS.
: Function is enabled. Data transfer is available.
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Fieldbus Technical Information

INDEX
A
Accuracy Improvement due to Digitalization ..... A3-4 ACF11 Fieldbus Communication Module Specifications of CENTUM CS .............. A4-9 ACF11 Fieldbus Communication Module Specifications of CENTUM CS 1000 ...... A4-7 ACF11 Fieldbus Communication Module Specifications of CENTUM CS 3000 ...... A4-5 Actuator ........................................................... A3-8 Advanced Functionality of Field Devices .......... A3-2 ALF111 Fieldbus Communication Module Specifications ........................................ A4-3 Analog Transmission ....................................... A2-2 Audit Trail Function .......................................... C3-5
D
Daily Field Inspection ....................................... B5-1 Daily Maintenance ........................................... B5-1 Data Exchange between Field Devices ............ A2-8 Design ............................................................. B1-2 Design of FF Device Grouping per Segment .... B2-8 Designing Process Control Systems with Fieldbus Technology .............................. B2-1 Detail Design Considerations ........................... B2-3 Device Master .................................................. C3-5 Device Navigator ............................................. C3-3 Devices Managed by PRM .............................. C1-7 Devices Managed by PRM and Online Function Support .................................................. C1-7 Difference between Analog Transmission and Fieldbus Communication Systems ......... A3-1 Difference between Fieldbus and Analog Signal Process Control System ........................ B1-4 Disassembly and Consumables Replacement .............................................................. B5-2 Distributed Functions ....................................... A2-9 Distributing Functions to the Field .................... A2-9
B
Basic Design Considerations ........................... B2-2 Bidirectional Communication ........................... A2-8 Browser ........................................................... C3-7
C
Cabling ............................................................ B3-4 Calibration ....................................................... C3-6 Changes in Transmitters .................................. A3-3 Class View ....................................................... C3-4 Comparison with Conventional Communication .............................................................. A2-2 Connecting the Fieldbus Cable and Handling the Shield Mesh for Fieldbus Communication Module .................................................. B3-4 Connection of FF Devices from Other Vendors to Yokogawas CENTUM Control Systems ............................................................ A4-10 Connection with Computerized Maintenance Management System (CMMS) .............. C4-1 Consideration of Voltage Drop Restrictions ...... B2-5 Considerations in Basic and Overall Design ..... B2-2 Construction .................................................... B1-2 Control Valve Changes .................................... A3-8
E
Enhanced Data Transmission .......................... A2-8 Establishment of the Fieldbus Foundation ........ A1-2 Evolution of Maintenance ................................. B5-3 Example of Serial Link Type Wiring .................. B3-1 Example of Tree Type Wiring ........................... B3-2 Expansion and Modification of Existing System .............................................................. B2-8 Export .............................................................. C3-7
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Integration of Instrumentation and Self-diagnostics Functions ................... A3-10 Interlock Check ................................................ B4-5 Interoperability ............................................... A2-10 Investigation of Number of Field Devices connected to an H1 Segment ................. B2-4
F
Features of Control Valves with the Fieldbus Communication ..................................... A3-9 Features of Fieldbus ........................................ A2-1 Field Communications Server .......................... C1-5 Field Device Maintenance Tool ........................ B4-1 Fieldbus Communication ................................. A2-3 Fieldbus Engineering Process ......................... B1-1 Fieldbus Monitor .............................................. B4-1 Fieldbus Package Types .................................. B1-5 Fieldbus Standard Specifications ..................... A1-4 Fieldbus Support in CENTUM CS .................... A4-8 Fieldbus Support in CENTUM CS 1000 ........... A4-6 Fieldbus Support in FCS for FIO of CENTUM CS 3000 ................................ A4-2 Fieldbus Support in FCS for RIO and Compact FCS of CENTUM CS 3000 ..... A4-4 Fieldbus Support in Yokogawas CENTUM Control Systems ................................................ A4-1 Fieldbus-ready Field Devices ........................... A3-1 Function and Accuracy Check .......................... B5-2 Functions of Field Devices and System ............ A2-9
K
Knowledge of Application Software .................. B4-2 Knowledge of System Software ....................... B4-2
L
Labor Savings in Startup Work ......................... B4-3 Large-scale CENTUM CS 3000 System Configuration when Connecting FF-H1 .. C2-2 Link to Document ............................................. C3-5 Loop Check ..................................................... B4-3
M
Maintenance .................................................... B1-3 Maintenance during System Operation ............ B5-1 Maintenance Information Management ............ C3-5 Maintenance Management (Maintenance Plan, Device Managemell Audit Trail) ............ B5-3 Making the Most of Field Device Accuracy ....... A2-7 Managing Fieldbus Engineering ....................... B1-1 Mounting Couplers ........................................... B3-3 Mounting Terminators ...................................... B3-3 Multi-drop Connections .................................... A2-4 Multi-sensing Function Equipment ................... A3-6 Multifunction Equipment ................................... A3-7 Multivariable Detection and Transmission ........ A2-5
G
Glossary .......................................................... C1-2
H
Handling the Shield Mesh ................................ B3-4 Hybrid Communication .................................... A2-2
I
IEC/ISA Standard Specifications ...................... A1-4 Importance of Process Control System Design .............................................................. B2-1 Improved Transmission Accuracy ..................... A2-6 Improvement of Transmission Accuracy ........... A3-4 Improvement of Transmitter Measuring Accuracy .............................................................. A3-5 Inspection and Maintenance ............................ B5-2 Inspection Memo ............................................. C3-5 Inspection Schedule ........................................ C3-5 Installing Advanced Functions in Field Devices .............................................................. A2-9 Installing an Intrinsic Safety Barrier .................. B3-4 Instrument of Digital Signal Measurement ........ B4-1 Insulating Material of Twisted Pair Cable .......... B2-5 Integrating or Grouping Range and Scope ....... B2-3
N
Network View ................................................... C3-4
New Construction of Fieldbus Process Control System ................................................... B3-1 Number of Branch Cables and Total Length ..... B2-7 Number of Control Modules Managed by PRM ............................................................... C3-1 Number of Users and Clients ............................ C3-1
O
Online Manual (R2.02 or later) ......................... C3-7 Overall Design Considerations ......................... B2-2 Overview of Plant Resource Manager (PRM) ... C1-1 Overview of PRM Functions ................... C3-1, C3-2
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Ind-3
Serial Port Connection via HART Multiplexer (using P&F HART Multiplexer) ............... C2-6 Services for Fieldbus Support Devices ............. A1-5 Setting Parameters for Fieldbus Communication and Its Functions ................................... B1-4 Setting Parameters Specific to Field Devices ... B1-4 Small-scale CENTUM CS 1000 System Configuration when Connecting FF-H1 .............................................................. C2-3 Software Packages for Fieldbus ....................... B1-5 Startup ............................................................. B1-3 Supported Functions Related to MAXIMO ....... C4-1 System Configuration when Connecting FOUNDATION Fieldbus (FF-H1) ........... C2-2 System Configuration when Connecting HART .............................................................. C2-4 System Construction Considerations ............... B3-1 System Design Considerations ........................ B2-1 System Maintenance Considerations ............... B5-1 System Startup Considerations ........................ B4-1
P
Parameter Tuning and Comparison ................. C3-6 Parts List .......................................................... C3-5 Plant View ........................................................ C3-3 PLUG-IN Applications ...................................... C3-7 PRM Client ...................................................... C1-4 PRM Positioning .............................................. C1-6 PRM Server ..................................................... C1-4 PRM Software Configuration ............................ C1-4 PRM Supported Functions for Conventional, FF-H1 and HART Devices ..................... C3-8 PRM System Configuration .............................. C2-1 PRM System Size ............................................ C3-1 Problem Prediction Function .......................... A3-10 Process of Standardization .............................. A1-3 Production ....................................................... B1-2 Progress of Fieldbus Standardization ............... A1-2 Progress of International Standardization of Fieldbus ................................................. A1-1
R
Range Free Devices ........................................ B4-5 Recognition as a Standardization Work Item .... A1-2 Reduced Wiring Cost ....................................... A2-4 Relationship between System and CENTUM CS 3000/CENTUM CS 1000 Project ...... C3-1 Removing Error Factors ................................... A2-6 Restriction by Macrocycle Corresponding to Control Period ........................................ B2-4 Restriction by Power Supply Current Capacity .............................................................. B2-4 Reusing Existing Cables .................................. B3-5 Reusing the Cables from Field Devices to Field Junction Box .......................................... B3-6 Reusing the Cables from Field Junction Box to Control Room ........................................ B3-6 Role Sharing between PRM and CMMS .......... C4-2
T
Technologies and Expertise Necessary for Startup .............................................................. B4-2 Technology for Field Devices ........................... B4-2 Tool .................................................................. C3-6 Tool Necessary for Startup ............................... B4-1 Trial Operation ................................................. B4-5 Tuning and Diagnosis Functions ...................... C3-6
U
Using Self-diagnostics Function ..................... A3-10 Utilities ............................................................. C3-7
V
Various Types of Data Transmission ................ A2-8 Vnet Connection via HART Modules (CENTUM CS 3000 FCS for FIO) .......... C2-4
S
Safety Design and Reliability Improving Design .............................................................. B2-3 Security ........................................................... C3-7 Self-documentation .......................................... C3-7 Selection of Bus Topology and Maximum Number of FF Devices per Segment ....................... B2-5 Selection of Cable Type and Total Length ........ B2-6 Selection of Fieldbus Cable and Wiring Method .............................................................. B2-5 Selection of Wiring Cables ............................... B2-5 Serial Port Connection via HART Multiplexer (CENTUM CS 3000 FCS for RIO) .......... C2-5
W
What is Fieldbus? ............................................ A1-1 Wiring Technology ............................................ B4-2
Y
Yokogawas Efforts for Fieldbus Standardization .............................................................. A1-5 Yokogawas Fieldbus-ready Field Devices Line-up ............................................................. A3-11 Yokogawas Fieldbus-ready Systems ............... A4-1
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Revision Information
Title : Fieldbus Technical Information Manual No. : TI 38K03A01-01E Mar. 1998/1st Edition Newly published Nov. 1998/2nd Edition Fieldbus support in CS 1000 and CS 3000 Fieldbus cable type revised Electronic format applied A4.1 Fieldbus-support CS 1000 and CS 3000 added A4.2 Description revised and added B1.3 Method of installing Fieldbus tools added B2.2 Description in wiring method revised and added B3.1.1 Shielding method added B3.1.4 Description added B3.1.5 Fieldbus-shielding method added B3.2 Cable type added B4.1 Description corrected B4.2 Description corrected Sep. 2002/3rd Edition Introduction Revised descriptions of Introduction and Trademarks Added Structure of This Manual and Target Readership for This Manual For all sections Revised system device to system Revised analog communication and analog communication protocol to analog transmission Part A Revised Outline of Fieldbus and Its Support Products to Overview of Fieldbus and Yokogawas Fieldbus-ready Products A1. Revised this section title International Standardization of Fieldbus to Progress of International Standardization of Fieldbus Shifted section A2 in 2nd Edition to section A1 Updated description A1.1 Added this section A2. Shifted section A1 in 2nd Edition to section A2 Updated description A2.6 Updated description Described about Interoperability Test of Fieldbus Foundation Described about Host Interoperability Support Test of Fieldbus Foundation A3. Updated description A3.4 Revised this section title Upgrading from BRAIN System to Yokogawas Fieldbus-ready Field Devices Line-up Revised description of this section A4. Revised this section title Fieldbus-ready System Devices to Yokogawas Fieldbus-ready Systems A4.1 Revised this section title Fieldbus Support in CENTUM CS 1000, CS3000 and CENTUM CS to Fieldbus Support in Yokogawas CENTUM Systems Updated description Sectioned from section A4.1.1 to A4.1.4 Added section A4.1.1 Fieldbus Support in FCS for FIO of CENTUM CS 3000 A4.2 Revised this section title Fieldbus-ready Field Devices from Other Vendors to Connection of FF Devices from Other Vendors to Yokogawas CENTUM Control Systems Described about Interoperability Test of Fieldbus Foundation Updated description Part B Updated descriptions of all sections B1.3 Revised this section title Fieldbus Tools to Software Package of Fieldbus Updated description
TI 38K03A01-01E
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ii
B2.2 B3.1 B5.4 Part C
Updated description Sectioned from section B2.2.1 to B2.2.4 Described about limit and restriction items in sections B2.2.1 and B2.2.2 Revised this section title New Construction of Fieldbus to New Construction of Fieldbus Process Control System Updated description Revised this section title Future Maintenance to Evolution of Maintenance Updated description Added this part
Written by
Product Marketing Dept. Industrial Automation Systems Business Division Yokogawa Electric Corporation Published by Yokogawa Electric Corporation 2-9-32 Nakacho, Musashino-shi, Tokyo 180-8750, JAPAN Printed by Yokogawa Graphic Arts Co., Ltd.
Subject to change without notice.
TI 38K03A01-01E
Sep.01,2002-00

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<Int> <Ind> <Rev>

Fieldbus Technical Information

TI 38K03A01-01E Copyright Mar. 1998 3rd Edition Sep. 2002

<Toc> <Ind> <Rev>

Structure of This Manual

<Toc> <Ind> <Rev>

Target Readership for This Manual

<Int> <Ind> <Rev>

Features of Fieldbus ............................................................................. A2-1

Fieldbus-ready Field Devices ............................................................... A3-1

Yokogawas Fieldbus-ready Systems .................................................. A4-1

<A1. Progress of International Standardization of Fieldbus>

A1. Progress of International Standardization of Fieldbus

A1.1 What is Fieldbus?

<A1. Progress of International Standardization of Fieldbus>

A1.2 Progress of Fieldbus Standardization

Recognition as a Standardization Work Item

Establishment of the Fieldbus Foundation

<A1. Progress of International Standardization of Fieldbus>

WorldFIP North America

ISA SP50 Committee

The Fieldbus Foundation

Figure Process of Fieldbus Standardization

<A1. Progress of International Standardization of Fieldbus>

A1.3 Fieldbus Standard Specifications

IEC/ISA Standard Specifications

Table Type of Low-speed Fieldbus Cables and Transmissible Length

1,900 m 1,200 m 400 m 200 m

<A1. Progress of International Standardization of Fieldbus>

A1.4 Yokogawas Efforts for Fieldbus Standardization

Services for Fieldbus Support Devices

Development of Field Device Management and Diagnostics Packages

<A2. Features of Fieldbus>

A2. Features of Fieldbus

<A2. Features of Fieldbus>

A2.1 Comparison with Conventional Communication

<A2. Features of Fieldbus>

Type of signal Standard

Multiplex signal Standardized in 1996.

Single signal Standardized

<A2. Features of Fieldbus>

A2.2 Reduced Wiring Cost

Figure Multi-drop Connections

<A2. Features of Fieldbus>

Multivariable Detection and Transmission

Control valve Number of cables Fieldbus : 1 pair

<A2. Features of Fieldbus>

A2.3 Improved Transmission Accuracy

Removing Error Factors

Error due to analog signal transmission

Data transmission direction

Fieldbus Communication System

Data transmission direction

PVs without transmission errors

<A2. Features of Fieldbus>

Making the Most of Field Device Accuracy

<A2. Features of Fieldbus>

A2.4 Enhanced Data Transmission

Various Types of Data Transmission

Data Exchange between Field Devices