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Process Instrumentation and Analytic

PROFIBUS
The Fieldbus conforming to IEC61158
Bereichskennung
oder Produktname

PROFIBUS - The Fieldbus for Totally Integrated Automation 1 of 67


Process Instrumentation and Analytic

PROFIBUS
The Fieldbus for Totally Integrated Automation
Bereichskennung
oder Produktname

C C C

B B B B

A A A A A
Raw Goods
material out
Process

Upstream Mainstream Downstream

Integrated communication in the field via PROFIBUS

PROFIBUS is the only Fieldbus today that allows total plant


automation using only one protocol for communication.

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Process Instrumentation and Analytic

PROFIBUS
One protocol – different physical layers
Bereichskennung
oder Produktname

Physical layer Application

PROFIBUS DP RS485 for standard applications (2-wires and shield)

PROFIBUS DP Fibre Optic fast, long distance, RFI immunity

PROFIBUS DP RS485-is connects remote I/Os and DP/PA Links in


hazardous areas with safe areas

PROFIBUS PA MBP for Process Devices in safe and hazardous areas,


Manchester Coded powers Process Devices, flexible topology, Profiles
Bus Powered interoperability, interchange-ability, standardised
data format

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Process Instrumentation and Analytic

PROFIBUS
Fundamental properties
Bereichskennung
oder Produktname

Systembus Industrial Ethernet / Fast Ethernet  S7 Controllers allow up to 10 PROFIBUS DP


communication processors
 Speed of PROFIBUS DP is adjustable up to
S7 400 Controller 12Mbit/s.
PROFIBUS DP  Each PROFIBUS DP allows up to 123 slaves.
Slaves The DP/PA-Link is one DP-Slave with up to 30
Fibra Optica RS485 process devices (PA-Slaves) per link.
PROFIUS DP

 Each PROFIBUS DP segment with RS485) allows


RS485 connection of 31 slaves.. RS485 segments are
cascaded using repeaters. The length of one
OLM OLM DP/PA-Link RS485 segment is 200m @ 1.5Mbit/s.
 Fibre optic and RS485 segments are connected
using Optical Link Modules (OLM).
Repeater  Fibre optic segments can have a length up to
PROFIBUS PA 2.8km. Fibre optic segments can be cascaded
Process Devices using OLMs. Fibre optic buses can have a ring
structure.
 RS485 and fibre optic physical layers are
transparent for the protocol.

Repeater
PROFIBUS DP Salves

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Process Instrumentation and Analytic

PROFIBUS
Integration of Remote I/Os und
Bereichskennung
oder Produktname

Systembus Industrial Ethernet / Fast Ethernet  The integration of remote I/Os in PROFIBUS is a
prerequisite for complete plant automation in order
to handle signals from:
S7 400 Controller - Pressure switches
- Temperature switches
- Level switches
ET 200M - Flow switches, etc.
Remote I/O to operate
- on/off valves
- solenoid valves
PROFIUS DP

to integrate conventional analogue I/Os and


special modules such as weighing batching,
digital I/Os positioning and back up PID loop control.
Counters
Analogue I/Os  PROFIBUS maps the HART Protocol.
ET 200is including HART This allows central engineering of existing field
Remote I/O Protokoll instruments and thus protects past investment.
 The trend is to locate remote I/Os inside
hazardous areas.

ET 200M Special modules for


Remote I/O Weighing
Batching
PID Loop Control
SIWAREX Positionierung
Weighing etc.
PROFIBUS - The Fieldbus for Totally Integrated Automation 5 of 67
Process Instrumentation and Analytic

PROFIBUS
Integration of Remote I/Os wireless
Bereichskennung
oder Produktname
Wireless integration to ETHERNET at
control level.
Systembus Industrial Ethernet / Fast Ethernet
Integration of both standards .

S7 400 Controller
PROFINET IO

Remotes I/O
PROFIUS DP

Remotes I/O
Drives

Motor

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Process Instrumentation and Analytic

PROFIBUS
Integration of Motor Control Centres (MCC)
Bereichskennung
oder Produktname

Systembus Industrial Ethernet / Fast Ethernet


 The integration of the motor control centres in
PROFIBUS is a prerequisite for total plant
S7 400 Controller automation
 PROFIBUS provides comprehensive
Variable speed drives diagnostics such as.:
MASTERDRIVES - overload
MICROMASTER - motor temperature
- monitoring of current consumption
PROFIUS DP

- earth fault
Motor - torque monitoring
- operating hours, etc.
Motormanagement
SIMOCODE

Motor

Electric Actuators
SIPOS

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Process Instrumentation and Analytic

PROFIBUS
Integration of local Operator Panels
Bereichskennung
oder Produktname

Systembus Industrial Ethernet / Fast Ethernet


 Operator panels for display and operation

S7 400 Controller  Text displays


 Push Button Panels
 Bar Code Readers

OP37
PROFIUS-DP

OP7

TD17

PP17

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Process Instrumentation and Analytic

PROFIBUS
Integration of ASI and PID Loop Controllers
Bereichskennung
oder Produktname

Systembus Industrial Ethernet / Fast Ethernet


 The Actuator Sensor Interface AS-I is designed for
Controller fast transmission of digital signals such as signals
from push buttons, limit switches, etc.
The DP/AS-I Link connects AS-I and
PROFIBUS DP.
 PID Loop Controllers provide:
- Conventional loop control via 4 bis 20 mA, e.g.
for Back up
PROFIUS DP

- Single Loop Integrity


- Distributed control with local operation
- Standardised Human Machine Interface
DP/AS-I Link Integration via PROFIBUS provides remote
Actuator-Sensor-Interface operation and central visualisation.

PID Loop Controllers

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Process Instrumentation and Analytic

PROFIBUS
Integration of Process Devices via PROFIBUS PA
Bereichskennung
oder Produktname

Systembus Industrial Ethernet / Fast Ethernet  The DP/PA-Link connects the fast
PROFIBUS DP (up to 12 Mbit/s) and
PROFIBUS PA (31.25 kbit/s)
S7 400 Controller  Each DP/PA-Link can connect up to 5
PROFIBUS PA using DP/PA-Couplers.
DP/PA-Couplers for safe and hazardous areas
can be mixed.
 DP/PA-Couplers are compact devices providing
DP/PA-Link
the following functions:
PROFIUS DP

- swap physical layer from RS485 to


PROFIBUS PA
Manchester Coded Bus Powered (MBP)
Flow Valve - galvanic isolation
pH,C,O2 positioner - separation of safe and hazardous areas
- provide current for the bus
 Up to 31 process devices can be connected to
each DP/PA-Link.
 Each DP/PA-Link can read and write 244 bytes
net information.
 The maximum is to connect more than 3600
Temperature Process Devices to one PROFIBUS DP.
Gas
Analyser Pressure Level

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Process Instrumentation and Analytic

PROFIBUS
Addresses of PROFIBUS Slaves
Bereichskennung
oder Produktname

System bus Industrial Ethernet / Fast Ethernet


 All devices connected to PROFIBUS have a
unique address allocated prior to commissioning.
S7 400 Controller The range for the address is 0 to 125.
Addresses 0, 1 and 2 are usually reserved for the
system.
 The DP/PA-Links have their own range of
2 PROFIUS DP
addresses between 0 and 125.
3 • • • • • • • 125 The address of the link as a master for
PROFIBUS PA is 2.
DP/PA-Link DP/PA-Link
 The default address of field devices with
2 2 6 125 PROFIBUS PA is 126.
6 7 Address setting is either via local operation or via
PROFIBUS PA

PROFIBUS PA

SIMATIC PDM.

3 4 5 3 4 5

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Process Instrumentation and Analytic

PROFIBUS
Properties PROFIBUS PA
Bereichskennung
 PROFIBUS PA is by design suitable for
oder Produktname field devices in safe and hazardous areas
Zone 0, 1 and 2 (Class 1 Div 1 and Class 1 Div 2)
 PROFIBUS PA can bus-power field devices
DP/PA-Link  PROFIBUS PA allows a flexible bus topology
PROFIUS-DP

with drops up to 30 m.
 Standardised functionality of PROFIBUS PA
devices via profiles. Profiles describe the function
blocks, mandatory and optional parameters.
 Devices with PROFIBUS PA Profile 3 are not only
interoperable but also interchangeable without
any re-engineering

Drop Chicken foot

Manufacturer A
Manufacturer B

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Process Instrumentation and Analytic

PROFIBUS PA und FISCO


Plug & Play in hazardous areas
Bereichskennung
oder Produktname

 FISCO
Fieldbus Intrinsically Safe Concept
Model of an intrinsically safe fieldbus
 FISCO is a prerequisite for an intrinsically safe fieldbus

 PROFIBUS PA conforms to FISCO

 CENELEC approves conformance to FISCO


(CENELEC: European Committee for Electrotechnical Standardization
PROFIBUS-PA Comité Européen de Normalisation Electrotechnique
intrinsically safe Europäisches Komitee für elektrotechnische Normung )

 Provided all products used for a PROFIBUS PA segment


conform to FISCO then:
Calculation of inductivity and capacity is not necessary
Instruments can be added at a later time
Inspection of the segment is not needed
PROFIBUS PA is intrinsically safe after devices have
been changed

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Process Instrumentation and Analytic

PROFIBUS PA
Length of the bus
Bereichskennung
oder Produktname

DP/PA-Couplers
ia/ib - safe area  The DP/PA-Couplers provide the available voltage
PROFIUS DP

 The minimum voltage for a PROFIBUS PA device is 9V


DP/PA-Link
 The typical impedance of the bus cable for
PROFIBUS PA is 44  km
Length PROFIBUS PA:
 Calculation of the bus length is based upon Ohm’s law
PROFIBUS PA

 Assumption:
Safe area: 560 m The DP/PA-Coupler provides it’s maximum current.
This allows to add more field devices at a later date
 The maximum length of PROFIBUS PA includes the total
Hazardous area: 680 m length of all drops

The maximum length of a PROFIBUS PA is 1900 m. Following design rules for


real plants the total length of a PROFIBUS PA is 560 m in safe areas and up to 680 m in
hazardous areas.

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Process Instrumentation and Analytic

PROFIBUS PA
How many devices can be connected??
Bereichskennung
oder Produktname  The available current for the field devices is provided by the
DP/PA-Couplers
PROFIUS DP

1 A for non safety areas


DP/PA-Link with
DP/PA-Couplers 110mA for safety areas
 Typical current consumption of process devices:
Available current: Bus powered: 12 mA
PROFIBUS PA

Devices with separate


Safe area: 110 mA power supply: 10 mA
 Design guide:
Total current consumption of all devices connected to
Hazardous area PROFIBUS PA must not exceed the available current
a/ib classified: 110 mA provided by the DP/PA-Coupler.

 Example: 110 / 12 mA = 9.17 bus powered devices

Up to 9 bus powered devices within hazardous areas can be connected to one DP/PA-Coupler.
Up to 31 devices within safe areas can be connected to one DP/PA-Coupler.
Up to 5 PA Couplers per DP/PA Link
Up to 64 devices can be connected to one DP/PA-Link.

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Process Instrumentation and Analytic

Bereichskennung
oder Produktname

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Process Instrumentation and Analytic

Bereichskennung1º Caso - Red Profibus PA en area no clasificada (Non-Ex) 


oder Produktname
Datos iniciales:
Up to 5 couplers
Max. 64 devices in total
Max. 244 bytes of input data and 244 bytes of output data
For Analog Input devices each device has 5 bytes of data:
244/5 = 48.8
Therefore you can have a maximum of 48 analog input devices per link
Devices start at address 3
Número de instrumentos Profibus PA direccionables por un DP/PA Link: 64
Número total de DP/PA Couplers por DP/PA Link: 5 
Consumo de corriente típico por instrumento PA: 12 mA
Corrente adicional por instrumento PA (Siemens) en caso de falla: 3 mA
Capacidad nominal de corriente del DP/PA Coupler (Non-Ex): 400 mA (versiones antigüas) 
Para cada segmento alimentado por el DP/PA Coupler tenemos:
 a) 400 mA / 12 mA = 33 Instrumentos
 Se puede considerar que todos los instrumentos esten en condición de falla simultaneamente, tendríamos:
 b) 400 mA / 15 mA = 26 Instrumentos (corresponde a una reserva de 84 mA en relación a una situación normal de operación)
Siemens A&D PI usa como regla de proyecto una caída de 20 mA por segmento. De esta forma, tenemos:
c) (400 mA - 20 mA) / 12 mA = 31 Instrumentos (este es el número oficial que utilizamos para los DP/PA Coupler)
 

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Process Instrumentation and Analytic

Bereichskennung
Para los calculos subsecuentes utilizaremos este número (item C) como número máximo de instrumentos por segmento PA no Ex (o
oder Produktname
sea por DP Coupler no Ex).
 
Para un número total de instrumentos por DP/PA asumiremos la cantidad de 40, que resulta de los siguientes valores:
 
d) Número total de Slots procesados por el DP/PA link = 40 x 5 + 40 = 240 > 236 (limite del DP/PA link, a 5 Slots por instrumento y un
factor de seguridad. Por ejemplo, un transmisor de temperatura ocupa 2 slots).
 Conclusión, tenemos los siguientes limites para un DP/PA link para área no Ex:
e) Número max. de instrumentos por DP/PA Link: 40
f) Número max. de instrumentos por DP/PA Coupler: 31
g) Número max. de DP/PA Couplers: 5
 
2º Caso - Red Profibus PA en área clasificada Ex [b] (Zona 1 y Zona 2)
 Datos iniciales:
Número de instrumentos Profibus PA direccionables por un DP/PA Link: 64
Número de Slots que pueden ser procesados por un DP/PA Link: 236 - nº de PA slaves (instrumentos)
Número total de DP/PA Couplers por DP/PA Link: 5 
Número típico de Slots por instrumento PA: 5
Consumo de corrente típico por instrumento PA: 12 mA
Corriente adicional por instrumento PA (Siemens) en caso de falla: 3 mA
Capacidad nominal de corriente del DP/PA Coupler (Ex): 110 mA
Corriente máxima por segmento PA EEx [b]: 110 mA (definido por norma IEC)
 

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Process Instrumentation and Analytic

Bereichskennung
Para cada segmento alimentado por un DP/PA Coupler tenemos (considerando la corrente máxima definida por norma):
oder Produktname
 
a) 110 mA / 12 mA = 9 Instrumentos (este es el número oficial que utilizamos para los DP/PA Coupler)
 
Pueden ser considerados que todos los instrumentos esten en condición de falla simultaneamente, tenemos:
 
b) 110 mA / 15 mA = 7 Instrumentos (corresponde à una reserva de 21 mA en relación a una situación normal de operación)
 
Siemens A&D PI usa como regla de proyecto una caída de 20 mA por segmento. De esta forma, tenemos:
 
c) (110 mA - 20 mA) / 12 mA = 7 Instrumentos 
Para los cálculos subsecuentes utilizaremos este número (item C) como número máximo de instrumentos por segmento PA EEx
[b] (esto es por DP Coupler Ex)
 Para el número total de instrumentos por DP/PA link asumiremos el número 40, que resulta de los siguientes valores:
 
d) Número total de Slots processados por el DP/PA link = 40 x 5 + 40 = 240 > 236 (limite del DP/PA link, por 5 Slots por instrumento es
un número que ya posee un factor de seguridad. Por ejemplo, um transmisor de temperatura ocupa 2 slots).
 
Conclusión, tenemos los siguientes limites para un DP/PA link para área Ex [b]:
e) Número total de instrumentos por DA/PA Link: 35
f) Número total de instrumentos por DP/PA Coupler: 7
g) Número de DP/PA Couplers: 5
 

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Process Instrumentation and Analytic

Bereichskennung
3º Caso - Rede Profibus PA en área classificada Ex [b] (Zona 0)
oder Produktname
 Datos iniciales:
Número de instrumentos Profibus PA direccionables por un DP/PA Link: 64
Número de Slots que pueden ser procesados por un DP/PA Link: 236 - nº de PA slaves (instrumentos)
Número total de DP/PA Couplers por DP/PA Link: 5 
Número típico de Slots por instrumento PA: 5
Consumo de corriente típico por instrumento PA: 12 mA
Corriente adicional por instrumento PA (Siemens) en caso de falla: 3 mA
Capacidad nominal de corrente do DP/PA Coupler (Ex): 110 mA
Corriente máxima por segmento PA EEx [b]: 90 mA (definido por norma IEC)
 
Para cada segmento alimentado por DP/PA Coupler tenemos(considerando la corriente máxima definida por norma):
 
a) 90 mA / 12 mA = 7 Instrumentos
 
Pueden se considerado que todos los instrumentos esten en condición de falla simultaneamente, tenemos:
 
b) 90 mA / 15 mA = 6 Instrumentos (corresponde à una reserva de 18 mA en relación a una situación normal de operación)
 
Siemens A&D PI usa como regla de proyecto una caída de 20 mA por segmento. De esta forma, tenemos:
 
c) (90 mA - 20 mA) / 12 mA = 5 Instrumentos
 

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Process Instrumentation and Analytic

Bereichskennung
Para los calculos subsecuentes utilizaremos el número del item B (6) como número máximo de instrumentos por
oder Produktname
segmento PA EEx [a] (esto es por DP Coupler Ex)
 
Para el número total de instrumentos por DP/PA link asumiremos el número 40, que resulta de los siguientes valores:
 
d) Número total de Slots procesados por el DP/PA link = 40 x 5 + 40 = 240 > 236 (limite del DP/PA link, pueden ser 5 Slots
por instrumento y es un número que ya posee un factor de seguridad. Por ejemplo, un transmisor de temperatura ocupa 2
slots).
 
Conclusión, tenemos los siguientes limites para un DP/PA link para área Ex [b]:
 
e) Número total de instrumentos por DA/PA Link: 30
f) Número total de instrumentos por DP/PA Coupler: 6
g) Número de DP/PA Couplers: 5
 
 
    Estos números son valores conservadores que contienen un buen margen de seguridad, debiendo ser utilizados para
elaboración de ofertas , y quedando sujeto a una verificación final con el detalle del proyecto. 
    Otros valores son posibles, pero exigen un cálculo mas detallado, tener en consideración el consumo exacto de
corriente por instrumento.

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Process Instrumentation and Analytic

PROFIBUS PA
Topology and installation
Bereichskennung
oder Produktname

 Maximum length of drops is 30 m


DP/PA-Link This includes drops off chicken
foot
PROFIUS DP

 The use of professional


installation equipment is strongly
recommended, i.e. from
- WEIDMÜLLER, or
- HIRSCHMANN, or
Chicken foot - TURCK, or
- SIEMENS, etc.
 One common potential ground is
necessary

PROFIBUS PA T-connectors  Multiple connections to this


potential ground is strongly
Terminator recommended
 PROFIBUS PA requires
Potential ground termination

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Process Instrumentation and Analytic

PROFIBUS PA FOR HIGH


AVAILABILITY CONFIGURATIONS
Bereichskennung
oder Produktname

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Process Instrumentation and Analytic

PROFIBUS PA
Installation using Split Connect
Bereichskennung
oder Produktname

 Split connect enables fast


installation of a PROFIBUS PA
network
 The central locking screw can be
grounded and is available as a
terminator
 T-Connectors can be cascaded in
order to create a multi point connector
 An M12-outlet is available for the
T-Connector for the screw
connection of a field device.
 M12-Connector in the field devices
are an alternative to the standard
cable gland

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Process Instrumentation and Analytic

Design Process
Bereichskennung
oder Produktname
Grounding Practices Rules for PA Network
Design
For non-IS
 Ground the shield at one point only and continue the shield from device to
 Do not exceed max. distance specification for cable type
device (i.e. do not ground shield at the unit).
 Spur lines length depend on number of spurs
For IS:  Voltage at every device must be > 9V
 Ground the shield at each device  Distance also depends on coupler
 Have a equal-potential grounding grid

IS Design Process
FISCO:
Max length is 1900m 1. Layout the network
Spur Lines (1-24 lines) can have a max. length of 30m 2. Pick your connection method
Barriers are built into coupler 3. Pick your coupler
Have to use Class A cable
4. Add up all the device current ratings = Total Current
Add up current draws
5. Verify that the total Current < Couplers current rating
Entity: 6. Calculate worse case voltage drop
Use different cables
7. Verify that Coupler Voltage – Voltage drop > 9V
Do hand calculations your self
Less devices per network

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Process Instrumentation and Analytic

Calculate Voltage at last device


Bereichskennung
Calculate Voltage at last device
Calculating
oder Produktname Total Current of the
V last = V coupler – V drop
Segment
Where:
I segment = ∑ I n V last = Voltage at last device
V coupler = Voltage supplied by Coupler
V drop = Voltage drop in system
Where:
I segment = Total Current of the segment Rule:
V last > 9V
In = Current of device number ‘n’
Note:
Typical loop resistance of a class A cable is 44 ohms/km
Coupler Voltage is max. of 32VDC for non-IS
Coupler Voltage is max. of 13.5VDC for IS
Calculating Voltage Drop
(Worse Case) 10mA 40m 30m
V drop = I segment * (R loop * L segment) 20m 25m
35m 25m

Where:
240m 2m 60m 1m
V drop = Voltage drop
I segment = Total current of the segment 45m 35m
R loop = Loop Resistance of the cable
L segment = Length of the segment

Total Length = 240+20+40+35+45+2+60+25+30+25+1+35= 558 meters < 1900 meters


Total Current = 10*20mA = 200 mA < 1A
Voltage drop (worst case) = 0.2A*0.558km*44ohms/km= 4.91 Volts
Voltage at last device = 32V-4.91V = 27.09V>9 V

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Process Instrumentation and Analytic

PROFIBUS
Cyclic and acyclic communication
Bereichskennung
oder Produktname

Master Class 1 Master Class 2


cyclic acycic
acyclic cyclic

1 2 3 1

Read process variables, Read/write parameters and


write manipulated variables process variables
2
PROFIBUS DP

PROFIBUS PA

Slave 1 Slave 2 Slave 3

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Process Instrumentation and Analytic

PROFIBUS PA
Cycle time
Bereichskennung
oder Produktname

cyclic
(4 Byte measured value + 1 Byte Status)

acyclic
(read TAG: 32 Byte)
PROFIBUS DP
up to 12 MBit/s
max. 1 ms @ 12 MBit/s
Example:Cycle time =
3 x 20 ms + 22 ms + 20 ms = 102 ms
DP/PA Link 20 ms

PROFIBUS PA 31,25 KBit/s

Cycle time per device for first


variable is max. 20 ms
Cycle time for additional variables is
max. 2 ms per variable.
20 ms 22 ms

20 ms 20 ms

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Process Instrumentation and Analytic

PROFIBUS PA
Device Profiles
Bereichskennung
oder Produktname

 Device Profiles standardise the functionality of


field devices with PROFIBUS PA, incl.
Status
function blocks such as Physical block
cyclic and Transducer blocks and Analogue Input blocks.
Measured variable acyclic The profiles standardise mandatory and
optional parameters of Transducer Block for
all principles, e.g. flow
TAG
- Magnetic flow meters
Vendor - Coriolis mass flow meters
- Ultrasonic flow meters, etc.
HW-/SW-Revision
PA-Profile  Device Profiles exist for
PROFIBUS ID
acyclic - Transmitters
(e.g.. for
Filter time
pressurer)
- Analysers
- Actuators
Alarm-/Warning limits - Digital Input
- Digital Output
 The Profile 3 for PROFIBUS PA provides
besides interoperability also the option of
Vendor-specific acyclic
parameters interchangeability. Field devices from different
manufacturers can be exchanged without
reengineering of the system.

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Process Instrumentation and Analytic

PROFIBUS PA
Advantages of Profile 3 versus Profile 2
Bereichskennung
oder Produktname

Certification Profile  More precise definition of the profile


Version 2.0 Version 3.0
 Functional enhancement
- definition of additional function blocks
Signal behaviour
(hardware)   - diagnostic messages (e.g. maintenance required)
- definition for failsafe
 Interchange-ability
Cyclic - Profile GSDs
Communication - Profile DDs
(DP V0 service)    Bug fixing

Acyclic
Communication
(DP V1 service) 
Conformity
to profile

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Process Instrumentation and Analytic

PROFIBUS PA
The block model
Bereichskennung
oder Produktname

 Block model of a simple simple field


device (e.g. SITRANS T3K)
 Multivariable field devices can have
Device Management multiple sensors, transducer blocks

PROFIBUS - PA
and function blocks
 SITRANS P DS3 can have a flow
Physical Block totaliser
 For simulation purposes both, the
input and the output of the function
block can be simulated.

Sensor Transducer Function


Block Block
Analogue Input

Measured value = input value


Process value = output value

PROFIBUS - The Fieldbus for Totally Integrated Automation 31 of 67


Process Instrumentation and Analytic

PROFIBUS PA
Transducer blocks
Bereichskennung
oder Produktname

• Transducer blocks are being specified for the


various measuring principles.
• Access to the sensor or actor is via a device
independent interface between Transducer
Block and Function Block.

PROFIBUS - The Fieldbus for Totally Integrated Automation 32 of 67


Process Instrumentation and Analytic

PROFIBUS PA
Functions Blocks
Bereichskennung
oder Produktname

Function Blocks

Analog Input Analog Output Discrete Input Discrete Output PID-Control

Totalisator Counter
Nicht Bestandteil des Profils
Bestandteil des Profils

• Function blocks provide a standardised interface (e.g. 4byte measured variable plus 1 byte status) in
for the cyclic communication between controller and field device.
• Function blocks can provide basic functionality for automation tasks (e.g. scaling,
characterisation).
• Function blocks standardise the format of the data transmitted to the DCS System. This allows to
access the data within the DCS System via generic drivers.

PROFIBUS - The Fieldbus for Totally Integrated Automation 33 of 67


Process Instrumentation and Analytic

PROFIBUS PA
Measured variables and status byte
Bereichskennung
oder Produktname

00 . . . . . .= bad  PROFIBUS PA provides high


Measured variable resolution for process variables.
01 . . . . . .= uncertain
IEEE Floating 10 . . . . . .= good  All process variables have a status
Point Format byte.
(4 Byte) .... = Sub status
 Evaluation of the status byte allows
. . . . . . 00 = Limits o.k. validation of the variable and online
Status Byte . . . . . . 01 = low limit diagnostic of field device
. . . . . . 10 = high limit

Parameter
and
Process measured Cyclic
Device variables communication Status Byte

PROFIBUS - The Fieldbus for Totally Integrated Automation 34 of 67


Process Instrumentation and Analytic

PROFIBUS PA
Coding of the status byte to Profile 3.0
Bereichskennung
oder Produktname Status Combinations supported
by SITRANS T3K

Quality Code Sub status Limits


bad uncertain good
0 0 0 0 0 0 x x = non-specific 0 1 0 0 0 0 x x = non-specific 1 0 0 0 0 0 x x = ok
0 0 0 0 0 1 x x = configuration error 0 1 0 0 0 1 x x = last usable value 1 0 0 0 0 1 x x = update event
0 0 0 0 1 0 x x = not connected 0 1 0 0 1 0 x x = substitute-set 1 0 0 0 1 0 x x = active advisory
alarm (priority < 8)
0 0 0 0 1 1 x x = device failure 0 1 0 0 1 1 x x = initial value 1 0 0 0 1 1 x x = active critical
alarm (priority > 8)
0 0 0 1 0 0 x x = sensor failure 0 1 0 1 0 0 x x = sensor conversion 1 0 0 1 0 0 x x = unacknowledged
not accurate block alarm
0 0 0 1 0 1 x x = no communication 0 1 0 1 0 1 x x = engineering unit 1 0 0 1 0 1 x x = unacknowledged
(last usable value) violation (unit not in advisory alarm
the valid set) 10 0110 xx=1 unacknowledged
0 0 0 1 1 0 x x = no communication 0 1 0 1 1 0 x x = sub-normal critical alarm
(no usable value) 1 0 0 1 1 1 x x = initiate fail safe
0 0 0 1 1 1 x x = out of service 0 1 0 1 1 1 x x = configuration error 1 0 1 0 0 1 x x = maintenance
required

0 0 = Limits o.k.
0 1 = low limit
1 0 = high limit
1 1 = constant

PROFIBUS - The Fieldbus for Totally Integrated Automation 35 of 67


Process Instrumentation and Analytic

SIMATIC PCS7
Redundancy concept for PROFIBUS
Bereichskennung
oder Produktname

 Redundancy of Controller, including


System bus Industrial Ethernet / Fast Ethernet - Power Supply
- CPU
S7 417H Controller - Communication processor for system bus
- Communication processors for PROFIBUS DP
Communication between redundant CPUs is via
fibre optic bus
ET 200M
PROFIBUS DP

 Redundancy of up to 5 PROFIBUS DP buses


Remote I/O HART
Communication  Redundancy of master module for ET200M Remote
Digital I/Os I/O
 Redundancy of master module for DP/PA Link
DP/PA-
PROFIBUS PA
Link  Connection of non redundant slaves for PROFIBUS
DP via Y-Link

Devices with non-redundant


Y-Link Motor connection for PROFIBUS DP

PROFIBUS - The Fieldbus for Totally Integrated Automation 36 of 67


Process Instrumentation and Analytic

PROFIBUS und PROFISAFE


SIMATIC S7-400F/FH - the failsafe controller
Bereichskennung
oder Produktname

System bus Industrial Ethernet / Fast Ethernet  Failsafe communication to IEC61508 via PROFIBUS
 Coexistence of standard and failsafe communication
S7 417F
Failsafe Controller  Failsafe controllers and failsafe remote I/Os providing
SIL 1 to SIL3
 Coexistence of standard and failsafe applications in
PROFIBUS DP
one controller
 Redundant architecture for high availability possible
ET200 ET200MF
 TÜV certified
Remote I/O Remote I/O
Failsafe  Prototypes for PROFIBUS PA under development
DP/PA-
Link
PROFIBUS PA

Failsafe Failsafe
Actuator Limit
Failsafe switch
Transmitter
Data exchange broadcast

PROFIBUS - The Fieldbus for Totally Integrated Automation 37 of 67


Process Instrumentation and Analytic

PROFIBUS
System architecture SIMATIC PCS7
Bereichskennung
oder Produktname
Operator Terminals
(1...16)

Terminalbus Ethernet

Engineering OS Server OS
Station ES (1...6) Single user
system
Systembus Industrial Ethernet / Fast Ethernet
OS
S7 417 Controller
S7 414 Controller S7 H Controller

ET 200M
Remote I/O
PROFIUS DP

ET 200M
PROFIBUS DP

Remote I/O

PROFIBUS DP
Intrinsically safe
SIWAREX Operator Panel
PROFIBUS-PA PROFIBUS-PA
Weighing
DP/PA-Link
DP/PA-
Link Y- Link
AS-Interface

PROFIBUS - The Fieldbus for Totally Integrated Automation 38 of 67


Process Instrumentation and Analytic

PROFIBUS
Process devices from A&D PI
Bereichskennung Family SIPART DR
Temperature Flow Analyse
oder Produktname SITRANS FM r
OXYMAT
SITRANS F US

SITRANS T3K ULTRAMAT23

SIWAREX

ULTRAMAT SIPAN32
Pressure Level
SITRANS P DSIII SITRANS LR 400 SITRANS LC

DP
OXYMAT 61 CALOMAT 6

Positioner

SIPART PS2 SITRANS LR 300 SITRANS LS


200/300

PA / Profile 3
•cyclic/acyclic data
•safe data
•Diagnosis

: available : recent development

PROFIBUS - The Fieldbus for Totally Integrated Automation 39 of 67


Process Instrumentation and Analytic

SIMATIC PCS 7
Engineering Tool Set
Bereichskennung
oder Produktname

Library of Software-Tools allows central engineering of:


 Operator Stations
 Controllers
Continuous Function Chart (CFC)
Sequential Flow Chart (SFC)
Structured Control Language (SCL)
Hardware Configuration HW CONFIG
 Configuration of PROFIBUS networks
 Asset Management of Field Devices
including configuration via SIMATIC PDM,
the Process Device Manager
 All Tools are WINDOWS based and provide ease of
use (one hand engineering)

PROFIBUS - The Fieldbus for Totally Integrated Automation 40 of 67


Process Instrumentation and Analytic

SIMATIC PCS 7
Central Engineering of Process Devices
Bereichskennung
oder Produktname

Operator Engineering Station  Routing function allows communication


Station with SIMATIC PDM
Device between Central Engineering Station and
Description Field Device via PROFIBUS DP and
PROFIBUS PA or HART
Industrial Ethernet / Fast Ethernet Systembus  SIMATIC PDM is the integrated tool for
asset management i.e.
- configuration of field devices
S7 400 Controller - diagnostic and maintenance
- loop checks
- manager of central data base of field
devices
PROFIBUS DP  Integration of new field devices is via
Routing Device Descriptions. This opens SIMATIC
ET 200 M PDM for all manufacturers. DD-Library of
with HART DP/PA-Link the HART Communication Foundation is
AI or AO integrated as standard
PROFIBUS PA
4 to 20 mA

PROFIBUS - The Fieldbus for Totally Integrated Automation 41 of 67


Process Instrumentation and Analytic

SIMATIC PCS 7
Hardware Configuration
Bereichskennung  Hardware Configuration of the
oder Produktname controllers is via Drag & Drop.
Integration of GSD files is
performed
automatically in the background.
 The address of the field device
(in this example “8”) needs to
match the address in HW-CONFIG
 The controller starts communicating
with field device after compilation
and download of configuration
 The data of the process device is
available for applications via
the TAG of the device
Drag & Drop  Double click on the icon of field
Adresse: 8 device opens SIMATIC PDM, the
Process Device Manager for
configuration of field device

PROFIBUS - The Fieldbus for Totally Integrated Automation 42 of 67


Process Instrumentation and Analytic

SIMATIC PCS 7
Continous Function Chart (CFC)
Bereichskennung
oder Produktname

 Engineering of the CFC is via


Technological block Drag & Drop.
Input driver Diagnostic block  Driver block “PA_AI” is a generic
driver for all PROFIBUS PA
transmitters. Reference for the
driver is the TAG.
 PA_AI provides the process variable
in a high resolution 4 byte floating
point format. A status byte is
allocated to all process variables.
 Evaluation of the status bytes allows
online diagnostic of field device
V= Measured variable in IEEE floating  The data of the field device is
point format (4 Byte) available after compilation and
STATUS = Status of variable (1 Byte) download of CFC to controller.

PROFIBUS - The Fieldbus for Totally Integrated Automation 43 of 67


Process Instrumentation and Analytic

SIMATIC PCS 7 und PROFIBUS PA


Loop checks via simulation (1)
Bereichskennung
oder Produktname

 SIMATIC PDM forces a field device in


Display Operator Engineering Simulation and simulation mode and downloads a value.
valve position Station Station with display of valve The field devices takes this value as it‘s
66.66% SIMATIC PDM position 66.66% process variable. SIMATIC PDM can read
via SIMATIC PDM back this process variable. This verifies
Industrial Ethernet / Fast Ethernet Systembus acyclic communication between Engineering
Station and field device. Also the status of a
process variable can be simulated,
Read valve S7 400 Controller  The controller reads the process variable
position with it‘s status in cyclic communication from
66.66% the field device. The correct function of the
controller following the simulated value. This
PROFIBUS DP verifies cyclic communication between field
device and controller and the correct
Routing
function of the controller program.
4 to 20 mA  The controller sends the process variable to
DP/PA-Link
the Operator Stations. The correct
PROFIBUS-PA visualisation of the simulated variable can
be verified.
 The online diagnostic in controller identifies
simulated variables from PROFIBUS PA
devices.
Simulation of valve
position 66.66%

PROFIBUS - The Fieldbus for Totally Integrated Automation 44 of 67


Process Instrumentation and Analytic

SIMATIC PCS 7 and PROFIBUS PA


Loop checks via simulation (2)
Bereichskennung
oder Produktname

 Loop checks can be performed via the


Display Operator Engineering Simulation and central engineering by one person only.
valve position Station Station with display of valve  Several loops can be checked
66.66% SIMATIC PDM position 66.66% simultaneously.
via SIMATIC PDM  Loop checks can be performed 3 to 4 times
Industrial Ethernet / Fast Ethernet Systembus faster compared to conventional technology.
 Experience shows: 1 Person can check 100
loops per day
Read valve S7 400 Controller  Failure of the loop can be analysed very
position quickly. Detailed information of the loop is
66.66% available via central engineering.

PROFIBUS DP
Routing
4 to 20 mA DP/PA-Link

PROFIBUS-PA

PROFIBUS - The Fieldbus for Totally Integrated Automation 45 of 67


Process Instrumentation and Analytic

PROFIBUS and
SIMATIC PDM - Process Device Manager
Bereichskennung
oder Produktname

 Suitable tool for all field devices


 Open tool for all manufacturers due to
device descriptions
 Uniform Human Machine Interface provides
ease of use
 Integrated or stand alone version available
 Capable of communicating all parameters of
a field device
 Special functions such as
- address setting of field device
- line recorder display
-comparison of parameter sets

coloured marking of changed parameters

white read / write parameters


Parameter groups of
Process Devices grey read only parameters
(e.g. SITRANS P)
Online display of process variables

PROFIBUS - The Fieldbus for Totally Integrated Automation 46 of 67


Process Instrumentation and Analytic

Conventional instrumentation via 4 to 20 mA


The information gap
Bereichskennung
oder Produktname
Operator Engineering Interface to Enterprise
Stationen Station Resource Planning Büronetz

Industrial Ethernet TCP/IP

S7 400 Controllers

PROFIBUS DP

Remote I/O

Information gap between DCS and field level

4-20mA Process devices

PROFIBUS - The Fieldbus for Totally Integrated Automation 47 of 67


Process Instrumentation and Analytic

PROFIBUS
Closes the information gap to the field level
Bereichskennung
oder Produktname
Operator Engineering Interface to Enterprise
Stations Station Resource Planning Büronetz

Industrial Ethernet TCP/IP

S7 400 Controllers

PROFIBUS DP

DP/PA-Link PROFIBUS PA

Bi-directional
Central Device multi variable
Digital Diagnostic
Engineering Profiles communication
process
variables

Feldgeräte

PROFIBUS - The Fieldbus for Totally Integrated Automation 48 of 67


Process Instrumentation and Analytic

Block diagram
PROFIBUS PA versus 4 to 20 mA
Bereichskennung
oder Produktname

PROFIBUS DP  PROFIBUS PA provides


- a digital process variable in a 4 byte floating point
Sensor SITRANS T3K PA DP/PA-Link format
- a status for each process variable
- cycle times < 20 ms per transmitter (one variable)
PROFIBUS PA - full access to all information inside field devices
A µP PA-
Interface
D

PROFIBUS DP  4 to 20 mA requires one additional D/A converter


and one additional A/D converter. These
Remote I/O converters
SITRANS TK- H
- require a compromise between resolution and
D conversion time
4 to 20 mA A - require a measuring range for optimum resolution
A D the range of the transmitters needs to match the
µP
D A range in the system
- drift over time and depending on ambient
temperature
- produce an information gap

PROFIBUS - The Fieldbus for Totally Integrated Automation 49 of 67


Process Instrumentation and Analytic

Validation of readings
PROFIBUS PA versus 4 to 20 mA
Bereichskennung
oder Produktname

PROFIBUS DP
SITRANS LR  Online diagnostic of PROFIBUS PA
Radar Level Meter DP/PA-Link
validates all readings.
The process operates with valid process variables only.
PROFIBUS PA Invalid or no readings produce alarms.
A breakdown of communication requires further
Bus fault
investigation (e.g. live list, SIMATIC PDM,
HW_Config Online, >9V at field device etc.).

PROFIBUS DP
 Output of transmitter 4 to 20 mA.
Output of transmitter is not necessarily identical to
Remote I/O reading of Remote I/O.
Remote I/O or DCS/PLC can provide alarm if signal is
4 to 20 mA outside 4 to 20 mA.
Only a loop check can identify problem as long as
the problem is not intermittent.

Loop fault

PROFIBUS - The Fieldbus for Totally Integrated Automation 50 of 67


Process Instrumentation and Analytic

Bi-directional Multivariable communication


PROFIBUS PA versus 4 to 20 mA
Bereichskennung Many field device can measure more than one variable.
oder Produktname Field devices communicate process variable with the DCS and
receive information from the DCS. Example SITRANS F US PA:
- actual flow
PROFIBUS DP - total flow with reset input for flow counter
- total flow forward with reset input for flow counter
SITRANS F US DP/PA-Link - total flow reverse with reset input for flow counter
Ultrasonic - temperature
Flow meter - ultrasonic sound velocity
PROFIBUS PA - damping of ultrasonic sound amplitude
 PROFIBUS PA provides bi-directional communication of all variables.

PROFIBUS DP

Remote I/O  Transmission of only one variable via 4 to 20 mA loop.

4 to 20 mA

PROFIBUS - The Fieldbus for Totally Integrated Automation 51 of 67


Process Instrumentation and Analytic

Sensor failure
PROFIBUS PA versus 4 to 20 mA
Bereichskennung
oder Produktname

SITRANS T
PROFIBUS DP
Transmitter
for temperature
Sensor DP/PA-Link

PROFIBUS PA  Online diagnostic of PROFIBUS PA provides


instant information that sensor has failed.
SIMATIC PDM can provide more detailed information
Corrective action can be taken immediately.

Sensor failure PROFIBUS DP


 Identification of failure only if output of field device is
outside 4 to 20 mA.
Differentiation between failed sensor, failed transmitter
Remote I/O
or overload not possible.
> 20 mA or < 4 mA Inspection of sensor/transmitter necessary to diagnose
the problem.
Corrective action is delayed.

PROFIBUS - The Fieldbus for Totally Integrated Automation 52 of 67


Process Instrumentation and Analytic

Process device failure


PROFIBUS PA versus 4 to 20 mA
Bereichskennung
oder Produktname

SITRANS T PROFIBUS DP
Transmitter
for temperature  Online diagnostic of PROFIBUS PA provides
DP/PA-Link instant information that self diagnostic of field device
has detected a fault.
PROFIBUS PA SIMATIC PDM can provide more detailed information.
Corrective action can be taken immediately.

PROFIBUS DP
Process device
failure  Identification of failure only if output of field device is
outside 4 to 20 mA.
Remote I/O
Differentiation between failed sensor, failed transmitter
> 20 mA or < 4 mA or overload not possible
Inspection of sensor/transmitter/wiring necessary to
diagnose the problem
Corrective action is delayed even after a problem has
been identified.

PROFIBUS - The Fieldbus for Totally Integrated Automation 53 of 67


Process Instrumentation and Analytic

Sensor overload
PROFIBUS PA versus 4 to 20 mA
Bereichskennung
oder Produktname

SITRANS P PROFIBUS DP
Transmitter
for pressure
DP/PA-Link

PROFIBUS PA  Online diagnostic of PROFIBUS PA provides


instant information that sensor has failed.
SIMATIC PDM can provide more detailed information
Corrective action can be taken immediately.

Sensors overload PROFIBUS DP


 Identification of failure only if output of field device is
outside 4 to 20 mA.
Differentiation between failed sensor, failed transmitter
Remote I/O
or overload not possible.
4 to 20 mA Inspection of sensor/transmitter necessary to diagnose
the problem.
Corrective action is delayed.

PROFIBUS - The Fieldbus for Totally Integrated Automation 54 of 67


Process Instrumentation and Analytic

Operating conditions “Out of specification”


PROFIBUS PA versus 4 to 20 mA
Bereichskennung
oder Produktname

SITRANS P PROFIBUS DP
Transmitter for
pressure
DP/PA-Link

PROFIBUS PA  Field device continues to provide readings.


Online diagnostic of PROFIBUS PA provides
instant information that field device operates out of
specification.
SIMATIC PDM can provide more detailed information.
Corrective action can be taken immediately.
PROFIBUS DP
Ambient temperature out of spec

 Output of transmitter 4 to 20 mA.


Remote I/O
Problem will not be identified.
4 to 20 mA

PROFIBUS - The Fieldbus for Totally Integrated Automation 55 of 67


Process Instrumentation and Analytic

Local override
PROFIBUS PA versus 4 to 20 mA
Bereichskennung
oder Produktname
A control valve in local override is not available for
automatic control
PROFIBUS DP
SIPART PS2
 Online diagnostic of PROFIBUS PA provides
Valve positioner
an alarm that local override is active.
DP/PA-Link

PROFIBUS PA

Local override
PROFIBUS DP
 Recognition of problem only possible with additional alarm
Remote I/O outputs of positioner.

4 to 20 mA

PROFIBUS - The Fieldbus for Totally Integrated Automation 56 of 67


Process Instrumentation and Analytic

Recognition of process irregularities


PROFIBUS PA versus 4 to 20 mA
Bereichskennung A valve positioner can not position a control valve correctly
oder Produktname following a loss of instrument air or if there is a mechanical
problem with the valve.

PROFIBUS DP
SIPART PS2
Valve positioner
DP/PA-Link
 Online diagnostic of PROFIBUS PA provides
PROFIBUS PA an alarm that a positioning error has occurred.
Corrective action can be taken immediately.

Loss of
instrument air
PROFIBUS DP

Remote I/O  Recognition of problem only possible with additional alarm


outputs of positioner. Otherwise a control error will occur
4 to 20 mA
that can trigger an alarm.

PROFIBUS - The Fieldbus for Totally Integrated Automation 57 of 67


Process Instrumentation and Analytic

Predictive maintenance
PROFIBUS PA versus 4 to 20 mA
Bereichskennung
oder Produktname Valve positioners can accumulate the strokes of a control
valve. A limit can be downloaded into the positioner via
SIAMTIC PDM.
PROFIBUS DP
SIPART PS2
Valve positioner
DP/PA-Link  Online diagnostic of PROFIBUS PA provides
an alarm when stroke counter exceeds limit.
PROFIBUS PA Valve positioner continues operation.
SIMATIC PDM can provide more detailed information.
Maintenance of valve when valve specialist is available.

Stroke counter
exceeds limit
PROFIBUS DP

 No predictive maintenance possible


Remote I/O
4 to 20 mA

PROFIBUS - The Fieldbus for Totally Integrated Automation 58 of 67


Process Instrumentation and Analytic

Change of operating parameters


PROFIBUS PA versus 4 to 20 mA
Bereichskennung
oder Produktname

SIMATIC PDM
SIPAN 32
PROFIBUS DP
Transmitter for
pH, C and O2
DP/PA-Link
 Field device can provide incorrect readings with a good
PROFIBUS PA status following a change of operating parameters (e.g.
calibration parameters).
Online diagnostic of PROFIBUS PA provides instant
information that a parameter has been changed.
Validation of field device is necessary.
PROFIBUS DP Critical control loops can be forced into manual operation.
SIMATIC PDM can show changed parameters.
Local operation
 Field device can provide incorrect readings following a
Remote I/O change of parameters.
4 to 20 mA Output of field device is 4 to 20 mA.
Change of operating parameters will not be identified

Hand Held Configurator

PROFIBUS - The Fieldbus for Totally Integrated Automation 59 of 67


Process Instrumentation and Analytic

Function control of process device


PROFIBUS PA versus 4 to 20 mA
Bereichskennung Analysers require a function control in a certain frequency.
oder Produktname This requires calibration using calibration gases.
This procedure can be automated.
The analyser can not provide actual and valid process
PROFIBUS DP variables during calibration.
ULTRAMAT 23
Gas analyser for
emission monitoring DP/PA-Link
 Online diagnostic of PROFIBUS PA provides instant
PROFIBUS PA information that function control is in operation.

Calibration
of
analyser PROFIBUS DP
 No information via 4 to 20 mA that function control is in
operation.
Remote I/O Additional signals from analyser to control system
necessary.
4 to 20 mA

PROFIBUS - The Fieldbus for Totally Integrated Automation 60 of 67


Process Instrumentation and Analytic

SIMATIC PCS7 and PROFIBUS


Diagnostic screen of Process Devices in OS
Bereichskennung
oder Produktname

Life
indicator

for
Diagnostic-Faceplate incl..
DP-Bus
symbol for process device,
life indication
TAG,
PA-Address,
Life
indicator Device name

for
DP/PA-Coupler
and
DP/PA- Link

PROFIBUS - The Fieldbus for Totally Integrated Automation 61 of 67


Process Instrumentation and Analytic

SIMATIC PCS 7 and PROFIBUS


Alarm messages on Operator Station
Bereichskennung
oder Produktname

Alarm

Failure of 3 Process
with PROFIBUS PA

Failure
PROFIBUS
PA

PROFIBUS - The Fieldbus for Totally Integrated Automation 62 of 67


Process Instrumentation and Analytic

Online diagnostic via PROFIBUS PA


Element of Asset Management
Bereichskennung
oder Produktname

OS ES
(24h-operation)
3 Lis
to
5
fa
Operator informs ct i
v it
OS archives al alarms C&I Engineer ies

Obtain detailed information


and messages incl..
Co

via SIMATIC PDM


date, time, origin, TAG, m ntr
etc. es ol
sa ler

2
ge se
to n d
OS s
4 • Locate defective device
• Obtain service and
maintenance instructions
• Diagnostic blocks in controller evaluate online • Instruct service engineer
status of process devices and send alarms and
messages to OS 1 • Order spare instrument of
spare parts
• Validation of readings co • etc.
• Failure information mm cyc
• Diagnostic information Controller un lic
ica
• Maintenance required tio PROFIBUS PA
n
Change of status process device
following event

PROFIBUS - The Fieldbus for Totally Integrated Automation 63 of 67


Process Instrumentation and Analytic

Online Diagnostic in SIMATIC PCS7


Recognise, locate and fix problems
Bereichskennung
oder Produktname

CO- and NO-measurements of the Gas pressure in ULTRAMAT 6 Exchange of gas sample
ULTRAMAT 6 (TAG=QIA1820) in in reactor 2 (TAG=QIA1820) pump.
reactor 2 have failed. is low for components
DP-/PA-Address 9. CO and NO.
More detailed information via The gas sample pump needs
display of the device or via to be exchanged.
SIMATIC PDM available.

Operator informers C&I Engineer instructs


C&I engineer maintenance engineer

Maintenance engineer
C&I Ingenieur (tools, test equipment
Operator spare parts)
(SIMATIC PDM)
(PCS7-OS)

PROFIBUS - The Fieldbus for Totally Integrated Automation 64 of 67


Process Instrumentation and Analytic

SIMATIC PCS7 with PROFIBUS


Factory Acceptance Test (FAT) via SIMBA
Bereichskennung The objective is to perform a factory acceptance test without
oder Produktname connecting all PROFIBUS slaves
SIMBA Simulation Station consists of:
Test PC
Operator Engineering Simulation SIMBA Software Package
Station Station Station SIMBAsys_DP interfaces
 Simultaneous test of up to 32 DP-slaves per SIMBAsys_DP
interface
 DP-slaves can be simple devices or complex devices such
as:
ET200M Remote I/O
DP/PA-Link
 Simulation of all I/Os of all ET200 Remote I/Os
 Simulation of all PA-Slaves of all DP/PA-Links
Simulated slaves and real slaves can co-exist

S7-400
Controller SIMBAsys_DP

PROFIBUS DP

ET 200 M
DP/PA-Link
Remote I/O

PROFIBUS - The Fieldbus for Totally Integrated Automation 65 of 67


Process Instrumentation and Analytic

PROFIBUS
Cost reduction versus central I/Os
Bereichskennung
oder Produktname

 Note: Remote I/Os are very popular


100% today. Connection between DCS and
100% Savings > 40%
remote I/O is frequently performed via
PROFIBUS DP. The additional benefit
22% En
of using PROFIBUS PA in term of saving
gi of cabling is then reduced!
ne
er
in
27% Ins
g 57%  Any analogue signals produce an
information gap.
50%
ta l
lat
i on
12%
 POFIBUS PA closes this information
22% gap.

51% Har
dwa
re
23%
0% Central I/Os PROFIBUS

Source: NAMUR, AK 3.5, as well as practical experience from many applications

PROFIBUS - The Fieldbus for Totally Integrated Automation 66 of 67


Process Instrumentation and Analytic

PROFIBUS
Customer benefit
Bereichskennung
oder Produktname

 It is correct but insufficient to explain the customer benefit of PROFIBUS PA with a


reduction of cabling, less cabinets and easier installation (Capital expenditure).

 The customer benefit comprises additional aspects relating to the cost of operating
the plant that reflect the total cost of ownership.

 The objective of Asset Management is to reduce the cost of operating a plant and
to increase output.

PROFIBUS - The Fieldbus for Totally Integrated Automation 67 of 67


Process Instrumentation and Analytic

PROFIBUS PA
The world leading fieldbus for Process Devices
Bereichskennung
oder Produktname

90000

80000  Global unit sales of field devices with


80000 PROFIBUS PA has has been growing at an
annual rate of 100% since 1997 according to
70000 workgroup marketing of PTO
 The installed based is more than 150.000
60000
units

50000  The forecast for 2002 is approximately


150.000 units
40000
40000  More than 300 plants are using
PROFIBUS PA. Most of these plants are
30000 multi vendor installations.
20000
20000
10000
10000 5000

0
1997 1998 1999 2000 2001

PROFIBUS - The Fieldbus for Totally Integrated Automation 68 of 67


Process Instrumentation and Analytic

PROFIBUS
Vendors and products
Bereichskennung
oder Produktname

ASICS
Bus Monitor–Camera
Commissioning–Certification
DCS–Electric Actuator–Flow
Gas Analyser–Gateway–Hotline
Support–Installation Material–Level
Liquid Analyser–Literature–Motor Starter
Operator Panel–PC Module–PLC
Pressure–Protocol Tester
Remote I/O–Temperature–Software
Tool–Training–Valve Positioner
Variable Speed Drive
** Valve Manifold
Weighing
Reference: http://www.profibus.com * random list
** not a member of PI

 more than 1000 companies are member of PROFIBUS International


 more than 2000 products for PROFIBUS are available

PROFIBUS - The Fieldbus for Totally Integrated Automation 69 of 67


Process Instrumentation and Analytic

References in USA
Bereichskennung
Baker Petrolite, Sandsprings, OK
oder Produktname
We have a tank farm which has about 125 storage tanks. We have implemented PA with Siemens Level
and Temp and wireless DP back into the Siemens Moore Control System.
 This one has about 250 PA instruments (Radar Level and Temp Trans)

Biodiesel
We have about 5 projects implemented with a company called Jatrodiesel who builds biodiesel plants.
Their HQ is in Ohio.
Project locations are Mauston, WI; Baltimore; Miamisburg, OH; El Centro, CA; Michigan.
 Each project has 75-125 PA instruments of all type
  
Beatrice Biodiesel
This is a 40M Gallon Biodiesel plant being built in Beatrice, NE. It has still not started up.
 
This one has about 300+ PA instruments
  
Cornhusker Ethanol
This is a 40M Gallon Ethanol plant in NE too. This one would not be a good reference due to plant
personal who dont like bus systems

PROFIBUS - The Fieldbus for Totally Integrated Automation 70 of 67

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