PROFIBUS Workshop EN B U I L D I N G P R O C E S S M A N U F A C T U R I N G EUROPEAN FIELDBUS STANDARD. Chapter 1 Date 11/04/99, page 1

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1 PROFIBUS Workshop EUROPEAN FIELDBUS STANDARD B U I L D I N G P R O C E S S EN M A N U F A C T U R I N G Date 11/04/99, page 1

2 PROFIBUS Overview chapter 1 PROFIBUS EN PTO Protocols FMS, DP, PA reliability wiring DP-details chapter 2 GSD - file functions ASICs chapter 3 PIC and certification chapter 4 Date 11/04/99, page 2

3 PROFIBUS Why select a fieldbus system independent of proprietary solution vendor independent cost savings increase of productivity in terms of faster more flexible easy expandable customized Date 11/04/99, page 3

4 PROFIBUS What a fieldbus system needs to offer deterministic (since parallel wiring will be replaced) flexible interoperable (multi-vendor use) cost effective (installation, startup, service) reliable and safe easy to use solution for all your automation needs standardization Date 11/04/99, page 4

5 EN Volume 2 General Purpose Automation PROFIBUS-FMS RS 485 / FO Universal - Large variety of applications - Multi-master communication Factory Automation PROFIBUS-DP RS 485 / FO Fast - Plug and play - Efficient and cost effective Process Automation PROFIBUS-PA IEC Application Oriented - Powering over the bus - Intrinsic safety Date 11/04/99, page 5

6 EN The PROFIBUS Standard EN is complete, open, vendor- independent and validated The PROFIBUS Technology is in accordance with existing parts of the IEC Fieldbus Standard IEC 1158 PROFIBUS is proven and has an installed base of > 3,000,000* devices that are in use all over the world The stable PROFIBUS Standard protects the investments of users and vendors world-wide PROFIBUS EN *Status: Q3/1999 Date 11/04/99, page 6

7 INTERNATIONAL More than 900 members - 23 regional user associations PROFIBUS International America America Africa Africa Europe Europe Asia Asia Australia Australia Brazil USA South Africa Austria Belgium Czech Republic Denmark Finland France Germany Ireland Italy Netherlands Norway Russia Sweden Switzerland United Kingdom China Japan Korea Singapore Australia New Zealand *Status: Q3/1999 Date 11/04/99, page 7

8 PRODUCT Variety Today there are more than 1,900* products from more than 280* different vendors available Get your free copy of the latest PROFIBUS product guide: on CD available from every user group world-wide or visit the Web - Site: *Status: Q3/1999 Date 11/04/99, page 8

9 PRODUCT Variety Drives AC Drives DC Drives Decentralized I/O Binary I/O Analog I/O Regulators Timer Valves Counter Ident-Systems Pneumatic Valves Magnetic Valves Controllers PLC/NC/RC VME, PC Workstation Network components Repeaters Fiber optics MMI Cables Operator Panels Text Displays Software Drivers DOS/Windows/NT/95 RT-OS/OS9/VRTX Services VxWorks/PSOS+ OS2, QNX UNIX/VMS Development Support Implementation Support Training Instruments Level Flow Pressure Temperature Tools Gateways Configuration AS-Interface Bus Monitor Engineering Host Interfaces VAX computers VME computers Proprietary networks Date 11/04/99, page 9

10 Factory level Bus Cycle Time < 1000 ms Ethernet/TCP/IP CNC Area Controller TCP/IP/Ethernet PC/VME Cell Level Bus Cycle Time < 100 ms VME/PC PLC PROFIBUS-FMS DCS Field Level PROFIBUS-DP PROFIBUS-PA Bus Cycle- Time < 10 ms Date 11/04/99, page 10

11 EN The PROFIBUS Protocol is in Accordance with the ISO/OSI Reference Model for Open Systems FMS DP PA User Layer FMS Device Profiles DP-Profiles PA-Profiles DP-Extensions DP Basic Functions Application (7) Fieldbus Message Specification (3)-(6) Data Link (2) Physical (1) not used Fieldbus Data Link (FDL) RS-485 / Fiber Optic IEC Interface IEC EN PROFIBUS guidelines + profiles (page 14 in the binder) Date 11/04/99, page 11

12 Product Profiles PROFIBUS has defined profiles for the easy interconnectivity of certain product ranges NC/RC Profile (3.052) Encoder Profile (3.062) Variable-Speed Drive Profile (3.071) Operator Control and Process Monitoring Profile (HMI) PA Profile (page 12 in the binder) Date 11/04/99, page 12

13 Bus Access The PROFIBUS Bus Access Method combines Multi-Master and Master-Slave communications Active Stations, Master Devices PLC PC PROFIBUS Passive Stations(Slave Devices) are polled Date 11/04/99, page 13

14 Bus Access the PROFIBUS Bus Access Protocol (Layer 2) is identical for all three PROFIBUS variations this enables transparent communication and easy combinations of FMS/DP/PA Network sections Because FMS/DP use the same Physical Media (RS- 485/FO), they can be combined on the same cable Active Stations, Master Devices PLC PC PLC PROFIBUS Date 11/04/99, page 14

15 Bus Access Hybrid Bus Access Protocol Token-Passing between Masters Master - Slave Protocol between Master and Slaves Master active stations with the right to control the bus for a limited amount of time (Token - Hold - Time) Slave Slaves only respond on request of a Master - they have no rights to control the bus Date 11/04/99, page 15

16 Bus Access in Multi-Master Networks, the Token Passing procedure must ensure that each master has enough time to fulfill its communication tasks the user therefore configures the overall Target Token Rotation Time (TTR) taking into account the communication tasks of all masters each Master calculates the available amount of time for its communication tasks at token receipt according to the following rule: TTH = Token Hold Time TTR = Target Token Rotation Time TRR = Real Token Rotation Time TTH = TTR - TRR Date 11/04/99, page 16

17 FMS, DP, PA FMS stands for Fieldbus Messaging System peer to peer communication DP stands for Decentralized Periphery fast data exchange PA stands for Process Automation intrinsically safe environment Date 11/04/99, page 17

18 FMS/DP In Common FMS DP User Layer FMS Device Profiles DP-Profiles DP Basic Functions Application (7) Fieldbus Message Specification (3)-(6) Data Link (2) Physical (1) Fieldbus data link (FDL) RS-485 / Fiber Optic IEC Interface* EN PROFIBUS guidelines + profiles Date 11/04/99, page 18

19 FMS/DP In Common DP and FMS are based on Layer 1 and 2: DP and FMS can be operated on the same bus Message header and data length are identical The bus physics are identical One master can service several slaves Several masters can participate on the bus Baudrates from 9.6 kbd up to 12 MBd are possible Date 11/04/99, page 19

20 FMS/DP In Common Data transmission can be between 1 and 244 bytes 126 stations can be connected System can consist of several segments 32 stations (RS 485 drivers) per segment Common components Cabling, connectors, repeater, fibre optic Savings in maintenance and spare parts inventory Date 11/04/99, page 20

21 PA/DP In Common DP PA User Layer DP-Profiles DP-Extensions PA-Profiles DP Basic Functions Application (7) Specification (FMS) (3)-(6) Data Link (2) Physical (1) Fieldbus FDL Data Link (FDL) RS-485 / Fiber Optic IEC Interface* IEC EN PROFIBUS guidelines + profiles Date 11/04/99, page 21

22 PA/DP In Common DP and PA are based on the same protocol definition - DP/V1 (extended DP) DP and PA can use the same master systems Message header and data length are identical Configuration tools are the same Data transmission can be between 1 and 244 bytes Date 11/04/99, page 22

23 PA/DP In Common PLC or PC with PROFIBUS PROFIBUS-DP, up to 12 Mbit/s DP-Slave DP/AS-i link 24 V DP/PA coupler, DP/PA link PA kbd Actuator/Sensor interface PROFIBUS-PA Date 11/04/99, page 23

24 FMS Features FMS is optimized for universal, object oriented communication of intelligent master devices at the cell level FMS permits a subset of the MMS-Functions (Manufacturing Message Specification, ISO 9506) A slave can be assigned to several masters Several masters can write to the same slave Communication connections can be temporary or permanent Communication is defined in a communication relation list Date 11/04/99, page 24

25 FMS Features Main application areas are: Transmission of large amounts of data e.g.. programs, data blocks... Integration of several decentralized process parts to one common process Communication between intelligent stations Date 11/04/99, page 25

26 FMS Features FMS access procedure Slave 1 Slave 2 Slave 3 Slave x Date 11/04/99, page 26

27 PA Features Based on the extended PROFIBUS-DP Protocol and IEC Transmission Suitable to replace today's ma Technology Only two wires for data and power Connects Instruments to the control system via a serial bus Functional improvements plus reliable serial digital transmission Control, regulation and monitoring via a simple twisted pair cable A single engineering tool for all devices Date 11/04/99, page 27

28 PA Features Based on the extended PROFIBUS-DP Protocol and IEC Transmission Interoperability and interchangeability due to the PROFIBUS-PA Profile Maintenance and diagnostic information from the instruments available low power management and therefore suitable for EEx- Applications with Intrinsic Safety Distance up to 1900m per segment Date 11/04/99, page 28

29 PA Features Typical System Configuration with PROFIBUS-PA Area Controller (PLC) ex Engineering or B&B Tool H2 PROFIBUS-DP RS 485 up to 12 MBit/s I + ex IEC with 31,25 kbit/s PROFIBUS-PA Segmentcoupler/Link Transmitter H1 Date 11/04/99, page 29

30 DP Features DP communication is permanent and cyclic the transmitted data is specified during the configuration (optimized data exchange) only one master can write outputs (safety aspect) data can be read by controlling and Class 2 master acyclic data via DPV1 functions alarm acknowledgment fastest fieldbus system (up to 12 MBaud) up to 244 byte input AND 244 byte output data per station Date 11/04/99, page 30

31 DP Features DP- Access Procedure Master - Token exchange Class 2 Slave 1 Slave 2 Slave 3 Slave x Date 11/04/99, page 31

32 Reliability-DP/FMS Hamming Distance HD = 4 HD 4 means, that up to 3 transmission failures at a time can be detected (done by the ASICs) By detecting a faulty telegram, it will be resent automatically without affecting other existing stations HD 4 is a term used to describe the reliability of the data transmission on the Profibus network. Special Start and End Sentinels Parity Bit for Each Byte Slip Free According to IEC Delimiter Synchronization Date 11/04/99, page 32

33 Reliability-DP/FMS HD 4 enables the detection of the following errors: Line Protocol Errors Framing Errors Overrun Errors Parity Errors Transmission Protocol Errors Faulty Start Delimiter Frame Check Bytes End Delimiters Invalid Frame Length Invalid Response Times Date 11/04/99, page 33

34 PROFIBUS Wiring PROFIBUS DP/FMS wiring can be done with: twisted shielded pair copper cable fiber optic components infrared components detailed installation guideline is available PTO order no Date 11/04/99, page 34

35 PROFIBUS Wiring twisted shielded pair cable line parameters are defined in EN standard cable available from Belden and Siemens standard connectors available Baudrate Max. Segment length Max. Expansion m / 3278feet 10,000m / 32786feet m / 3278feet 10,000m / 32786feet m / 3278feet 10,000m / 32786feet m / 3278feet 10,000m / 32786feet m / 1311feet 4,000m / 13114feet 1, m / 655feet 2,000m / 6557feet 3, m / 327feet 1,000m / 3270feet 6, m / 327feet 1,000m / 3270feet 12, m / 327feet 1,000m / 3270feet max. expansion is done with 9 repeaters in a row Date 11/04/99, page 35

36 PROFIBUS Wiring Special requirements for baudrates >1.5 MBaud use of Baudrates greater than 1.5 MBaud requires special connectors. The connector or the device has to have built in Inductors in order to run with higher baudrates (as stated in the PROFIBUS guidelines) spur lines are not allowed when using baud rates greater than 1.5 MBaud in some applications, several bus connectors are used at electrically short distances; 12 MBaud installations require a minimum cable length between two stations of 1m/ 3feet Date 11/04/99, page 36

37 PROFIBUS Wiring Cable Shielding use only cables with braided shields. the shield density should be more than 80 % always connect the cable shields at both ends if a potential difference occurs between the grounding points, an equalization current can flow through a shield connected at both ends. In this case, install an additional potential equalization line Date 11/04/99, page 37

38 PROFIBUS Wiring one preferred connector type - 9 pin Sub-D connectors with integrated termination available for use of higher baudrates, inductivity built in easy plug and unplug without interrupting the communication to other devices other connector types are possible; mandatory signals (A,B, GND, 5V) must be provided as well as a possibility for termination Date 11/04/99, page 38

39 PROFIBUS Wiring 9 pin sub D Date 11/04/99, page 39

40 PROFIBUS Wiring fiber optic components plastic and glass fiber optic is available optical plugs and modules are available noise immune potential difference independent longer distances (up to 20 miles) redundant operating is possible line, ring and star configuration Date 11/04/99, page 40

41 PROFIBUS Wiring infrared components wireless linking of devices in close-up ranges communication with moving devices communication with changing devices noise immune ground independent Date 11/04/99, page 41

42 PROFIBUS Wiring PROFIBUS FMS / DP both based on RS 485 Termination is necessary Expansion of network through segments the two wire cable is usually color coded!! recommendation: use always the red wire for signal B (pin3 - TXD/RXD-positive) and the green wire for signal A (pin 8 - TXD/RXD-negative) the shield is connected to housing Date 11/04/99, page 42

43 PROFIBUS Wiring Termination (RS485 feature) each segment needs to be terminated at both ends termination needs to be powered at all time if possible use one termination at the master power for termination or the termination itself needs to be provided by the device +5V(6) A-Line (3) 390 Ohm 220 Ohm B-Line (8) GND(5) 390 Ohm Date 11/04/99, page 43

44 PROFIBUS Wiring Segment structure with termination Master Repeater or last device... Termination on (usually whenever only one cable is connected to a device the termination needs to be on ) Date 11/04/99, page 44

45 PROFIBUS Wiring Segments are needed for exceeding the length exceeding 32 devices (incl. Repeater/OLM) Segments can be used for building branch segments connecting up to 126 stations (no addr. for Repeater/ OLM) Rules segment has a max. of 32 devices (incl. Repeater/OLM) the first and the last segment can have 31 stations segments between have 30 stations as a maximum Date 11/04/99, page 45

46 PROFIBUS Wiring segment structure with termination Connect segments. Remote Repeater Link Segment (Segment without stations). Interface for fiber optic... Branch segments Max. Number Repeater Cascading: 9 Termination on Date 11/04/99, page 46

47 PROFIBUS Wiring Redundancy Improves System Reliability System redundancy Media redundancy FO coupler FO coupler Two devices per measuring point FO coupler FO coupler Several interfaces enable redundant systems Fiber optic segments enable redundant wiring Date 11/04/99, page 47

48 COST Savings Cost Savings in Hardware and Assembly Less hardware components (I/O, terminal blocks, barriers) Easier, quicker and less expensive installation Cost Savings in Engineering Easier configuration (only one tool for all devices) Easier preventive maintenance Easier and much faster system start-up Greater Manufacturing Flexibility Improved functionality increases plant productivity Improved availability and reduced down time Accurate and reliable diagnostic data Reliable digital transmission technology Date 11/04/99, page 48

49 COST Savings 100% 22% 50% 27% 51% 57% 12% 22% Engineering Assembly 0% 23% Today (4...20mA) PROFIBUS Hardware Assembly Engineering Hardware Date 11/04/99, page 49