PROCESS AUTOMATION SIMPLIFY PROCESSES FIELDCONNEX INFRASTRUCTURE FOR PROFIBUS PA

Transcription

1 PROCESS AUTOMATION SIMPLIFY PROCESSES FIELDCONNEX INFRASTRUCTURE FOR PROFIBUS PA

2 SIMPLIFY PROCESSES The best solutions are usually very simple The fieldbus is a perfect example of simplicity at its best. It offers straight forward communication from the control room all the way to each individual field device. One common cable is sufficient to supply power to the field devices and transport all communications. It is this versatility that has turned the fieldbus into the enabling technology for modernday process plants. It not only supports process control, but also allows a totally new level of device management. Via the fieldbus, the process control system is given total control over each individual instrument. Field devices can be configured and checked from the control room. Status information and process values are available anytime. Preventive maintenance has finally become reality. When compared to conventional 4 20 ma technology, the fieldbus provides a much higher level of reliability and accuracy. There is no longer a need for scaling and device drift is a matter of the past. Besides actual process control, the fieldbus offers cost-efficient benefits all along the system lifecycle. System planning requires less effort. Installation and commissioning are easier and less time consuming. Fewer shutdowns dramatically increase plant performance and availability. Being an internationally accepted industry standard, the fieldbus is supported by numerous manufacturers. New technologies are based on the same standards, thus protecting the investment in installations, training and technology. Being a well established technology, the fieldbus offers a solid communications infrastructure which combines innovation with proven reliability. There are countless plants all over the world successfully using the fieldbus for more than ten years. This brochure will give you an overview over FieldConnex, the innovative and comprehensive product line from Pepperl+Fuchs for fieldbus communications.

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4 SYSTEM OVERVIEW PROFIBUS PA HIGH-POWER TRUNK CONCEPT FIELDBUS INFRASTRUCTURE FOR PROCESS AUTOMATION PLC/DP-MASTER Hazardous Area Zone 2/Class I, Div. 2 SEGMENT COUPLER/ POWER SUPPLY TERMINATOR INTEGRATED SEGMENT PROTECTOR UP TO 12 SPURS PER SEGMENT PROTECTOR SEGMENT PROTECTOR SHORT-CIRCUIT PROTECTION HIGH-POWER TRUNK Ex nl FIELD DEVICES FIELD DEVICES General Purpose Area

5 Hazardous Area Zone 1/Class I, Div. 2 FIELDBARRIER WITH GALVANIC ISOLATION Ex na Ex e HIGH-POWER TRUNK Ex i FIELDBARRIER WITH GALVANIC ISOLATION Ex i SEGMENT PROTECTOR R-SP-E12 FIELD DEVICES Ex e Ex d TERMINATOR INTEGRATED SURGE PROTECTION PROCESS INTERFACES FIELDBUS DISTRIBUTION SEGMENT COUPLER FIELD DEVICES CONVENTIONAL FIELD I /O FIELD DEVICES Hazardous Area Zone 0/Class I, Div. 1

6 FIELDCONNEX THE LEADING FIELDBUS INFRASTRUCTURE Benefit from the know-how of the inventors The fieldbus is the leading technology with a future. FieldConnex is the keyword for fieldbus technology at its highest level. With FieldConnex, Pepperl+Fuchs offers a comprehensive product portfolio for efficient process control. Setting the pace with over 60 years of experience in process control, Pepperl+Fuchs has repeatedly surprised the market with innovative solutions. Technologies such as the High- Power Trunk concept were originally developed by Pepperl+Fuchs and have gained industry-wide acceptance. FieldConnex represents the sum of our experience and is comprised of highly reliable products that realize tangible competitive benefits for our customers. All products from Pepperl+Fuchs were designed with utmost quality and reliability in mind. We not only develop and distribute a comprehensive range of fieldbus interface products, but also build them in our own manufacturing facilities. Insisting on a manufacturing depth of 90% gives us total control over the overall quality. This guarantees fast delivery and puts us into the position to tailor our products to the individual needs of our customers. Pepperl+Fuchs is technology partner of all major players in the process industry. Being present on all major markets around the world, we are able to offer comprehensive support and support our customers with our comprehensive know-how in fieldbus and explosion protection. If you like to get into a dialog with Pepperl+Fuchs, please feel free to contact us at

7 CONTENTS INTRODUCTION FIELDBUS TECHNOLOGY Fieldbus Definition and Design 8 Explosion Protection with the High-Power Trunk Concept 10 The Physical Layer and Signals 12 PRACTICE AND PRODUCT DESCRIPTIONS System Components 14 Advanced Diagnostics for the Physical Layer 16 PROFIBUS Segment Coupler and Power Supply 18 Fieldbus Distribution in the hazardous area 20 Enclosure Solutions for Fieldbus Distribution 22 Process Interfaces 24 Termination, Wiring and Surge Protection 26 Fieldbus Training 27 COMPLEMENTARY PRODUCTS LB/FB PROFIBUS Remote I/O 28 Ethernet Isolator 29 MADE BY PEPPERL+FUCHS Driving the Development 30

8 FIELDBUS TECHNOLOGY WORK STATION ETHERNET/TCP/IP MANAGEMENT INTERNET/INTRANET PC/VME FACTORY LEVEL Bus Cycle time < 1000 ms PROCESS CONTROL SYSTEM ETHERNET/TCP/IP MAINTENANCE CELL-LEVEL Bus Cycle time < 100 ms PLC/DP-MASTER PROFIBUS DP PROFIBUS PA FIELD-LEVEL Bus Cycle time < 10 ms 8

9 PROFIBUS PA DEFINITION AND DESIGN Digital process control is based upon a three-tier hierarchy. At administrational and factory level Ethernet has established itself as the communications backbone, allowing direct data exchange between the PCS system and the ERP system. At the field level, the process industry has adopted FOUNDATION Fieldbus H1 and PROFIBUS PA as the dominant fieldbus systems. They comply with the international standard IEC (Fieldbus for use in Industrial Control Systems). IEC , defines the physical layer of the H1 fieldbus. Requirements for PROFIBUS PA: Transmission of both data and field device power over the same two-wire cable Various topology structures Interoperability of all field devices Explosion protection for hazardous environments Division of one infrastructure into multiple segments Connection of up to 31 devices to each segment FIELDBUS INFRASTRUCTURE Segment A fieldbus network is divided into multiple segments, which are usually electrically independent and can have an overall cable length of up to 1900 m. Depending on factors, such as current consumption, cable type, explosion protection and the required response or bus cycle time, up to 31 devices may be connected to one segment. Trunk The trunk also called home run cable is the main cable within a fieldbus structure that carries power and communication into the field. Fieldbus termination and power supplies are con - nected to the trunk. Spur A spur is the cable that connects the field instrument to the trunk. It may have a length of up to 120 m. The maximum length of a spur depends upon several aspects, such as cable type and total number of devices on the segment. It is recommended to connect only one device per spur. Although the IEC standard allows any kind of topology, the trunkand-spur topology has become the most common topology for process plants. Due to its clearly structured design it is both easy to understand and maintain. DESIGN CONSIDERATIONS Designing a fieldbus infrastructure starts with typical control and monitoring loops. At this stage, it is vital to carefully consider the number of devices, cable resistance, and distances in order to meet all design criteria of the fieldbus standard. Segment Checker is a widely accepted segment planning tool that will speed up the design process considerably. It has become the standard software package for planning and documenting fieldbus networks and offers valuable functions to verify the design based on the selected explosion protection: Calculation of voltage drop on the cable Validation of cable length and number of devices Segment Checker as well as standard libraries for field instrumentation are available for download at The software also allows the creation and storage of custom libraries with specific devices. When it comes to fieldbus technology in process automation, Pepperl+Fuchs has established itself as a worldwide market leader with a wealth of experience and expertise. We offer our customers comprehensive support and know-how transfer anytime and anywhere. 9

10 THE HIGH-POWER TRUNK CONCEPT PLC/DP-MASTER PLC/DP-MASTER PROFIBUS DP PROFIBUS PA SEGMENT COUPLER/ POWER SUPPLY FIELDBARRIER/ SEGMENT PROTECTOR HIGH-POWER TRUNK SPURS WITH ENERGY LIMITATION AND SHORT- CIRCUIT PROTECTION 10

11 EXPLOSION PROTECTION WITH THE HIGH-POWER TRUNK CONCEPT The High-Power Trunk Concept is a widely accepted approach for hazardous areas and general-purpose fieldbus applications. Part of the concept is the protected installation of the trunk (US: Div 2 wiring method) in accordance with IEC (US: NEC 505). It also needs to be equipped with short-circuit protection and is run without energy limitation. To provide energy limitation for explosion protection, all devices are connected to the trunk via smart wiring blocks, such as Segment Protectors or FieldBarriers. Using such a topology allows hot working on the spur and the field device without requiring access to the trunk. It also allows maximum cable lengths and a high number of devices; while the trunk itself is protected from short-circuit conditions at the spur. FISCO AND ENTITY VALIDATION FISCO and Entity are well-established concepts for the validation of explosion protection. Both standards are described in IEC-standards IEC and IEC and define attributes for the fieldbus infrastructure that simplify validation. Basically, system planers need to observe only two requirements: (1) only one power source is allowed per segment, and (2) all components including the cables need to conform to any of these standards. Observing product-specific restrictions, such as energy consumption, electronic design, stray capacitance and inductance is the manufacturer s responsibility. Practically all hardware available today conforms to FISCO, Entity or both. Independent validation of explosion protection for each spur and device The High-Power Trunk concept greatly simplifies validation of explosion protection, because each spur is validated separately with the wiring block as the only power source and the field device as the only power drain. Validation of explosion protection only requires to observe the rating of each device and to verify FISCO or Entity conformance of the entire fieldbus infrastructure. This concept allows the mixed use of FISCO or Entity devices. It is therefore not surprising that three times more devices are connected using the High-Power Trunk concept compared to FISCO power supplies limiting the energy on the trunk. High-Power Trunk Concept simplifies application of fieldbus The High-Power Trunk concept offers a number of practical benefits to both system installers and users: Live work and maintenance is permitted on field instrumentation without gas clearance Longest cable runs and maximum number of devices enabled in any hazardous area Use of cost-effective standard power supplies Easy plant modification and expansion Mixed use of FISCO or Entity devices 11

12 PHYSICAL LAYER NOISE SIGNAL LEVEL Supply voltage TYPICAL PHYSICAL LAYER MEASUREMENTS Ideal OK Value Signal level Noise Unbalance Jitter CRC Error Framing Error Description The voltage level of the data signal. Measured per device Unwanted disturbance. Measured per device or per segment Difference in isolation levels between each of the two leads and the shield. Ground fault Deviation of the actual from the optimal zero crossing. Measured per device and per segment Cyclic Redundancy Check Error: A telegram where the checksum is invalid, i.e.: one or more bits were detected as invalid A fault or an inconsistency in the telegram structure, i. e. caused by an interruption in the middle of a transmission. Part of the telegram is lost Tolerance JITTER Bit error 12

13 THE PHYSICAL LAYER AND SIGNALS According to the fieldbus protocol only one device may transmit data at any given time. Information is transmitted in data packets called telegrams which include address information and checksums to ensure accuracy of the transmission. If a telegram is detected as bad, invalid, or incomplete it is rejected and will be transmitted again. Field devices act as loads drawing at least 10 ma of current. The signal is transmitted through a change in the load current of ± 9 ma, a rectangular wave indicating the 1 and 0 state of digital communication. Signal Level The signal level describes the actual signal voltage transmitted by a device. It can be measured at the power supply as the voltage drop on the cable. A change in signal level may indicate unintended load changes on the segment. Noise Low or high frequency noise describes any unwanted voltage on the cable. It can be caused by any active component on the segment or result from EMI generated by power cables and frequency inverters. The fieldbus terminators at each end of the trunk cable translate the current change into a signal voltage detectable on the cable. Additionally, the terminators suppress signal reflections, which can have a negative effect on signal quality. Highly accurate data transmission and fast cycle times are typical of a well-designed and maintained fieldbus infrastructure. Any increase in lost or rejected telegrams is a clear indication of problems at the fieldbus physical layer. Without the use of online diagnostics, slowly deteriorating signal quality usually remains undetected until it severely affects plant performance. Monitoring the quality of the fieldbus signals is vital in order to maintain the physical health of the fieldbus infrastructure. There are three different indicators pointing to problems at segment and device level: Jitter Jitter describes the timing of each individual bit. The width of the digital signal is a key performance indicator of the overall physical health of the network. Since all components within the network interact to some extent, changes of the electric values of any circuit also influence fieldbus timing. The resulting effect on signal quality is measured as jitter. Advanced continuous monitoring of the physical layer is a cost-effective step towards increased productivity and plant output. It has a positive effect on all stages of the network lifecycle from commissioning to online-monitoring and troubleshooting and is a vital contribution to increased plant availability. 13

14 SYSTEM COMPONENTS Power Hub for 4 Segments Complete with redundancy, flexible configuration. For use with various Exprotection concepts. Compact Power Hub Most compact design for two segments. For many standard applications. Advanced Diagnostic Module For supervision of the fieldbus physical layer, for retrofit of existing Power Hubs. Segment Coupler 1 Compact single modules for safe and intrinsically safe segments. Mountable on DIN Rail. FieldBarrier in stainless steel housing. Instrinsically safe connection of devices to the High-Power Trunk. Galvanic isolation Segment Protector R2 Simple connection of field instruments. Short circuit protection for the Segment. Energy limitatation Ex nl Preconfigured housing solutions. Installation ready. With FieldConnex components and accessories. Excertification included Aluminum housing for Segment Protector or FieldBarrier for mounting in the field. With a selection of cable glands Sensor Interface For 12 binary inputs. Version for DIN Rail installation. Valve Coupler for four intrinsically safe low power valves Modular Surge Protector Complete unit for installation in the cabinet Fieldbus Terminator for installation in the field with robust screw-in type housing 14

15 Availability and reliability are the key requirements in the process industry. This is particularly important for the fieldbus infrastructure as the backbone for reliable communication in the field. Pepperl+Fuchs has supported the worldwide process industry for over 60 years. We not only provide innovative products for even more efficient process control. We also offer comprehensive support and know-how transfer on a global basis. RELIABILITY AS A CORE VALUE Innovative solutions are of limited value if they do not live up to the challenges of real-life process plant operation. Pepperl+Fuchs has established a name for proven technologies that are based upon established standards and are designed up to the detail with utmost reliability in mind. As a result, every component of the FieldConnex system stands out for its long product lifecycle even under demanding process conditions. It is therefore not surprising that Pepperl+Fuchs has developed into a preferred supplier of major system planners and gained a clearly positive approval by the experts in the renowned FuRIOS study. Pepperl+Fuchs is dedicated to the needs of the global process industry. Our products are characterized by a simple and robust design, leading to superior quality and long-time reliability. Knowing the practical needs in the field, we even give attention to seemingly small details that improve operation and simplify installation. The following pages will provide you with an overview of FieldConnex system components. You will find product descriptions and basic selection criteria to aid you in choosing exactly the right products for your fieldbus application. 15

16 ADVANCED DIAGNOSTICS FOR THE PHYSICAL LAYER IN GENERAL Installation practices have a tremendous influence on the long-term signal quality of a fieldbus infrastructure. Maintenance work, moisture, loose wire strands, corrosion and other factors can degrade communications in course of time and eventually lead to network instabilities. Conventional handheld diagnostic tools provide only basic analysis of the physical layer. Only real-time monitoring will detect the slow process of degrading fieldbus signal quality. This approach maximizes system availability by providing advance notification before changes can affect system integrity. Tools for monitoring the fieldbus physical layer also offer support in every stage of the fieldbus project from installation to operation and troubleshooting. In this way, installation and maintenance personnel do not need to have in-depth knowledge of the physical aspect of the fieldbus infrastructure. Fieldbus diagnostic tools with online monitoring capabilities are typically integrated into the fieldbus power supply. Here, the module can monitor everything from load conditions to noise, ground faults, or earth leakage and measure the device signal level. Status information is easily communicated to the DCS. PEPPERL+FUCHS Advanced Diagnostic Module HD2-DM-A integrated into the FieldConnex Power Hub Mobile Advanced Diagnostic Module DM-AM-KIT available for single segment monitoring Stand-alone Diagnostic Module KT-MB-DMA for upgrade of existing fieldbus systems APPLICATION DATA Modules HD2-DM-A DM-AM-KIT KT-MB-DMA DTM-FC.AD* Application and Features Plug-in module for FieldConnex Power Hub system supporting four segment with remote access Mobile module for single segment check-out and troubleshooting Stand-alone Module and motherboard for upgrade of any fieldbus system. Up to four segments Diagnostic Manager Professional Edition for the FieldConnex Advanced Diagnostic Module - Wizard for commissioning including automated documentation - Detailed measurements and monitoring per device and segment - Integrated oscilloscope for detailed view and troubleshooting - Remote diagnostics included Selection of Physical Layer Diagnostics Bulk power health Segment voltage and current Ground leakage or fault Segment noise Device signal level Signal polarity Signal jitter Selection of communication statistics Segment live list CRC error counter (Cyclic Redundancy Check) Frame error counter Number of received frames 16

17 PEPPERL+FUCHS THE ADVANCED DIAGNOSTIC MODULE The FieldConnex Advanced Diagnostic Module (ADM) for the FieldConnex Power Hub system provides realtime monitoring and local data storage of physical layer values for up to four fieldbus segments. It automatically triggers alarm messages and allows easy node commissioning and remote access for troubleshooting. DIAGNOSTIC MANAGER PROFESSIONAL EDITION The Diagnostic Manager Professional is an intelligent software platform with wizard support, designed for fast commissioning and effective monitoring of the physical layer. The built-in segment monitor displays communication data per segment and device. Each item is clearly classified as excellent, good, or out of spec. Reports, alarm lists and historic data can be exported for detailed analysis. SIMPLIFIED COMISSIONING The Commissioning Wizard is part of the Diagnostic Manager and is used to measure device signal level, proper termination, and cable continuity. It provides a baseline report, comprehensive system documentation and points to potential installation problems. Verifying cables and nodes only requires a few mouse clicks, thereby reducing the time for system checkout by more than 80%. During commissioning, the wizard automatically eval - uates and recommends warning and alarm levels for each segment and component. These levels can be modified to adapt them to the operating philosophy of the plant. They form a baseline, which is stored in a non-volatile memory inside the ADM. TARGETED ACTION THROUGH REAL-TIME MONITORING AND TRENDING The baseline is continuously compared against actual values. Alarms can be communicated as summary alarms to the DCS or via solid state contact. An alarm list shows the history of alarms with time stamps and indicates possible causes and remedies guiding the user with actionable information in plain text. The ADM captures scheduled snapshots of all values. It is able to store two years of historic data Offering various analysis functions and data export to the maintenance system, the Diagnostic Manager supports proactive maintenance strategies to increase overall system availability at reduced maintenance cost. REMOTE ACCESS FOR EXPEDITED, IN-DEPTH TROUBLESHOOTING The Diagnostic Manager provides online access to the Advanced Diagnostic Module. This allows live monitoring of the fieldbus physical layer directly from the control room or remote analysis by an offsite fieldbus expert. Besides measurement and display of vital network characteristics such as crosstalk/noise, signal jitter, and resonance, the ADM also includes a powerful fieldbus oscilloscope for in-depth analysis of network communication. Fieldbus-specific triggers even allow tracing of complex or intermittent errors that would otherwise be hard to find. In other words: the ADM significantly enhances troubleshooting and provides the basis for quick diagnosis and repair. Alarm History with time stamps. Clear text points out potential issues and guides the user to quick identification and resolution. Segment Monitoring with color indication for easy identification clarifies and brings transparency to the fieldbus physical layer. Integrated oscilloscope allows users to track down intermittent communication problems. Use the link below for further detailed information and to see the data sheets. 17

18 PROFIBUS SEGMENT COUPLER AND POWER SUPPLY IN GENERAL PROFIBUS PA is always operated as a sub network to PROFIBUS DP. The segment coupler connects the two networks for data transmission and supplies power to the PROFIBUS PA segment. Data is transmitted from the DP-Master via the segment coupler to the PA field device. The segment coupler provides a transparent connection so that all PA slaves appear to be connected to the PROFIBUS DP segment. This is true for all aspects of communication: cyclic data exchange, field device configuration and status information. Field instruments are configured and operated based on their native GSDfiles. Transparent behavior removes complexity in segment design, engineering, operation and maintenance and the segment coupler remains configuration free. The segment coupler provides up to 31 V at 500 ma to power up to 31 devices connected to a fieldbus segment. Typically, the segment coupler is installed in a cabinet near the control room, where the trunk with a length of up to 1900 m terminates. For increased availability, many process plants demand redundancy. The Segment Coupler needs to be designed for longtime operation at low MTBF and low power dissipation. A modular design is preferred where plug-in modules can be exchanged without disrupting plant operation. For explosion hazardous areas, FieldConnex segment couplers will power segments designed according to the High-Power Trunk concept. PEPPERL+FUCHS Segment Coupler SK3 the PROFIBUS Power Hub for four segments with optional redundancy. The optional grounding bar solidly connects the fieldbus cable and its shield to the Power Hub Compact Segment Coupler SK3 the two segment solution Compact and cost-effective for smaller applications demanding full speed on the DP network Basic Segment Coupler SK1 For single safe-area and intrinsically-safe FISCO segments 18

19 PEPPERL+FUCHS FieldConnex PROFIBUS Segment Couplers always feature transparent connection between PROFIBUS DP and PROFIBUS PA. They establish an industry standard for fieldbus networks by providing superior service life, optimized electrical symmetry, and maximum use of passive components. Impedance generation and galvanic isolation ensure minimum distortion of the fieldbus signal, thereby contributing to high system availability. FieldConnex power supplies are available in two versions: Power Supply Modules feature galvanic isolation and a choice of controlled output voltages. Power Conditioner Modules are equipped with current limitation without galvanic isolation. Their output voltage depends on the bulk power supply. PROFIBUS POWER HUBS FieldConnex PROFIBUS Power Hubs feature high output power, greater signal quality, and advanced circuitry. Their modular design allows easy, tool-free installation. All terminals are removable. All power and communication connections feature retaining screws. The versatility of the Power Hub together with a variety of power modules allows easy and transparent connection of PA devices to any DCS system via PROFIBUS DP. CREST (Crosstalk and Resonance Suppression Technology) guarantees perfect communication even under extreme operating conditions. Unique features include: Redundancy the motherboard can hold two power modules per segment. Diagnostic Functions Self monitoring system with alarm reports power supply status, fieldbus short circuit or overload condition, as well as insufficient voltage from the bulk power supply. Advanced Diagnostic Module available as an option BASIC SEGMENT COUPLERS FieldConnex Basic Segment Couplers are designed to supply PROFIBUS PA devices with ample voltage and current or with intrinsically-safe energy limitation. Use the link below for further detailed information and to see the data sheets. APPLICATION DATA Segment Coupler Motherboard Gateway Redundancy PROFIBUS DP transmission rate No. of Segments V/500 ma V/500 ma V/400 ma V/360 ma V/500 ma Power Module Redundancy Galvanic Isolation High-Power Trunk Intrinsically-safe Trunk CREST Noise reduction ADM Option Attributes Segment Coupler SK kbps 12 Mbps 4 Option Option Plugin Highest output power and advanced circuitry Compact SK3 Segment Coupler kbps 12 Mbps 2 Standalone For small installations and laboratories Basic Segment Coupler SK kbps 1 Standalone For single segments 19

20 FIELDBUS DISTRIBUTION IN THE HAZARDOUS AREA IN GENERAL With FOUNDATION Fieldbus, typically 8 through 16 devices are connected to one segment. A Trunk-and-spur topology is used as de facto standard. It is recommended to connect only one device per spur. The number of instruments per segment determines bus cycle time as well as the available cable length at the spur. Typically installations connect between 8 and 16 devices to one trunk. EXPLOSION PROTECTION WITH THE HIGH-POWER TRUNK CONCEPT At the core of the High-Power Trunk concept are Segment Protectors or FieldBarriers. These smart wiring interfaces are mounted near the field devices to provide short-circuit protection as well as energy limitation for explosion protection. They also guarantee that the segment remains in operation even during a fault condition at a spur. FISCO or Entity are typical concepts for easy validation of explosion protection. The High-Power Trunk concept expands established FISCO and Entity validation methods by considering each spur connection separately. This not only simplifies validation, but also allows the mixed use of Entity and FISCO certified devices. PEPPERL+FUCHS The FieldBarrier The High-Power Trunk concept applied: Four outputs for intrinsicallysafe fieldbus devices Segment Protector R-SP-E12 For increased safety installations in Zone 1 T-Connector: R2-Segment Protector with innovative connection to the trunk and a well-defined place for the terminator Test points at trunk and spur enable hasslefree connection of measurement devices Modular Segment Protector snaps on the DIN-Rail with internal connection between modules 20

21 PEPPERL+FUCHS FieldConnex Segment Protectors and FieldBarriers are backed by extensive experience. They offer best-inclass segment reliability even with a large number of field devices. All wiring interfaces are easily mounted on DIN-Rails with built-in or connectable terminators included. LED trunk and spur status indication further simplify fieldbus operation and repair. FIELDBARRIER The FieldConnex FieldBarrier is an innovation by Pepperl+Fuchs, which revolutionized the fieldbus industry through the introduction of the High-Power Trunk concept. The majority of devices installed in the hazard - ous area Zone 1/Class I, Div. 0 is connected to the fieldbus via FieldConnex FieldBarriers with many plants and many hours of operation. An important safety feature is the IP 30 cover for the trunk connectors, which prevents unintended opening of the trunk circuits. Combined short-circuit protection and intrinsic safety at each output Galvanic isolation between trunk and spurs SEGMENT PROTECTOR The new R2 series Segment Protectors feature innovative design for superior availability: Easy connection of multiple Segment Protectors Incorrect termination is prevented by design, since the terminator can be placed only on the T-Connector of the last Segment Protector Durable installation due to connectors with retaining screws Test points allow the connection of diagnostic tools such as the Mobile Advanced Diagnostic Module without disturbing the wiring All field devices within a segment, as well as the R2 Segment Protector can be maintained, exchanged or upgraded without disturbing plant operation. APPLICATION DATA Number of masters & devices Spur length m/400 ft m/300 ft m/200 ft m/100 ft m/3.28 ft Use the link below for further detailed information and to see the data sheets. Wiring Device Spur No. of Spurs Installed in Field Devices installed in FieldBarrier Ex i 4 Zone 1/Div. 2 Zone 0/Div. 1 Segment Protector R-SP-E12 Ex e 12 Zone 1/Div. 2 Zone 1/Div. 2 R2 Segment Protector Ex nl 4 12 Zone 2/Div. 2 Zone 2/Div. 2 Modular Segment Protector Ex nl 2 28 Zone 2/Div. 2 Zone 2/Div. 2 21

22 ENCLOSURE SOLUTIONS FOR FIELDBUS DISTRIBUTION IN GENERAL In many process plants throughout the world, Segment Protectors, Field- Barriers and associated accessories need to be installed in applications involving hazardous and corrosive environments. This involves ready-to-install solutions on the basis of certified components as well as the assembly of enclosures in accordance with the specific rules and regulations for hazardous areas. Modern enclosures come with the hazardous area certification, saving considerable time and costs for planning, engineering, and installation while providing worry-free fieldbus implementation. PEPPERL+FUCHS Stainless Steel Enclosure with 2 Segment Protectors, 12 spurs each Stainless Steel Enclosure with 3 FieldBarriers, 4 outputs each Stainless Steel Enclosure with FieldBarrier and a choice of plastic or metallic cable glands Polyester Enclosure with Segment Protector Polyester Enclosures Choice of isolated grounding bar for the shield and surge protection shown FieldBarrier in aluminum housing with metallic glands. Most compact design for installation in the field near the instrumentation 22

23 PEPPERL+FUCHS FIELD JUNCTION BOX WE PUT THINGS TOGETHER... POLYESTER (GRP) HOUSING STAINLESS STEEL HOUSING Pepperl+Fuchs fieldbus products are found in process plants throughout the world. From the initial concept to start-up and commissioning, we provide professional service and unmatched performance. As market leaders especially with solutions for hazardous environments, we are able to offer worldclass products in a variety of panels and enclosures. Due to our own engineering capacity, we are also able to design and build solutions according to customer specifications. One example is our wide range of custom-engineered field junction boxes, which are manufactured in house in order to guarantee superior consistency and quality....and DELIVER SOLUTIONS. Each process plant is different and comes with its own set of unique requirements. This also applies to the configuration of the Field Junction Boxes. The answer of Pepperl+Fuchs to specific process requirements and individual plant circumstances is the modular FieldConnex Field Junction Box system. It represents a modular solution based upon a set of standardized components and is designed to match a variety of interface standards. It is even available as a certified solution matching the special requirements of hazardous areas. reduces engineering efforts. It also provides fast installation on site and contributes to a reduced cost structure during all phases of the system life cycle: Ex-approved fieldbus installation solutions for zones 1/2/2 /22 and Div. /Div. 2 Customer-oriented availability Customer- and industry-specific solutions for fieldbus distribution. Non-Ex solutions also available STAINLESS STEEL ENCLOSURES Our stainless steel enclosures are ideal for use in applications requiring frequent washing of the equipment. They offer fully watertight seals and are the perfect choice for highly corrosive areas where standard enclosures would not hold up. Pepperl+Fuchs stainless steel enclosures are available with ingress protection ratings IP68 and Type 6. POLYESTER (GRP) ENCLOSURES Pepperl+Fuchs GRP Field Junction Boxes are the perfect choice, where low weight and cost are the issue. They represent an ideal solution for most installations requiring ingress protection rating IP66 and Type 4X. ELECTRONICS CABLE GLANDS TERMINALS OVERVOLTAGE PROTECTION ACCESSORIES Simple steps leading to ready-toinstall Field Junction Boxes Due to this modular design concept, system planners are able to customize each Field Junction Box to match any given application and requirement, by simply selecting specific characteristics, such as dimensions, cable glands, electronic components and surge protection. This unique solution not only ALUMINIUM ENCLOSURES For non-corrosive environments aluminium field junction boxes are an even more economical choice. They are the best match for most installations requiring ingress protection ratings IP67 and Type 4X. 23

24 PROCESS INTERFACES IN GENERAL Efficient data exchange with field devices is an important requirement for any fieldbus infrastructure. Proximity switches, on/off valves, digital inputs, low-power valves and other devices are connected to the fieldbus via Process Interfaces. Multiple devices may share a single Process Interface and fieldbus address. Integration into the DCS is achieved via standard EDDL or FDT/DTM technology. The ability of the fieldbus to transport power and communication makes Process Interfaces an economic solution especially for explosion hazardous areas. They can be installed close to the sensors in Zone 1/Class I, Div. 2, while the sensors themselves can be located in Zone 0/Class I, Div. 1. PEPPERL+FUCHS Valve Coupler FD0-VC-EX4.FF for four instrinsically safe low-power valves Sensor Interface FD0-BI-Ex12.PA Twelve inputs connect conventional digital, intrinsically-safe control circuits such as NAMUR sensors and mechanical contacts Pneumatic Interface for twelve pneumatic control valves APPLICATION DATA Process Interface Protection No. of Outputs Installed in Devices installed in Signals and Sensors Valve Coupler Ex i 4 DO/8 DI Zone 1/Div. 1 Zone 0/Div. 1 Low power valves, Digital I/O Fieldbus Pneumatic Interface Ex i Configurable Zone 1/Div. 1 Zone 1/Div. 1 High power valves Sensor Interface Ex i 12 DI Zone 1/Div. 1 Zone 0/Div. 1 NAMUR Sensors 24

25 PEPPERL+FUCHS VALVE COUPLER FieldConnex Valve Couplers connect low-power solenoid valves to a fieldbus segment. They serve to translate control commands into discrete output signals to actuate the valve. Two end position sensors per valve may share one cable. Valve Couplers are able to conduct partial stroke tests in either valve position and generate alarm messages for preset limit values, lead breakage or short circuits on the cables. Galvanic insulation between the fieldbus segment and each valve further enhances simplicity and plant availability. HIGHLIGHTS: Power and control via the fieldbus cable Up to four valves via one fieldbus address Galvanic isolation between fieldbus and valves Integrated end position monitoring with two sensors Partial stroke test and other software functions integrated Lead breakage and short-circuit monitoring for each conventional signal cable FIELDBUS PNEUMATIC INTERFACE The Fieldbus Pneumatic Interface is a typical example of Pepperl+Fuchs packaging solutions. One housing with electronic components is designed for safe and easy connection of up to 32 high-power valves and can be used in hazardous areas. Power and control via fieldbus and pressured air only Pre-fabricated connection points for heavyduty valves on the sturdy Field Junction Box Choice of 3/2-way and 5/2-way solenoid valves PROFIBUS DP Remote I/O solutions provide additional power for driving sensors and actuators SENSOR INTERFACE The Sensor Interface provides galvanic isolation and connects digital inputs to the fieldbus using one PROFI- BUS address. Each output is certified intrinsically safe. The sensor interface will monitor lead breakage and short-circuit conditions at each input. An extensive and up to date list of valves and sensors compatible with the valve coupler can be found on 25

26 TERMINATION, WIRING AND SURGE PROTECTION IN GENERAL PROPER TERMINATION FOR OPTIMAL FIELDBUS QUALITY Proper termination of fieldbus segments is extremely important. Attaching one terminator at the end of each trunk provides the impedance to suppress signal reflections and improve signal quality. This terminating impedance also translates data signals transmitted as current change into a detectable voltage change. The load created by the terminator determines the signal voltage on the cable. Consequently, over-termination can result in signal levels which cannot be recognized at the other end of the line. Incorrect termination also increases the signal jitter which can lead to communication errors. Advanced Diagnostics is able to detect both incorrect termination and impedance changes caused by aging. SURGE PROTECTION Due to their design and exposed situation, process plants are often affected by direct or indirect lightning strikes. Other surge risks include static discharges from plastic materials, crosstalk from cables installed in close proximity to the fieldbus cable and surges from power lines. Such conditions can damage the fieldbus electronics and even lead to plant shut down. Surge protection adds to the availability of a plant by eliminating or at least reducing power surges to ground potential. For best possible protection, surge protection devices need to be installed between power supply and wiring interface, between wiring interfaces, and at the ends of each spur. To reduce surge protection cost, risk analysis is used to identify those parts of the plant with a high risk for power surges. PEPPERL+FUCHS Fieldbus Terminator for installation in the field with robust screw-in type housing Modular Surge Protector Complete unit for installation in the cabinet 26

27 PEPPERL+FUCHS FIELDBUS TERMINATORS FieldConnex terminators according to IEC ensure reliable fieldbus communication. Based upon a high-availability design, they create the needed impedance by means of a resistor and multiple capacitors. To further increase system availability, changes in the physical layer including termination errors can be detected through online monitoring with the Advanced Diagnostic Module. SURGE PROTECTION FieldConnex Surge Protectors are based on a modular design, consisting of a base unit and protection modules and match the EMC-orientated Lightning Protection Zones Concept in accordance with IEC They offer system planners the option to determine whether the signal is interrupted or continued while the protection module is removed from the socket. STURDY HOUSINGS Use the link below for further detailed information and to see the data sheets. FieldConnex includes devices in sturdy IP67 housings designed for installation of terminators or surge protectors in hazardous areas. These units come with a choice of threads and offer explosion protection. PRACTICE: FIELDBUS TRAINING Building or updating a process plant with fieldbus-based process control has a strong impact on planning, installation and commissioning procedures. Pepperl+Fuchs provides extensive know-how transfer to share their knowledge, experience and expertise on fieldbus technology. With training services ranging from basic knowledge to detailed product handling, we assist our customers in all aspects of fieldbus infrastructure from initial planning all the way to production start. Proper training is the key to success. Public courses are often offered through public engineering and management organizations. Custom trainings tailored to the needs of the team on site will incorporate practical details which might be vital for the success of a project. 27

28 COMPLEMENTARY PRODUCTS LB/FB PROFIBUS REMOTE I/O There are still many field devices without direct fieldbus connection. LB/FB Remote I/O offers a cost-efficient way to integrate such devices into a fieldbus infrastructure. It adapts all types of analog and digital signals, such as on/off status information and classic 4 20 ma/hart signals to PROFIBUS DP. A wide spectrum of single-channel and multi-channel I/O modules offer intrinsically-safe and non-intrinsically safe field connections. Engineering becomes easy and adaptable to the needs of your plant concept. LB REMOTE I/O FOR INSTALLATION IN ZONE 2 Matching Ex-Zone 2/Div. 2 requirements Outputs rated for Zone 1, Zone 0 and Div. 1 SIL 2 for digital and analog outputs 24 V DC power supply FB REMOTE I/O FOR INSTALLATION IN ZONE 1 Matching Ex-Zone 1 /Div. 2 requirements Protection methods Ex-i and Ex-e Exchange of modules while energized in the hazardous area Integration of FieldBarrier and Modular I/O into one field enclosure Fully encapsulated for demanding environments 24 V DC or 120/230 V AC power supply PROFIBUS LB Remote I/O PROFIBUS FB Remote I/O 28

29 ETHERNET ISOLATOR The FieldConnex Ethernet Isolator is designed especially for temporary installations, mobile applications and equipment that needs to be connected and disconnected frequently. It provides galvanic isolation and intrinsically-safe energy limitation and allows plug and play connections at 100 Mbit/sec even within hazardous areas. Built-in galvanic isolation eliminates the need for equipotential bonding and solid grounding between the safe area and the connection point inside the hazardous area. Advanced electronic circuits combine durability with high performance. A highly energy-efficient design with extremely low heat dissipation makes the Ethernet Isolator an ideal match for switching cabinets with limited space. The Ethernet Isolator is a cost-efficient alternative to costly and inflexible installations. TECHNICAL SPECIFICATIONS Approval for intrinsically-safe Ethernet in Zone 0 Installation in Zone 2 or in flame-proof housing (Ex d) in Zone 1 Two Ethernet Isolators per connection Connecting cable type CAT5e, 100 m max. length Transfer rate 10/100 MBit/s, 10-BASE-T/100 BASE-TX Connector type 2 x RJ45 Half/Full Duplex and Auto-Negotiation LEDs for Power, Communication and Transfer rate recognition Ambient Temperature range 40 C 60 C Ethernet Isolator EI-0D2-10Y-10B Intrinsic safety now available for 100 MBit fast Ethernet 29

30 DRIVING THE DEVELOPMENT MADE BY Pepperl+Fuchs All the way from its beginnings, Pepperl+Fuchs was characterized by a spirit of invention. We are a driving force in all symposiums and committees setting standards for fieldbus technology. We have provided the market with numerous innovations that have turned the fieldbus into a safe environment for process control and plant asset management. 30

31 Teaming up with all leading suppliers of systems for process automation, Pepperl+Fuchs has gathered a wealth of experience from countless projects of the global process industry. We not only provide a complete range of products and solutions for fieldbus installations of any dimension. We are also able to develop custom solutions tailored to the specific requirements of any given application. INNOVATIONS AND INVENTIONS One typical example of the innovative power of Pepperl+Fuchs is the invention of the High-Power Trunk concept. It reflects our comprehensive experience with solutions for explosion hazardous areas and has become a widely accepted fieldbus technology which many other suppliers have adopted. The High-Power Trunk is a major step towards simplified installation and operation of field devices within classified Ex zones and conforms to all relevant safety standards. CONTROLLED QUALITY FOR MORE RELIABILITY Pepperl+Fuchs has a long history as manufacturer of products for process automation. We not only insist on our own research and product development. We also maintain own manufacturing facilities with a manufacturing depth of 90%. This guarantees the development of market-driven products with tangible benefits and puts us into a position to fully control the quality and reliability of our products. GLOBAL EXPERT SUPPORT Being present on all major markets, Pepperl+Fuchs is the ideal partner for the global process industry. We are able to supply any product to just about any location of the world. We also back it by the comprehensive support of experienced experts. Simply ask us and we will not hesitate to support you from the problem to the solution. SOLID PARTNER WITH A FUTURE For many decades, Pepperl+Fuchs is well known in the global process industry. We are world market leaders with intrinsically safe components for explosion hazardous areas. We are also technology partner of major players and play a vital role in international associations. This makes Pepperl+Fuchs a depend- able partner that will continue its history of innovation and drive the further development of fieldbus technologies. 31

32 PROCESS AUTOMATION PROTECTING YOUR PROCESS For over a half century, Pepperl+Fuchs has been continually providing new concepts for the world of process automation. Our company sets standards in quality and innovative technology. We develop, produce and distribute electronic interface modules, Human-Machine Interfaces and hazardous location protection equipment on a global scale, meeting the most demanding needs of industry. Resulting from our world-wide presence and our high flexibility in production and customer service, we are able to individually offer complete solutions wherever and whenever you need us. We are the recognized experts in our technologies Pepperl+Fuchs has earned a strong reputation by supplying the world s largest process industry companies with the broadest line of proven components for a diverse range of applications Worldwide/German Headquarters Pepperl+Fuchs GmbH Mannheim Germany Tel pa-info@de.pepperl-fuchs.com Asia Pacific Headquarters Pepperl+Fuchs PTE Ltd. Singapore Company Registration No E Tel pa-info@sg.pepperl-fuchs.com 3 Western Europe & Africa Headquarters Pepperl+Fuchs N.V. Schoten/Antwerp Belgium Tel pa-info@be.pepperl-fuchs.com 6 Northern Europe Headquarters Pepperl+Fuchs GB Ltd. Oldham England Tel pa-info@gb.pepperl-fuchs.com 4 Middle East/India Headquarters Pepperl+Fuchs M.E (FZE) Dubai UAE Tel pa-info@ae.pepperl-fuchs.com 7 Southern/Eastern Europe Headquarters Pepperl+Fuchs Elcon srl Sulbiate Italy Tel pa-info@it.pepperl-fuchs.com 5 North/Central America Headquarters Pepperl+Fuchs Inc. Twinsburg Ohio USA Tel pa-info@us.pepperl-fuchs.com 8 Southern America Headquarters Pepperl+Fuchs Ltda. São Bernardo do Campo SP Brazil Tel pa-info@br.pepperl-fuchs.com Subject to modifications Copyright PEPPERL+FUCHS Printed in Germany Part. No /08 03