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Page 1: Scaleable Automation Infrastructure For Optimum Plant Efficiency · 2010-11-11 · Insert for atp 10 / 2008 Scaleable Automation Infrastructure For Optimum Plant Efficiency Fieldbus-Special_engl.indd

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Scaleable Automation InfrastructureFor Optimum Plant Efficiency

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A well managed plant is a vigilantplant.

SEE CLEARLY

DPharp EJX SeriesDigital Pressure Transmitter

KNOW IN ADVANCE

PRMIntegrated Plant Resource Manager

ACT WITH AGILITY

CENTUM VP

Technology like Foundation Fieldbus.

Integrated Production Control System

www.yokogawa.com/eu

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tween the DCS/PLC and the field devices. This creates an information infrastructure which allows information to be accessed with the greatest possible variability and speed.

With FOUNDATION Fieldbus technology, which has met with worldwide approval, there exists an architecture of operational excellence which extends beyond standard fieldbus functionality. In this FF magazine, we hope to provide you with important in-formation from the market on this very topic.

Imagine what it would be like if a partic-ular error occurred in a field device and the serial number of the field device was sent automatically to the manufacturer who then sent you a suitable replacement part before the process came to a standstill due to a malfunction. Wouldn’t that be a dream come true?

Best wishes

Wolfgang HöferlinFOUNDATIONTM Fieldbus

First Chairman of German Marketing Committee

e-mail: [email protected]

In an era of wildly fluctuating oil prices, when the idea of refrigerators having their own IP address for the sake of effective en-ergy management is becoming a serious possibility, we need to ask ourselves what we should be doing to ensure that our pro-cess systems are fully equipped for the fu-ture. It is becoming increasingly difficult to make the right choice when taking deci-sions, and it is not unusual to opt for a tried and trusted technology that we’re familiar with. However, time stands still for no man. Things are changing, and it’s a matter of be-ing flexible, looking ahead to the future and sometimes, of course, having the courage to leave your personal comfort zone and ex-plore new territory.

How do we take the right decision?

If we take a look at developments in the ar-ea of process automation and where and how process information originates, it is mostly the field devices which have devel-oped into little miracles of technology, lis-tening to the process like a stethoscope. In addition to numerous process parameters (actual values), powerful microcontrollers also provide additional diagnostic informa-tion and details for predictive maintenance. Buildup or abrasion etc. on the field device can be identified on time, before the device malfunctions. Excessively high sensor tem-peratures do not go undetected. Multivari-able measuring devices supply several pro-cess parameters simultaneously, including a status signal indicating if the measured val-ue is valid. At a time of cost pressures and just-in-time production, this information helps us to optimize our processes.

The right information at the right time!

Recently, I had an interesting conversation with the operations manager of a paper fac-tory. He said to me, “I have 10,000 measur-ing devices installed on my premises, and I don’t know how they’re doing or when one of them malfunctions. It’s only when a pro-cess comes to a standstill and production stops, that I find out.“ Using 4 to 20mA HART, he tries painstakingly to access the necessary information.

This confirms my belief that, in order to be equipped for the future, there is an ur-gent need for a data highway, a fieldbus be-

Foreword

Wolfgang Höferlin,First Chairman of the Fieldbus FoundationGerman Marketing Committee

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Contents

Index of Advertisers

Foreword page 3

FNICO – Cost-effective installation in Ex zone 2 page 5

FOUNDATIONTM Fieldbus now accepts binary and analog signals page 8

Frequently asked questions about FOUNDATIONTM Fieldbus page 10

What makes FOUNDATIONTM Fieldbus so valuable to Plant Asset Management? page 16

A look at the fieldbus page 20

Your FOUNDATIONTM Fieldbus Contacts page 22

Interface module for integrating FOUNDATIONTM Fieldbus page 22

Company Page

Bürkert GmbH & Co. KG, Fluid Control Systems, Ingelfingen page 17

Emerson Process Management GmbH & Co. OHG, Hasselroth page 23

Endress + Hauser, Messtechnik GmbH + Co. KG, Weil am Rhein page 7

Germex GmbH, Grevenbroich page 9

LEONI KERPEN GmbH, Stolberg page 14

MTL Instruments GmbH, Kaarst page 12

Northwire, Osceola, Wisconsin, USA page 22

Pepperl+Fuchs GmbH, Mannheim page 18

R. STAHL Schaltgeräte GmbH, Waldenburg page 15

SAMSON AG Mess- und Regeltechnik, Frankfurt am Main page 11

Softing AG, Haar b. München page 13

Yokogawa Deutschland GmbH, Ratingen page 2

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In recent years, Foundation Fieldbus H1 (FF) has established itself alongside Profibus PA as a new standard for signal exchange in process technology. FF is a two-wire bus which supplies power and transmits pro-cess data via a bus cable and complies with IEC 61158. In the field of process technolo-gy, the installation of devices in hazardous areas is always in demand. To ensure safe operation in hazardous areas, special instal-lation standards must be observed, which initially complicate the installation process. At the same time, Ex certification bodies and hardware manufacturers are working on concepts which should simplify how the necessary components are used. An exam-ple of such a partnership is the Fieldbus Non-Incendive Concept, FNICO for short, which was jointly devised by the Physika-lisch-Technische Bundesanstalt (PTB) and MTL Instruments.

A tried and trusted concept for Ex zone 1

FISCO – Fieldbus Intrinsically Safety Con-cept is the outcome of work completed by the PTB in partnership with different com-panies. According to this, each bus string may be powered by only one power supply. The bus participants themselves (field de-vices and the bus terminator) are passive and only consume energy. Average basic current consumption is approx. 10 mA. The signal amplitudes of the digitally modulat-ed basic current are 19 and 1 mA. In the meantime, FISCO has also become an inte-gral component of explosion protection standards and has been standardized inter-nationally as IEC 60079-27.

When planning and installing an FF net-work based on FISCO in hazardous areas, the user must observe only a few simple rules. These interconnection rules apply to devices which are certified in accordance with the FISCO model. These devices should have “FISCO“ printed on the nameplate in the case of a fieldbus supply unit or “FISCO Device” in the case of a bus participant. In this case, with regard to explosion protec-tion requirements, the devices can be inter-connected without the need for any further calculations.

Cable types which conform to the FISCO specification should be used as bus cables. This means that only the maximum allow-able lengths specified must be observed. According to the standard, intrinsically safe FISCO devices must be set up in such a way that they satisfy the requirements for the

FNICO – Cost-effective installation in Ex zone 2

gas groups IIC and IIB. The certified power supply, which is configured as an IIB or IIC device, then determines the type of FF seg-ment and therefore also the approved gas group for the application. The number of devices permitted on a bus string is based on the total current of all bus participants and the maximum current of the power supply.

Ex zone classification

Hazardous areas are classified into zones. The zone classification depends on the probability, in terms of time and location, of the presence of an explosive atmosphere.

In North America (USA/Canada), hazard-ous areas are classified into divisions (con-ventional system, in USA as per NEC 500) or zones (new system based on IEC, in USA as per NEC 505).

In Europe, hazardous areas are classified into zones according to the level of danger. Equipment is divided into categories (direc-tive 94/9/EC) in accordance with its desig-nation for use in the different zones. The category therefore indicates the zone in which the user is allowed to use the equip-ment.

Classification of potentially explosive gases and vapors: � Zone 0Areas in which dangerous concentrations of

combustible gases/vapors are present on a permanent or long-term basis.

� Zone 1 Areas in which dangerous concentra-

tions of combustible gases/vapors are sometimes present.

� Zone 2 Areas in which dangerous concentra-

tions of combustible gases/vapors are

seldom present and if present, then only on a short-term basis.

Simplified installation of Ex n field devices

FNICO makes use of the known advantages of the FISCO model for fieldbuses installed in Ex zone 2. FNICO simplifies documenta-tion for the user and eliminates the labori-ous task of calculating cable parameters. In addition, FNICO power supplies provide more energy, thereby allowing more field devices to be used per each fieldbus string. FNICO is based on protection type Ex n.

Ex n is easy to manage

An important requirement when it comes to using fieldbuses in practice is that field devices can be added during operation without interruption. If the fieldbus is in a hazardous area, this must be done in accor-dance with the regulations for hazardous areas. For installations in zone 1, this is pos-sible only with protection type Ex i. How-ever, with protection type Ex n, installations in zone 2 can also be serviced during opera-

Fig. 1

Fig. 2

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tion. Ex n is a type of energy limit, similar to Ex i. The differences are clarified in Table 1:

Ex n approved devices work closer to the ignition limit curve, as the safety factor is lower. For this reason, they can supply more energy in zone 2. For a fieldbus installation, this means that by using FNICO power sup-plies, more field devices can be operated on the fieldbus strand.

Practical layout of a FNICO-FF system

Fig. 1 shows the typical layout of a fieldbus strand that has been approved in accor-dance with FNICO. The necessary compo-nents are the FNICO power supply, FF cable, signal distributor, bus terminator and of course the FF field devices.

FNICO power supply

The FNICO power supply (fig. 2) is the inter-face between the safe area and the hazard-ous area. The power supply connects the FF interface in the automation unit (FF master) to the field devices. In this interface, the fieldbus cable is thus supplied with power, and Ex isolation is implemented at the same time. The function of this power supply can

therefore be compared to the function of a barrier in the context of traditional wiring. The output voltage and current are depen-dent on the gas group required. The power supply can be installed in the safe area or directly in Ex zone 2, in a suitable enclosure. In addition, the necessary bus terminator is integrated directly into this power supply.

FF connection technology

The FF bus cables for FNICO applications must meet the same requirements as all bus cables for Foundation Fieldbus H1. The main point to note is that parasitic inductances and capacitances (energy stores) must be low. The safety-related data for FNICO and FISCO cables are identical (Table 2).

The field devices are usually not con-nected to the fieldbus directly via the field-bus cable but via special signal distributors. Typically, these signal distributors are de-signed to enable the connection of up to 10 field devices. An optional bus terminator is integrated. Each FF field device has a re-movable terminal which is used to connect it. Thanks to special electronics, the outputs to the field devices (bus spur) are free from interference. This makes it possible to add or remove FF field devices during operation

Table 1.

Protection type Identification Permitted errors Safety factor for zone

Intrinsically safe yes EEx ia 2 1,5 0,1 and 2

Intrinsically safe ib EEx ib 1 1,5 1 and 2

Energy-limited EEx nL none 1,1 2

Table 2. Key data for cables.

Typ. resistance 15–150 Ohm/km

Typ. inductance 0.4–1.0 mH/km

Typ. capacitance 80–200 nF/km

max. length of a bus spur 30 m for gas group IIC and IIB

max. length of total fieldbus 1km for gas group IIC and 5 km for IIB

without restricting bus communication. In a FNICO installation, the requirements for the signal distributor are simple. The distributor is mounted in a suitable enclosure, and this unit must be approved for installation in Ex zone 2. A costly EEx d enclosure is therefore not required for safe operation.

FF field devices

Currently, there are not many field devices available which are certified in accordance with EEx nL. However, this means that there is practically no restriction because intrinsi-cally safe (EEx i) FF field devices are also per-mitted in a FNICO installation. These field devices are usually approved for FISCO ap-plications. The operation of FISCO field de-vices is permitted because FNICO and FISCO use the same safety parameters. This pre-vents the overloading of FISCO-approved field devices in a FNICO application. Here, the user has the advantage of being able to use the same field devices in Ex zone 1 and Ex zone 2. This eliminates the need to hold double the amount of stock.

The documentation standards for FNICO applications are similar to those for FISCO applications. There is no need for the labori-ous calculation of cable parameters. For documentation to be complete, only the following data are required:� The bus cable must comply with FNICO/

FISCO requirements.� The FF devices must be EEx nL or EEx i

approved.� All Ui values pertaining to the field de-

vices must always be greater than the Uo of the power supply.

� The connection components must com-ply with FNICO requirements.

� List of devices used. This must include:� Manufacturer� Device type� Ex approval� Temperature class� Permitted ambient temperature

Conclusion

FNICO is an easy-to-use installation technol-ogy for use in Ex zone 2. If the necessary hardware is available, devices approved in accordance with FISCO can be used as field devices. For users who are already familiar with FISCO, it can be used without having to undergo any reorientation. Due to the high-er performance, more field devices can be connected to a fieldbus strand, and so the overhead costs are spread over more mea-suring points. This results in cost savings for each individual measuring point. www.MTL.deFig. 3

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Endress+HauserInstruments International AGKaegenstrasse 24153 Reinach/BL1Switzerland

Phone +41 61 715 81 00Fax +41 61 715 25 [email protected]

Foundation Fieldbus – we put the pieces in place.

The right skills to optimize your projects. It’s powerful and versatile, but getting the most from your FOUNDATION™ fieldbus architectureis a major challenge. At Endress+Hauser, we complement our wide product offering with top industry expertise and experience. This enables you to realize your project’s potential and achieve the return on investment you expect.Independent of the DCS we offer you solutions integration for condition monitoring, asset management and control in the field. We deliver improved plant performance and better business results and reduce hassle and risk. Nothing puzzling about that.

www.automation.endress.com/fieldbus

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It was not that long ago that a number of signals could not be transferred directly to Foundation Fieldbus. Pepperl+Fuchs now offers a total concept, from FieldConnex components specially designed for valves and temperature inputs to a Foundation Fieldbus (FF) Modular I/O for intrinsically safe inputs and outputs. These modular sta-tions also supply classic, intrinsically safe 4 to 20  mA transmitters and process high-energy signals for transfer to control sys-tems via Foundation Fieldbus H1 . This fa-cilitates the operation of the entire range of sensors and actuators required for plant au-tomation in hazardous areas.

By adding an FF Gateway, the reliable hardware of the tried and trusted Remote I/Os was used in order to avail of the standard FF multifunction blocks. Now, for the first time, there are modular stackable Founda-tion Fieldbus modules available, which in-terface all types of signals, including high-energy devices, and the bus. At the same time, this ensures better use of the 31.25 kbps data transfer rate and a reduction in instrumentation costs.

FOUNDATIONTM Fieldbus now accepts digital and analog signalsMayor systems manufacturers have successfully tested and approved Pepperl+Fuchs Foundation Fieldbus Modular I/O for use with their systems. Any sensor and actuator can now be connected to the control system via the fieldbus.

FF Modular I/O Architecture

Unlike tailored I/O boxes, the FF Modular I/O can combine digital and analog inputs and outputs with each other in one single station. It supports NAMUR contact inputs valve outputs, temperature signals or the power supply to two-wire transformers as well as the processing of active signals from four-wire transmitters. Modular I/Os have their own power supply and therefore do not burden the bus. On the contrary, they are even able to power high-energy valves.

At the same time, the stations are ex-tremely compact. Up to 40 digital or 20 ana-log inputs or outputs or a combination of these signals is possible.

Applications

The principle was derived from the stan-dard remote I/O, of which hundreds of thou-sands of modules are in operation world-wide. The new Foundation Fieldbus Modu-lar I/O incorporates all the functionality that the user requires for process instrumenta-

tion in an ideal combination. This means that traditional analog and digital inputs and outputs or temperature sensors can be connected to the bus in the case of a plant upgrade or when building an new plant.

The FF Modular I/O may be regarded as a single FF device with several variables. It is integrated into the HOST system with the help of DDs (device descriptions) and CFFs (configuration files). This enables full system integration and easy engineering.

The modular I/O station behaves physi-cally in the same way as other FF participants. Additional barriers are not required as it is connected directly to the fieldbus trunk (H1 bus). Traditional field devices are connected in an intrinsically safe manner to the I/O mod-ules in the same way as for conventional technology with galvanically isolated signal conditioners. It is even possible to install non-intrinsically safe circuits directly beside intrin-sically safe circuits.

In this way, all non-Foundation Fieldbus signals can be brought to the fieldbus with-out having to replace existing instruments. This results in significant cost savings as it is no longer necessary to purchase new field devices when upgrading existing plants.

The installed base of pressure and differ-ential pressure transmitters can also be re-tained, as can motorized valves, positioners and solenoid valves. In hazardous areas, these field devices are wired to the FF Mod-ular I/O station in the traditional way using intrinsically safe wiring or the Entity Con-cept.

The FF Modular I/O from Pepperl+Fuchs represents the missing link between con-ventional digital and analog signals and modern Foundation Fieldbus technology, and therefore completes the range of Foun-dation Fieldbus devices.

Rainer Hillebrand, Dipl.-Ing. / D.I.C.Head of Remote I/O systems product groupBusiness area process automationPepperl+Fuchs GmbH, 68307 Mannheim, Tel.: +49 621 776-22 22, Fax: +49 621 776-27-22 22, e-mail: [email protected], Internet: www.pepperl-fuchs.comFig 1: FF Modular I/O Architecture

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[email protected]

Portable calibratorsWorkstationsCalibration softwareProfessional servicesIndustry solutions

GERMEX GmbHD-41515 GrevenbroichTel: +49 (0)2181 [email protected]

Beamex® MC5-IS Intrinsically Safe Fieldbus Calibrator

The safest way to calibrate fi eldbus instruments.

• Calibrate fi eldbus instruments in hazardous areas

• Calibration results are automatically documented

• Profi bus PA or Foundation Fieldbus H1

• ATEX and IECEx certifi ed

• Calibrate and confi gure pressure and temperature transmitters

NEW!

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1. Service technicians have been used to dealing with 4–20mA signals for years. They are familiar with the procedure in the event of an error and have suitable tools/measuring devices at their fingertips. In contrast, troubleshooting in the case of FF is often complicated and costly.

What tools are available to make troubleshooting easier?

Pepperl+Fuchs:

As usual, when using new technologies, there are new tools and methods which you need to become familiar with and learn to use in practice. When it comes to diagnos-ing the fieldbus physics, the Advanced Di-agnostic Module from Pepperl+Fuchs, for example, provides the full range of options and more for testing the installation. This is done on-screen in a user-friendly manner. Color coding in accordance with the NA-MUR traffic signals is used to indicate the status, and plain text messages provide in-formation on the possible cause of the error and request action. Following a very short learning curve, it is actually even easier to diagnose errors in a fieldbus installation than in the case of 4 to 20 mA technology.

Most importantly, fieldbus diagnostics enable continuous monitoring of, for exam-ple, control loops. This makes it possible to predict the reliability and availability of the fieldbus itself and to schedule maintenance work. Instead of carrying out maintenance in reaction to errors, users can perform pre-dictive maintenance, thereby increasing availability. At the same time, maintenance costs are reduced.

MTL: Diagnostic methods in fieldbus systems are different to those used for conventional wiring

Nowadays, every automation concept in the process industry must reduce operating costs and extend the service life of the prod-ucts and systems used. Preventive mainte-nance is designed to reduce unintentional

Frequently asked questions about FOUNDATIONTM Fieldbus

stoppages to a minimum. New technolo-gies and concepts must guarantee that products from a wide range of manufactur-ers will be compatible with each other, re-gardless of the fieldbus standard.

These requirements are not new, and yet diagnostic methods differ. In the case of conventional wiring, only devices were di-agnosed. Where necessary, a cable open cir-cuit were also detected. However, this can-not be classed as a diagnosis, as signal transmission was not possible following a cable open circuit.

The demands on modern fieldbus diag-nostics are considerably greater. Users want to determine the status of the transmission network with all its interfaces and use this to determine the probability of failure for the entire plant.

Turck:

The ADU module (Advance Diagnostic Unit) of the DPC system (Diagnostic Power Conditioner) from Turck is a very helpful di-agnostic tool for the user. Among other things, the ADU module supports the user in commissioning a fieldbus system. In ad-dition, the system is capable of detecting subtle changes within the individual field-bus segments over a long period of time. With an appropriate alarm system in place, this means that errors or failures in the sys-tem can be avoided. In addition to physical layer diagnostics, the DPC system is also capable of recording and evaluating the protocol statistics of individual segments, in order to ensure a high level of availabili-ty. All available data are displayed via stan-dard FF function blocks or graphically via a DTM.

Which are the different types of errors which can occur in fieldbus systems?

In the commissioning and operating phas-es, there are essentially two types of system status in which different errors can occur. Typical errors that can occur during com-missioning are: short-circuit in the fieldbus cable or to the shielding, cable break, too many or too few terminators (terminating resistors), supply voltage too low and faulty signal distributors.

These errors are not specific to a fieldbus installation. Short-circuits and cable breaks

were also a feature of conventional wiring. The advantage of fieldbus technology is troubleshooting. The system monitors itself and provides help with establishing the lo-cation of errors.

During operation, other errors can occur. Typical errors during operation are: the sup-ply voltage or LAS level is too low, low-fre-quency or high-frequency interference, the contact resistance of the connection tech-nology is not permitted, sporadically occur-ring errors in field device due to runtime effects.

The abovementioned errors are also known to occur in the operation of conven-tional systems. The causes of these errors can be found in the installation technology. Contact resistance often increases at termi-nals. This happens if water penetrates or if the atmosphere is aggressive, and results in a drop in voltage. In addition, new machine parts may give rise to higher interference radiation. If, for example, additional motors with frequency-regulated drives are in-stalled, the worst case scenario is that the level of interference will increase. This may restrict communication. While measured values used to be distorted, they now re-main stable as long as communication is possible. Another plus point is the fact that field devices which fail sporadically can now be identified in a relatively uncompli-cated manner. What maintenance techni-cians used to dread in the case of conven-tional wiring is now easily resolved. Field-bus diagnostics identify devices with spo-radic failures, save the bus addresses af-fected and make note of them for the next service.

Which diagnostic device technology is currently available?

We first of all have to define how a physical layer diagnosis is to be carried out. In principal, there are two options: permanent installation of a diagnostic device and mobile use of diagnostic devices.

Mobile use of diagnostic devices is not that much different to the familiar multim-eter for 4 to 20mA standard signals. If there is a system error, the service personnel ana-lyze the installed device technology on site. To ensure that the error is resolved quickly, mobile diagnostic devices must satisfy the following requirements: plain text display for diagnosis message, easy operation simi-

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lar to multimeter, suitable for use in hazard-ous areas, error memory for several seg-ments, transfer of saved diagnostic data to a PC.

2. One particular feature that FF has to offer is the possibility of setting up control in the field. What are the advantages of this option compared to conventional processing in the controller, and in which applications is control in the field used?

Emerson:

Every FF field device has integrated func-tional components which it uses for control in the field. This means, for example, that the PID algorithm is executed directly in the field device and not in the control system.

Configuring “control in the field” in the DeltaV is no different to a standard configu-ration i.e. no additional software is required in order to be able to use FF functionality.

The programmer selects the relevant functional component in the control studio of the DCS and assigns this to the relevant functional component in the field device. In addition, when using control in the field, a field device in the FF segment may be de-fined as a backup LAS ( Link Active Sched-uler).

This field device takes charge of all com-munication in the segment if there is a breakdown in the connection to the host system, thereby enabling control to contin-ue. This is useful if, for example, the pressure or temperature in the system must be main-tained, as in the case of important control loops which must remain in operation.

Samson:

Control in the field allows plant operators to relieve the controller in the control system and implement simple control loops in indi-vidual segments using the PID control block included in the field device, e.g. in a large fieldbus network containing many seg-ments and different cycle times or in a sys-tem with many closed-control loops.

A further additional feature of control in the field arises out of the LAS (Link Active Scheduler) functionality of FF. This function controls traffic on the bus and can be taken on by specific field devices in addition to the DCS. As a result, backup LAS could be

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implemented in a segment which keeps up data exchange when the DCS communica-tion fails. Another option for the operator is to set up autarchic control loops, e.g. when the excessive distance to the control system impedes connection.

Yokogawa:

The Fieldbus Foundation has defined 25 function blocks in the specification. These function blocks are processed indepen-dently by the field devices. Due to publish/subscribe communication, the function blocks can exchange values with each other on a cyclical basis. It depends on the device in which the function blocks are implement-ed. This means that applications can be pro-cessed in a distributed manner in the indi-vidual field devices. If a function block does not need to be processed in a process sta-tion, this reduces the burden on the process station. This is not of any real significance in the case of a single control loop. However, where there are 300 control loops in one process station, the difference in very obvi-ous. The load reduction is all the greater the lower the cycle time setting of a control loop. In addition, shutdowns can be imple-mented quickly and directly in the field, with the result that a binary contact can put a controller in the field out of automatic op-eration without a process station.

Typical applications which are imple-mented within an FF segment are simple control loops, cascades and split-range con-trol loops.

3. FF devices are even more expensive than standard 4–20mA HART devices. Are the manufacturers not hindering the spread of this technology as a result?

Endress+Hauser:

This is a question that cannot be answered with a simple yes or no. Firstly, we need to bear in mind that the integration of a field-bus interface into the field devices elimi-nates the need for input or output cards in the DCS or PLC. Planning is required for these cards, as is a power supply, wiring etc. As these I/O cards are no longer necessary and they no longer take up space in the cabinet, this results in cost savings. Howev-

er, in the case of the field devices for the fieldbus interface, there is a minimal in-crease in cost due to the need for an indi-vidual communication board and its driver software. With Foundation Fieldbus, func-tionality such as PID controllers, for exam-ple, is also included in the field devices. This functionality would otherwise use up re-sources in the DCS controllers and would often necessitate a more powerful micro-controller in the field devices. Therefore, if we are to look at this realistically, the entire automation system must be taken into ac-count. The result is only apparent at the end. Many planners and end customers are aware of this cost displacement. However, it is often individually acquired packages (e.g. a measuring device package) bundled to-gether, which appear cheaper when HART field devices are compared head-to-head against fieldbus field devices. Do not allow yourself to be blinded by this, but instead consider the system as a whole.

Samson:

In general, it is not so easy to thoroughly compare the cost of the conventional de-vices and the fieldbus devices. Of course, the purchase price of an FF device is higher due to the implemented hardware and soft-ware. Nevertheless, such a comparison should also keep sight of the big picture, i.e. planning, installation, commissioning, op-eration etc.

Fieldbus systems not only reduce the time and money needed for installation and commissioning, they also provide more fea-tures. For example, asset management based on extended diagnostic functions of the field devices allows predictive mainte-nance. The resulting cost savings are diffi-cult to include in a calculation. However, they should be taken into account when planning a plant.

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4. Work is currently being done on a specification for HSE RIOs. As far as we know, there is still no HOST system that is 100% compliant with the HSE specification. Once this specification is complete, will there be control systems available which comply with FF-HSE and FF-HSE-RIO?

R. Stahl:

While the FF HSE specification has been in existence for almost 10 years, we are still faced with a chicken and egg problem. There are no HSE hosts which have imple-mented the HSE specification in its entirety, the reason being that there are no HSE field devices. HSE field devices do not exist be-cause there is no host. One of the aims of the FF-HSE-RIO and also the FF wireless workgroup is to break through this vicious circle and finally launch some products on the market. Once the specification and inte-gration have been completed, several mul-tivendor demo systems with appropriate host and RIO prototypes will be installed at end user sites worldwide. This is planned for the start of 2010. As things stand, there should be HSE-compliant control systems available in time for this from APAT, SMAR, Yamatake and Emerson (Ovation). One needs to be clear in one’s mind that, from the point of view of a control system, HSE integration does not have any appreciable advantages over existing solutions incorpo-

rating, for example, FF H1 or manufacturer-specific buses. Instead it primarily generates development costs. For this reason, it is only really the end users who can put pressure on the host manufacturers as they are the ones who benefit considerably from FF HSE thanks to its standardized technology and the associated integration options afforded by Remote I/O, among other things. It is then just a question of time and demand before the other control system manufac-turers make products available.

5. The NE107 requires, among other things, that the device status be depicted in accordance with a predefined schematic using standardized symbols, in order to facilitate an end-to-end operating concept across different field devices. When will this be implemented by FF?

Yokogawa:

The Fieldbus Foundation regards diagnostic capabilities and the associated display for-mat as one of the core functions of FF. They worked closely with NAMUR in order to specify the NE107 profile in the protocol. Compliance with the NE107 profile will be a prerequisite for passing future ITK (Interop-

erability Testing Kit) versions. The user is thus guaranteed this useful functionality by registering an ITK version.

Emerson:

Even before the NE107 was published, Em-erson had acknowledged the importance of “self-monitoring and diagnostics in field de-vices” and used it as the basis for the intelli-gent PlantWeb architecture. When using DeltaV and Foundation Fieldbus field de-vices from the Emerson product range, the user is able to avail fully of the advantages of these intelligent field devices. The alarms which are transmitted by the field devices, referred to in Emerson-speak as PlantWeb alerts, are based on NE 107. The operator can decide which messages from the field devices should appear as an alarm in the user interface and which, for example, are intended only for maintenance personal.

Pepperl+Fuchs:

Signaling in the Advanced Diagnostic Mo-dule supplied by Pepperl+Fuchs and other system components has already been com-pletely implemented in accordance with NE 107.

Endress+Hauser:

There is already a draft specification de-scribing how FF implements NE 107. It will not be much longer before this specifica-tion is published.

Softing is the No. 1 technology supplier for Foundation Fieldbus systems.

Softing offers flexible, well-established and economical solutions for field devices in Foundation Fieldbus systems as well as for connection of controllers and con-figuration of networks. Our competence is of especially great benefit to system and device manufacturers. We rely on communication standards, which is yet another reason why solutions from Softing protect your investments in process automation.

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6. For users, the integration of field devices into the automation system is of great significance. Due to the lengthy life-span, the upwards and downwards compatibility of automation components is crucial if new field devices are to be integrated in future or if faulty devices need to be replaced. How does FF guarantee the interoperability of devices and systems?

Yokogawa:

There are test procedures for both. For sys-tems (host), the Foundation manufacturers independently guarantee interoperability by means of the Host Interoperability Sup-port Test (HIST).

The field devices are registered through the ITK Interoperability Test Kit. A device is not listed by the Fieldbus Foundation until it has passed the complete test. Users can

find all registered systems and devices on the organization’s homepage at www.field-bus.org.

7. A field device is faulty. Unfortunately, the replacement device supplied has a higher version number. What steps must be carried out in the automation system in order to restore functionality?

Yokogawa: Field devices with a higher version number usually include new functionality. In order to make the control system aware of this new functionality, the customer must install the latest drivers (supplied) in the system. Before the device is replaced in the field, the current parameter set of the device should

be uploaded. However, this should already have happened once commissioning was successfully completed. The new field de-vice then logs on automatically to the sys-tem’s live list. Each device has a unique identification, known as the device ID. This device ID is also transferred to the live list. Now the user must simply assign the legacy parameter set to the new device ID with a click of the mouse. The subsequent down-load, which does not restrict the other de-vices in the segment, ensures that the new device is equipped with the parameter set specific to the application.

If it should happen that an up-to-date driver is not supplied with the device and there is no internet access to enable the driver to be downloaded, a standard driver is available in the device. This simply en-sures that the device transfers its process value to the bus. All additional functions cannot be included in a universal standard driver. However, this at least ensures that the customer can put the application into operation at any time. All additional func-tionality can be activated once the appro-priate driver becomes available.

Measurement

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The ICON® cable product range is based on internationally recognized standards and offers standard as well as customized solutions.

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The best connection in plant engineering

Control

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Emerson:

The DeltaV control system from Emerson Process Management supports the user when replacing field devices. New DDs (De-vice Description) for the field devices can be loaded into the DCS at any time without af-fecting the current process in any way. Should a field device need to be replaced, the user can either use an identical field de-vice with the same version number or a newer version of the same field device type.

The only additional step re-quired when using field devic-es with a higher version num-ber is that the DD must first be uploaded into the DeltaV sys-tem.

Also, the steps involved when using a newer version are identical. The new field de-vice is commissioned by first of all connecting the new field device to the FF string.

The Replacement Wizard supports the user in carrying out the necessary steps (de-commissioning, commission-ing, download) so that the de-vice can be put back into op-eration. To do this, the user simply navigates to the rele-vant field device in the DCS Ex-plorer and starts the Replace-ment Wizard from there. This guides the user through the complete commissioning pro-cess, while also providing the option of exporting the con-figuration data from the old device and transferring them to the new one. This eliminates the need to reengineer the field device.

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8. How can you ensure that the correct cables are used or specified during installation?

Leoni:

As a cable manufacturer, we can only rec-ommend to users that they should always specify the requirements specification type A as per IEC 61158-2 for the fieldbus cable. This ensures that a component of the FF

system will guarantee the function for field-bus applications and that additional op-tions will be available for the future expan-sion of a plant. Furthermore, mechanical, thermal and other requirements in a plant (e.g. chemical resistance and fire behavior of cables) must be taken into account. In the case of type B fieldbus cables, it must be borne in mind that restricted lengths and “lower” electrical requirements are specified normatively.

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It is a fact that users will implement modern technologies only if there are measurable advantages to be gained by doing so. And this is clearly the case with Foundation Field-bus (FF), which was specially developed for use in process engineering systems. The ad-vantages are noticeable throughout the en-tire life cycle of these systems - during the planning, installation and commissioning phases as well as during operation. This has a positive impact on investment costs (CAPEX; Capability Expansions) and operat-ing costs (OPEX; Operation Expansions). If you ask users nowadays why they want to

What makes FOUNDATIONTM Fieldbus so valuable to Plant Asset Management?

implement FF, the reasons given relate pri-marily to the safe and reliable operation of the system. In order to operate a system in the best possible operating state, customers don’t just require information directly from the process. There must also be a certain amount of predictability. That is why more and more companies are relying on Plant Asset Management Systems (PAMS) in order to optimize maintenance work and the ef-fectiveness of their process engineering sys-tems. The aim is at least to sustain and at best to increase the value of the not insub-stantial investment in a plant.

Plant Asset Management

In general, there are three different types of maintenance, each of which has a different impact on the availability of a system. The most expensive type is corrective mainte-nance, i.e. an asset is not replaced unless it is defective. A possible consequence is the undesirable or unplanned shutdown of a system, which in turn can give rise to con-siderable costs. Preventive maintenance with cyclical maintenance intervals is an ef-fective way to prevent this. Modern systems already have an integrated maintenance in-terval planner together with the relevant maintenance protocols. The most elegant solution is to introduce predictive mainte-nance using a PAMS. This guarantees the highest level of availability with a minimal amount of work. However, it does assume that the system receives the necessary in-formation or diagnostics and is capable of managing and processing these in an intel-ligent manner. After all, a Plant Asset Man-agement System is not enough on its own. To be effective, the information must be in-tegrated into the system. This information can either be maintained by employees or imported from external files and systems (PIMS) or obtained through communicating directly with the field devices. The greatest success is achieved by combining all infor-mation pathways. What is crucial is that the Plant Asset Management System is kept up to date.

Managing Foundation Fieldbus field devices

As already indicated, there are assets which supply information digitally to the PMS, ei-ther automatically or, in the case of the HART protocol, on request. There are also system components, which are managed only “passively”. FF devices definitely count among those assets which are the easiest to integrate and which transmit their informa-tion independently. Drivers (Device Descrip-tions, DD) are copied over to ensure that the PAMS is aware of all of the capabilities of an FF device even when offline, in other words during the engineering phase. For this step, it makes sense to copy the field device doc-umentation, the relevant spare parts lists and additional maintenance information electronically to the system at the same time. Using templates, this means that a

PRM with interfaces to all systems.

The Device Viewer can interpret parameters graphically.

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large number of field devices can be inte-grated in a very short space of time.

If the field devices are arranged into a plant hierarchy in accordance with standard S88, you can obtain status information not just in relation to the assets. The status in-formation is passed through the individual levels, from equipment module, unit, cell, area, up to the site level.

This classification into a plant hierarchy means that diagnostics can be classified ap-propriately in the online alarm manage-ment system.

The status of the asset is shown using a traffic light system. In order to display field device diagnostics in a more standardized way in future, the NAMUR recommendation NE107 will be applied to an increasing ex-tent. There are already field devices avail-able today which implement this form of display. The FF specification already in-cludes a description of the NE107 profile. Its implementation is to be tested using the ITK (Interoperability Testing Kit). From the end of the year, standardized diagnostics will be available as an option in the ITK 5.1 test protocol. In all later versions, it will no longer be possible to pass the ITK without NE107.

If the user’s attention is drawn to a field device by means of the status symbols, more detailed information is required from the device. There are several ways to go about this, each of which differs primarily in terms of presentation. The simplest option is to have the current diagnostic parameters displayed in a parameter list supported by DDs. However, many users get bogged down by the range of parameters, and it is difficult to separate important information from unimportant information.

A question of presentation

That is why there are now ways to interpret these parameter lists graphically. Of these graphical solutions, the Device Viewers are the simplest. Both the production control system CENTUM VP as well as the Plant As-set Management System PRM (Plant Re-source Manager) from Yokogawa make use of this. The window uses a simple color change to indicate the status of a device to the plant operator. This solution is based on a graphical interpretation of txt files and is available as a standard solution for all FF devices. Alternatively, device manufactur-ers have the option of displaying their field devices in the best possible way using DT-Ms (Device Type Manager) or EDDs (Elec-tronic Device Descriptions). This has the at-traction of being able to display complex diagnostic interrelationships in perfect co-ordination with the field device. The more

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complex a field device and its diagnostic capabilities, the greater the challenge of displaying them in a user-friendly manner. Presentation can make the difference be-tween new technologies being accepted or not.

A nice example of how field device in-formation can be displayed graphically is in the case of valve diagnostics. Here, the user can kick off a partial lift test in control valves via the graphical display. This can be orga-nized completely using the PAMS so that ir-

regularities can be quickly detected through automated regular testing and the data saved to the database. In this way, the his-tory of key assets such as valves is automat-ically recorded in the Plant Asset Manage-ment database.

Displaying field device diagnostics is on-ly one small subtask of a modern PAMS. These diagnostics must also be managed in a database. For each maintenance alert, in-formation concerning the location, prob-lem, cause and required action must be stored.

From local to regional diagnostics

In order to carry out predictive mainte-nance, it must be possible to correlate the diagnostics of individual assets. Conse-quently, a Plant Asset Management System must be capable of linking up system diag-nostics and information from different field devices and connections with the knowl-edge of employees in order to generate re-gional diagnostics. The operator is obliged to ensure that assets which are particularly interrelated are monitored by a diagnostic module configured to suit the application.

Information from different assets are processed in PRM to provide a regional diagnostics.

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The status of an asset is passed upwards through the individual hierarchies.

here than in the case of individual assets. This diagnostic function is also completely integrated in Yokogawa’s plant asset man-agement system - all messages (location, problem, cause, action) are displayed in the database.

Although the bus physics of Foundation Fieldbus are extremely robust, changes in the system may affect the transmission me-dium. Over the long operating life, unno-ticeable degradation such as jitter or noise may arise. If users monitor these parame-ters automatically using a diagnostic unit which supplies the relevant information to the PAMS, changes can be detected early and located. This status is also displayed as a traffic light in the plant hierarchy and sent as a message via SMS or e-mail to the pro-duction control system.

Operators are also always interested in keeping the firmware of their field devices up to date, be this to correct errors or to avail of new functionality. The administra-tion of the different firmware versions should be taken care of in the PAMS. From there, the current version of any firmware can be downloaded into the device via the fieldbus. This is of particular significance for devices in zone 1, as it means they do not need to be dismantled in order to be up-graded.

Summary

FF automatically provides all the necessary information to the PAMS and provides solu-tions for displaying diagnostics in a user-friendly manner. To depart from pure device diagnostics and parameterization, a mod-ern system must also provide the option of generating regional diagnostics. FF devices are capable of providing key information. Of course, it is not the case that a process engi-neering system can only be automated us-ing Foundation Fieldbus. Nonetheless, this technology has shown how efficiently and easily it can be used in a Plant Asset Man-agement System.

Tim-Peter Henrichs, Product Manager Systems IA System Sales, Yokogawa Deutschland GmbH, D-40880 Ratingen, Telephone: (02102)-49 83-4 12 Telefax: (02102)-49 83-4 08,  [email protected], www.yokogawa.de

Alternatively, the operator must use one of the modules supplied.

These regional diagnostics are a further indication of the system status. They are al-so used to generate messages which can be sent to the online alarm management sys-tem implemented in the production control system.

The physical layer as a manageable asset

One asset which must not be ignored is the physical layer of the Foundation Fieldbus. As every segment has a high I/O, informa-tion and diagnostic density, predictive maintenance is of even greater significance

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Using established standards such as FDT/DTM, Turck - the specialist in sensors, field-buses and interfaces - is launching more and more products on the market which will at last enable physical layer componen-ts to be managed in asset management sy-stems too. Physical layer components form the infrastructure which connects field de-vices and control systems. The highlight of the product range is the Diagnostic Power Conditioner system (DPC), which can supp-ly power to Foundation Fieldbus networks and monitor them.

The DPC is capable of long-term detec-tion of faults such as jitter or noise in Foun-dation Fieldbus segments. As it can also quickly locate the source of an error, the sy-stem also supports the user when commis-sioning a fieldbus system. Using an appro-priate alarm system, fieldbus-related faults or even failures can be completely elimina-ted.

With a redundant configuration, the sy-stem primarily provides each segment (up to 16 segments) with a maximum of 800 mA of output current and 30 VDC of output voltage. In practice, this facilitates the im-plementation of long-distance segments of up to 1,900 m. The ADU (Advanced Dia-gnostic Unit) records the fieldbus signal and its characteristics without any feedback. To ensure that this happens, Turck has imple-mented all-round galvanic isolation. After all, it would not make sense to diagnose the bus and, at the same time, to incorporate another source of error. That is why it is im-portant to be consistent in not only galvani-cally isolating the individual segments from each other, but also in guaranteeing that this isolation exists between the segments and the bulk power, between the segments

A look at the fieldbus

and the ADU and between the segments and the bus system, which transmits dia-gnostic data to the higher-order system.

Separate diagnostic bus

To guarantee that the diagnostic data ob-tained are transmitted safely to the higher-order system, the Foundation Fieldbus H1 must not be used. On the one hand, it is pre-cisely in the H1 segments that errors should be detected. On the other hand, the large amount of diagnostic information on each H1 segment would put an unnecessary bur-den on the limited bandwidth of 31.25 kBit/s. That is why the company is using High-Speed Ethernet (HSE) as a separate di-agnostic bus.

Only the physical layer changes in the process, not the protocol. Nowadays, Foun-dation Fieldbus High-Speed Ethernet is used as an interface to the control system in order to connect a large number of H1 seg-ments (which are converted to HSE using linking devices) to the control system via an interface card. A second area where it is used is in the connection of HSE linking de-vices to asset management systems. In this case, only the diagnostic data, alarms and parameter data are taken from the H1 seg-ments and transmitted via HSE.

The interface to the asset management system in the DPC is a HSE field device. This is a field device whose sensors are identified as ADUs. This field device also has Foundati-on Fieldbus function blocks, which map the individual diagnostic values. In this way, the physical layer diagnostic data can be trans-mitted via the same block library to the higher-order system as has been done for years in the case of pressure, temperature,

level or flow transmitters. The diagnostic da-ta for the segment are transmitted to the higher-order system using the same proto-col but via a separate bus (HSE). As the seg-ment diagnostics are supplied by a HSE field device, values are transmitted via standard function blocks, and the alarm system uses standard FF alarms. The DPC system can be connected simply by using standard ether-net components, with the result that an exi-sting ethernet structure can be used for segment diagnostics.

Diagnostic data from three areas

There is a lot that can be measured in the case of a digital bus. So as not to distract the user from what is important and in order to be able to identify weak points in the long-term, the individual values are categorized into different groups. In general, the DPC system supplies diagnostic data from three areas:� Diagnosis from the physical layer Foun-

dation Fieldbus H1� H1 protocol statistics� Diagnosis via the DPC system itself

The focus is on diagnosing Foundation Fieldbus H1. The results are divided into the groups “Electrical measured values“ and “Communication measured values“. The first group includes jitter, noise, ripple and si-gnal amplitude. These indicate how good a segment is. These “electrical measured va-lues“ usually change during the plant life cycle (mostly over 20 years), deviating from the values obtained during and after com-missioning. Reliable detection of these de-

Asset Manage-ment for fieldbus connections: with the DPC system (Diagnostic Power Condi-tioner), Turck offers plant oper-ators unimagined possibilities for asset manage-ment.

Long-term fieldbus diagnostics: The DTM of the new DPC system even detects subtle changes within individual fieldbus segments.

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viations is the main function of the DPC sy-stem. It is not only able to determine the status of a segment during commissioning, but continuously observes the many mea-sured values of each individual segment. Something similar applies to the communi-cation parameters. The DPC system thus es-tablishes if the number of frame errors and token sequence errors is increasing. For the plant operator it is also helpful to be able to see online if enough free communication time for an additional field device is still pre-sent on a segment.

The plant operator can display all the re-levant values - and considerably more on request - online via a device description (DD) or a DTM. The HSE field device in the DPC system monitors all segments and ge-nerates an alarm in the case of a limit value violation. This means that the plant opera-tor is informed early on of changes in the physical layer. The HSE field device not only transmits the diagnostic values but also analyzes the bus signal recorded by the ADU, generates the diagnostic information and assesses it. The individual data are pro-cessed in this way and are transmitted using

a standard mode of communication (Foun-dation Fieldbus High-Speed Ethernet) to the higher-order system.

To make these nontrivial fieldbus dia-gnostics transparent for the user, a HSE field device DTM developed by Turck displays the individual values and parameters in graphical form. This information can be in-tegrated into a wide range of FDT frames. Users can use the FDT frames as standalone tools or anchor them in modern asset ma-nagement systems. The DTM enables on-line and offline parameterization, as well as the display of individual measured values and different statistics in the form of pie charts.

Jan Rieks ZondermanProduct Manager, Fieldbus technology process automationHans Turck GmbH & Co. KG, D-45472 Mühlheim an der RuhrTelephone: +49- 02 08 49 52-0, e-mail: [email protected], www.turck.com

In addition to the flagship DPC-49-ADU, Turck is now offering the DPC-49-DU introductory model for FF networks.

Your contacts at the Fieldbus Foundation

www.fieldbus.org

[email protected]

FF German Marketing Organisation_R06

© 1999 – 2008 Fieldbus Foundation5

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Kerpen

Automation

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Foundation Fieldbus (FF) has established itself as a standard technology in the area of process technology. This is due in particular to the extensive capabilities it provides in terms of device configuration and bus sy-stem diagnostics. As a result, a special confi-guration interface on the sensor can be dis-pensed with. The same applies to the one-rous task of accessing the sensor, depen-ding on the installation site.

The Foundation Fieldbus specification facilitates usage in hazardous areas, with the devices connected to the H1 segment normally being implemented in an intrinsi-cally safe manner. In order to keep the cost of hardware design or software integration as low as possible, Softing now provide an interface module (FBK) which can be inte-grated at minimum cost into almost any field device due to its extremely small exter-nal dimensions.

Valuable information

There are already various solutions available for connecting 4-20mA devices to FF. Howe-ver, the majority of these products are not suitable for implementation in the existing enclosure. They are deployed in a special enclosure between the fieldbus and the de-vice. This means that it is not possible to configure or diagnose devices accordingly. Therefore, a crucial precondition for asset management is not met.

Maintenance activities and device re-placements always necessitate the shut-down of the plant and give rise to consi-derable costs. For this reason, they should be avoided for as long as possible. That is why it is necessary to obtain as much infor-mation as possible on the current status of a field device, without necessarily having to be on site.

In addition to cyclical data transmission, which is used to transfer measured values in real-time, Foundation Fieldbus offers acyclic (untimed) data transmission. This is availa-ble for device configuration and diagnostic purposes. It gives the plant operator a use-ful tool with which to change the device configuration or access information on the status of any individual device during sy-stem operation This information may be used as the basis for decisions on when to service or replace a device.

Simple, compact and cost-effective

Nowadays, there are still many field devices with an analog or HART interface because manufacturers are shying away from the ad-ditional capital investment required for the implementation of an FF interface. In order to keep the barrier to investment as low as possible, Softing has developed an inter-face module (FBK – Fieldbus Kit) for Founda-tion Fieldbus, which has a serial or HART in-terface on the device side. If the serial inter-

face is used to connect the field device, Softing guarantees communication with the field device using the Modbus RTU pro-tocol or, optionally, using a proprietary pro-tocol.

To integrate the FBK into a field device from a hardware point of view, the device is connected to the main circuit board using a plug-in connector. This has the advantage that the main circuit board of the field de-vice can also be fitted with components be-low the module. This results in an extremely compact, simple and cost-effective soluti-on. The overall height of the solution (from the main circuit board to the tallest compo-nent) is only 10mm when installed. Measu-ring 40 x 40mm, the module fits into almost all field devices. In addition to ATEX certifi-cation, the FBK module is also certified for use in group IIC/IIB in Ex zone 1. In this case, the outputs may also be passed into Ex zo-ne 0.

Lars MickanIndustrial Automation Product MarketingSofting AG, D-85540 Haar, Tel. +49 89 456 56-168, Fax -399,e-mail: [email protected], Internet: www.softing.com

Interface module for integrating FOUNDATIONTM Fieldbus

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The Emerson logo is a trademark and service mark of Emerson Electric Co. ©2007 Emerson Electric Co.

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Foundation membership: One step ahead of the competitionRegardless of your company size or industry, Fieldbus Foundation membership offers you significant bene-fits. Gain a competitive edge - join the Fieldbus Foun-dation today!

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