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D800003X172

May 2010

Fieldbus Installations in a

DeltaV™ Digital Automation System


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Printed in the Republic of Singapore.

© Emerson Process Management 1996 - 2010. All rights reserved. For Emerson Process Management trademarks and service

marks, go to http://www.emersonprocess.com/home/news/resources/marks.pdf. All other marks are property of their respective

owners. The contents of this publication are presented for informational purposes only, and while every effort has been made to

ensure their accuracy, they are not to be construed as warranties or guarantees, expressed or implied, regarding the products or

services described herein or their use or applicability. All sales are governed by our terms and conditions, which are available on

request. We reserve the right to modify or improve the design or specification of such products at any time without notice.

Emerson Process Management

Distribution Ltd. Process Systems and

Solutions

Meridian East

Meridian Business Park

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Emerson a.s.

European System and Assembly

Pieštanská 1202/44

Nové Mesto nad Váhom 91528

Slovakia

Fisher-Rosemount Systems, Inc. – an

Emerson Process Management company

12301 Research Blvd.

Research Park Plaza – Bldg. III

Austin, TX 78759


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Contents iii

Contents

Welcome. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .viiAbout This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii

Assumptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ix

Conventions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ix

Chapter 1 Overview to Fieldbus Technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Redundant Series 2 H1 Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Fieldbus Power Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Redundant Fieldbus Power for Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Terminators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Wiring Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Topologies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Design Considerations, Restrictions, and Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Cable Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Cable Lengths . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Spur Lengths . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Selection Decisions and Trade-Offs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Geographic Distribution. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Control Strategy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Types of Field Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Recommendations for Installing a Fieldbus System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Grounding and Shielding of Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Overview to Installing a Fieldbus Segment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Installing Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Chapter 2 High Availability Fieldbus Applications. . . . . . . . . . . . . . . . . . . . . . . . . .27

Relcom Fieldbus Power System for Redundant Fieldbus Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27DC Power Considerations for High Availability Applications Using the Fieldbus Power System . . . . . . . . . . . 31

Short Circuit Protection with Megablocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Designing an Application for Short Circuit Protection Using Megablocks. . . . . . . . . . . . . . . . . . . . . . . . . . 34

Installing and Connecting the Fieldbus Power System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Installing and Connecting Megablocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Verifying the Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

High Availability Application Example for the Fieldbus Power System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Pepperl+Fuchs Fieldbus Power Hub for Redundant Fieldbus Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

http://ch2.pdf/http://ch2.pdf/


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iv Fieldbus Installations in a DeltaV Digital Automation System

DC Power Considerations for High Availability Applications Using the Fieldbus Power Hub . . . . . . . . . . 42

Short Circuit Protection with Segment Protectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Designing an Application for Short Circuit Protection Using a Segment Protector . . . . . . . . . . . . . . . . . . . 45

Installing and Connecting the Fieldbus Power Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46Installing and Connecting the Fieldbus Segment Protector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Verifying the Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

High Availability Application Examples for the Fieldbus Power Hub. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Chapter 3 Intrinsically Safe Fieldbus Applications . . . . . . . . . . . . . . . . . . . . . . . . .51DC Power Considerations for Intrinsically Safe Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Fieldbus Power Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53Field Barrier for Intrinsically Safe Applications in Hazardous Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Installing and Connecting the Fieldbus Power Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Installing and Connecting the Field Barrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55


Intrinsically Safe Application Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Chapter 4 Non-Incendive Fieldbus Applications . . . . . . . . . . . . . . . . . . . . . . . . . . .57DC Power Considerations for Non-Incendive Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Fieldbus Power Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Short Circuit Protection with Segment Protectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Installing and Connecting the Fieldbus Power Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Installing and Connecting the Fieldbus Segment Protector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59


Non-Incendive Application Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Appendix A Fieldbus Segment Checkout Procedure. . . . . . . . . . . . . . . . . . . . . . . .63Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Checkout Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Fieldbus Segment Checkout Form . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

Appendix B MTL Power Supplies for Intrinsically Safe Fieldbus Applications. . .71DC Power Considerations for IS Power Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

Host Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

Installing the MTL Intrinsically Safe Power Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

Intrinsically Safe Application Example with an MTL9122 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

Appendix C MTL Power Supplies for Non-Incendive Fieldbus Applications. . . . .79DC Power Considerations for Non-Incendive Power Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

Host Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82


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Installing the Non-Incendive Power Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

Non-Incendive Application Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

Application Example with two MTL9111-NI Power Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85Application Example with one MTL9112-NI Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

Appendix D Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89Troubleshooting with the H1 Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

Troubleshooting with the DeltaV Explorer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

Troubleshooting with DeltaV Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

Troubleshooting Common Fieldbus Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96Device or Segment Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

The H1 Card is not Communicating with the DeltaV System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

Communication Error or Incorrect Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

Problems Commissioning Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

Missing Values in Resource or Transducer Block. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

Simulate not Working in Control Studio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

Trouble-Shooting Q and A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

Fieldbus Third Party Products . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .103

References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .107


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Welcome vii

Welcome

Welcome to the Emerson Process Management DeltaV digital automation system. The DeltaV system offers easy-to-install hardware and powerful, user-friendlysoftware for advanced process control scaled to the system size you need.

About This Manual

This manual provides an overview of the fieldbus technology and presents asimplified approach to installing and using a fieldbus system with the DeltaVsoftware. For complete information on the fieldbus protocol, refer to the FieldbusFoundation. This manual contains the following sections:

Chapter 1, Overview to Fieldbus Technology , provides general information on fieldbuscomponents and design considerations and an overview on installing a fieldbussegment.

Chapter 2, High Availability Fieldbus Applications , provides instructions for

installing fieldbus components for applications requiring redundant Series 2 H1cards, redundant fieldbus power, and short circuit protection.

Chapter 3, Intrinsically Safe Fieldbus Applications , provides instructions for installingfieldbus components for applications requiring Intrinsically Safe protection.

Chapter 4, Non-Incendive Fieldbus Applications , provides instructions for installingfieldbus components for applications requiring Non-Incendive protection.

The Appendices include a fieldbus segment checkout procedure, atroubleshooting guide, and additional Non-Incendive and Intrinsically Safeapplication examples.

Other sections contain references for locating recommended third party productsreferences for additional information on the fieldbus protocol.


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viii Fieldbus Installations in a DeltaV Digital Automation System

This manual documents the use of Third Party Products for fieldbus installations. Thereader should understand that this indicates only that the product has been tested forinteroperability with the DeltaV system. EMERSON PROCESS MANAGEMENT

PROVIDES NO WARRANTY OF DESIGN, MATERIAL, WORKMANSHIP,PERFORMANCE, FITNESS, MERCHANTABILITY OR OTHERWISE INCONNECTION WITH SUCH PRODUCTS. Warranties for Third Party Productsmay be obtained only from the applicable manufacturer.


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Welcome ix

Assumptions

It is assumed that you have read the Site Preparation Guide for DeltaV Automation Systems

and have followed the instructions for properly preparing your site for electricalpower and grounding before installing your DeltaV System. It is also assumed thatyou have read the Installing Your DeltaV Digital Automation System manual and havecorrectly installed your DeltaV system. Contact your Emerson Process Managementsales office for these documents.

This manual, Fieldbus Installations in a DeltaV Digital Automation System , shows factorytested and supported wiring connections. If your system requires a different

configuration, contact your Emerson Process Management representative or salesoffice for help with design or review. It is assumed that all installation andmaintenance procedures described in this document are performed by qualifiedpersonnel and that the equipment is used only for the purposes described.

Conventions

Warnings, cautions, notes and procedures are used in this manual to emphasizeimportant information.

Warning A warning describes a critical procedure that must be followed to prevent asafety risk or equipment damage.

Caution A caution describes a procedure that must be followed to prevent equipmentmalfunction.

Note A note is a procedure, condition, or statement that will help you understand and operate your system.

Itemizes steps necessary to execute installation procedures.


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Overview to Fieldbus Technology 11

Chapter 1 Overview to Fieldbus Technology

This document provides the information required to select components from

Emerson Process Management and third party suppliers to design and install a working fieldbus segment. It presents a simplified approach and covers a variety ofapplications.

Figure 1 Fieldbus Segment

s

s

Fieldbus

IPM IPM

FPS-RCI

A 1 A 2

A

BPowerIn

Series2

FieldbusH1

Power/Active

Error

Port 1

Port 2

Series2

FieldbusH1

Power/Active

Error

Port 1

Port 2

RedundantSeries 2 H1 Cards

RedundantFieldbuspower supply

H1 Fieldbus

Segment

WorkstationDeltaV


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12 Fieldbus Installations in a DeltaV Digital Automation System

Several documents exist that cover the technical aspects of fieldbus in great detail. Forthe purposes of this discussion, fieldbus technology allows devices from multiplemanufacturers to connect to a communications bus. The communications protocol is

designed to allow multiple devices to share information based on a schedule that isexecuted by a Link Active Scheduler (LAS).

A Link Master device controls when devices access the fieldbus and executes the linkschedule which synchronizes communications with function block execution on thefieldbus. The H1 card or any field device that supports Link Master functionality canfunction as a Link Master device. Only one Link Master device can be active at a timeon the fieldbus segment. This device is called the LAS. The DeltaV system can

configure one Link Master device to function as the primary Link Master device. When the primary Link Master device is attached to the fieldbus, it takes over as theLAS. The H1 card always functions as the primary Link Master. When the H1 card isredundant, the secondary H1 functions as the primary Link Master if the primary H1card fails. All other Link Master devices are backup Link Master devices that can takeover as LAS only if the primary Link Master device fails. One backup Link Masterfield device is supported per fieldbus segment. The fieldbus devices communicate on

a schedule (executed by the LAS) as required to implement the control strategy. A key benefit of fieldbus technology is interoperability – the ability to operatemultiple devices, independent of manufacturer, in the same system, without loss offunctionality.

This document is based on the following assumptions about a fieldbus application orinstallation:

Each device has an average load of 20 mA. Devices are connected at one end of the segment and the fieldbus power supply is

connected at the other end of the segment.

Spur lengths are short – 10 meters.

If these assumptions are incorrect for your application, this document attempts toprovide information that will help you to resolve the issues and design a suitable

solution. For complete information on the fieldbus protocol, refer to the FieldbusFoundation.

The applications in this document make use of redundant Series 2 H1 cards,redundant fieldbus power supplies, and device connection blocks with short circuitprotection. For applications that do not require this level of high availability, simplexH1 cards, simplex fieldbus power supplies, and device connection blocks withoutshort circuit protection are also available.


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Components

The following sections describe the primary components in a fieldbus segment:

Redundant Series 2 H1 card

Fieldbus power supply

Terminators

Wiring components

Redundant Series 2 H1 Card

The DeltaV Series 2 H1 interface card is the starting point for the communications ona fieldbus segment. The DeltaV system provides initialization, diagnostics, and run-time monitoring for a fieldbus segment. Depending on the control strategy, theDeltaV system either executes the control algorithm or, if control resides in thefieldbus devices, displays the ongoing parameters.

The Series 2 H1 card supports redundancy. A Series 2 H1 card reports its operating

mode (simplex or redundant) to the DeltaV controller (MD controller for Series 2 H1in redundant mode) based on the type of terminal block on which it is installed. Whena redundant pair (an Active and a Standby Series 2 H1 card) is installed on theRedundant H1 terminal block, it reports itself as operating in redundant mode. Whena single Series 2 H1 card is installed on the Series 2 H1 terminal block, it reports itselfas operating in simplex mode.

For redundant applications, the redundant Series 2 H1 cards ensure uninterruptedcommunications between a fieldbus segment and the DeltaV system. For applicationsrequiring protection such as high availability applications, the redundant Series 2 H1card can be used in conjunction with redundant power and short circuit protection.Figure 7 on page 38 and Figure 10 on page 49 show the use of Series 2 redundant H1cards in high availability applications. Figure 2 shows a redundant Series 2 H1 card.


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Figure 2 Redundant Series 2 H1 Card

The Series 2 H1 card requires 12 mA of fieldbus power in simplex mode and anadditional 12 mA of fieldbus power (24 mA total) in redundant mode. Be sure toaccount for the additional power requirements in your segment design.

The Installing Your DeltaV Digital Automation System manual contains specifications and wiring and pinout diagrams for the H1 card and the Series 2 H1 card (in both Simplexand Redundant modes). In addition, the manual contains specifications and pinoutdiagrams for the H1 terminal block, the Series 2 H1 terminal block, and theRedundant H1 terminal block.

Note The H1 card is the only primary Link Master allowed on the fieldbus segment. TheDeltaV system supports one backup Link Master device on each fieldbus segment.

Series 2

FieldbusH1

Power/Active

Error

Port 1

Port 2

Series 2

FieldbusH1

Power/Active

Error

Port 1

Port 2


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Fieldbus Power Supplies

The fieldbus specifications call for a power supply on the segment to provide power

to all devices that are not self-powered. A standard DC power supply connecteddirectly to the segment would attempt to regulate out the digital communicationsbetween devices on the segment. To prevent this, a power supply with powerconditioning that contains a specific impedance profile must be installed between thebulk power supply and the fieldbus segment. A fieldbus power supply provides therequired conditioning and powers the individual field devices. Fieldbus powersupplies are available for simplex, redundant, Intrinsically Safe, and Non-Incendiveapplications.

Important In addition to the conditioning requirement, neither signal on the segment can beconnected directly to ground. The power supplied to the segment must be isolated from ground and from any other uses.

The power requirements for fieldbus devices differ, but the average is 20 mA perdevice. The DeltaV system supports 16 field devices on a segment.

Redundant Fieldbus Power for Applications

Emerson Process Management recommends the use of redundant fieldbus power inconjunction with short circuit protection for the following types of fieldbusapplications:

High Availability

Intrinsically Safe

Non-Incendive

When redundant fieldbus power is used, the process remains in control if one supplyfails because the other supply continues to provide power to the devices on thesegment.

High Availability Fieldbus ApplicationsFor information on high availability applications refer to “High Availability Fieldbus

Applications” on page 27.

Intrinsically Safe Fieldbus Applications

For information on Intrinsically Safe fieldbus applications for use in both entity andFISCO (Fieldbus Intrinsically Safe COncept) IS applications, refer to “Intrinsically

Safe Fieldbus Applications” on page 51.


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Non-Incendive Fieldbus Applications

For information on Non-Incendive applications refer to “Non-Incendive Fieldbus Applications” on page 57.

Terminators

A fieldbus segment acts as a transmission line for data communications between the various devices. A terminator balances the impedance at each end of a transmissionline to ensure reliable communications. Fieldbus power supplies and deviceconnection blocks may provide a fixed or switchable terminator for one end of the

segment. Ensure that each segment is terminated in two places.

Wiring Components

Emerson Process Management recommends a family of connection blocks and cablecomponents for use in installing your fieldbus segment. These components includestandard junction blocks, junction blocks with short circuit protection, and

terminators. These components can be used with fieldbus cable that you can purchasefrom recommended suppliers. All of these components are selected to not degradethe communications between devices.


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Topologies

A simple view of a fieldbus segment is shown below. This picture shows a bulk power

supply, fieldbus power supply, two terminators, two field devices, and an H1 host. Thefieldbus power supply provides the power required for the devices and contains theconditioning element.

In this document, the wire or cable between the two terminators is referred to as thetrunk, and any connections that branch off from the trunk are referred to as spurs. Inthe image above, the fieldbus power supply, the H1 host, and field devices, are shownconnected between the terminators. Any of these three devices can be connected asspurs between the terminators or as spurs beyond the main trunk.

There are several ways to design a fieldbus segment topology: point-to-point, chicken-foot, daisy chain, trunk with spurs, and tree. This document focuses on a trunk withspurs topology and takes into account the different types of wiring that are available

for fieldbus segments, wire distribution issues, length restrictions, and power issues.

Note Daisy chaining from device to device is not recommended. The wiring strategy detailedwithin this document does not lend itself to daisy-chaining from one device to the nextwithin the spur.

To minimize the possibility of communication problems, Emerson ProcessManagement recommends that the trunk be a continuous run of the same type of

cable. Fieldbus Type A cable is recommended. Devices can be connected anywherealong the trunk, following the rules associated with spur length.

T

Bulk power supply

Fieldbus

power supply

T

H1 host


18/112


Fieldbus was designed to operate properly on a variety of existing plant wiring and it ispossible that your specific application could operate on existing runs of instrumentcable. However, as the cable length and number of devices increase, it is possible to

exceed the reliable operating margins of the fieldbus segment if you do not keep theapplication-specific requirements in mind when you design the segment.

The following sections describe the restrictions on the total length of spurs on asegment, the number of devices allowed on individual spurs, and the impact on thatindividual spur’s length.

Design Considerations, Restrictions, and Limitations There are some restrictions around cable type, cable and spur length and DC powerthat you should be aware of when planning a fieldbus segment.

Cable Type

The fieldbus specifications recommend that new fieldbus Type A cable be used

whenever possible. The standard fieldbus Type A cable provides a maximum distanceof 1900 meters for a single segment. Before using any other type of cable, verify thecable characteristics to determine its suitability and the maximum distances associated

with its use.

When upgrading a system to fieldbus devices, you can use existing instrument wiringsuch as multi-conductor cable if you require a significantly reduced cable length.

Where it is required, we recommend at a minimum the use of Type B cable which hasmultiple twisted pairs with an overall shield. This type still provides reasonabledistance at 1200 meters.

Since the DeltaV Controller and I/O can be remotely mounted, there should beminimal need for the multi-conductor cables.

Note For new and upgrade installations, Emerson Process Management highly recommends

only new fieldbus Type A cable for the trunk and spurs.


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At a minimum, use new fieldbus Type A cable for all trunk portions of the segment,and use existing field wiring only for spurs of short length. Table 1 providesinformation on fieldbus Type A cable.

For further information on types of cable, distances, and other specifications, contactthe Fieldbus Foundation.

Cable Lengths

The length of the cable is calculated as the overall length of the main trunk cable plusthe length of all of the spur cables. This document assumes short spur lengths of 10meters and the calculation for the main trunk should be sufficient in many cases. Ifyou are using longer spur cables, include their length in the overall calculation. Referto the next section for more information on spur length.

Table 1 Specifications for Fieldbus Type A Cable

Item Specification

Cable SP50 fieldbus Type A 18 AWG

1 twisted pair with foil shield and stranded

drain wire tinned stranded conductors

105 C

Approvals UL CSA or C(UL)

Max Distance Meters/

(Feet)

1900/(6270)

Characteristic

impedance

100

Resistance Ohms/km 22 (loop resistance is 44 ohms/km)

Attenuation db/km 3 attenuation @ 39K Hz


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Spur Lengths

A spur is a drop off of the main trunk (the cable between the two terminators). If you

have a choice about spur length, shorter is better. The total spur length is limitedaccording to the total number of devices on the segment.


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Selection Decisions and Trade-Offs

The plan and design of the individual segments depend upon several criteria. Some of

the things that need to be taken into account are: Geographic distribution of the field devices

Control strategy

Types of field devices

Geographic Distribution

Generally speaking, you can connect a maximum of 16 field devices plus one H1 card(simplex or redundant) to a fieldbus segment. Geographic distribution of the fieldbusdevices can reduce the number of devices when the length of the cable exceeds 400 to500 meters. In general, short spurs that allow longer trunk lengths are recommended.For additional information on distances for:

High availability applications, refer to Table 5 on page 43.

Intrinsically Safe applications, refer to Table 6 on page 53

Non-Incendive applications, refer to Table 7 on page 59.

Control Strategy

When you design your control strategy, consider loop execution rates, the number offunction blocks running on the segment, and pre and post processing calculations. An

H1 card can support two independent fieldbus segments. Refer to Books Online formore information on designing a fieldbus control strategy.

Types of Field Devices

Be sure to verify that the field devices you intend to connect to the segment aresupported by the DeltaV system and account for increased power if they draw more

than the assumed 20 mA from the bus.


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Recommendations for Installing a Fieldbus System

This section provides recommendations for installing the system, a brief description

of the steps required, and includes detailed instructions and diagrams for installation.

Warning This installation procedure contains steps that are to be performed in non-hazardous or safe locations only. For installations in hazardous locations,follow your plant's procedures to make the area safe during installation.

Note It is highly recommended that you follow the segment checkout procedure in Appendix A prior to system startup.

Tools

Installing fieldbus devices and segments is similar to installing other types of devicesor products. Many of the standard electrical tools are required for the installation.

However fieldbus is also a communications network. In addition to the standardelectrical tools (voltmeter, wire cutter, wire stripper, pliers, and screwdrivers) you willneed the following tools for troubleshooting communications networks:

Fluke 123 or 124 Digital Scope Meter or equivalent scope with resistance, DC voltage, and capacitance measurement capability. (Most capacitance metersmeasure components only and may not provide the expected results whenmeasuring a complete segment.)

Grounding and Shielding of Cable

Important Fieldbus segments should never have either conductor grounded. The shield for thesegment wiring should be continuous and connected to ground in only one place: either atthe shield bar beneath the H1 card or at the fieldbus power supply. Making more than

one connection to ground on the shield can cause a ground loop to form and the unexpectedcurrent flow could disrupt communications.


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Overview to Installing a Fieldbus Segment

This section lists the basic steps for installing a fieldbus segment.

1. Route the fieldbus cable and ensure that each segment is properly terminated.

2. Install the Series 2 H1 card(s), connect the card(s) to the segment, and enable theappropriate ports.

Remember to allow for 12 mA of fieldbus power for the Series 2 cards: (12 mA insimplex mode and 24 mA total in redundant mode).

3. If the devices have previously had their device tags assigned:• connect all the devices to the segment.

• commission the devices, following the instructions in the DeltaV Exploreronline help.or

4. Most devices ship with a label on which is printed the device’s serial number anddevice ID. The label is used to identify the device in the field. Assign the devicetags based on the labels, and then:• connect all the devices to the segment.

• commission the devices, following the instructions in the DeltaV Exploreronline help.or

5. If the devices have not had their device tags assigned or there is no label with

device ID and serial number:• connect the devices to the segment one at a time.

• verify that each device appears in the de-commissioned devices list for theport.

• commission the devices, following the instructions in the DeltaV Exploreronline help.

6. Perform the installation checkout in Appendix A.

Tip Without knowing the device ID, it is difficult to determine which device you areattempting to commission if you connect several devices of the same type to the segment atthe same time.


24/112


Figure 3 provides an overview of cable connections between a redundant Series 2 H1card, redundant fieldbus power supply, megablock, and terminator. The terminator inthe power supply and external terminator are used in this application.

Figure 3 Installation Overview

1 2 3 6 7 84 5

Port

1

Port

2

S

S

MegablockMB 8-SG

4

1 2 3

5 6 7 8

P o w e r

F C S - M B 8 - S G

S S S S S

S S S S S

Trunk Trunk

GND

S

S

s

s

Fieldbus

IPM IPM

FPS-RCI

A 1 A 2

A

BPowerIn

Series 2

FieldbusH1

Power/Active

Error

Port 1

Port 2

Series 2

FieldbusH1

Power/Active

Error

Port 1

Port 2

Ground

F C S - M B T T e r m i n a t o r

R e l c o m I n c .

S

RedundantSeries 2 H1 Card


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Installing Cable

Installing cable to the H1 Card

Refer to Figure 3 on page 24.

Wire the segment paying close attention to the signal wiring positive (+) and negative(-) connections.

Installing cable to the power supply

For general information, refer to Figure 3 on page 24.

For applications using the Relcom Fieldbus Power System, refer to “Installingand Connecting the Fieldbus Power System” on page 35.

For applications using the Pepperl+Fuchs Fieldbus Power Hub, refer to“Installing and Connecting the Fieldbus Power Hub” on page 46

Installing cable for short circuit protection

Short circuit protection can be provided by Megablocks, Segment Protectors, andField Barriers.


For applications using Megablocks, refer to “Installing and ConnectingMegablocks” on page 36.

For applications using Segment Protectors, refer to “Installing and Connectingthe Fieldbus Segment Protector” on page 47.

For applications using Field Barriers, refer to “Installing and Connecting the FieldBarrier” on page 55.

Important If using ferrules on the wires, use ferrules with an uninsulated shaft of adequate lengthto prevent the ferrule insulator from interfering with the connectors.


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Installing cable to the terminators


Once the segment layout is determined, a terminator must be used at both the powersupply side and the field side of the main trunk cable. The segment layout willdetermine the location of the terminators and whether or not the integratedterminator on the power supply or device connection block is used. Remember thatspur cables are not part of the main trunk and are normally not considered in theplacement of the terminators.

Installing cable to shield ground


For applications using Megablocks, refer to “Installing and ConnectingMegablocks” on page 36.

For applications using Segment Protectors, refer to “Installing and Connecting

the Fieldbus Segment Protector” on page 47.

For applications using Field Barriers, refer to “Installing and Connecting the FieldBarrier” on page 55.

Refer to “Checkout Procedure” on page 63 after installing the cable to ensure that thecable is correctly installed and that the segment is properly grounded, powered, andisolated.


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High Availability Fieldbus Applications 27

Chapter 2 High Availability Fieldbus Applications

This chapter provides information about fieldbus applications that require high

availability. A high availability application includes a redundant Series 2 H1 card andredundant fieldbus power. In addition, a high availability application includes shortcircuit protection for the segment.

The first application shown in this chapter uses the Redundant Fieldbus PowerSystem (FPS-Series) and Megablock with SpurGuards from Relcom, Inc. The secondapplication uses the FieldConnex® Fieldbus Power Hub and FieldConnex® SegmentProtector from Pepperl+Fuchs. The Relcom power supply is a redundant fieldbus

power supply for a single segment with options for multi-segment use. ThePepperl+Fuchs power supply is a redundant fieldbus power supply for up to foursegments with options for single-segment use.

Refer to the Relcom and Pepperl+Fuchs documentation for additional informationon their products.

Relcom Fieldbus Power System for Redundant FieldbusPower

The FPS-I connects to one or two +24 VDC input power supplies and providesredundant fieldbus power to a single fieldbus segment. A single FPS-I consists of:

A Redundant Coupler (RC)

Two isolated fieldbus power modules (IPMs) Table 2 shows the FPS-I specifications.

Table 2 Fieldbus Power System Specifications

FPS-I Specification

Input voltage 24 VDC (18-30 VDC)

Fieldbus output current 350 mA @ 25-28 VDC

Maximum power dissipation 4.5 W max @ rated output

Dimensions 4.9 cm. x 10.1 cm. x 13.3 cm. (1.95 in. x 4 in.

x 5.25 in.)

Operating temperature range -40 to 60 º C

Alarm contact rating 1 A max @ 30 VDC max


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Figure 4 Fieldbus Power System

The FPS-I consists of two isolated power modules (IPM) that plug into eachRedundant Coupler (RC). The IPMs are removable under power. The RCs aremounted on a DIN rail. One RC is used for each fieldbus segment. RCs can beconnected together with pre-made jumpers to add additional fieldbus segments asshown in Figure 5 on page 30. One fieldbus terminator is built into each RC.Remember that each segment must have two terminators.

s

s

Fieldbus

IPM IPM

FPS-RCI

A 1 A 2

A

BPower In

Alarm jumper

Jumper connections

Isolated Power Modules

24 V B

24 V A

Alarm

Redundantcoupler

FieldbusSegmentConnection

H1 Connection

Terminator


29/112


Refer to Figure 4. Each RC has:

Two, 3-position pluggable connectors. One connector is intended for the H1 hostand the other for the fieldbus segment.

Two 6-position pluggable connectors for two nominal 24 VDC input powersources and an alarm circuit. When the FPS-I is powered and functioning withinits specifications, the alarm circuit provides a closed contact circuit. A failure ineither input power supply, either IPM, or an over-current or short on any fieldbusoutput, opens the alarm circuit. The alarm circuit is galvanically isolated from thefieldbus segments and input power supplies. Connect the alarm pins together tocomplete the circuit. When using multiple Fieldbus Power Systems, connect

together the last alarm pins in the group as shown in Figure 5.

Figure 5 shows multiple Fieldbus Power Systems connected together with pre-madejumpers. To add RCs without removing power to the other units when using multipleFieldbus Power Systems, wire the two power sources to both ends of the group.


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Figure 5 Multiple Fieldbus Power Systems

Refer to “Installing and Connecting the Fieldbus Power System” for installationinformation.

s

s

Fieldbus

IPM IPM

FPS-RCI

A 1 A 2

A

BPower In

s

s

Fieldbus

IPM IPM

FPS-RCI

A 1 A 2

A

BPower In

s

s

Fieldbus

IPM IPM

FPS-RCI

A 1 A 2

A

BPower In

Last alarm jumper

24 V A

FieldbusSegmentConnections

H1 Connections Jumper Connections

24 V B

Alarm

24 V A

24 V B


31/112


DC Power Considerations for High Availability Applications

Using the Fieldbus Power System

The available power to a field device depends on the length and resistancecharacteristics of the fieldbus cable. The formula for the calculations in Table 3 onpage 32, which shows the maximum distance for a given load on the Fieldbus PowerSystem, is based on the following assumptions:

Power Supply Voltage = 25.0 VDC @ 350 mA

Minimum Device Voltage = 9 VDC (calculations use 9.5 VDC)

Maximum Voltage drop from cable = 15.5 VDC Each device has an average load of 20 mA

Fieldbus Type A 18 AWG cable @ 22 ohms/km (44 ohms/km loop resistance) at22°C

Devices are connected on one end of the cable and the Fieldbus Power System isconnected on the other end of the cable

Maximum Distance (km) = (Allowed Loop V drop / Loop current) / Loopresistance per km

There will be different restrictions and limitations on your segment if theseassumptions do not hold for your segment layout. If your devices average more than20 mA per device, reduce the maximum cable length indicated in the table for thatnumber of devices or reduce the number of devices on the segment. Refer to thedevice documentation for information on current requirements for the device.

When referring to Table 3, remember that the H1 card requires 12 mA of fieldbuspower in simplex mode and an additional 12 mA of fieldbus power (24 mA total) inredundant mode. Table 3 includes the maximum distance, in meters, for applications

with and without Megablocks with SpurGuards. The distance is reduced to allow foran application design that uses a Megablock with SpurGuards to prevent a short onthe spur from disrupting the trunk.


32/112


.

Table 3 Distance per Load on the Fieldbus Power System with and without Megablocks with SpurGuards

Number ofDevices / Load

(mA)

Power Supply Load (mA) Maximum Distance without Megablock

with SpurGuards

(meters)

Maximum Distance with Megablock

with SpurGuards

(meters)Series 2 H1

Simplex

Series 2 H1

Redundant

1 / 20 32 44 1900 1900

2 / 40 52 64 1900 1900

3 / 60 72 84 1900 1900

4 / 80 92 104 1900 1900

5 / 100 112 124 1900 1850

6 / 120 132 144 1900 1670

7 / 140 152 164 1900 1520

8 / 160 172 184 1855 1395

9 / 180 192 204 1725 1290

10 / 200 212 224 1570 1200

11 / 220 232 244 1440 1120

12 / 240 252 264 1330 1050

13 / 260 272 284 1240 990

14 / 280 292 304 1155 N/A

15 / 300 312 324 1085 N/A

16 / 320 332 344 1020 N/A


33/112


Short Circuit Protection with Megablocks

The Relcom Megablocks with SpurGuards (SG) connect field devices to the fieldbussegment cable and provide short circuit protection to the segment. Figure 6 shows anFCS-MB8- SG for eight devices. The Megablock mounts on a DIN rail and requires aconnection to a terminator (+, -, and S) from one of the trunk connectors. To connectmultiple Megablocks together, use a short jumper cable between the trunk connectorson the Megablocks.

Figure 6 Megablock Spur Guard for 8 Devices

Trunk Trunk

F C S - M

B 8 - S

G 4 5 6 7 8

1 2 3

P o w e r

S S S S S

S S S S S


34/112


Designing an Application for Short Circuit Protection Using

Megablocks

When designing an application that uses a Megablock for short circuit protection,allow an additional 60 mA in the design to give the power supply the additionalcurrent capability to support a short circuit in one device (should it occur) andcontinue to power the segment without interruption. Normally a 0.5 voltage drop(assuming a 20 mA device) occurs across the Megablock to the device. An additional

voltage drop occurs during a short circuit condition. To prevent devices fromdropping off the segment because of reduced voltage, be sure that the applicationdesign allows for the voltage drop in both the normal and short circuit condition. Usethe following calculation to calculate the short circuit voltage drop to the farthestdevice:

.060A X (44 ohms/km) X distance in km

The following example calculates the voltage drops on 0.5 km segment to the farthestdevice:

Normal voltage drop = 0.5 Volts

Short circuit voltage drop =.060A X (44 ohms/km) X.5 km = 1.32 Volts

Total voltage drop = normal voltage drop + short circuit voltage drop = 1.82 volts.

This calculation is based on a design that allows for one short circuit in a runningsegment. For example, a situation in which an inadvertent shorting of a device occursduring routine replacement on an operating system. The calculation does not allowfor multiple short circuit conditions in a new installation that has not been verified

with the segment checkout procedure. Table 3 includes maximum distances when theapplication uses a Megablock with SpurGuards.

I t lli d C ti th Fi ldb P S t


35/112


Installing and Connecting the Fieldbus Power System

To install the Redundant Coupler and connectors

1. Attach the top latch of the Redundant Coupler onto the DIN rail and push theunit into place.

2. Plug the IPMs, H1 connector, fieldbus segment connector, and the input power/alarm circuit connector into the Redundant Coupler.

To connect the Fieldbus Power System (FPS-I)


1. Connect the primary 24 VDC input positive (+) to the 24 V A + terminal and theprimary 24 VDC input negative (-) to the 24 V A - terminal.

2. Connect the secondary 24 VDC input positive (+) to the 24 V B + terminal andthe secondary 24 VDC input negative (-) to the 24 V B - terminal.

3. For a single unit, connect the alarm wires and short the alarm pins on theopposite side of the fieldbus power system.

4. Connect the segment positive (+) wire to the fieldbus segment + and thesegment negative (-) wire to the fieldbus segment -.

5. Connect the segment shield wire (S) to the fieldbus segment S.

6. Connect the H1 card positive wire (+) to the H1 + and the H1 card negative wire (-) to the H1 -.

7. Connect the H1 card shield wire (S) to the H1 S.

Note Ground the shield at only one point — usually at the H1 card on the shield ground bar.


36/112


To connect additional Fieldbus Power Systems


1. Install the second Redundant Coupler (RC 2) onto the DIN Rail next to RC 1 andplug in the IPMs, H1 connector, and fieldbus segment connector.

2. Insert one end of the pre-made jumper into the right-hand side power and alarm wiring connector on RC1 and the other end into the left-hand side power andalarm wiring connector on RC 2.

3. Connect the segment wiring and H1 cards.

4. Follow steps 1-3 for each additional RC.

5. Connect the last alarm pins in the group together to complete the circuit.

A maximum of eight Fieldbus Power Systems can be connected together in a group.

Installing and Connecting MegablocksRefer to Figure 6 on page 33.

To install and connect a Megablock

Notice that the Trunk connectors are black and the spur connectors for the devices

are gray.

1. Attach the top latch of the Megablock onto the DIN rail and push the unit intoplace.

2. For the Trunk connector (black): connect the positive (+) segment wire to thepositive, connect the negative (-) segment wire to the negative, and connect thesegment shield (S) to the S.

3. For each device connector (gray): connect the positive (+) spur wire to thepositive, connect the negative (-) spur wire to the negative, and connect theshield wire (S) to the S.

4. If this Megablock is the end of the segment, connect a terminator (Relcom FCS-MBT) at the end of the Trunk and at a ground connection. Use a properly sizedground wire to reduce the risk of a surge affecting the segment.

5 If the segment continues and connects to another Megablock continue the


37/112


5. If the segment continues and connects to another Megablock, continue the Trunk by connecting it to the next Megablock and make the connectionsdescribed in steps 2 and 3.

6. At each device, ensure that the shield is isolated and not connected to the device.

7. If this Megablock is the end of the segment, connect a terminator (Relcom FCS-MBT) at the end of the Trunk and at a ground connection. Use a properly sizedground wire to reduce the risk of a surge affecting the segment.

Verifying the Installation

Use the segment checkout procedure on page 63 to measure resistance, capacitance,DC voltage, and the AC waveform (steps 1, 2, 4, and 5) with only one of the IPMsinstalled. Then, measure DC voltage and the AC waveform (steps 4 and 5) again withboth IPMs installed. Verify that the measured DC voltage allows for the additional

voltage drop if a short circuit should occur.

High Availability Application Example for the Fieldbus PowerSystem

Figure 7 shows an application that uses a redundant pair of Series 2 H1 cards withredundant fieldbus power for both segments and short circuit protection for deviceson a long (0.5 km) trunk cable. If a failure occurs on an H1 card, a 24 V power supply,or a fieldbus power supply, the segments continue to operate as expected. A status

indication on connected alarms alerts the operator that an error has occurred. It isassumed that the application design follows the criteria specified in “Designing an

Application for Short Circuit Protection Using Megablocks”. Therefore, if a shortoccurs when a device is installed or removed from the segment, only that device isaffected; the rest of the segment is unchanged.


38/112


Figure 7 High Availability Application Example

RedundantSeries 2 H1cards

Port 1 Port 2

IPM IPM

s

IPM IPM

s

GND

H1H1

0.5 km CablePort 1 Port 2

Secondary24 VDC

Primary24 VDC

Shielded pair with drain wire

Alarmcontacts

Secondary

24 VDC

Primary24 VDC

Jumper

Fieldbuspower supplies

Shieldedpair withdrain wire

MB8 - SGMegablock

MB8 - SGMegablock

Terminator

Surgeprotectionground

Devices

Devices

Carrier shield bar

GND

Pepperl+Fuchs Fieldbus Power Hub for Redundant Fieldbus


39/112


Pepperl+Fuchs Fieldbus Power Hub for Redundant Fieldbus

Power

The Fieldbus Power Hub connects to one or two +24 VDC input power supplies andprovides redundant fieldbus power to up to four fieldbus segments. A Fieldbus PowerHub system includes:

Fieldbus Motherboard - MB-FB-4R

Galvanically Isolated Fieldbus Power Supply Modules - FBPS-1.500 (two persegment for four segments maximum)

Fieldbus Diagnostic Module - DM-B Table 4 shows specifications for the Fieldbus Power Hub with the FBPS-1.500Isolated Power Supply module.

Figure 8 shows a Fieldbus Power Hub installed with redundant power supplies forfour segments and a Diagnostics module.

Table 4 Fieldbus Power Hub with FBPS-1.500 Isolated Power Supply Module Specifications

Fieldbus Power Hub with FBPS-1.500 Specification

Input voltage 24 VDC (19.2-35 VDC)

Fieldbus output current – FBPS-1.500 500 mA @ 28-30 VDC

Typical power dissipation 2.5 W per segment

Dimensions 22.1 cm. x 24.6 cm. x 16.2 cm. (8.7 in. x 9.7

in. x 6.4 in.)

Operating temperature range -40 to 60 º C

Alarm contact rating - Diagnostic Module 1 A max @ 50 VDC max


40/112


Figure 8 Fieldbus Power Hub with Four Redundant Segments and a Diagnostics

Module

The Fieldbus Power Hub consists of a DIN rail-mounted Motherboard whichsupports plug-in modules that provide redundant power for up to four fieldbussegments plus one Diagnostic Module. Two FBPS-1.500 Isolated Power Supplies pluginto the Motherboard to power each segment. The Diagnostic Module providesdiagnostic monitoring and relay contacts for the segments. The plug-in modules areremovable under power. A fieldbus terminator on the motherboard can be switched

on for each segment. Each segment must have exactly two terminators.

S

Alarm

Diagnostic Bus

PRIPWR

SECPWR

PEPPERL-FUCHS

Fieldbus Power Hub

Fieldbus MotherboardOFF +

Segment 1

SOFF +Segment 2

SOFF +Segment 3

SOFF +Segment 4

FieldConnex

Host A

OFF

S --- +

Host BSEG1

ON

S +

Host A

OFF

S --- +

Host BSEG2

ON

S +

Host A

OFF

S --- +

Host BSEG3

ON

S +

Host A

OFF

S --- +

Host BSEG4

ON

S +

PWR

ERR

HD2FBPS-1.500

PWR

ERR

HD2FBPS-1.500

PWR

ERR

HD2FBPS-1.500

PWR

ERR

HD2FBPS-1.500

PWR

ERR

HD2DMB

HD2FBPS-1.500

PWR

ERR

HD2FBPS-1.500

PWR

ERR

HD2FBPS-1.500

PWR

ERR

HD2FBPS-1.500

PWR

ERR

Primary and secondary

power connectors

Alarm contacts

Diagnostic bus

Shield ground connection

Diagnostics moduleTrunk connectors for segments 1-4

Redundantpower suppliesfor segments 1-4

Host powerswitches forsegments 1-4

Host connectors

A & B for segments 1-4

Termination switchesfor segments 1-4

Refer to Figure 8 on page 40. The Fieldbus Power Hub has:


41/112


g p g

Two, 2-position pluggable connectors for Primary and Secondary 24 VDC inputPower.

Three, 4-position pluggable connectors for the alarm contacts and the DiagnosticBus.

Four, 3-position pluggable connectors for connection to the H1 host (Host A);one for each of the four segments.

Four, 3-position pluggable connectors for connection to a second host (Host B,not used); one for each of the four segments.

Four redundant host power switches for connecting host power to each of thefour segments. All switches must be in the On position.

Four, 3-position pluggable connectors for connection to the fieldbus segment,one for each of the four segments.

Four termination switches for connecting an integrated fieldbus terminator toeach of the four segments.

One connection for connecting the cable shields to ground.

When the Fieldbus Power Hub is powered and functioning within its specificationsthe alarm circuit provides a closed-contact circuit. A failure in either input powersupply, any fieldbus power supply module, or an over-current or short on any fieldbusoutput, opens the alarm circuit. The alarm circuit is galvanically isolated from thefieldbus segments and input power supplies. The alarm pins at the last unit must beconnected together to complete the circuit.

DC Power Considerations for High Availability Applications


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g y pp

Using the Fieldbus Power Hub

The available power to a field device depends on the length and resistancecharacteristics of the fieldbus cable. The formula for the calculations in Table 5 onpage 43, which shows the maximum distance for a given load on the Fieldbus PowerSystem, is based on the following assumptions:


Minimum Device Voltage = 9 VDC (Calculations use 9.5 VDC)

Maximum Voltage drop from cable = 18.5VDC

Each device has an average load of 20 mA


Devices are connected on one end of the cable and the Fieldbus Power Hub isconnected on the other end of the cable

Maximum Distance (km) = (Allowed Loop V drop / Loop current) / Loop

resistance per km

There will be different restrictions and limitations on your segment if theseassumptions do not hold for your segment layout. If your devices average more than20 mA per device, reduce the maximum cable length indicated in the table for thatnumber of devices or reduce the number of devices on the segment. Refer to thedevice documentation for information on current requirements for the device.

When referring to Table 5, remember the Series 2 H1 card requires 12 mA of fieldbuspower in simplex mode and an additional 12 mA of fieldbus power (24 mA total) inredundant mode. There are distance columns for applications both with and withoutsegment protectors. The distance associated with the segment protector is reduceddue to the possible condition of a short on a spur which would increase the current onthe trunk and also reduce the voltage to the other devices.


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Table 5 Distance per Load on the Fieldbus Power Hub with and without Segment Protectors

Number of

Devices / Load

(mA)

Power Supply Load (mA) Maximum Distance

without Segment

Protector (meters)

Maximum Distance with

Segment Protector

(meters)Series 2 H1

Simplex

Series 2 H1

Redundant

1 / 20 32 44 1900 1900

2 / 40 52 64 1900 1900

3 / 60 72 84 1900 1900

4 / 80 92 104 1900 1900

5 / 100 112 124 1900 1900

6 / 120 132 144 1900 1900

7 / 140 152 164 1900 1855

8 / 160 172 184 1900 1695

9 / 180 192 204 1900 1565

10 / 200 212 224 1875 1450

11 / 220 232 244 1720 1350

12 / 240 252 264 1590 1265

13 / 260 272 284 1480 1190

14 / 280 292 304 1380 1120

15 / 300 312 324 1295 1060

16 / 320 332 344 1220 1005

16 / 340 352 364 1155 960

16 / 360 372 384 1090 915

Short Circuit Protection with Segment Protectors


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The Pepperl+Fuchs Segment Protector connects field devices to the fieldbussegment cable and provides short circuit protection to the segment. Figure 9 shows a

Segment Protector for eight devices.

Figure 9 Segment Protector for Eight Devices

1+ 1 1s 2+ 2 2s 3+ 3 3s 4+ 4 4s 5+ 5 5s 6+ 6 6s 7+ 7 7s 8+ 8 8s Ti+Ti Tis To+To Tos TS

PEPPERL+FUCHS

F2-JBSC-8-CGB

FieldConnex

Off

S1

Spur connections

Trunkconnections

S1terminator switch

Jumper S to T andGnd to Gnd

Spur connections 1-8 Trunk connections 1-2

Designing an Application for Short Circuit Protection Using

S t P t t


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a Segment Protector

When designing an application that uses a Segment Protector for short circuitprotection, allow an additional 50 mA in the design to give the power supply theadditional current capability to support a short circuit in one device (should it occur)and continue to power the segment without interruption. Normally a 1.0 voltage drop(assuming a 20 mA device) occurs across the Segment Protector to the device. Anadditional voltage drop occurs during a short circuit condition. To prevent devicesfrom dropping off the segment because of reduced voltage, be sure that theapplication design allows for the voltage drop in both the normal and short circuit

condition. Use the following calculation to calculate the short circuit voltage drop tothe farthest device:

.050A X (44 ohms/km) X distance in km

The following example calculates the voltage drops on 0.5 km segment to the farthestdevice:

Normal voltage drop = 1.0 Volt

Short circuit voltage drop =.050A X (44 ohms/km) X.5 km = 1.1 Volts

Total voltage drop = normal voltage drop + short circuit voltage drop = 2.1 volts.

This calculation is based on a design that allows for one short circuit in a runningsegment. For example, a situation in which an inadvertent shorting of a device occursduring routine replacement in an operating system. The calculation does not allow formultiple short circuit conditions in a new installation that has not been verified withthe segment checkout procedure.

Table 5 on page 43 provides the maximum distance when the application includes theSegment Protector.

Installing and Connecting the Fieldbus Power Hub


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To install the Fieldbus Motherboard, Power Supply Modules, and Diagnostic Module

1. Attach the top latch of the Fieldbus Motherboard onto the DIN rail and push itinto place. Tighten the two DIN rail latching screws until the Motherboard is heldsecurely onto the rail.

2. Plug the Fieldbus Power Supply Modules (FBPS-1.500) and the DiagnosticModule on to the Motherboard. Secure the modules to the Motherboard by

depressing the two latching levers on each module.

To connect the Fieldbus Power Hub


1. Connect the primary 24 VDC input to the PRI PWR connector.

2. Connect the secondary 24 VDC input to the SEC PWR connector.

3. Connect the alarm wires and short the alarm pins on the opposite side of theFieldbus Motherboard. If multiple Motherboards share the same alarm circuitry,short the alarm pins on the last one in the chain.

4. Connect the H1 segment wire to the Host A connector for each segment that is

used.

5. Ensure that Host B is not connected.

6. Ensure that the redundant host power switch is On for each segment.

7. Connect each field segment wire to the appropriate terminal on theMotherboard for each segment that is used.

8. If the Fieldbus Power Hub is on the end of each segment, switch the terminatorfor each segment On.

9. Connect the shield ground connection on the Motherboard with an adequatelysized grounding wire to an appropriate grounding location. Ensure that allsegment shields are connected to ground at this one location only. Do not connect the shields to ground at the 8-wide carrier shield bar or at any device in

the field.

Installing and Connecting the Fieldbus Segment Protector


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To install and connect a Fieldbus Segment Protector

1. Securely attach the Fieldbus Segment Protector at the desired location. Choose alocation that minimizes the length of the spur cables.

2. For the Trunk segment connection: connect the positive (+) segment wire to thepositive; connect the negative (-) segment wire to the negative; and connect thesegment shield (S) to the S.

3. For each device connection: connect the positive (+) spur wire to the positive,connect the negative (-) spur wire to the negative, and connect the shield wire (S)to the S.

4. The two shorting jumpers must be repositioned so that the Trunk (T) and Spur(S) shields are connected together and not connected to case. Jumper T to S andGnd to Gnd.

5. If this Segment Protector is at the end of the segment, the terminator switch S1should be in the On position. If it is not at the end of the segment, ensure thatterminator switch S1 is in the Off position.

6. If the segment continues and connects to another Segment Protector, continue

the Trunk segment by connecting the Trunk Out connections to the nextSegment Protector and proceed with the connections described in steps 2, 3, and4.

7. For all Segment Protectors, ensure that the two shorting jumpers arerepositioned so that the Trunk (T) and Spur (S) shields are connected togetherand not connected to case. Jumper T to S and Gnd to Gnd.

8. At each device ensure that the shield is isolated and not connected to the device.

9. If this Segment Protector is at the end of the segment, ensure that the terminatorswitch S1 is in the On position.

Verifying the Installation


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After the segment is installed with all devices connected, use the segment checkoutprocedure on page 63. First measure resistance, capacitance, DC voltage, and the AC

waveform (steps 1, 2, 4, and 5) with only one of the power supply modules installed. Then, measure DC voltage and the AC waveform (steps 4 and 5) again with bothpower supply modules installed. Verify that the measured DC voltage allows for theadditional voltage drop if a short circuit occurs on one spur.

High Availability Application Examples for the Fieldbus Power

HubFigure 10 shows an application that uses a redundant pair of Series 2 H1 cards withredundant fieldbus power for both segments and short circuit protection for deviceson a long (0.5 km) trunk cable. If a failure occurs on an H1 card, a 24 V power supply,or a fieldbus power supply, the segments continue to operate as expected. A statusindication on connected alarms alerts the operator that an error has occurred. It isassumed that the application design follows the criteria specified in “Designing an

Application for Short Circuit Protection Using a Segment Protector”. Therefore, if ashort occurs when a device is installed or removed from the segment, only that deviceis affected; the rest of the segment is unchanged.


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Figure 10 High Availability Application with 16 Devices Using the Fieldbus Power Hub

and Segment Protectors

Series 2

FieldbusH1

Power/Active

Error

Port 1

Port 2

Series 2

FieldbusH1

Power/Active

Error

Port 1

Port 2

S

Alarm

Diagnostic Bus

PRIPWR

SECPWR

PEPPERL-FUCHS

Fieldbus Power Hub

Fieldbus Motherboard OFF +Segment 1

SOFF +Segment 2

SOFF +Segment 3

SOFF +Segment 4

FieldConnex

Host A

OFF

S --- +

Host BSEG1

ON

S +

Host A

OFF

S --- +

Host BSEG2

ON

S +

Host A

OFF

S --- +

Host BSEG3

ON

S +

Host A

OFF

S --- +

Host BSEG4

ON

S +

PWR

ERR

HD2FBPS-1.500

PWR

ERR

HD2FBPS-1.500

PWR

ERR

HD2FBPS-1.500

PWR

ERR

HD2FBPS-1.500

PWR

ERR

HD2DMB

HD2FBPS-1.500

PWR

ERR

HD2FBPS-1.500

PWR

ERR

HD2FBPS-1.500

PWR

ERR

HD2FBPS-1.500

PWR

ERR

GND

GND

GND

GND

Txvbo 3x\88 - wxb8m

T uf xu p t y w fo cl ex

Lsnrtpm

rupt K serup o 6x TU 81 x buk

sorulx Bxup 02x b2 xul 4- 8m

Ibex ywqv 09x fxq03-3v TERMINATOR ON OF F

F2-JBSC-8-CGBSegment Protector

PEPPERL+FUCHS FieldConnex TM

Segment Protector

Txvbo 3x\88 - wxb8m

T u fx u p t y w f oc l ex

Lsnrtpm

rupt K serup o 6x TU 81 x buk

sorulx Bxup 02x b2 xul 4- 8m

Ibex ywqv 09x fxq03-3v TERMINATOR ON OF F

F2-JBSC-8-CGBSegment Protector

PEPPERL+FUCHS FieldConnex TM

Segment Protector

Port 1 Port 2

Carrier

shield bar

RedundantSeries 2 H1cards

Alarm jumper

Shielded pair with drain wire

0.5 km Cable

T - OFF

T - ON

Primary24 VDC

Secondary24 VDC

Alarmcontacts

T - ON


50/112


Chapter 3 Intrinsically Safe Fieldbus Applications


51/112

Intrinsically Safe Fieldbus Applications 51

This chapter provides information about fieldbus applications that provide

Intrinsically Safe (IS) power to fieldbus devices located in hazardous areas. ThePepperl+Fuchs FieldConnex® Fieldbus Power Hub and FieldConnex® FieldBarrierprovide Intrinsically Safe power for both Intrinsically Safe – entity applications andFISCO (Fieldbus Intrinsically Safe COncept) applications. Refer to thePepperl+Fuchs (P+F) documentation for additional information on these products.

Ensure that the fieldbus devices and all components used in the application are ratedand certified for IS applications.

Warning In any hazardous area installation it is important to read and follow the devicemanufacturer's design and installation documents. Failure to follow thedocumentation could result in an unapproved and unsafe application. Additionally, in hazardous locations follow your plant's procedures for makingthe area safe during installation and maintenance operations.

DC Power Considerations for Intrinsically Safe Applications

The basic IS application uses the Fieldbus Power Hub with the FBPS-1.500 IsolatedPower Supply Module to provide power to field devices connected through one ormore IS Field Barriers.

The available power to a field device depends on the length and resistancecharacteristics of the fieldbus cable to each Field Barrier and the output characteristicsof the Field Barrier to the field device. The P+F segment calculator tool was used tomake the example calculations in Table 6 on page 53. The calculations show themaximum distance for a given load on the Fieldbus Power Hub for applications using

2, 3, and 4 Field Barriers to connect up to 16 field devices. The calculations are basedon the following assumptions:


52/112



Minimum Voltage at last Barrier = 16 VDC Minimum Device Voltage = 9 VDC

Maximum Voltage drop from cable to last barrier = 12 VDC

Redundant H1 connected at a load of 24 mA

Each device has an average load of 20 mA

Ensure that any device load on a spur output from the field barrier is 30 mA or

less

Each Barrier spur has a maximum of one device connected.

Barriers and Devices are connected on one end of the cable and the FieldbusPower Hub is connected on the other end of the cable

Each device is connected on a 10 meter maximum spur cable.

Barriers are inter-connected on a 10 meter maximum trunk cable.


Maximum Distance (km) = (Allowed Loop V drop / Loop current) / Loopresistance per km

There will be different restrictions and limitations on your segment if theseassumptions do not hold for your segment layout. If your devices average more than

20 mA per device, reduce the maximum cable length indicated in the table for thatnumber of devices or reduce the number of devices on the segment. Refer to thedevice documentation for information on current requirements for the device.

When referring to Table 6, remember the Redundant Series 2 H1 card requires 24 mAof fieldbus power.

The loads listed are the normal loads required by the barriers and devices. However,

the numbers take into account the additional current required if the smallest load onone barrier is accidentally shorted (during a maintenance operation) to protect thesegment from being affected.

If these assumptions do not properly represent your specific application, it isrecommended that a calculation be completed to verify that the segment designadequately meets your process requirements.

Table 6 Distance per Load on the Fieldbus Power Hub with Field Barriers


53/112


Fieldbus Power Hub

Refer to “Pepperl+Fuchs Fieldbus Power Hub for Redundant Fieldbus Power” onpage 39 for information on the Fieldbus Power Hub system.

p

Number of

Devices / Load

(mA)

Distance (meters) and Power Supply Load (mA)

Max

Distance

with 2

Barriers

Power Supply

Load

with 2 Barriers

Max

Distance

with 3

Barriers

Power Supply

Load with 3

Barriers

Max

Distance

with 4

Barriers

Power Supply

Load with 4

Barriers

1 / 20 1875 75 1850 103 1575 131

2 / 40 1850 94 1625 123 1400 151

3 / 60 1675 112 1425 143 1250 171

4 / 80 1500 130 1275 161 1125 192

5 / 100 1325 149 1150 180 1025 211

6 / 120 1200 163 1050 198 950 231

7 / 140 1000 184 975 218 875 250

8 / 160 1000 208 900 237 800 267

9 / 180 N/A N/A 825 256 750 288

10 / 200 N/A N/A 775 274 700 307

11 / 220 N/A N/A 725 290 650 325

12 / 240 N/A N/A 725 316 625 346

13 / 260 N/A N/A N/A N/A 600 366

14 / 280 N/A N/A N/A N/A 550 378

15 / 300 N/A N/A N/A N/A 525 395

16 / 320 N/A N/A N/A N/A 525 422

16 / 340 N/A N/A N/A N/A 475 429

16 / 360 N/A N/A N/A N/A 425 433

Field Barrier for Intrinsically Safe Applications in Hazardous

Locations


54/112


The Field Barrier connects up to four field devices located in hazardous locations tothe fieldbus segment and provides short circuit protection to each device. Ensure thatany device load on a spur output from the field barrier is 30 mA or less. Figure 11 shows a Field Barrier for four devices.

Figure 11 Field Barrier for Four Devices

Installing and Connecting the Fieldbus Power HubRefer to “Installing and Connecting the Fieldbus Power Hub” on page 46 forinformation on installing the Motherboard, Power Supply Modules, and DiagnosticsModules and connecting the Fieldbus Power Hub.

10+ 11 13+ 1412s 16+ 1715s 19+18s 20 21sON

OFF

PWR

S1 BUS _

TERM. 123

4

143+ 4- 5s 6s 7- 8+1B 2B

Spur connections Trunk connections

S1 terminator switch

Trunk connections 1-2Spur connections 1-4

Installing and Connecting the Field Barrier



55/112


g p g

To install and connect a Field Barrier

1. Securely attach the Field Barrier at the desired location.

2. For the Trunk segment connection: connect the positive (+) segment wire to thepositive, connect the negative (-) segment wire to the negative, and connect thesegment shield (S) to the S.

3. Remove the shorting jumpers (1B, 2B) so that the Trunk (S) shields are isolatedfrom, not connected to the Field Barrier case.

4. For each device connection: connect the positive (+) spur wire to the positive,connect the negative (-) spur wire to the negative, and connect the shield wire (S)to the S.

5. The Spur (S) shields must be connected to the Field Barrier case and isolated atthe device in the field. The best way to ground the output shields at the barrier is

with a mechanical connection through a metal gland or bar at the barrier.

6. If this Field Barrier is at the end of the segment, the terminator switch S1 shouldbe in the On position. If this is not the end of the segment, ensure that theterminator switch S1 is in the Off position.

7. If the segment continues and connects to another Field Barrier, continue the Trunk segment by connecting the Trunk Out connections to the next FieldBarrier and proceed with

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