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PROFIBUS
The Fieldbus conforming to IEC61158
Bereichskennung
oder Produktname
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
PROFIBUS
One protocol – different physical layers
Bereichskennung
oder Produktname
PROFIBUS
Fundamental properties
Bereichskennung
oder Produktname
Repeater
PROFIBUS DP Salves
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
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
PROFIBUS
Integration of Motor Control Centres (MCC)
Bereichskennung
oder Produktname
- earth fault
Motor - torque monitoring
- operating hours, etc.
Motormanagement
SIMOCODE
Motor
Electric Actuators
SIPOS
PROFIBUS
Integration of local Operator Panels
Bereichskennung
oder Produktname
OP37
PROFIUS-DP
OP7
TD17
PP17
PROFIBUS
Integration of ASI and PID Loop Controllers
Bereichskennung
oder Produktname
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
PROFIBUS
Addresses of PROFIBUS Slaves
Bereichskennung
oder Produktname
PROFIBUS PA
SIMATIC PDM.
3 4 5 3 4 5
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
Manufacturer A
Manufacturer B
FISCO
Fieldbus Intrinsically Safe Concept
Model of an intrinsically safe fieldbus
FISCO is a prerequisite for an intrinsically safe fieldbus
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
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
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
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.
Bereichskennung
oder Produktname
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)
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
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
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.
PROFIBUS PA
Topology and installation
Bereichskennung
oder Produktname
PROFIBUS PA
Installation using Split Connect
Bereichskennung
oder Produktname
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
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
PROFIBUS
Cyclic and acyclic communication
Bereichskennung
oder Produktname
1 2 3 1
PROFIBUS PA
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
20 ms 20 ms
PROFIBUS PA
Device Profiles
Bereichskennung
oder Produktname
PROFIBUS PA
Advantages of Profile 3 versus Profile 2
Bereichskennung
oder Produktname
Acyclic
Communication
(DP V1 service)
Conformity
to profile
PROFIBUS PA
The block model
Bereichskennung
oder Produktname
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.
PROFIBUS PA
Transducer blocks
Bereichskennung
oder Produktname
PROFIBUS PA
Functions Blocks
Bereichskennung
oder Produktname
Function Blocks
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 PA
Measured variables and status byte
Bereichskennung
oder Produktname
Parameter
and
Process measured Cyclic
Device variables communication Status Byte
PROFIBUS PA
Coding of the status byte to Profile 3.0
Bereichskennung
oder Produktname Status Combinations supported
by SITRANS T3K
0 0 = Limits o.k.
0 1 = low limit
1 0 = high limit
1 1 = constant
SIMATIC PCS7
Redundancy concept for PROFIBUS
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
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
Process devices from A&D PI
Bereichskennung Family SIPART DR
Temperature Flow Analyse
oder Produktname SITRANS FM r
OXYMAT
SITRANS F US
SIWAREX
ULTRAMAT SIPAN32
Pressure Level
SITRANS P DSIII SITRANS LR 400 SITRANS LC
DP
OXYMAT 61 CALOMAT 6
Positioner
PA / Profile 3
•cyclic/acyclic data
•safe data
•Diagnosis
SIMATIC PCS 7
Engineering Tool Set
Bereichskennung
oder Produktname
SIMATIC PCS 7
Central Engineering of Process Devices
Bereichskennung
oder Produktname
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
SIMATIC PCS 7
Continous Function Chart (CFC)
Bereichskennung
oder Produktname
PROFIBUS DP
Routing
4 to 20 mA DP/PA-Link
PROFIBUS-PA
PROFIBUS and
SIMATIC PDM - Process Device Manager
Bereichskennung
oder Produktname
S7 400 Controllers
PROFIBUS DP
Remote I/O
PROFIBUS
Closes the information gap to the field level
Bereichskennung
oder Produktname
Operator Engineering Interface to Enterprise
Stations Station Resource Planning Büronetz
S7 400 Controllers
PROFIBUS DP
DP/PA-Link PROFIBUS PA
Bi-directional
Central Device multi variable
Digital Diagnostic
Engineering Profiles communication
process
variables
Feldgeräte
Block diagram
PROFIBUS PA versus 4 to 20 mA
Bereichskennung
oder Produktname
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 DP
4 to 20 mA
Sensor failure
PROFIBUS PA versus 4 to 20 mA
Bereichskennung
oder Produktname
SITRANS T
PROFIBUS DP
Transmitter
for temperature
Sensor DP/PA-Link
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.
Sensor overload
PROFIBUS PA versus 4 to 20 mA
Bereichskennung
oder Produktname
SITRANS P PROFIBUS DP
Transmitter
for pressure
DP/PA-Link
SITRANS P PROFIBUS DP
Transmitter for
pressure
DP/PA-Link
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 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
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
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
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
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
Alarm
Failure of 3 Process
with PROFIBUS PA
Failure
PROFIBUS
PA
OS ES
(24h-operation)
3 Lis
to
5
fa
Operator informs ct i
v it
OS archives al alarms C&I Engineer ies
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
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.
Maintenance engineer
C&I Ingenieur (tools, test equipment
Operator spare parts)
(SIMATIC PDM)
(PCS7-OS)
S7-400
Controller SIMBAsys_DP
PROFIBUS DP
ET 200 M
DP/PA-Link
Remote I/O
PROFIBUS
Cost reduction versus central I/Os
Bereichskennung
oder Produktname
51% Har
dwa
re
23%
0% Central I/Os PROFIBUS
PROFIBUS
Customer benefit
Bereichskennung
oder Produktname
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 PA
The world leading fieldbus for Process Devices
Bereichskennung
oder Produktname
90000
0
1997 1998 1999 2000 2001
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
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