process automation protecting your process

Transcription

1 process automation protecting your process PROCESS AUTOMATION For over a half century, Pepperl+Fuchs has provided 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 offer complete individual 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 2 8 Asia Pacific Headquarters Pepperl+Fuchs PTE Ltd. Singapore Company Registration No E Tel pa-info@sg.pepperl-fuchs.com Central/Western Europe & Africa Headquarters Pepperl+Fuchs N.V. Schoten/Antwerp Belgium Tel pa-info@be.pepperl-fuchs.com The best solutions are usually very simple SIMPLIFY PROCESSES FIELDCONNEX INFRASTRUCTURE FOR FOUNDATIONTM FIELDBUS SIMPLIFY PROCESSES 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 fieldbus into the enabling technology for modern day process plants. It not only supports process control, but also allows a totally new level of device management. Via 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, 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, fieldbus offers cost-efficient benefits all along the system lifecycle. System planning requires less effort. Installation and 6 Northern Europe Headquarters Pepperl+Fuchs GB Ltd. Oldham England Tel pa-info@gb.pepperl-fuchs.com 4 Middle East 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 Bernado do Campo SP Brazil Tel pa-info@br.pepperl-fuchs.com Subject to modifications 2008 PEPPERL+FUCHS, INC. Printed in USA Part No /08 00 commissioning are easier and less time consuming. Fewer shutdowns dramatically increase plant performance and availability. Being an internationally accepted industry standard, 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, fieldbus offers a solid communications infrastructure which combines innovation with proven reliability. There are countless plants all over the world successfully using fieldbus for more than ten years. This brochure will give you an overview of FieldConnex, the innovative and comprehensive product line from Pepperl+Fuchs for fieldbus communications.

2 SYSTEM OVERVIEW FOUNDATION FIELDBUS H1 PROCESS INTERFACES FIELDBUS DISTRIBUTION POWER SUPPLIES General-Purpose Area

3 process automation protecting your process PROCESS AUTOMATION For over a half century, Pepperl+Fuchs has provided 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 offer complete individual 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 2 8 Asia Pacific Headquarters Pepperl+Fuchs PTE Ltd. Singapore Company Registration No E Tel pa-info@sg.pepperl-fuchs.com Central/Western Europe & Africa Headquarters Pepperl+Fuchs N.V. Schoten/Antwerp Belgium Tel pa-info@be.pepperl-fuchs.com The best solutions are usually very simple SIMPLIFY PROCESSES FIELDCONNEX INFRASTRUCTURE FOR FOUNDATIONTM FIELDBUS SIMPLIFY PROCESSES 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 fieldbus into the enabling technology for modern day process plants. It not only supports process control, but also allows a totally new level of device management. Via 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, 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, fieldbus offers cost-efficient benefits all along the system lifecycle. System planning requires less effort. Installation and 6 Northern Europe Headquarters Pepperl+Fuchs GB Ltd. Oldham England Tel pa-info@gb.pepperl-fuchs.com 4 Middle East 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 Bernado do Campo SP Brazil Tel pa-info@br.pepperl-fuchs.com Subject to modifications 2008 PEPPERL+FUCHS, INC. Printed in USA Part No /08 00 commissioning are easier and less time consuming. Fewer shutdowns dramatically increase plant performance and availability. Being an internationally accepted industry standard, 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, fieldbus offers a solid communications infrastructure which combines innovation with proven reliability. There are countless plants all over the world successfully using fieldbus for more than ten years. This brochure will give you an overview of FieldConnex, the innovative and comprehensive product line from Pepperl+Fuchs for fieldbus communications.

4 CONTENTS INTRODUCTION FIELDBUS TECHNOLOGY Fieldbus Definition and Design 3 Explosion Protection with the High-Power Trunk Concept 5 The Physical Layer and Signals 7 PRACTICE AND PRODUCT DESCRIPTIONS System Components 8 Advanced Diagnostics for the Physical Layer 10 Fieldbus Power Supply 12 Fieldbus Distribution in the Hazardous Area 14 Enclosure Solutions for Fieldbus Distribution 16 Termination, Wiring, and Surge Protection 18 Fieldbus Training 19 Process Interfaces 20 Complementary Products 21 product selection Model Number & Description 22

5 FIELDBUS TECHNOLOGY WORK STATION ETHERNET/TCP/IP MANAGEMENT INTERNET/INTRANET PC/VME FACTORY LEVEL Bus cycle time < 1000 ms OPERATIONS HIGH SPEED ETHERNET (HSE) MAINTENANCE CELL LEVEL Bus cycle time < 100 ms HOST/LAS LINKING DEVICE H1-BUS NON-IS GENERAL-PURPOSE AREA H1-BUS IS HAZARDOUS AREA FIELD LEVEL Bus cycle time < 10 ms 2

6 FIELDBUS DEFINITION AND DESIGN Digital process control is based on a three-tier hierarchy. Ethernet has established itself as the communications backbone, allowing direct data exchange between the process control system and the ERP system. 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. 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. H1 fieldbus: 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 that are usually electrically independent and can have an overall cable length 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 connected to the trunk. Although the IEC standard allows any topology, the trunk-andspur topology is the most common topology for process plants. Its structured design is easy to install 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. It is a free 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 and a standard library for field instrumentation are available for download at When it comes to fieldbus technology, Pepperl+Fuchs is established as a worldwide market leader with a wealth of experience and expertise. 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 3

7 THE HIGH-POWER TRUNK CONCEPT HOST/LAS POWER SUPPLY SEGMENT PROTECTOR HIGH-POWER TRUNK SPURS WITH ENERGY LIMITATION AND SHORT- CIRCUIT PROTECTION 4

8 Explosion protection with THE high-power trunk concept DIVISION 1 VALIDATION FISCO and Entity are well-established concepts for the validation of explosion protection. Both standards are described in the IEC and IEC IEC-standards and define attributes for the fieldbus infrastructure that simplify validation. Basically, system planners 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 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. DIVISION 2 AND NONHAZARDOUS VALIDATION When validating Div 2 or nonhazardous area protection, the use of segment protectors is highly recommended. They provide short-circuit, energy-limited (nonincendive) outputs. When used in a Div 2/nonincendive application, they can connect to either a nonincendive field wiring apparatus or intrinsically safe rated devices, which enables the end user to connect/disconnect instruments under power. The High-Power Trunk (HPT) concept greatly simplifies validation of explosion protection. 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 has only two requirements: (1) observe the rating of each device, and (2) verify FISCO or Entity conformance of the entire fieldbus infrastructure. field instruments and facilitates a consistent installation design regardless of the area classification. By limiting the energy in the field rather than in the control room, power is more efficiently distributed to the instruments where it is required. As a result, segment protection devices are similarly installed for either hazardous or ordinary location applications. Consistency, available energy, cable runs, and cost savings are all increased with HPT. Another benefit of the High-Power Trunk concept allows the user to standardize on one power conditioning system with optional redundant modules for all areas of the plant. Supplying 30 V/500 ma allows the user to achieve maximum cable lengths and maximum loading without using repeaters. If desired, live maintenance without gas clearance on the instruments is possible in combination with segment protectors (for safe area or Zone 2/Div. 2 applications) and FieldBarriers (for Zone 1/Div. 1 applications) when using instruments with the appropriate certifications (I.S. Entity or FISCO). The High-Power Trunk concept offers a number of practical benefits to end 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 The High-Power Trunk concept limits the energy on the trunk to 500 ma. This concept increases the amount of energy available for 5

9 PHYSICAL LAYER Noise Signal level Jitter 6

10 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 that 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. 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. 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. 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. Continuous monitoring of the physical layer is a cost-effective step towards increased productivity. From commissioning to online monitoring and troubleshooting, it is a vital contribution to increased plant availability. 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 the segment and device level: 7

11 SYSTEM COMPONENTS - Advanced Diagnostic Module Monitors the fieldbus physical layer Power Hub for 4 Segments Complete with redundancy Flexible configuration For use with various Exprotection concepts High-density Power Hub Compact design and highest packing density Many standard applications Basic Power Supplies Simplex modules available with or without voltage limitation and galvanic isolation Mountable on DIN Rail Segment Protector R2 Simple connection of field instruments and short circuit protection for the segment Preconfigured housing solutions Installation ready FieldConnex components and accessories Aluminum housing for FieldBarrier For mounting in the field A selection of cable glands FieldBarrier in stainless steel housing Instrinsically safe connection to the High-Power Trunk Galvanic isolation Valve Coupler For four intrinsically safe low power valves Fieldbus cables Cordsets and extension cables Bulk fieldbus Type A, armored and Type A/ER Modular Surge Protector Complete unit for installation in the cabinet Fieldbus Terminator For installation in the field with robust screw-in type housing 8

12 Availability and reliability are the key requirements in the process industry. This is particularly important for the fieldbus infrastructure because it is the backbone for reliable communication to all field devices. FieldConnex is synonymous with high-quality fieldbus technologies. Pepperl+Fuchs offers a comprehensive fieldbus interconnectivity product portfolio. 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 operations. Setting the pace with over 60 years of experience and a heritage of innovation, Pepperl+Fuchs FieldConnex fieldbus infrastructure represents the sum of our experience and comprises reliable products that are designed with quality and reliability in mind. Every FieldConnex system component is guaranteed to perform even under demanding process conditions. We not only develop and distribute a comprehensive range of fieldbus interface products, we build them in our own manufacturing facilities. This guarantees fast delivery and puts us into a position where we can tailor our products to the individual needs of our customers. Pepperl+Fuchs has technology partnerships with all major vendors involved in the process industry. Our presence in all major markets around the world enable us to offer comprehensive service and support. 9

13 ADVANCED DIAGNOSTICS FOR THE PHYSICAL LAYER 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 over 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 affect system integrity. Tools for monitoring the fieldbus physical layer offer support in every stage of the fieldbus project from installation to operation and troubleshooting. Installation and maintenance personnel do not need 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. 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 Modules HD2-DM-A DM-AM-KIT KT-MB-DMA DTM-FC.AD* Features Plug-in module for FieldConnex Power Hub system supporting four segments with the ability to connect remotely for troubleshooting purposes 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 - Commissioning Wizard automates baseline reporting and loop checks - Detailed measurements and monitoring per device and segment - Integrated oscilloscope for detailed view and troubleshooting - Commission & troubleshoot from the control room - Remote monitoring & diagnostic capabilities Physical Layer Measurements Bulk power health Segment voltage and current Ground fault or leakage 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 10

14 The Advanced Diagnostic Module The FieldConnex Advanced Diagnostic Module (ADM) for the FieldConnex Power Hub system provides real-time 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 The Diagnostic Manager is an intelligent software platform designed to automate commissioning and effectively monitor the physical layer. The built-in segment monitor displays communication data for the entire segment and each device. Each value 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 loop check documentation, and points to potential installation problems. Verifying cables and nodes requires only a few mouse clicks, reducing the time for system checkout by up to 80%. During commissioning, the Wizard automatically evaluates and recommends warning and alarm levels for each segment and component. These levels can be modified to the operating philosophy of the plant. They form a baseline that is stored in a nonvolatile memory inside the ADM. REAL-TIME MONITORING AND TRENDING enables proactive maintenance The ADM measures device signal level, proper termination, and cable continuity. It provides a baseline report and comprehensive system documentation. The baseline is continuously compared against actual values and if there s a problem, it shows exactly what that problem is, indicates possible causes, and then offers possible solutions. The ADM captures scheduled snapshots of all values. It is able to store two years of historic data and offers various analysis functions and data export to the maintenance system. Rather than reacting to problems after a shut sown, the Diagnostic Manager enables proactive maintenance strategies to increase overall system availability and reduce maintenance costs. 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 off-site. Alarm history with time stamps, potential issues, and guides for the user to quickly identify and resolve the problem. 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. In addition to measurement and display of vital network characteristics such as crosstalk/noise, signal jitter, and resonance, the ADM includes a powerful fieldbus oscilloscope for in-depth analysis of network communication. Fieldbusspecific triggers allow tracing of complex or intermittent errors that would otherwise be hard to find. The ADM significantly enhances troubleshooting and enables quick diagnosis and shorter repair time. 11

15 FIELDBUS POWER SUPPLY The power supply is a crucial element within any fieldbus infrastructure. It provides up to 31 V at 500 ma to power up to 31 devices connected to a fieldbus segment. For increased availability, many process plants require redundant power supplies. Typically, the power supply is installed in a cabinet near the control room. It needs to be designed for longtime operation at low MTBF and low power dissipation. A modular design is generally preferred, since it allows the exchange of defective components without disrupting plant operation. For explosion hazardous areas, FieldConnex power supplies will power segments designed according to the High-Power Trunk concept while meeting either hazardous or ordinary location requirements. Power Hub MB-FB-4R with up to 500 ma output, redundancy and Advanced Diagnostic Module for 4 segments. The optional grounding bar solidly connects the fieldbus cable and its shield to the Power Hub Power Hub for 4 segments, simplex MB-FB-4 Low power dissipation and up to 500 ma output High-density Power Hub MBHD-FB-4R The most compact version to power fieldbus segments with built-in redundancy Basic Power Supply KLD2-FBPS with low heat dissipation enables high packing density and DIN rail mounting Motherboard V/500 ma V/500 ma V/360 ma V/500 ma Galvanic Isolation Current Limiter Only No. of Segments CREST Noise Reduction Redundancy ADM Option Additional Features MB-FB-4R MB-FB-4 (500 ma Power Hub) MBHD-FB4R (High-density Power Hub) KLD2-FBPS (Basic Power Supply) 1, 2, 4 Option Plug-in 4 Standard Plug-in 1 Mobile Highest output power and advanced circuitry Up to 25 V and a high packing density Everything packed in one housing Custom Motherboard solutions with DCS-specific connections are available for: Emerson, Honeywell, Invensys, and Yokogawa 12

16 FieldConnex power supplies are the industry standard for fieldbus networks. Providing superior service life, they feature 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. Power Hubs FieldConnex Power Hubs feature high output power, greater signal quality, and advanced circuitry. Their modular design matches virtually all process plants. All terminals are removable. All vital connections feature retaining screws. DCS-specific motherboards are available with special connectors or integrated host interfaces. The versatile 500 ma Power Hub allows easy connection of field devices to any DCS system. CREST (Crosstalk and Resonance Suppression Technology) guarantees reliable communication even under extreme operating conditions. The highly compact High-Density Power Hub is specially designed for large installations and applications. Both models come with a set of unique features: 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 Power Supplies FieldConnex fieldbus power supplies are designed to supply Foundation fieldbus H1 devices with ample voltage and current. For easy installation, the popular K-system housings feature removable terminals and a fieldbus terminator. 13

17 Fieldbus Distribution in the hazardous area With Foundation fieldbus, 8-12 devices are typically connected to one segment. A trunk-and-spur topology is used as the de facto standard. It is recommended to connect only one device per spur. The number of instruments per segment determines the bus cycle time as well as the available cable length at the spur. Explosion protection with THE High-Power Trunk Concept Segment Protectors and FieldBarriers are at the core of the High-Power Trunk concept. These smart wiring interfaces are mounted near the field devices to provide short-circuit protection as well as energy limitation for explosion protection. They guarantee that the segment remains in operation even during a fault condition on a spur. FISCO or Entity are 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, FISCO, and nonincendive certified devices. The FieldBarrier Intrinsically safe device connections ircuit protection Zone 1/Class I, Div. 2 with Class I, Div. 1 spur connections Galvanic isolation and short circuit protection Segment Protector R2 Simple connection of field instruments Short circuit protection for the segment Energy limitation Ex nl/ Div. 2 nonincendive Modular Segment Protector snaps on the DIN rail with internal connection between modules 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 troublefree connection of measurement devices 14

18 FieldConnex Segment Protectors and FieldBarriers offer best-in-class segment reliability. All wiring interfaces are easily mounted on DIN rails and include integrated or attachable terminators. LED indication for trunk and spur status further simplify fieldbus operation and repair. Fieldbarrier The FieldConnex FieldBarrier revolutionized the fieldbus industry. A greater number of devices is now available with the use of a FieldBarrier and the High-Power Trunk concept. An important safety feature is the IP30 cover for the trunk connectors, which prevents unintended opening of the trunk circuits. Combined short-circuit protection and intrinsically safe outputs Galvanic isolation between trunk and spurs Segment Protector The new R2 series Segment Protectors feature an 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 Connectors with retaining screws offer durable connections Test points allow the connection of diagnostic tools such as the Mobile Advanced Diagnostic Module or handheld configurator without disturbing the wiring All field devices and R2 Segment Protectors can be maintained, exchanged, or upgraded without disturbing plant operation. Number of Devices Spur Length m/400 ft m/300 ft m/200 ft m/100 ft m/3.28 ft Wiring Device Spur No. of Spurs Installed in Field Devices Installed in R2 Segment Protector NI 4 12 Zone 2/Div. 2 Zone 2/Div. 2 Modular Segment Protector NI 2 28 Zone 2/Div. 2 Zone 2/Div. 2 FieldBarrier I.S. 4 Zone 1/Div. 2 Zone 0/Div. 1 15

19 ENCLOSURE SOLUTIONS FOR FIELDBUS DISTRIBUTION In many process plants throughout the world, Segment Protectors, FieldBarriers, and associated accessories need to be installed in applications involving hazardous and corrosive environments. This involves ready-to-install solutions as well as the assembly of enclosures in accordance with the specific rules and regulations for hazardous and ordinary locations. 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 metal 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 metal glands. Most compact design for installation in the field near the instrumentation protection shown Polycarbonate Enclosures with Segment Protector 16

20 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 with solutions for hazardous environments, we are able to offer world-class 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. reduces engineering efforts, it also provides fast installation on-site and reduces costs during all phases of the system life cycle: Ex-approved fieldbus installation solutions for Zones 1/2/21/22 and Div. 1 /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 where the equipment requires frequent washing. They offer 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. ELECTRONICS CABLE GLANDS TERMINALS OVERVOLTAGE PROTECTION ACCESSORIES Simple steps leading to ready-toinstall Field Junction Boxes The modular FieldConnex Field Junction Box system is Pepperl+Fuchs answer to specific process requirements and individual plant circumstances. 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. Due to this modular design, 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 POLYESTER (GRP) and POLYCARBONATE enclosures Pepperl+Fuchs GRP and polycarbonate Field Junction Boxes are the perfect choice when low weight and cost are the issue. They provide an ideal solution for most installations requiring ingress protection rating IP66 and Type 4X. ALUMINUM Enclosures For non-corrosive environments, aluminum field junction boxes are the most economical choice. They are the best match for most installations requiring ingress protection ratings IP67 and Type 4X. 17

21 TERMINATION, WIRING, AND SURGE PROTECTION 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, overtermination can result in signal levels that cannot be recognized at the other end of the line. Incorrect termination also increases the signal jitter that can lead to communication errors. Advanced Diagnostics are able to detect both incorrect termination and impedance changes caused by aging. Surge protection Due to their design and location, 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 protects electrical devices from voltage spikes. Surge suppressors are devices installed to protect electrical wiring, electronic systems, and industrial equipment. They divert harmful voltage transients and surge currents to ground, protecting all measurement and control signals. For best possible protection, surge protection devices need to be installed between the power supply and the 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. Fieldbus Terminator for installation in the field with robust screw-in type housing Modular Surge Protector Complete unit for installation in the cabinet Bulk Cable Bulk type A/ER, armored, and type A multicore cable available in spools 100 m-1500 m Cordsets& Extension Cables Available in micro or mini, type A and A/ER. All colors available 18

22 FIELDBUS TERMINATORS FieldConnex terminators according to IEC ensure reliable fieldbus communication. Based upon a high-availability design, they create the needed impedance using a resistor and multiple capacitors. 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. BULK CABLE & EXTENSION CABLE Type A/ER, Type A multicore, and armored fieldbus cables are available in a variety of colors. Molded micro and mini extension cables and cordsets are also available. Our fieldbus cable product configuration tool, Build your Fieldbus Cordset, lets you build complete FieldConnex fieldbus Type A/ER cordsets and extension cables in 10 easy steps and get a price and availability quote! Build your Fieldbus Cordset is available with all of our FieldConnex fieldbus products on our website, FIELDBUS and ADVANCED DIAGNOSTIC TRAINING The physical layer installation and maintenance are critical issues surrounding the successful implementation of fieldbus. To truly realize the installation and more importantly operational financial benefit of fieldbus, everyone in the plant must understand how to utilize and maximize these assets. The quality of the fieldbus physical layer is more critical when compared to a 4-20 ma signal; one failure can affect all devices connected to a segment. Building or updating a process plant with fieldbus-based process control has a strong impact on planning, installation, and commissioning procedures. Pepperl+Fuchs has a wealth of experience in fieldbus technology. We provide training services ranging from basic knowledge to detailed product handling. At your site or ours, we assist our customers in all aspects of fieldbus infrastructure from the initial planning all the way to start-up including the Advanced Diagnostic training. Advanced Diagnostic Modules provide the ability to visualize the health of your network and better predict system availability. The ADM s Diagnostic Manager operates in a Windows environment to assist in plant life cycle management. Your staff will learn: Physical layer commissioning Fieldbus operation Fieldbus communication troubleshooting And, we ll work with you to include your own customized topics For more information visit 19

23 PROCESS INTERFACES & COMPLEMENTARY PRODUCTS Efficient data exchange with field devices is an important requirement for any fieldbus infrastructure. Proximity switches, on/off valves, digital inputs, low-power valves, temperature sensors, 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 with standard EDDL or FDT/DTM technology. The ability of the fieldbus to transport power and communication makes process interfaces an economic solution even in 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. Valve Coupler FD0-VC-EX4.FF for four instrinsically safe low-power valves Pneumatic Interface for twelve pneumatic control valves 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 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 isolation 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 heavy duty valves on the sturdy Field Junction Box Choice of 3/2-way and 5/2-way solenoid valves FF modular I/O solutions provide additional power for driving sensors and actuators 20

24 FOUNDATION FIELDBUS Modular I/O There are still many field devices without direct fieldbus connection. Foundation fieldbus modular 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 signals to Foundation fieldbus. Due to its built-in power supply, Foundation fieldbus modular I/O is fully independent from the power available via the trunk and does not draw power from the bus. It is also compatible with all standard explosion protection methods. Foundation Fieldbus LB Modular I/0 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 Foundation Fieldbus FB Modular I/0 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 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, intrinsically-safe energy limitation, and allows plug-and-play connections at 100 Mbit/s 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. An energyefficient 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 Foundation Fieldbus LB Modular I/O Foundation Fieldbus FB Modular I/O Ethernet Isolator EI-0D2-10Y-10B Intrinsic safety is now available for 100 MBit fast Ethernet 21

25 MODEL NUMBER & DESCRIPTION HD2-FBPS HD2-FBPS HD2-FBPS HD2-FBPS HD2-FBCL ACC-MB-HSK ACC-MB-HDC MB-FB-1R MB-FB-2R MB-FB-4 MB-FB-4R Fieldbus Power Hub Power Supplies Isolated, VDC, 500 ma Isolated, VDC, 500 ma Isolated, FNICO Installation, VDC, 500 ma Isolated, 25 VDC, 360 ma Power conditioner, 500 ma Fieldbus Power Hub Motherboards & Accessories Shielding bar Diagnostic bus jumper cable Motherboard 1 redundant segment Motherboard 2 redundant segments Motherboard 4 simplex segments Motherboard 4 redundant segments MBHD-FB-4R MBHD-FB-4R.YO MB-FB-HO.SC FBTA-228-BPFB-R-4R MB-FB-4R.GEN ACC-MB-FOX1.0 KLD2-PC-1.1.IEC MB-FB-PC4 KLD2-FBPS HD2-DM-A DTM-FC-AD DTM-FC-AD.1 DM-AM-KIT DTM-FC.ADM KT-MB-DMA HD2-DM-B DM-AM-WPS COMM-KT ADM-COMM-KT ADM-COMM-NI-KT Compact motherboard, 4X redundant **only HD2-FBPS Yokogawa compact motherboard, 4X redundant **only HD2-FBPS Honeywell compact motherboard, 4X redundant Termination asssembly baseplate redundant FBM 228, no ADM Power Hub motherboard for FBM228 Cable to connect I/A series 8 position baseplate Power Supplies for Foundation Fieldbus DIN rail power conditioner, 1 A, 24 VDC DIN rail power conditioner motherboard for 4:1 A or 360 ma DIN rail power conditioner, 25 V, 360 ma Advanced Physical Layer Diagnostics Power Hub: Advanced Diagnostic Module (ADM) Professional DTM license for HD2-DM-A under 100 segments Professional DTM license for HD2-DM-A over 100 segments Mobile ADM Kit, includes ADM, carrying case, mounting bracket, cables & screw driver Professional DTM license for Mobile ADM Stand alone ADM Kit Basic diagnostic module AC adapter DM-AM Unit Fieldbus commissioning kit, 120 V 500 ma PS, 24 V fieldbus PS (No DM-AM/DTM license) Fieldbus commissioning kit, 120 V 500 ma PS, 24 V fieldbus PS, DM-AM/DTM license Fieldbus commissioning kit, 120 V 500 ma PS, 24 V fieldbus PS, DM-AM/DTM license & National Instruments FF H1 interface 22

26 FD0-VC-EX4.FF FD0-BI-EX12.PA FD0-VC-EX4.PA KMD0-FT-EX FN-FT-EX1.D.IEC RD0-FB-Ex4 F2D0-FB-Ex4.CG F2D0-FB-Ex4.CGB F2D0-FB-Ex4.CGS R2-SP-N4 R2-SP-N6 R2-SP-N8 R2-SP-N10 R2-SP-N12 DB-LB-I DP-LBF-I1.34 DB-LB DP-LBF-1.34 FN-LBF-D1.32 FN-LBF-I1.32 C-*- 300 C-*- 750 C-* Process Interfaces Foundation fieldbus valve coupler, Div 1 / Zone 1 area PROFIBUS PA sensor interface, Div 1 / Zone 1 area PROFIBUS PA valve coupler, Div 1 / Zone 1 area Terminators DIN rail fieldbus terminator, I.S. or safe area Screw mount terminator, I.S. or safe area IS Field Barriers DIN rail, Class I DIV 2/Zone 1, 4 outputs, 40mA, Aluminum enclosure, Class I DIV 2/Zone 1, 4 outputs, 40 ma, plastic CG Aluminum enclosure, Class I DIV 2/Zone 1, 4 outputs, 40 ma, NPB CG Aluminum enclosure, Class I DIV 2/Zone 1, 4 outputs, 40 ma, SS CG Segment Protectors Short circuit, DIN rail 4-spur, T-connect and terminator Short circuit, DIN rail 6-spur, T-connect and terminator Short circuit, DIN rail 8-spur, T-connect and terminator Short circuit, DIN rail 10-spur, T-connect and terminator Short circuit, DIN rail 12-spur, T-connect and terminator Fieldbus Surge Protection DIN rail base module, I.S. fieldbus surge protection I.S. protection module DIN rail base module, general-purpose fieldbus surge protection General-purpose protection module 1/2 NPT screw in surge protection, fieldbus general-purpose 1/2 NPT screw in surge protection, I.S. fieldbus Bulk Foundation Fieldbus Type A Cable Bulk FOUNDATION Fieldbus Type A /ER (Exposed Run) - Orange/Yellow/Blue Fieldbus Type A: shield TP, 18 AWG - PVC type PLTC, ITC cable, 300 m (1000 ft) Fieldbus Type A: shield TP, 18 AWG - PVC type PLTC, ITC cable, 750 m (2500 ft) Fieldbus Type A: shield TP, 18 AWG - PVC type PLTC, ITC cable, 1500 m (5000 ft) * OR = orange, * YL = yellow or * BL = blue C-OR-* MC-300 Bulk FOUNDATION Fieldbus Multicore - Orange Fieldbus Type A: * 2, 5 or 8 shield TP Pair, 18 AWG multicore PVC type A PLTC, ITC cable, 300 m (1000 ft) C-A-300 Bulk FOUNDATION Fieldbus Armored Type A - Black Type A fieldbus cable with aluminum armor, 18 AWG, PLTC/CM/ITC 300 m (1000 ft) 23

27 MODEL NUMBER & DESCRIPTION Armored Foundation Fieldbus Extension Cables & Cordsets See online part number configurator at C-V9F-G-BK- *M-ACL-V9M-G-FF-S 4-pole mini AL armored extension cable, S.S. coupling nut * = lengths m C-V9F-G-BK- *M-ACL-0-0-FF-S 4-pole mini female AL armored cordset, S.S. coupling nut * = lengths m FOUNDATION FIELDBUS TYPE A/ EXPOSED RUN EXTENSION CABLES & CORDSETS C-V9F-G-OR-*M-ER-V9M-G-FF-S 4-pole mini ( 7/8) extension cable, S.S. coupling nut C-V1F-G-OR-*M-ER-V9M-G-FF-S 4-pole micro ( M12) extension cable, S.S. coupling nut * = lengths m C-V9F-G-OR-*M-ER-0-0-FF-S 4-pole mini ( 7/8) cordset, S.S. coupling nut C-V1F-G-OR-*M-ER-0-0-FF-S 4-pole micro ( M12) cordset S.S. coupling nut * = lengths m Field Attachable Connectors Fieldbus Accessories V1-FA-M-B M12 (micro), male, NPB, shielded V1-FA-F-B M12 (micro), female, NPB, shielded V9-FA-M-B 7/8 (mini), male, NPB coupling nut shielded, straight V9-FA-F-B 7/8 (mini), female, NPB coupling nut shielded, straight V9-FA-M-S 7/8 (mini), male, plastic W/ SS coupling nut, straight V9-FA-F-S 7/8 (mini), female, plastic W/ SS coupling nut, straight V9-FA-M-B-R 7/8 (mini), male, plastic W/ NPB coupling nut, right angle V9-FA-F-B-R 7/8 (mini), female, plastic W/ NPB coupling nut, right angle V9-FA-M-S-R 7/8 (mini), male, plastic W/ SS coupling nut, right angle V9-FA-F-S-R 7/8 (mini), female, plastic W/ SS coupling nut, right angle Instrument Receptacles V9-R-M-S 7/8 (mini) male 1/2 NPT, 18 AWG, SS V9-R-M-A 7/8 (mini) male 1/2 NPT, 18 AWG, aluminum V9-R-M2-S 7/8 (mini) male 1/2 NPT, 18 AWG, SS, 2 wire V1-R-M-S 7/8 (mini) male 1/2 NPT, 18 AWG, SS, 4 wire V1-R-M2-S 7/8 (mini) male 1/2 NPT, 18 AWG, SS, 2 wire Other Accessories M20-CG-PLUG M20 cable gland plug enclosure V9-CL Mini connector lock, 10 pieces/bag VAZ-VR-1 M12 (micro) male receptacle cover V9-R-F-COV 7/8 (mini) female receptacle cover nylon JB-BR-TB Insertion bridge - 2 position, 10 pieces M16-NPT-CON Adapter - M16 to 1/2 NPT-brass C-V9-TEE-A 4-pole mini tee, aluminum nuts C-V9-TEE-S 4-pole mini tee, S.S. nuts 24