FF Physical Layer

FF Physical Layer Components
Best Practices
Binoy Kamath
AGM Project Pursuit
Pepperl+Fuchs India Pvt. LTd.,Bangalore
On behalf of
Fieldbus Foundation End User Council India
Agenda

Introduction to Ff and Ff Physical Layer

FF Physical Layer Components
FF Wiring Topologies
FF Segment Design
FF Monitoring and Diagnosis
Summary and Conclusion
2
1994 2011 Fieldbus Foundation
AG181 REVISION 3.1 Official FF Design Guidelines
3
What is Fieldbus?
A Fieldbus is a digital, two-way, multi-drop communication link among
intelligent measurement and control devices. It serves as a Local Area
Network (LAN) for advanced process control, remote input/output and highspeed factory automation applications.
HOST
Field Device
How Do we Link the Various components in the network?
4
Physical Layer Components

HOST
Wiring Block
FIELDBUS
TERMINATOR
Wiring Block
Ff POWER
SUPPLY
JUNCTION
BOX
Spurs
Home Run
SURGE
PROTECTOR
PROCESS
INTERFACE
FIELDBUS
DEVICES
CONVENTIONAL
FIELD DEVICES
5
Physical Layer and Its Components

The Physical Layer receives messages from the Communications Stack and
converts the messages into physical signals on the fieldbus transmission
medium, and vice-versa.

FF Power Supply
FF Cables
FF Wiring Blocks
FF Surge Protector
FF Terminators
6
FF Power Supply
FOUNDATION Fieldbus Power Supplies (6.2.2 AG 181 v3.1)
FOUNDATION fieldbus power supplies are specialized power supplies that

provide both the segment isolation from bulk power and the power
conditioner in one unit.
Power conditioning prevents the bulk power supply from shorting out the
communications signal, preventing the segment from functioning.
Isolation prevents ground loops and interference among segments.
They shall have the appropriate approval: FF-831 FOUNDATION

Specification; Fieldbus Power Supply Test Specification and associated
check mark
FOUNDATION fieldbus power supplies should be redundant, load sharing

and output current limiting, and provide facilities for monitoring faults and
failures. .
7
FF Power Supply General Purpose
8
FF Power Supply With DCS System Connectors
APPROVED
9
FF Power Supply Recommendations

Each Segment shall have a dedicated FFPS

FFPS shall be Isolated and Redundant
FFPS shall be modular and hot Swappable
FFPS shall provide facilities for monitoring faults
and failures
FFPS rating shall allow longer home run / Trunk
length to benefit user ( typically 28V / 500mA )
10
FF Wiring Blocks
11
Ff Wiring Blocks
FOUNDATION fieldbus Wiring block is located

where the trunk (home run) is connected to the
various device spurs. It is typically the location of
one of the terminators (associated with a
segment), and the location of spur short circuit
protection
12
Ff Wiring Blocks
13
FF Wiring Blocks - Summary

Only registered FOUNDATION fieldbus Wiring blocks shall be used
The couplers shall have built-in spur short-circuit protection (to

minimize the impact of a short at one device affecting the whole
segment)
Spur short-circuit protection shall have visual indication (on a spur

level) when short-circuit protection is active and the spur's maximum
current shall be limited by area classification and the current
available to the network
The couplers should provide visual indication of segment power as a

minimum
14
FF Cables
15
Types of FF Cables
The Physical Layer Specification of FOUNDATION
Fieldbus defines four types of cables

Type A
Type B
Type C
Type D
The max. cable length per segment of 1900m( trunk

+ Spurs) could be reached with cable type A only!
In the meantime there are cables available type A
with different cross sections
16
Types of Cables
17
a = not specified
FF Surge Protectors
Surge Protection ( 6.4 AG 181 V3.1)
Surge protection for FOUNDATION fieldbus devices may be

required in areas where induced voltage is an issue.
This includes areas such as close wiring proximity where large

inductive loads are started and stopped, or areas known for
lightning incidence.
Surge suppression consists of a low-capacitance device installed at

the device's electrical connection. It shall normally appear as an
open circuit to the spur and segment to prevent any adverse effect
on communications.
18
FF Surge Protectors
19
FF Surge Protectors - Summary

Surge suppression device should not measurably

attenuate the fieldbus signal
Shall be installed at the Field Devices and host H1

Interface
Current-limiting couplers ( Wiring Block spurs ) should

not be used in combination with surge protectors. The
surge protectors will cause failure of the current limiting
circuits when a lightning strike occurs
20
FF Terminators 6.3 AG 181 V3.1

FOUNDATION fieldbus segments require EXACTLY two terminators, one at
each end of the trunk (home run) cable. The terminator is comprised of an
RC network that provides 100 impedance.
The terminator allows the current-based FOUNDATION fieldbus
communications signal to be viewed as a voltage while being offset on the
DC segment voltage supply.
Constructing your own terminator using a 100

resistor and a 1 F
capacitor will not guarantee correct segment communications, and is
therefore not recommended
Most fieldbus power supplies and/or wiring blocks have a built-in

segment terminator. Some wiring components have switchable
terminators.
Terminators at a field device shall not be used (due to the impact on

the whole segment should the device need replacement)
21
FF Terminators 6.3 AG 181 V3.1

Terminator integrated
in Power Hub.
Selectable via DIP-Switch
Segment Protector R2-SP-N*

Terminator on the T-Connector
Flameproof in rugged housing (IP 67)

for the hazardous area
22
Spur Topology (Bus with Spurs)
This topology consists of fieldbus devices connected to a multi-drop bus segment through a length of
cable called a spur. This technology is technically acceptable, but generally not a good economical
choice when there is a high density of devices.
Combination Topology
Combinations of the above topologies must follow all the rules for maximum fieldbus network/segment
length, and include the length of spurs in the total length calculation. These types of topologies are
preferred for designs using bricks with tray cable. Spurs are permitted to extend only from trunk lines
and not from other spur lines.
23
Daisy Chain Topology
This topology consists of a network/segment that is routed from device to device, and
is connected at the terminals of the fieldbus device. It should not be used, as it is
unacceptable, for maintenance purposes.
24
FF Wiring Topologies in Hazardous Area
25
Fieldbus in Hazardous Area

Redundant
FISCO
The first step
Simplifying
validation
MAX power + FISCO
Re-inventing Intrinsic Safety

26
Comparison of Various Concepts
27
Typical Zone Certifications

Safe area, Zone2
Previous standards
-Ex nA ( Non arcing) / Ex nL ( energy Limiting)
-FNICO ( Non-Incendive)
Current standard Exic
From 2007 onwards Ex nL and FNICO standards are omitted
and replaced by Ex ic ( similar to IS)
Zone1
- Ex d ( Explosion Proof)
- Ex ia, Ex ib ( Intrinsically Safe -IS)
- High Power Intrinsically safe (DART)
28
New Ex ic Replaces Ex nL, FNICO at Zone2

IEC60079-11:2006 Includes Ex ic
IEC60079-27:2008 Updated FISCO Ex ic
Similar IS verifications are required.
ExnA/ExnL and FNICO standards was active until

2010 until all the manufacturers comply to the new
standard Ex ic. ATEX body expects the
manufacturers and customers to comply to Exic
standard for their Zone2 applications from 2011
onwards.
29
Application - Zone2 and Safe Area ExnA / ExnL/Exic

Accurate short circuit
current limitation for
each channel (58mA)
with LED indication
Ex nA
Ex nl / ic
30V,
500mA
16..32V
230VAC
30
230VAC
16..32V
A fault at one
instrument (e.g.
short circuit) has
no impact on the
other outputs or on
the segment
Safe
area
Zone2
Application - Zone1 installations

Non-IS(EEx d)
Trunk and spurs must be installed in increased safety EEx e
IS ( FISCO, HPT, DART)

A full intrinsically safe fieldbus segment (FISCO)

Intrinsic safe trunk and spur
Requires the use of IS Power Repeaters/Power Link module
A mixture of EEx e and EEx I (High Power Trunk)

Trunk has to be installed in increased safety
Spurs are intrinsically safe
Allows the use of Non IS Power Supplies/Power Repeaters/Power
Links
High Power Intrinsically safe (DART)
31
Application Area - Zone 1 (EEx d)

Fieldbus
Power Hub
Segment Protector Ex me
Ex e
16..32V
230VAC
16..32V
R-SP-E12 is resin filled as per

Exd installation requirements
Instruments
Ex d
Zone 1
32
Application Area - Zone1 IS HPT

High power trunk or FieldBarrier concept
Trunk is Ex e( increased safety as per IEC 60079-14 ) and Spurs

intrinsically safe ( As per Entity and FISCO IEC 60079-27)
Spurs as per FISCO or Entity IS
Longest cable run possible 1900m(Trunk+Spurs) and 120m Spur
No limitation of voltage and current on trunk
Redundant power supplies possible
Trunk could be live disconnect with approved Exd Switch
Hazardous area application with the least difficulties

33
Resin
Filling for
Zone 1
Installation
Application Area - Zone1 IS - HPT

Exd Trunk live disconnect switch
Fieldbus
Power Hub
FieldBarrier
Zone 1
Ex e
Ex ia
(FISCO + Entity)
16..32V
Zone 0/1
230VAC
16..32V
34
What does Exeprotected wiring mean?

In case of a non-IS cable will be passed
through the hazardous area the cable must be
protected in acc. with IEC 60079-14 against

Mechanical damaging
Chemical influences
Corrosion
Effects of heat
The same requirement you have for

Lamps
Ex d field devices
motors
frequency converters
35
Zone1 IS Enclosure solutions

FieldBarrier
Fieldbus
Power Hub
Zone 1
Ex e
Ex ia
(FISCO + Entity)
16..32V
Zone 0/1
230VAC
16..32V
36
AG181 REVISION 3.1 Official FF Design Guidelines
37
DART Fieldbus
DART Fieldbus
The Simplicity of Intrinsic Safety
DART fieldbus provides:
A completely intrinsically safe fieldbus segment in
gas groups IIB and IIC with real power redundancy and
advanced diagnostics.
For existing intrinsically safe field instrumentation,
Protects your investment
The Intrinsically Safe High-Power Trunk
38
DART Fieldbus
DART Fieldbus
The Simplicity of Intrinsic Safety
Main Attributes

Trunk cable up to 1000 m

Built-in power redundancy
Same topology as a general purpose high-power trunk
For FOUNDATION fieldbus H1 and PROFIBUS PA
DART Fieldbus is certified according to
the international I.S. standard IEC 60079-11
39
DART: Intrinsically safe High-Power

Trunk
Redundant, three-port isolated
DART Power Supply
General Purpose Area

Zone 2
The intrinsically safe High-Power Trunk

protected by DART
DART Segment Protectors
Intrinsically safe spurs

Ex ib IIC
Zone 1
40
DART Fieldbus Segment

DART protects the trunk
DART Power Hub:
Extinguishes a spark before it becomes incendive
Live disconnect permitted without hot work permit
Power redundancy with load sharing
With Advanced physical layer diagnostics
Intrinsically Safe Outputs

DART Segment Protector:
For any existing standard field instrument
Short-circuit protection
=> Intrinsically Safe Ex ib IIC

41
FF Segment Design
How to design Foundation Fieldbus segments?
42
Fieldbus Design Guides

FF follows the physical layer specification as per IEC 61158-2:
Transmission rate of 31.25 kBit/s
Total cable (Trunk + Spurs) distance of 1900m maximum
Maximum spur length 120 m upto 12 devices
Up to 32 devices per segment (Host + 31 field)
Manchester II coding used to transmit data
Data transmission by a 9mA modulation signal
Minimum working voltage 9 Volts ( Range is 9-32V) and average current

consumption 20mA per device
43
Segment Design and Validation Tools

Fieldbus allows to connect many devices on
the same bus cable, but

How many devices can I really connect?
What cable should I use, and what cable distances
can I really achieve?

What happens in case of a short circuit in the field?
44
Segment Design and Validation Tools

Graphical segment design tool example
www.segmentchecker.com
Download the NEW DesignMATE segment verification tool
Various other tools are available with Ff Vendors
45
46
47
Ff Physical Layer Monitoring and Diagnosis
48
Some practical cases we have seen

Improperly closed housing
Error log showing

intermittent faults
Loose wire
Internally modified
Electro-magnetic interference
Faulty field device

Cable degradation
Wrong termination
Fieldbus is tolerant to certain faults. How do you find them?

49
In most cases communication had not failed yet.

Typical problems and how to solve them

Tools to measure segment parameters

(voltage, current)
Tools to measure segment health
(termination, noise)
Tool to display EMC problems
Tools to test communication
Tool to measure cable degradation
over time (trending)
Tool to visualize signal quality of
individual devices (noise, jitter, telegram level)
Tool to allow remote access for expert
50
Measurements
Tools of the Trade
Multimeter
Handheld
Tester
Handheld
Communicator
Oscilloscope
Notebook Bus
Analyzer
P+F
Advanced
Diagnostic
Module
Segment voltage
Segment current
Segment noise (low freq.)
Segment noise (high freq.)
Segment signal level
Segment signal jitter
Instrument signal level
Instrument signal jitter
Instrument noise (individual)
Fieldbus termination
Segment earth fault( imbalance)
Device communication
Communication faults
Cable degradation (trending)
Device configuration
Remote access
51
Supported
= Result incomplete
Requires shutdown
Fully supported
Use Cases for Advanced Diagnostic

The Diagnostic modules shall be used
During Commissioning
During plant operation for Monitoring
For trouble shooting and Expert Diagnosis
52
Asset Management Integration

One Plant Asset Management

Includes fieldbus now as asset

Customary look and feel
Reduces required training
Reduces potential for errors
Experion PKS Station

Automatic
Setup
Included
Open Architecture Integration:

AMS Suite
PRM
FieldCare
FieldMate
PACTware
OPC Interface
53
The effect of Advanced Diagnostics

Plan and
purchase
Install and
commission
Cash Flow
Commission
Operate and maintain

Monitor
Troubleshoot
Longer plant uptime

Know before you act
Actionable information in clear text
Verify against original design
Automated checkout procedures
Segment Checker: design of the physical layer
54
Commissioning until now

Always on the critical path

Manual, step-by-step procedure
Labor intensive
Requires
Screw driver
Check sheet
Pencil
Multimeter
Oscilloscope
Connect one device at a time
Disconnect after testing
Test
TestReport
Report

55
Simple Commissioning Steps with ADM

Verify address setting

Wire up devices in the right location
Check shielding
Activate communication
Use automated work procedures
Testing
Documentation
All devices at once
Wiring remains undisturbed!
Test
Test
Report
Report

Commissioning Wizard

56
Commissioning Wizard
With Expert System Support

Takes snapshot
Identifies wiring erros
Ensures compliance with
AG181 and IEC 61158-2
Recommends limits for ADM messages
Stores limits in non-volatile memory
Automatic Tag Readout

Creates baseline report:

Snapshot of all measurements

Complete documentation
Saves 80% of pre-commissioning time
57
Automated Pre-commissioning Saves Time

Tasks 2 of 2
Pre/commissioning
instrument checks:
Pre/commissioning failure:
Totals
Model
4-20 mA
Fieldbus
without
diagnostics
Fieldbus
with
Advanced
Diagnostics
Time/Unit
10 min
60 min
8 min
Units
1200 loops
100 segments
100
segments
Total Time
25 days
12 days
1.6 days
Time/Unit
4h MTTR
4h MTTR
4h MTTR
Units
0.5% =
6 loops
0.5% =
1 segment
1.5% =
2 segments
Total Time
24 h =
3 days
4h=
day
8h=
1 day
46.5 daysU
days
21.5 daysU
days
2.6 daysU
days
58
Online monitoring
The Advanced Diagnostic Module:

Monitors physical layer health

Detects changing conditions
Sends messages with time stamps
Expert System diagnoses faults:

Precisely diagnoses causes

Creates messages with clear text
Enables proactive plant up keep
Alerts before the segment fails
59
Online monitoring
Clean layout shows boundaries

Displays measurement values

Highlights violations with color coding:
Issues diagnostic messages
Good value
Maintenance required
Out of specification
60
Diagnostic Menu
Expert System delivers
clear text information for
fast fault finding
1 Active messages
2 Actionable information with
solution guideance based on
expert system
3 History with timestamps
When the failure
11
33
2
22
occured
disappeared
Export function for external

analysis and storage
61
Built-in fieldbus oscilloscope

ADM provides expert tools
for fast fault finding

For diagnosing complex scenarios

For the fieldbus expert
With fieldbus specific triggers
Captures up to 10 shots in a row
62
Practical Example Noise in the Fieldbus
Approx. 7 ms
In this example the frequency of noise was

approx. 150Hz, which means FF cable is
running too close to 440V, 3phase power cable
63
Conclusion
Follow the proper selection of components and
design and installation guidelines

System design guidelines provided by AG 181

guidelines at www.Fieldbus.org
Fieldbus Physical layer specification IEC 61158-2
Good grounding and shielding concept as per the plant
conditions
Installation guidelines
Always use Approved and registered products
Right diagnostic tools to reduce installation and
commissioning time
64
Thank You
65

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FF Physical Layer Components

Introduction to Ff and Ff Physical Layer

AG181 REVISION 3.1 Official FF Design Guidelines

How Do we Link the Various components in the network?

Physical Layer Components

Physical Layer and Its Components

FOUNDATION fieldbus power supplies are specialized power supplies that

Isolation prevents ground loops and interference among segments.

They shall have the appropriate approval: FF-831 FOUNDATION

FOUNDATION fieldbus power supplies should be redundant, load sharing

FF Power Supply General Purpose

FF Power Supply With DCS System Connectors

FF Power Supply Recommendations

Each Segment shall have a dedicated FFPS

FOUNDATION fieldbus Wiring block is located

FF Wiring Blocks - Summary

Only registered FOUNDATION fieldbus Wiring blocks shall be used

The couplers shall have built-in spur short-circuit protection (to

Spur short-circuit protection shall have visual indication (on a spur

The couplers should provide visual indication of segment power as a

The max. cable length per segment of 1900m( trunk

Surge protection for FOUNDATION fieldbus devices may be

This includes areas such as close wiring proximity where large

Surge suppression consists of a low-capacitance device installed at

FF Surge Protectors - Summary

Surge suppression device should not measurably

Shall be installed at the Field Devices and host H1

Current-limiting couplers ( Wiring Block spurs ) should

FF Terminators 6.3 AG 181 V3.1

Constructing your own terminator using a 100

Most fieldbus power supplies and/or wiring blocks have a built-in

Terminators at a field device shall not be used (due to the impact on

FF Terminators 6.3 AG 181 V3.1

Segment Protector R2-SP-N*

Flameproof in rugged housing (IP 67)

FF Wiring Topologies in Hazardous Area

Fieldbus in Hazardous Area

The first step

MAX power + FISCO

Re-inventing Intrinsic Safety

Comparison of Various Concepts

Typical Zone Certifications

New Ex ic Replaces Ex nL, FNICO at Zone2

IEC60079-27:2008 Updated FISCO Ex ic

Similar IS verifications are required.

ExnA/ExnL and FNICO standards was active until

Application - Zone2 and Safe Area ExnA / ExnL/Exic

1994 2011 Fieldbus Foundation

Application - Zone1 installations

Trunk and spurs must be installed in increased safety EEx e

IS ( FISCO, HPT, DART)

A full intrinsically safe fieldbus segment (FISCO)

A mixture of EEx e and EEx I (High Power Trunk)

High Power Intrinsically safe (DART)

Application Area - Zone 1 (EEx d)

R-SP-E12 is resin filled as per

Application Area - Zone1 IS HPT

Trunk is Ex e( increased safety as per IEC 60079-14 ) and Spurs

Spurs as per FISCO or Entity IS

Longest cable run possible 1900m(Trunk+Spurs) and 120m Spur

No limitation of voltage and current on trunk

Redundant power supplies possible

Trunk could be live disconnect with approved Exd Switch