Practical steps for a successful PROFIBUS. Project... Presented by:- Derek Lane Systems Manager - WAGO Ltd. The PROFIBUS Group - UK PROFIBUS

Transcription

1 Practical steps for a successful Project... Presented by:- Derek Lane Systems Manager - WAGO Ltd The 1

2 Steps Application Areas for Starting Your Project Plant Layout Identify your equipment Network Types Design Issues Design Documentation Calculations Conclusions The 2

3 Application areas Manufacturing Automation Car manufacturing Bottling systems Brewing industry Car manufacture Storage systems Building Automation Traffic automation Heating, air-conditioning Water Treatment and sewage Process Automation Pipelines Water and sewage treatment Chemical and petrochemical plants Paper and textile industries Power industry and power distribution Paper and Printing Industry Building Automation Power plants Switchgear Food Industry Bottling Plants Precious metals recovery Polymer production and Storage The 3

4 Plant Layout The 4

5 The family original Factory Level Ethernet/TCP/IP TCP/IP/Ethernet Bus Cycle Time < 1000 ms CNC Area Controller PC/VME -FMS Cell Level -FMS or PROFINET Bus Cycle Time < 100 ms VME/PC PLC DCS Field Level -DP Bus Cycle Time < 10 ms DP / PA Link unit -PA The 5

6 The family common Factory/plant level TCP/IP Demanding tasks, extensive data Cell/control level PLC Ethernet PC DP/PA coupler High speed, modest data HMI DP Controllers DP PA Exi Field level Sensors Actuators Drives Remote Control Transmitters I/O valves DP cells The 6

7 The family new & future Factory/plant level TCP/IP Demanding tasks, extensive data Cell/control level PLC Ethernet PC High speed, modest data Controllers PROFInet DP HMI PROFInet PA Other fieldbus networks Exi Field level The Sensors Actuators Drives Remote Control Transmitters I/O AS-i valves DP cells 7

8 Detailed Network Requirements The 8

9 -DP topology The preferred topology is the Daisy Chain Bus The Beginning and end of each Bus segment, must be terminated One Segment may consist of max. 32 Loads inclusive of repeaters. Active Hubs allow 5 electrical separate segments (STAR) Station 1 Termination Termination Repeater Termination Repeater Termination Termination 61 Repeater Termination The

10 -DP segment length Baud Rate in kbit/s ,000 Line Length in mtrs (Cable Type A) The Length may be extended by using Repeaters a maximum of 9 repeaters may be used Baud Rates: 9.6k, 19.2k, 93.75k, 187.5k, 500k, 1.5M, 3M, 6M, 12M The 10

11 -DP cable termination Termination Resistors Station 1 Station 2 VP (6) 390 RxD/TxD-P (3) Red (3) RxD/TxD-P Data line (B) RxD/TxD-P (3) DGND (5) VP (6) RxD/TxD-N (8) Green (5) DGND (6) VP (8) RxD/TxD-N Data line (A) 220 RxD/TxD-N (8) Shield (1) Shielding (1) Shield protective ground protective ground 390 DGND (5) Cabling Bus termination for cable type A first & last devices on segment The 11

12 -DP defines three device types DP-Master Class 1 (DPM1) Central Controller which exchanges data with the distributed I/O devices (DP-Slaves) Several DPM1 are permitted. Typical devices are PLC, PC, VME DP-Master Class 2 (DPM2) Configuration, Monitoring or Engineering tool which is used to set up the network or parameterise / monitor the DP-Slaves The DP-Slave Peripheral device directly interfacing the I/O signals Typical devices are Inputs, Outputs, Drives, Valves, Operator Panels, etc. 12

13 Protocol Master Master PLC Token PC Master-slave protocol Slaves The 13

14 Network Configuration Master (PLC) Configuration tool GSD GSD GSD GSD GSD GSD General Station Description (GSD) files Slaves The 14

15 One solution for all Controller Standard Devices Failsafe Devices Safety I/O Standard I/O Drive Field Device Safety Process or Machine Safety up to SIL3, Cat.4 in Zone 0,1 en 2 Motion applications (synchronization between axes) The 15

16 IP67 The 16

17 IP67 M12 connector system The Devices often have two sockets for incoming and outgoing cables difficult to remove device without disrupting the bus. Special Tee connectors with can be used to connect to devices via a short spur line to overcome this problem. But do not use a spur line plug directly into device. Termination can be provided by special blind termination plugs. 17

18 Piggy Back Sockets The test tools must be able to be attached to each segment in order to see the waveforms. Thus every segment should be fitted with a piggy back socket for attachment of test tools. However, don t connect the test tool to the piggy back via a cable. This creates a stub line, which will itself generate reflections The 18

19 Isolating Connectors Properly wired plugs allow sections of the segment to be switched out. Connector with termination off Master Slave Slave Slave Slave Connector with termination on Properly terminated segment Isolated slaves The remaining part of the segment is always properly terminated. But only if the master is wired to the incoming connection! The 19

20 Isolating Connector The 20

21 Non Isolating Connector The 21

22 -PA Max 32 devices Hazardous Area up to 10 depending on load The 22

23 Good design practice Good design and layout with facilities to facilitate health checking and fault diagnosis. Good installation practice according to design drawings (also updating drawings as built ). Health checking to detect any non-critical communications and peripheral errors. Reporting of device diagnostics as they occur so that critical errors can be rapidly located and fixed and non-critical errors can be scheduled for maintenance. Development of a culture of good-practice in engineering and maintenance staff. The 23

24 Good design practice Stick to the rules Layout and installation guidelines freely available. Make sure that design staff know the problems and pitfalls of installation and maintenance - Installer training is appropriate for design staff. Include features to facilitate health checking and fault finding Without having to shut the network down. Ensure drawings and documentation are accurate and appropriate for ongoing maintenance. The 24

25 Good Design Practice It is well known that communication errors become more critical at higher bit rates. A good piece of advice when designing a network is thus to: Design for the highest possible bit rate. Operate at the lowest possible bit rate. In this way, we maximise the tolerance margin for communication faults which may occur during the life of the plant. The 25

26 Standards and Guidelines International Guidelines Installation Guideline for Cabling and Assembly Version 1.0.6, May 2006 Installation Guideline for Commissioning Version 1.0.2, November 2006 Plus many others MMU Installation Guideline Concise overview used in Certified Installer Course. IEC Electromagnetic Compatibility (EMC) Installation and Mitigation Guidelines, Part 2: Earthing and Cabling IEC Industrial Process Measurement and Control Digital Communications. In preparation. The 26

27 Device Profiles A device profile is an agreed way to map data onto the bus for a particular type of device. The profile can also define how diagnostic data, device settings and calibration data are accessed. Profiles are manufacturer independent and provide a generic device with which to communicate. Use of profiles means that devices from different manufacturers can be exchanged without changing software. The 27

28 Device Profiles The The use of device profiles also considerably simplifies system engineering and maintenance functions because all devices have similar functions, organised in the same way. All devices have the same look and feel. This is particularly beneficial with PA instruments and actuators. Also with drives and servos. Designing your system to use profiles where possible means that much less time will be spent looking at manufacturer s manuals. 28

29 Cyclic process value (profile PA-devices) Process value + Status information Status information: Quality Quality- Sub-status Limit if Quality = bad = bad = ok 0 1 = uncertain = configuration error, (value not accepted) 0 1 = low limited 1 0 = good (Not cascaded) = not connected 1 0 = high limited 1 1 = good (cascade) = device failure 1 1 = constant = sensor failure = no communication (last usable value) = no communication (no usable value) = out of service The Example: 923 mbar + quality=good, limit=ok 29

30 Spot the Errors The 30

31 Spot the Errors The 31

32 Spot the Errors The 32

33 Spot the Errors The 33

34 Documentation The 34

35 Documentation The 35

36 Documentation The 36

37 Documentation The 37

38 Documentation The 38

39 Documentation The 39

40 Conclusions The design of maintainable systems is not just a matter of following the specification. Often very subtle design and layout differences can make the difference between a network that can be maintained without shutting the plant down and one which cannot. Errors in layout are relatively common and can result in considerable time being wasted and errors being undetected. Designers need to undertake training in order to appreciate the impact of design decisions on installation and maintenance issues. The 40

41 Conclusions contd. The most common problems on control and automation networks are concerned with wiring. Many problems are introduced at the initial stages of layout and installation. Common pitfalls are often easily avoidable. Health checking is an essential stage in the commissioning process. Training is essential for network designers, installers and maintenance personnel. There is no golden rule on how to layout and install networks a range of good solutions exist. The 41

42 America Asia W- EU E- EU Presence and Support Worldwide 25 Regional Associations () worldwide 37 Competence Centers (PCC) in 22 countries 10 Test Laboratories (PTL) worldwide for certification tests Belgium PCC Denmark Finland France PCC Great Britain PCC Germany + Austria PCC, PTL Ireland Italy Netherlands PCC, PTL Norway Sweden PCC Switzerland PCC Czech Rep. Poland PCC Russia Slovakia China PCC, PTL Japan PCC, PTL Brazil USA PCC, PTL S. Africa PCC Australia/ New Zealand Korea S.-E.-Asia PCC Thailand PCC The = Regional Association PCC = Competence Center PTL = Test Laboratory 42

43 Product Spectrum Industrial PCs Frequency converters Ident systems Remote I/O Image processing Drives Displays Pressure sensors Encoder DCS PLC SCADA Transmitters Temperature sensors Ranging sensors Flow meters HMI Analyzers Light lattices Barcode scanners More than 24 Million devices installed more than 5,000 products available from more than 250 manufacturers The 43

44 Conclusion contd No matter how good the equipment or people Without:- 1. The Proper Planning 2. The Proper Preparation 3. The Proper Execution & Deployment You could possibly end up like this:- The 44

45 Conclusion - final British Commando s training near Poole Dorset A professionally trained and equipped fighting unit! Thank You for your time and attention.. The 45