AUMA 50 YEARS OF ELECTIC ACTUATON

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1 AUMA 50 YEARS OF ELECTIC ACTUATON Motor controls and remote communication Werner Laengin, AUMA Germany

2 ONCE UPON A TIME. 2

3 THE HISTORY OF COMMUNICATION All these communication protocols are now standardised in IEC and IEC Wireless Mesh 2007 Industrial Ethernet Modbus TCP/IP ma

DIGITAL COMMUNICATION Various aspects fieldbus systems Topology Repeaters Cycle time Cable length No of participants Baudrate Reaction time Control in the field Application interfaces

4 DIGITAL COMMUNICATION Various aspects fieldbus systems Topology Repeaters Cycle time Cable length No of participants Baudrate Reaction time Control in the field Application interfaces Communication services Field device integration Capex / Opex References DCS integrations Certification / Registration Guidelines Standardisation Redundancy options Service / Commissioning support 4

DIGITAL COMMUNICATION Network characteristics of Profibus DP / Modbus

247 (Modbus RTU) devices Typical: 40 60 devices / network Cycle time

5 DIGITAL COMMUNICATION Network characteristics of Profibus DP / Modbus RTU Line topology Supports also star topology (with repeaters) RS-485 Max m / segment Max. 32 devices / segment Total max 125 (Profibus DP) resp. 247 (Modbus RTU) devices Typical: devices / network Cycle time (Profibus) 250 ms (@ 50 actuators 93,75 kbit/s) Cycle time (Modbus) 1 s (@ 50 actuators 115,2 kbit/s) R R Repeaters (if necessary) 5

6 DIGITAL COMMUNICATION Profibus DP Most favoured fieldbus system with AUMA actuators Widespread Worldwide knowledge available supported by Profibus & Profinet International ( Fast and deterministic 5 ms / Actuator (@ 93,75 kbit/s) Relieable further redundancy options including an integral fibre optic interface Ideal for Water/ waster water applications Power plants Tank farms Dedicated services DP-V0 Optional: DP-V1 (add-on for diagnosis and asset management) Optional: DP-V2 (add-on for specified redundancy and timestamped alarms) 6

7 DIGITAL COMMUNICATION Communication services of Profibus DP Cyclic communication (DP-V0) by PLC/DCS Acyclic communication (DP-V1) User initiated Res.: Req.: 1 Motor h andoperating 12 min time? Res.: Req.: O.k. Stepping mode = ON RS-485 Signal 7

8 DIGITAL COMMUNICATION Communication services of Profibus DP Cyclic communication (DP-V0) by PLC/DCS Acyclic communication (DP-V1) User initiated Host system integration required EDD DTM

9 DIGITAL COMMUNICATION Communication services of Profibus DP Cyclic communication (DP-V0) by PLC/DCS Acyclic communication (DP-V1) User initiated Further services (DP-V2) Specified redundancy Time Stamping of alarms 9

10 DIGITAL COMMUNICATION Modbus RTU Universal communication protocol Basically you can do anything with Modbus RTU Simple and reliable Various additional redundancy options Quick communication 20 ms / Actuator (@ 115,2 kbit/s) Typical applications Any 10

11 DIGITAL COMMUNICATION Modbus RTU Provides the communication foundation for our redundant Loop communication with our SIMA Master Station Modbus TCP/IP SIMA 11

DIGITAL COMMUNICATION Fast commissioning with Modbus loop Ex works

2: SIMA address = 247, baud rate = Auto Automatic configuration of the

baud rate further actuators can be added later no change of existing

12 DIGITAL COMMUNICATION Fast commissioning with Modbus loop Ex works settings of AC.2: SIMA address = 247, baud rate = Auto Automatic configuration of the Modbus loop Consecutive and automatic configuration of slave address baud rate further actuators can be added later no change of existing slave addresses no change of existing data memory mapping to DCS Benefit: Simple and fast commissioning 5 12

13 DIGITAL COMMUNICATION SIMA Master Station applications Complete systems Cabinets Network design Network equipment SIMA 13

14 DIGITAL COMMUNICATION Foundation Fieldbus Different philosophy DCS FF H1 400 VAC Power suppy and data over the same wires 14

15 DIGITAL COMMUNICATION Foundation Fieldbus Different philosophy DCS FF H1 400 VAC Power suppy and data over the same wires Process values are represented by Function blocks AI PID OUT IN OUT IN AO 15

16 DIGITAL COMMUNICATION Foundation Fieldbus Different philosophy DCS FF H1 400 VAC Power suppy and data over the same wires Process values are represented by Function blocks Link Master LAS Basic Device LAS Link Master Control in the field?! AI PID OUT IN OUT IN AO 16

combined with conventional interface) DCS with

17 DIGITAL COMMUNICATION Hybrid technology AUMA actuators support hybrid interface types (fieldbus combined with conventional interface) DCS with conventional interfaces and fieldbus interface fieldbus conventional 17

18 DIGITAL COMMUNICATION Hybrid technology AUMA actuators support hybrid interface types (fieldbus combined with conventional ESD input) ESD PLC 18

19 DIGITAL COMMUNICATION Hybrid technology AUMA actuators support hybrid interface types (fieldbus combined with SIL capability) Safety PLC 19

20 DIGITAL COMMUNICATION Hybrid technology AUMA actuators support hybrid interface types (fieldbus combined with conventional control box in the field, installed e.g. 15 m away from MOV) Control Box Control Box 20

21 DIGITAL COMMUNICATION Line redundancy AUMA actuators support redundant fieldbus communication directly to the MOVs 21

22 DIGITAL COMMUNICATION HART (Highway Addressable Remote Transducer protocol) Basically a plain 4 20 ma signal with additional digital Command and Response telegramms 22

23 DIGITAL COMMUNICATION HART provides two channels A plain 4 20 ma Signal and additional Command and Response telegrams Device category Actuator : 4-20 ma Signal = Setpoint 4-20 ma 2 2 wire cable 4-20 ma 23

24 DIGITAL COMMUNICATION HART provides two channels A plain 4 20 ma Signal and additional Command and Response telegrams Device category Current output : 4-20 ma Signal = Position feedback 4-20 ma 2 2 wire cable 4-20 ma 24

25 DIGITAL COMMUNICATION Wireless systems License free data transmission using the ISM (Industrial, Scientific and Medical) Band ISM (433 MHz, [868 MHz], 2,4 GHz, 5 GHz,.) Point to Point systems Bluetooth, WLAN, RFID, car keys, smoke detectors, ) Mesh systems WirelessHART, ISA100.11a, WIA(PA), (ZigBee) Data transmission based on licenses Radio frequencies Wireless systems for aviation control, sea control, ships / offshore applications, GPS, BOS (national authorities) systems Satellite applications Mobile network systems GSM, EDGE, GPRS, UMTS,.. 25

26 AUMA ACTUATORS WITH WIRELESS INTERFACE AUMA wireless system is based on WirelessHART IEEE Distances: Outdoor: max m Indoor: max m 26

PROJECT EXAMPLE Project scope Operation of jetties to load / unload oil

feedback over I/O wiring (point to point) Commands OPEN / CLOSE Setpoint

(backup) operation method: Used once primary operation path fails Same

27 PROJECT EXAMPLE Project scope Operation of jetties to load / unload oil products to / from ships Main (primary) operation philosophy: Control and feedback over I/O wiring (point to point) Commands OPEN / CLOSE Setpoint Feedback Endposition OPEN / CLOSE Position feedback Failure Alternative (backup) operation method: Used once primary operation path fails Same commands and feedback Dedicated Host / DCS system Dedicated physical layer => Wireless 27

28 PROJECT EXAMPLE The challenges 220 m Control room 14 WirelessHART actuators 350 m 14 WirelessHART actuators 28

29 PROJECT EXAMPLE The solution 1 Gateway 220 m (IEEE ) 1 Access point 14 WirelessHART actuators WirelessHART ( ) WirelessHART ( ) 350 m (IEEE ) 14 WirelessHART actuators 1 Gateway 29

30 PROJECT EXAMPLE System overview 220 m (IEEE ) DCS IEEE Ethernet (HART IP) WirelessHART WirelessHART ( ) ( ) 350 m (IEEE ) 30

31 PROJECT EXAMPLE System overview of a typical WirelessHART application Gateway Access Point Control room WLAN Controller DCS WirelessHART (IEEE ) Jetty m (IEEE ) Switch HART IP (IEEE 802.3) 350 m (IEEE ) Gateway WirelessHART (IEEE ) Jetty 3 31

required Access points, FO couplers, repeaters, remote mounted controls / antennas Site survey!

32 AUMA ACTUATORS WITH WIRELESS COMMUNICATION Typical system design Actuators with WirelessHART WirelessHART gateway Detailed configuration depends on the project Further system devices might be required Access points, FO couplers, repeaters, remote mounted controls / antennas Site survey! DCS HART IP over IEEE Modbus TCP/IP over IEEE Modbus RTU over RS-485 WirelessHART (IEEE ) 32

33 INDUSTRIAL ETHERNET Can you provide actuators with Ethernet?? There are various industrial ethernet protocols used in process automation Profinet (Profibus over industrial ethernet) Modbus TCP/IP (Modbus over industrial ethernet) HSE (FF over industrial ethernet) HART IP (HART over industrial ethernet) Ethernet/IP (CIP protocol [e.g. DeviceNet] over industrial ethernet)... 33

34 INDUSTRIAL ETHERNET PROTOCOLS 34

35 INDUSTRIAL ETHERNET PROTOCOLS Available now: Modbus TCP/IP interface for AUMA actuators Modbus TCP/IP 35

36 AUMA ACTUATORS WITH MODBUS TCP/IP Connection field mountable RJ-45 plug (Cat. 6 A ) Modbus TCP/IP 36

37 AUMA ACTUATORS WITH MODBUS TCP/IP Commissioning Modbus TCP/IP Webserver for commissioning Ex works settings: Adress Type Static IP Static IP Address Subnet Mask Default Gateway Login password: admin Display / CDT for commissioning Ex works settings: Baudrate: Auto (115,2 Kbit/s) Parity: Even Slaveaddress:

38 AUMA ACTUATORS WITH MODBUS TCP/IP Project example: Tunnel ventilation Modbus TCP/IP Industrial switch FO cable with Modbus TCP/IP (Backbone, used for tunnel automation) Modbus TCP/IP Ethernet cable

39 AUMA ACTUATORS WITH MODBUS TCP/IP Project example: Remote stations of e.g. pumping stations Modbus TCP/IP Small PLC (e.g. WAGO 750) Internet Mobile network Plant area VPN HSPA Router (e.g. INSYS EBW-H100) Remote area 39

40 AUMA ACTUATORS WITH MODBUS TCP/IP Network topology IEEE (copper cables): max. 100 m Engineering Industrial Ethernet Plant Asset Management Modbus TCP/IP IEEE 802.3, max. 100 m Modbus TCP/IP Controller Plant Access Point Switch Switch Switch 40

Management Modbus TCP/IP IEEE 802.3, max.

41 AUMA ACTUATORS WITH MODBUS TCP/IP Network topology FO for bigger distances Engineering Industrial Ethernet Plant Asset Management Modbus TCP/IP IEEE 802.3, max. 100 m FO, > 10 km Modbus TCP/IP Controller Plant Access Point Switch Switch Switch 41

42 AUMA ACTUATORS WITH MODBUS TCP/IP Applications: Actuators with network capability Modbus TCP/IP Ethernet network 42

43 AUMA ACTUATORS WITH MODBUS TCP/IP Modbus TCP/IP 1100 km 43

44 INDUSTRIAL ETHERNET PROTOCOLS Also available now: PROFINET interface for AUMA actuators 44

45 AUMA ACTUATORS WITH PROFINET PROFINET interface for AUMA actuators Connection field mountable RJ-45 plug (Cat. 6 A ) New: Integrated 2 port switch for utmost network design flexibility 45

46 AUMA ACTUATORS WITH PROFINET Network option 1a/3 Star topology IEEE (copper cables): max. 100 m IEEE 802.3, max. 100 m Engineering Controller Industrial Ethernet Plant Access Point Plant Asset Management Switch Switch Switch 46

47 AUMA ACTUATORS WITH PROFINET Network option 1b/3 Star topology FO for bigger distances combined with IEEE Engineering Industrial Ethernet Plant Asset Management IEEE 802.3, max. 100 m FO, > 10 km Controller Plant Access Point Switch Switch Switch 47

48 AUMA ACTUATORS WITH PROFINET Network option 2/3 Line topology IEEE (copper cables): max. 100 m Integral switches Engineering Controller Industrial Ethernet Plant Access Point Plant Asset Management Integral switch function IEEE 802.3, max. 100 m 48

AUMA ACTUATORS WITH PROFINET Network option 3/3 Ring topology IEEE 802.3 (copper cables): max.

49 AUMA ACTUATORS WITH PROFINET Network option 3/3 Ring topology IEEE (copper cables): max. 100 m Integral switches MRP (Media Redundancy Protocol) Engineering Controller Industrial Ethernet Plant Access Point Plant Asset Management Integral switch function IEEE 802.3, max. 100 m 49

50 FURTHER COMMUNCATION OPTIONS

51 FURTHER COMMUNCATION OPTIONS Connectivity to the AUMA freeware CDT Bluetooth communication path for data exchange Available as standard Focus of CDT Commisioning & Configuration

data exchange Available as standard Focus of CDT

52 FURTHER COMMUNCATION OPTIONS Connectivity to the AUMA freeware CDT Bluetooth communication path for data exchange Available as standard Focus of CDT Commisioning & Configuration Diagnosis & Asset Mangement

53 FURTHER COMMUNCATION OPTIONS Connectivity to the AUMA freeware CDT Bluetooth communication path for data exchange Available as standard Focus of CDT Commisioning & Configuration Diagnosis & Asset Mangement Testing & Simulation

FURTHER COMMUNCATION OPTIONS - OFFLINE AUMA App (available via App Store or Play Store) Provides device specific information and documents by scanning the bar code of the

54 FURTHER COMMUNCATION OPTIONS - OFFLINE AUMA App (available via App Store or Play Store) Provides device specific information and documents by scanning the bar code of the physical type plate Product identification: order number and serial number Documents Operation Instructions Wiring diagram Technical data sheet Inspection Certificate 3D solid model 54

55 FURTHER COMMUNCATION OPTIONS - OFFLINE AUMA App Further features List of devices Documentation Service calls 55

56 FURTHER COMMUNCATION OPTIONS - OFFLINE AUMA App Available for ios and Android Various languages 56

57 ONCE UPON A TIME. 57

58 DIGITAL COMMUNICATION Modbus TCP/IP 58

59 AUMA AUTOMATES VALVES

60 AUMA 50 YEARS OF ELECTRIC ACTUATION 60

ELECTRIC ACTUATORS with PROFINET interface

ELECTRIC ACTUATORS with PROFINET interface Top reliability and availability are prime requirements in process automation plants in terms of deployed communication technologies. Robust and versatile Industrial