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Technical Information
TI 38K02A01-01E

FOUNDATION Fieldbus Book - A Tutorial

Yokogawa Electric Corporation 2-9-32, Nakacho, Musashino-shi, Tokyo, 180-8750 Japan Tel.: 81-422-52-5634 Fax.: 81-422-52-9802

TI 38K02A01-01E Copyright Mar. 1998 2nd Edition Mar. 2003

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Introduction
This textbook is prepared for those who want to know more about technologies supporting FOUNDATION Fieldbus and Function Blocks. Yokogawa Electric Corporation and its group funded this textbook to encourage FOUNDATION Fieldbus adoption by as many people as possible. No commercial ambitions are in this book. This textbook is a tutorial on FOUNDATION Fieldbus technologies and does not intend to override any technical content of FOUNDATION Fieldbus. If this textbook contains any explanation that conflicts with Foundation documents, the Foundation documents are correct and such conflict should come from an error of explanation of this textbook or this textbook failed to follow the technology update of Fieldbus Foundation. Yokogawa hopes readers to use this textbook in getting more knowledgeable about FOUNDATION Fieldbus and apply the knowledge to their industrial projects. Fieldbus is the language of the 21st century.

Structure and Target Readership of This Textbook

This textbook consists of following four sections: Section 1 Overview of Fieldbus Section 2 Fieldbus Communication Technologies Section 3 Fieldbus Applications Section 4 Managing Fieldbus Projects Section 1 describes an overview of Fieldbus before going to the details of technologies. This section may not be enough for Fieldbus promotion activities. Refer to other documents to get more information. Section 2 describes communication technologies in FOUNDATION Fieldbus. Implementation engineers and field engineers need a certain amount of communication technologies explained in this section. Section 3 explains applications running over Fieldbus. They are very important for measurement and control on digital networks. All technical people working on instrumentation of digital communication need such knowledge for real projects. Section 4 shows an example of Fieldbus projects to make them successful. Project manager, instrumentation engineers and maintenance engineers are expected readers of this section. The acronyms and the index are appended at the end of this textbook.

Media No. TI 38K02A01-01E (MO) 2nd Edition : Mar. 2003 (YK) All Rights Reserved Copyright 1998, Yokogawa Electric Corporation

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Trademarks
FOUNDATION in FOUNDATION Fieldbus is a registered trademark of Fieldbus Foundation. CENTUM, YTA and YVP are registered trademarks of Yokogawa Electric Corporation. EJA is a trademark of Yokogawa Electric Corporation. Other product and company names may be registered trademarks of their respective companies (the TM or mark is not displayed).

DISCLAIMER OF WARRANTIES This document is provided on an as is basis and may be subject to future addimodifications, or corrections depending on the results of field trial testing. IMPORTANT tions, Yokogawa Electric Corporation hereby disclaims all warranties of any kind, express or implied, including any warranty of merchantability or fitness for a particular purpose, for this document. In no event will Yokogawa Electric Corporation be responsible for any loss or damage arising out of or resulting from any defect, error or omission in this document or from anyones use of or reliance on this document.

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FOUNDATION Fieldbus Book - A Tutorial

TI 38K02A01-01E 2nd Edition

CONTENTS
1. Overview of Fieldbus .............................................................................. 1-1
1.1 1.2 1.3 What is Fieldbus? ........................................................................................... 1-1 Fieldbus Benefits ............................................................................................ 1-3 FOUNDATION Fieldbus ................................................................................... 1-5

2.

Fieldbus Communication Technologies ................................................ 2-1

2.1 Communication Models ................................................................................. 2-2 2.1.1 2.1.2 2.1.3 2.2 2.2.1 2.2.2 2.2.3 2.2.4 2.3 2.3.1 2.3.2 2.3.3 2.3.4 2.3.5 2.3.6 2.3.7 2.4 2.4.1 2.4.2 2.5 2.5.1 2.5.2 2.5.3 OSI Reference Model ....................................................................... 2-2 Protocol Data Unit ............................................................................. 2-4 Communication through VCR ........................................................... 2-5 31.25 kbps Physical Layer ................................................................ 2-6 Signaling Method .............................................................................. 2-7 Wiring Rules ..................................................................................... 2-8 Intrinsic Safe (IS) Consideration ...................................................... 2-10 Medium Access Control ................................................................... 2-11 Addresses ...................................................................................... 2-12 Link Active Scheduler ..................................................................... 2-14 Scheduled Communication ............................................................. 2-15 Unscheduled Communication ......................................................... 2-16 Link Maintenance ........................................................................... 2-17 Data Link PDUs .............................................................................. 2-17 Fieldbus Access Sublayer ............................................................... 2-18 Fieldbus Message Specification ...................................................... 2-22 Tag and Address Assignment .......................................................... 2-28 Tag Location ................................................................................... 2-28 Application Time Synchronization ................................................... 2-28

Physical Layer ................................................................................................. 2-6

Data Link Layer .............................................................................................. 2-11

Application Layer .......................................................................................... 2-18

System Management Protocol ..................................................................... 2-28

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High Speed Ethernet ..................................................................................... 2-29 2.6.1 2.6.2 2.6.3 Why Ethernet? ................................................................................ 2-29 TCP/IP Protocol Suite ..................................................................... 2-29 Field Device Access Protocol .......................................................... 2-29

2.6

3.

Fieldbus Applications ............................................................................. 3-1

3.1 3.2 Virtual Field Devices ....................................................................................... 3-1 3.1.1 3.2.1 3.2.2 3.2.3 3.2.4 3.2.5 3.3 3.3.1 3.3.2 3.3.3 3.3.4 3.3.5 3.4 3.4.1 3.4.2 3.4.3 3.5 3.5.1 3.5.2 VFDs in a Fieldbus Device ................................................................ 3-1 What is a Function Block? ................................................................. 3-2 Link and Schedule ............................................................................ 3-6 Parameters ....................................................................................... 3-7 Important Parameters ....................................................................... 3-9 View Objects ................................................................................... 3-10 AI block ............................................................................................ 3-11 AO block ......................................................................................... 3-16 PID block ........................................................................................ 3-19 Resource Block and Transducer Block ........................................... 3-22 Unit Codes ...................................................................................... 3-24 Device Management ....................................................................... 3-26 Function Block Management .......................................................... 3-27 Application Time Management ........................................................ 3-27 Device Description .......................................................................... 3-28 Capabilities File .............................................................................. 3-31 Function Block ................................................................................................ 3-2

Important Blocks ............................................................................................ 3-11

System Management .................................................................................... 3-26

Device Information Files ............................................................................... 3-28

4.

Managing Fieldbus Projects .................................................................. 4-1

4.1 Planning Phase ............................................................................................... 4-2 4.1.1 4.1.2 4.1.3 4.2 4.2.1 4.2.2 4.2.3 4.3 4.3.1 Devices on a Bus .............................................................................. 4-3 Wiring Design ................................................................................... 4-5 System Design ................................................................................. 4-6 Installation ........................................................................................ 4-7 Commissioning ................................................................................. 4-8 Startup and Test Operation ............................................................... 4-8 Control Operation ............................................................................. 4-9

Installation Phase ........................................................................................... 4-7

Operation Phase ............................................................................................. 4-9

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Maintenance Phase ....................................................................................... 4-10 4.4.1 4.4.2 4.4.3 Device Alarms................................................................................. 4-10 Replacing a Faulty Device .............................................................. 4-10 Asset Management .......................................................................... 4-11 Addition of Applications ................................................................... 4-12 Device Upgrade .............................................................................. 4-12

4.4

4.5

Renovation Phase ......................................................................................... 4-12 4.5.1 4.5.2

Acronyms .......................................................................................................... A-1

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1.

Overview of Fieldbus
This section describes an overview of Fieldbus before going to the details of technologies. This section may not be enough for Fieldbus promotion activities. Refer to other documents to get more information.

1.1

What is Fieldbus?
Fieldbus Foundation defines Fieldbus is a digital, two-way, multi-drop communication link among intelligent measurement and control devices. It is one of several local area networks dedicated for industrial automation. Modern industries could not survive without information technologies and networks in the 21st century. From production line to enterprise level, digital communication supports all economical and social activities by its latest and powerful technologies. Fieldbus is a part of it and cannot be separated from others. Fieldbus is the lowest level in the hierarchy and exchange information with higher-level databases. Standards have been established for the transfer of measurement and control data between control room and plant floor by pneumatic and 4 to 20 mA electric signals. These standards offer interoperability and facilitate maintenance. Smart (hybrid) communication introduced in mid 80s opened an era of digital communication, but it had many limitations such as proprietary protocols, slow transmission speed and different data formats. The idea of fieldbus was proposed to solve such problems. A standardized digital communication for industrial automation is changing the production system very quickly. Figure 1.1 shows the position of Fieldbus in the industrial automation system.

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Plant Resource Manager R2.03.00 - Logon User ID: ADMINISTORATOR File Edit View Register Option Window Help
Device Navigator 1

1-2

Plant

Network

Class

History

Details

Memo

Parts

Schedule

Doc

Parameter

Tool

PLUG-IN

PLANT Foundation Fieldbus BOILER-0101-10111-1 R302DME-103-10113-1 DAQSTATION(Ready) EJA001 (Ready) FI1002 (Ready) YHL001 (Ready) YTA001 (Ready) YVP001(Ready)
HART

Device Tag Name Bock Tag Name Block Type

YVP001 FV100_YVP Analog Output

YVP001 FV100_YVP Analog Output Update Set

Individual

All

View1

View2

View3

View4

Alarm

Tune

Operate

Service

Diagnosic

Current

...

<<

05/07/2002 14:02:48

...

HART MYPJT-01-9999(MODEM) EJAHART(Off-Service) MYPJT-01-9999(MODEM) TI1002(Spare) MYPJT2-01-0100(MUX:KFD) R302DME-0103-10116-1 MODBUS PROFIBUS

Reason Last Update User

ST_REV TAG_DESO STRATEGY ALERT_KEY MODE_BLK TARGET ACTUAL PERMITTED NORMAL BLOCK_ERR PV SP OUT SIMULATE Man Man RCas+Cas+Auto+Man+O/S Cas+Auto 0x0000 26.467800 26.467800 26.461900 Man Man RCas+Cas+Auto+Man+O/S Cas+Auto 0x0000 0.020508 0.024414 0.024414 % % 309 (0x0135) 0x59565020414f000000000000000 1 (0x0001) 1 (0x01) ADMINISTRATOR 235 (0x00eb) 0x59565020414f000000000000000 1 (0x0001) 1 (0x01)

Control Drawing Builder - [Pjt:MYPJT Stn:FCS0101 Draw:DR0001 File:DR0001.edf- [100%]] File Edit View Insert Format Tools Draw Window Help 100% Tag Name Model Name Tag Comment TIC1001 PID TEMPERATURE FIC1001 PID STEAM FLOW
300
100

SIMULATE_STATUS Good_NonCascade::NonSpecific: SIMULATE_VALUE 26.468300

Good_NonCascade::NonSpecific: 0.020508 Good_NonCascade::NonSpecific: 0.020508 Disabled

TRANSDUCTER_STATUS Good_NonCascade::NonSpecific: TRANSDUCTER_VALUE 26.468300 Disabled

350

400

450

500

550

600

650

700

750

800

ENABLE_DISABLE PV_SCALE

001 002 003

FLOW CONTROL
%Z011104 TO EXTERNAL INDICATOR
Ready

EU_100 EU_0

100.000000 0.000000

100.000000 0.000000

% %

GR0001 Distillation column

150

Rows 1of 1

2/17/2003

Maintenance

FIC100 Column flow

250

Distillation column
TDA 37.5 C RC-10 23.4 %

TRC 49.2 C PAC 51.3 C

200

Tank 1 FIC100

SUB

OUT TIC1001 PID IN 0. 0-250. 0 DEGC IN

SET FIC1001 PID 0. 0-100. 0 M3 /H OUT

AUT NR PV SV MV

65.0

100.0

38.9 C FIC 41.4

LICA

FIC LICA 45.7 % 48.9

80.0

TIC301

Message

Function block list pane

TDT 53.8 C
AUT NR

400

M 3/H 70.0 M3/H 50.0 %

350

300

%Z015101

%Z011101

%Z011102

Drawing pane

60.0

40.0

FIC 25.4 %

100.0

Ready

X:675 Y:168

1024686

Select

Change

20.0

0.0

Plant Design
0.0

Ready

Operation Internet

Intranet

Management

Control LAN FOUNDATION Fieldbus PID AI 4 to 20 mA

F010101.EPS

Field Networks

Figure 1.1

Fieldbus Positioning

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1.2

Fieldbus Benefits
Fieldbus is expected to reduce the life-cycle cost of production line and then total cost of ownership (TCO) of the plant. Figure 1.2 shows the difference between analog transmission and fieldbus communication systems.
Conventional Analog Transmission System Fieldbus Communication System HSE using commercial off-the-shelf technology. Also redundancy.

Computer gateway

HSE

Controller

Sequencer gateway Sequencer Remote I/O card, terminal board 4 to 20 mA analog transmission cable Fieldbus Control station

Control Bus Control valve

One variable, one way One variable, one way

Multivariable, bi-directional

Field devices Field devices

Control valve
F010201.EPS

Figure 1.2

Differnce between Analog Transmission and Fieldbus Communication Systems

Planning Phase
Fieldbus allows the integration of plant through digital communication networks using a single plant automation system. Users can connect devices from multiple suppliers without custom software and these network-based systems allow control rooms and cabinet rooms to be smaller, and increase information productivity.

Installation Phase
Fieldbus offers reduced installation and material cost by replacing the traditional one-toone wiring scheme with networking or multi-drop configuration, while intelligent field instruments make commissioning and plant startup much faster and less expensive.

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Operation Phase
Fieldbus integrates various installations of control functions into one system to effectively optimize control of the plant. In addition, a unified human-machine interface (HMI) is provided for the plant operation. Function Blocks allow control functions to migrate into field devices allowing control functions to move to the field.

Maintenance Phase
Fieldbus allows for the reporting of self-diagnostics, calibration, and environmental conditions of field instruments without disturbing the plant control. Since it uses intelligent instruments, the stock for spare or replacement instruments can be dramatically reduced. Software packages for asset management are useful to minimize maintenance costs.

Renovation Phase
Enhanced functionality of field instruments is endless. Fieldbus devices are becoming standard off-the-shelf instruments, which make it very cost-effective and easy for users to extend the life of their plant. By simply connecting a new device, users can immediately benefit from advanced functionality. And, upgrade costs can be reduced because networkbased systems are modular, which means they are done on-line.

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1.3

FOUNDATION Fieldbus
Fieldbus is not a product but a technology to make above benefits available to users. The following two conditions are necessary to make them come true: Many vendors provide Fieldbus instruments. Those devices are interoperable.

Fieldbus Foundation was established in 1994 to achieve these goals. Its major activities are To promote a single international fieldbus to both users and vendors, To deliver FOUNDATION Fieldbus specification, To provide technologies for Fieldbus implementation including education, and To install an infrastructure to achieve interoperability.

FOUNDATION Fieldbus is a subset of IEC/ISA standard (IEC61158 and ISA S50.02). Fieldbus Foundation and its members adopt FOUNDATION Fieldbus as an enabling technology to utilize it to bring the above benefits to users. FOUNDATION Fieldbus is also called Fieldbus, FF in this textbook.

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2-1

2.

Fieldbus Communication Technologies

This section explains fundamental communication technologies that support Function Blocks and other applications. Though communication technologies are not visible to users except for the wiring, certain knowledge of underlying mechanism helps to understand how Function Blocks serve the plant. If readers already have knowledge about Fieldbus communications or wish to learn about Function Blocks quickly, skip this section and go to Section 3 of this textbook. This section explains how Fieldbus operates and supports the users applications, showing how Fieldbus is carefully designed for industrial automation applications. The technology described here is FOUNDATION Fieldbus, which is the specification of Fieldbus Foundation and is a subset of the IEC/ISA international standards.

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2.1
2.1.1

Communication Models
OSI Reference Model
Communication specifications are often explained with reference to the Open System Interconnect (OSI) layered model. FOUNDATION Fieldbus is specified according to the simplified OSI model, consisting of three (3) layers: Physical Layer (PHL), Data Link Layer (DLL) and Application Layer (APL). See Figure 2.1 for OSI reference model and Fieldbus model. Layers 2 to 7 are implemented mostly by software and therefore are often called the communication stack.
OSI Reference Model (*1) Fieldbus Model

User Application Application Layer Presentation Layer Session Layer Transport Layer Network Layer Data Link Layer Physical Layer FMS: Fieldbus Message Specification Communication Stack Data Link Layer Physical Layer FAS: Fieldbus Access Sublayer FMS FAS

*1: The user application is not defined in OSI model

F020101.EPS

Figure 2.1

OSI Reference Model and Fieldbus Model

Fieldbus Foundation specifies not only communication but also some user applications, which use FOUNDATION Fieldbus communication, though the OSI model does not specify any user application. Application Layer of Foundation Fieldbus consists of two sublayers: Fieldbus Access sublayer (FAS) and Fieldbus Message Specification (FMS). FAS is the glue to map FMS services to Data Link Layer. Figure 2.2 shows the architecture of FOUNDATION Fieldbus.

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Users discuss the business with their own semantics. Application Application

SM

Maintenance System Management Q=1.3 m3/h

Network Management

APL

Application Layer

Information

DLL

0110100

Data Link Layer

Data

Management

PHL

Physical Layer

Signal

Physical Layer transfers signal regardless its content.

F020102.EPS

Figure 2.2

FOUNDATION Fieldbus Architecture

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2.1.2

Protocol Data Unit

Figure 2.3 shows how a user data is transferred over the FOUNDATION Fieldbus. Each layer appends layer-control information called Protocol Control Information (PCI) and more information to the message of the higher layer. A data unit exchanged between the same layers is called Protocol Data Unit (PDU). A PDU may contain an optional data called Service Data Unit (SDU), which is a PDU of the next higher layer. A communication layer exchanges other PDUs without SDU to perform its functionality.
User Application FMS FAS Data Link Layer Physical Layer FMS PDU FAS PDU DL PDU Ph SDU Preamble 1+ bytes FMS:Fieldbus Message Specification FAS:Fieldbus Access Sublayer PDU:Protocol Data Unit FMS PCI User Data FMS encoded data 4 0-251 FAS PCI FAS SDU 1 4-255 DL PCI DL SDU FCS 5-15 5-256 2 Start Delimiter Ph SDU End Delimiter 1 byte 8-273 bytes 1 byte

SDU:Service Data Unit PCI:Protocol Control Information FCS:Frame Check Sequence

F020103.EPS

Figure 2.3

Transmissions of User Data

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2.1.3

Communication through VCR

Messages are exchanged between applications sitting on the FOUNDATION Fieldbus. When a message is transferred, it goes down through a channel called Virtual Communication Relationship (VCR) to add PCI before it goes to the wire. At the destination, it goes up through the partner VCR to the receiving application. PCIs are appended and removed when a message goes through VCRs to allow layers to perform their specific functionality. See Figure 2.4.

Sender

Receiver

index

index

FMS

VCR

FMS

FAS

FAS

DLL

VCR

DLL

DL-address PHL

DL-address PHL

VCR: Virtual Communication Relationship

F020104.EPS

Figure 2.4

Communications through VCR

A Fieldbus device has many VCRs so that it can communicate with various devices or applications at the same time. It is possible because the VCR guarantees the message goes to the correct partner without risks of losing information. A VCR is identified by an application with device-local identifier called index specified in Application Layer. It is also identified from other devices with DL-address specified in Data Link Layer. A VCR has a queue (fast-in, fast-out memory) or a buffer (memory to store data) to save messages. It is the responsibility of network configuration to give the correct information of the index and DL-address as well as other operating information to VCRs through Network Management.

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2.2

Physical Layer
Physical Layer is a mechanism to transmit and receive electric or optic signals to/from medium so that data consisting of ones and zeros is transmitted from one node to the others. Physical Layer interests are wires, signals, waveform, voltage, and others all related to electricity and optics. Though the IEC/ISA standard specifies various media with various speeds, Fieldbus Foundation chose its own subset, low speed wire and fiber media, and Ethernet. Ethernet is discussed in Section 2.6 of this textbook.

2.2.1

31.25 kbps Physical Layer

31.25 kbps Physical Layer is the most common since IEC and ISA approved it in 1992. This textbook explains only wire medium but optical fiber can be used as an alternative. Though 31.25 kbps sounds slow compared with the latest telecommunication technologies, it is necessary to replace traditional 4 to 20 mA analog transmissions. It is intended to apply to field devices for various environments of industries. Many users want to enjoy the simple installation of two-wired transmitters. Explosive gases prevent high-performance electronics in the hazardous area of the plant. Transmission of 31.25 kbps was chosen for those applications, which demand devices of very low power consumption. A field device can draw electric current from the medium to feed energy to its electronics. It is called a bus-powered device and is the Fieldbus equivalent of two-wire installation.

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2.2.2

Signaling Method
Fieldbus utilizes a similar technology for smart transmitters to transmit an electric signal to the wire. Figure 2.5 shows the electric equivalent circuit of signal transmission. Supply voltage is applied by a power supply through an impedance conditioner, typically consisting of inductors. DC current through the impedance conditioner feeds devices. Supply voltage is between 9 V and 32 V at the device terminals. The impedance conditioner makes output impedance of the power supply higher than 400 in the signal frequency bandwidth.
Electric equivalent circuit V0 I1+I2 100 100 Time I1 1F 1F Time Terminator
F020201.EPS

Example of signal waveform

Vs

Vs

I1

I2

Vo

Device 1 Terminator

Device 2

Figure 2.5

Electric Equivalent Circuit of Signal Transmission

Each cable end is terminated with a terminator of 100 impedance. It makes an instrumentation cable a balanced transmission line so that a signal of relatively high frequency can be transmitted with a minimum distortion. I1 and I2 in Figure 2.5 are the currents flowing through device 1 and device 2. When current I1 of device 1 increases by 10 mA, it is fed from capacitors in terminators because the impedance conditioner of the power supply prevents changes of current through inductors. Thus, the voltage between the wire pair decreases by 0.5 V (= 10 mA 50 (*1)). Current I1 in device 1 then decreases by 20 mA to generate a modulated signal of 1 V p-p amplitude, while the average current remains constant. Data is encoded as a voltage change in the middle of one bit time. Data one (1) is encoded as a voltage fall in the middle of the bit time, while zero (0) is encoded as a voltage rise. Additional out-of-band data are N+ and N- encoded as constant voltage during the bit time. They are used only for start and stop delimiters to encode the start and end of PHL SDU (= DL PDU) so that Physical Layer can transmit any combinations of zeros and ones in DL PDU. Figure 2.6 shows the typical waveform of a Physical Layer signal. The receiving Physical Layer retrieves bit time using the preamble and then the boundary of octets (bytes) using the start delimiter. The end delimiter indicates the end of the Physical Layer signal. Preamble length can be increased when the signal goes over repeaters.
*1: 50 is made by a parallel 100 impedance of the terminators

Signal waveform Preamble 1 0 1 0 1 0 1 0 Start-delimiter Data (DLL or higher) End-delimiter 1 N+ N- N+ N- 1 0 1

1 N+ N- 1 0 N- N+ 0 0 0 0 1 0 1 0 0

bit time
F020202.EPS

Figure 2.6

Typical Waveform of Physical Layer Signal

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2.2.3

Wiring Rules
The IEC/ISA standards specify the minimum amplitude and worst waveform of a received signal at a device at the any place of the Fieldbus network. The Physical Layer receiver circuit must be able to receive this signal. The transmission line can be configured in any way as long as the received signal quality is guaranteed at all receiving nodes. However, this is not always simple to do, and so the ISA SP50 Committee created a set of wiring rules to simplify the network design. The received signal is always of better quality than the minimum requirement if the Fieldbus is designed according to these rules. Although the rules seem somewhat conservative, they are useful for easily designing a workable network. Recommended rules by IEC/ISA standard: Rule 1: The number of devices on a Fieldbus shall be between 2 and 32. Rule 2: Cable shall be individually-shielded twisted pair (type A) 18 AWG wires. Rule 3: The total cable length shall not exceed 1900 m (including total spur length). Rule 4: The maximum total spur length shall not exceed 120 m. Rule 5: When overall-shielded twisted pair (type B) 22 AWG wires are used, the total length shall not exceed 1200 m. Table 2.1 shows the Fieldbus cable type and the transmission length, and Table 2.2 shows the number of devices and recommended maximum total spur lengths (*1). Figure 2.7 shows the trunk cable and the spur cables.
Table 2.1 Fieldbus Cables Type and Transmission Length (Rule 3 and 5) Type of cable Cable specifications Max. length of cable (reference value) 1,900 m 1,200 m 400 m 200 m
T020201.EPS

Type A : Individually-shielded twisted pair cable #18AWG (0.82 mm2) Type B : Overall-shield twisted pair cable Type C : Unshielded twisted pair cable Type D : Overall-shielded non-twisted cable #22AWG (0.32 mm2) #26AWG (0.13 mm2) #16AWG (1.25 mm2)

Note: Yokogawa recommends the use of Type A. Usage of Types B and D is restricted. Yokogawa does not recommend the use of Type C.

Table 2.2

Maximum Total Lengths of Spur Cables (Recommended values)(Rule 4)(*1)

Recommended maximum total spur length 120 m 90 m 60 m 30 m 0m
T020202.EPS

Number of devices on the Fieldbus 1 to 12 13 to 14 15 to 18 19 to 24 25 to 32

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HMI

2-9

Host I/F

Terminator Junction Box Trunk Cable (between Terminators) Terminator

FF power conditioner

Spur Cables

F020203.EPS

Figure 2.7

Trunk Cable and Spur Cables

Users can check whether the above rules are satisfied by reviewing the cable installation drawing. Note that these are not the only rules limiting the number of devices on a Fieldbus; other rules are discussed in Section 4.
*1: In principle, the spur cable lengths should be less than the lengths shown in table 2.2. However, in some applications these maximum total spur lengths are exceeded, so Yokogawa was requested to assess whether this is viable. Considering that the lengths shown in the IEC and ISA standards are recommended ones, Yokogawa has assessed the lengths and obtained the following result. Assuming that Yokogawa CENTUM is used as Fieldbus host system, the spur cable lengths can be increased under the following conditions: Use of Fieldbus Type A cable Number of field devices connected to a segment: max. 16 devices Maximum length of spur cable: 120 m Maximum total length of spur cable: 960 m Maximum length of trunk cable: 1900 m - total length of spur cable There is no restriction on the number of junction boxes used to connect field devices via spur cables. The content of Table 2.2 of this textbook is shown in Annex B (informative) of the standard IEC 61158-2 and ISA S50.02. Maximum total spur lengths are the same for Type A, B, C, and D cables.

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2.2.4

Intrinsic Safe (IS) Consideration

Intrinsic Safe (IS) installation is important for plants where explosive gases exist. Intrinsic Safe (IS) is the rule to design and install devices in a hazardous area to prevent an explosive gas being ignited by electric discharge or the surface temperature of a device. An IS field device must be carefully designed to prevent ignition even when a single failure of its component takes place. An IS barrier must be installed to separate the hazardous area from the safe area as shown in Figure 2.8 A barrier strictly limits the voltage, current and power fed to a device installed in the hazardous area. Therefore a field device must be operational with the restricted power supply. Devices and barriers must meet the same design criteria provided by safety organizations (IEC, FM, CENELEC, PTB, etc.). Note that IS is the only possible technology for zone 0 where explosive gases exist at any time. In zone 1 where such gases exist most of the time but not always, explosion proof technology is also applicable as well as IS Explosion proof is a technology of housing design and is independent from fieldbus technologies.
HMI

Host I/F

Terminator

Barrier (with FF power conditioner)

Safe area

Hazardous area
F020204.EPS

Figure 2.8

Separation between Safe Area and Hazardous Area

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2.3

Data Link Layer

Data Link Layer is a mechanism to transfer data from a node to the other nodes that need the data. It also manages the priority and order of such transfer requests. Data Link Layer interests are data, address, priority, medium control, and others all related to message transfer. Since Data Link Layer operates on the low speed Physical Layer, it has mechanisms to use the medium in an effective way. FOUNDATION Fieldbus Data Link Layer is a subset of ISA S50.02 part - 3/4 and type 1 in IEC61158-3/4.

2.3.1

Medium Access Control

The most important functionality of Data Link Layer is Medium Access Control (MAC) of the Fieldbus. Since all devices on the same cable receive the same Physical Layer signal, only one of them is allowed to transmit signal at a time. MAC is the method to achieve this goal. The domain of devices sharing the same Physical Layer signal is called a link. In other words, only one device on a link is allowed to use the medium (Physical Layer) at a time. Link Active Scheduler (LAS) has the role to control the medium access. Its functionality is explained in Section 2.3.3 of this textbook. The right to send a PDU is called a token. The LAS possesses the token and gives it to another device to allow it to send messages. The token is then returned to the LAS for further medium access control. Since application messages have various levels of urgency, Data Link Layer supports a mechanism to transmit messages according to their urgency. Data Link Layer provides three levels of priority, URGENT, NORMAL and TIME_AVAILABLE, in this order. An URGENT message is transmitted immediately even when other messages of NORMAL or TIME_AVAILABLE priority are in the waiting queue, and vice versa. Maximum data size allowed for each priority is shown in Table 2.3.
Table 2.3
Priority URGENT NORMAL TIME_AVAILABLE
DLSDU: Data Link Service Data Unit

Maximum Data Size in Each Priority

Maximum DLSDU data size 64 bytes 128 bytes 256 bytes
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2.3.2

Addresses
Communication partners in Data Link Layer are identified with DL-address, which consists of three components, Link, Node and Selector. Table 2.4 shows an example of bit lengths of Link, Node and Selector. Link field consists of 16 bits and identifies a link. When the communication is within a link, this field is often omitted. This field is necessary when a message is going to other links through bridges.
Table 2.4 Example of Bit Lengths of Link, Node and Selector Bit length example 16 bits 8 bits 8 bits
T020302.EPS

Data link address component Link Node Selector

Node field gives the node address of 8 bits. A Fieldbus device has a node address in the ranges between 0x10 and 0xFF, which is classified into LM range, BASIC range, default range and temporary range. Usually devices are in LM or BASIC range according to their device classes. When a device loses the node address, it communicates using one address in the default range. A temporary device such as a handheld communicator has node address in the temporary range. Link Active Scheduler has a node address of 0x04. Table 2.5 and Figure 2.9 show the address range used in a Fieldbus link. There is an address gap of size V(NUN). If a device has an address in this gap, it will never join the link. V(FUN) and V(NUN) are parameters to be able to access through Network management.

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Address range in Fieldbus link 0x10 to V(FUN) V(FUN) + V(NUN) to 0xF7 0xF8 to 0xFB 0xFC to 0xFF

Device class Address for Link Master (LM) class devices Address for BASIC class devices Default address for devices with cleared address Address for temporary devices like a handheld communicator
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0x00 Not used 0x10 Link Master (LM) class devices V(FUN)

Not used

V(NUN)

V(FUN)+V(NUN) 0xF7 0xF8 0xFC 0xFD 0xFF

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BASIC class devices Default addresses Temporary devices

Figure 2.9

Address Range in Fieldbus Link

Selector field gives a device-internal address of 8 bits to identify a VCR. When a VCR is connected to another VCR, it is identified with DLCEP (Data Link Connection End Point) shown in this field. When a VCR is not connected to any others but open to send/receive messages, it is identified with DLSAP (Data Link Service Access Point) shown in this field. DLCEP and DLSAP have different ranges. Several DL addresses are reserved for specific purposes. For example, devices can share the same global DLSAP for alarm reception.

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2.3.3

Link Active Scheduler

Link Active Scheduler (LAS) has the role to control the medium access. Fieldbus devices are classified with device classes: BASIC, Link Master (LM) and Bridge. A LM class device has a capability to work as the LAS, while BASIC class devices do not. A Bridge class device has, in addition to LM capability, the functionality to connect links. One and only one device in a link works as the LAS. Therefore at least one LM (or Bridge) class device is needed in a link. LM devices try to acquire LAS role when no LAS exists on start up or when the current LAS fails. The LM device with the least node address wins this contention. Other LM devices observe the LAS activity and take over its role when LAS goes away. Figure 2.10 shows the procedure through which a Link Master class device becomes the LAS.
(1) Fieldbus starts up.

BASIC

Link Master

BASIC

BASIC

Link Master

(2) A Link Master claims LAS. CL

BASIC

Link Master

BASIC

BASIC

Link Master

(3) A Link Master becomes LAS. LAS Link Master

BASIC

BASIC

BASIC

Link Master
F020302.EPS

Figure 2.10

Procedure for Link Master Class Device to Become the LAS

Note that the LAS is an additional functionality to basic communication. Therefore it has a different DL-address (0x04) than the node address.

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2.3.4

Scheduled Communication
The LAS is responsible for scheduled communication, which is necessary to link Function Blocks. Function Blocks are distributed applications operating in a synchronized manner. The LAS manages the communication part of the synchronized data transfer. A Function Block output parameter is a Publisher of data and other Function Blocks that receive this data are called Subscribers. The LAS controls periodic data transfer from a Publisher to Subscribers using the Network Schedule. When the time of scheduled communication comes, LAS sends Compel Data (CD) PDU to the Publisher DLCEP. Publisher is expected to transmit Data Transfer (DT) PDU stored in the data buffer of the DLCEP immediately. When Subscribers receive CD to the Publisher, they presume the next data transfer comes from the Publisher. Received data is stored in the buffer of Subscribers. A CD PDU is a token for a Publisher and the LAS interprets the publishing DT PDU as the returned token. See Figure 2.11.
(1) LAS issues CD (Compel Data) with token to the Publisher. LAS CD (token) Buffer Device Buffer Device Buffer Device

Device

(2) The Publisher publishes data and the Subscribers get data. Token is returned to LAS. LAS DT (token) DT (data)

Device

Buffer Device

Buffer Device

Buffer Device
F020303.EPS

Figure 2.11

LAS Control in Scheduled Communication

Data Link Layer appends freshness information as PCI to the data so that the Subscribers know whether data has been updated since the last publish.

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2.3.5

Unscheduled Communication
Other communications take place in an asynchronous way. The LAS is responsible to give all nodes on a link a chance to send messages. The LAS gives a token by sending Pass Token (PT) PDU to a node. A PT PDU contains priority and time interval information. When the node does not have messages of the given or higher priority to be sent, or the given time interval is expired, it returns token as Return Token (RT) PDU. The LAS controls the message transfer by updating the priority. When the token is given to all devices in a short time interval, the LAS gives more time to the nodes by lowering the priority. When the token does not go to all devices within a target token rotation time network parameter, the LAS increases the priority so that the token is given to all devices in a desired time interval. A device must return the token within the time interval given in the PT PDU. This is necessary to finish the unscheduled communication before the next scheduled communication. Note that the token is given to the node instead of DLCEP or DLSAP. Therefore the device is responsible to allow all DLCEPs and DLSAPs in the device to send messages. See Figure 2.12.
(1) LAS issues PT (Pass Token) to a device. LAS Device PT (token) Device Device Device

(2) The device holding token sends data to other devices. LAS Device DT Device token Device Device

(3) Device returns token to LAS when it has no further data or given time expires. LAS Device RT (token) Device Device Device
F020304.EPS

Figure 2.12

LAS Control in Unscheduled Communication

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2.3.6

Link Maintenance
The third role of LAS is to maintain the link. The LAS gives the token to all devices detected by the LAS. When a new device is added to the network, it must be recognized by the LAS and entered to the token rotation list called Live List. The LAS sends a Probe Node (PN) PDU to node addresses where a device was not found before. A new device waits until it receives PN and returns Probe Response (PR) PDU to the LAS. Then the LAS adds this device to the Live List after activating the full DLL functionality of the device. This activation procedure is beyond the scope of this textbook. This probing is repeated in a given interval. When a device is removed from the link, it does not respond to PT any more. The LAS detects this and deletes the device from the Live List. Whenever a change is detected in the Live List, the LAS broadcasts the change so that all LM devices share the latest list and are ready to take over. The LAS also broadcasts its Data Link Time (LS-time) to the link in a predefined interval so that all devices on the network share the same time, which is necessary to start Function Blocks. It is often called network time.

2.3.7

Data Link PDUs

Table 2.6 summarizes Data Link Protocol Data Units (DL PDUs) in FOUNDATION Fieldbus.
Table 2.6
DL PDU EC DC CD DT PT RT RI PN PR TD CT RQ RR CL TL IDLE

Data Link Protocol Data Units (DL PDUs)

Name Establish Connection Disconnect Connection Compel Data Data Transfer Pass Token Return Token Request Interval Probe Node Probe Response Time Distribution Compel Time Round-trip Time Query Round-trip Time Response Claim LAS Transfer LAS Idle Disconnect. Poll a Publisher. Send a data unit. Give the token. Return the token. Request more PT. Search new node. Join the link. Synchronize Time. Request TD. Measure delay in TD. Becomes LAS. Request LAS role. No activity
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Functionality Connect DLCEP.

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2.4
2.4.1

Application Layer
The Application Layer consists of two sublayers. Fieldbus Access Sublayer (FAS) manages data transfer while Fieldbus Message Specification (FMS) encodes and decodes user data.

Fieldbus Access Sublayer

Fieldbus Access Sublayer (FAS) is a part of secure communication. Since Fieldbus does not have layers (3 to 6) between DLL and APL, FAS directly maps APL requests to DLL services. This is the most important part of VCR management. The FAS provides three communication models for applications. They are explained below and summarized in Table 2.7 It is expected a network manager configures VCRs correctly according to the models communicating with each other. Once configured, FAS provides the communication facility according to these models.
Table 2.7 Communication Models in Fieldbus Access Sublayer (FAS)
Model Client-Serve Publisher-Subscriber Source-Sink DLL Queued Buffered Queued Schedule by User Network User Direction Bi-direction Uni-direction Uni-direction
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Client-Server Model
The Client-Server model is universal and used in many communication technologies. An application called Client requests another application called Server to do a specific action through FMS. When the Server finishes the requested action, its result is transferred to the Client. It is a one-to-one two-way communication using DLCEP. A typical example is a human-machine interface (Client) to read data of a Function Block (Server). The Client sends a Read request to the Server and then Server sends back the data to the Client. This communication takes place at any moment. A Client may want to issue many requests at a time. Client-Server VCR has a queue to store those requests and sends requests one by one when the node has a token. A flowcontrol mechanism is available to manage error recovery and Servers processing power. See Figure 2.13. The features of Client-Server communication model are as follows. One-to-one two-way connected communication Universal communication Manual operation Download configuration Maintenance

Response time depends on Device throughput Bus traffic

Client

Response: Its 10.3 kPa. Request: Give me current pressure. Server

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Figure 2.13

Client-Server Communication Model

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Publisher-Subscriber Model
Publisher-Subscriber model is designed to link Function Blocks. When a publishing Function Block runs, its output data is stored in the buffer of the Publisher VCR. Then the LAS sends CD to the VCR to force it to transfer the data in DT PDU. Subscriber VCRs receive this PDU and gives the data to the subscribing Function Blocks. A typical example is a linkage from output of an Analog Input (AI) block to process value input of PID control block. The features of Publisher-Subscriber communication model are as follows. One-to-many one-way connected communication Data transfer for instrumentation Connect Function Blocks

Periodic schedule with highest priority

LIC300

LIC300
AUT NR

AUT NR PV SV MV

M 5.5 M 5.0 % 67.1 10.0

0.0

Information Report: Pressure is 10.3 kPa. Subscriber Publisher

Subscriber
F020402.EPS

Figure 2.14

Publisher-Subscriber Communication Model

The Publisher-Subscriber model is one-to-many one-way communication using DLCEP. Subscribers are able to know whether data has been updated since the last publish. This mechanism is important because Data Link Layer transfers data as scheduled regardless if the publishing Function Block updates the data in the buffer.

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Source-Sink Model
The Source-Sink model is designed to broadcast messages. It is one-to-many one-way communication without schedule. This model is sometimes called Report Distribution Model. A Source VCR transfers a message in the queue to an assigned global DLSAP address when the device has the token. Sink VCRs have the same global address and receive the same message from a Source. Fieldbus devices use this model for two specific purposes. One is to report alarms or events detected in the Source, and the other is to transmit trend of Source Function Block. Alarms are acknowledged through a Client-Server VCR. It is desirable for an alarm logger to receive alarms from devices with one VCR. A Sink can receive messages from many Sources if the Sources are configured to send messages to the same global address. A Sink can identify the Source with its DLSAP address. The features of Source-Sink communication model are as follows. One-to-many one-way connection-less communication Event reporting Device or process alarms Trending

On-demand aperiodic communication

Sink Event Report: My hardware failed.

LIC300

LIC300

Source

AUT NR

AUT NR PV SV MV

M 5.5 M 5.0 % 67.1 10.0

0.0

Sink
F020403.EPS

Figure 2.15

Source-Sink Communication Model

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2.4.2

Fieldbus Message Specification

Fieldbus Message Specification (FMS) is a service interface for user applications to use Fieldbus services. When a service is requested, it encodes the request to transfer it to the other applications. The receiving FMS decodes the request to notify the application.

Virtual Field Device (VFD)

A Fieldbus device may have user applications, which are independent from each other and do not interact. A Fieldbus device consists of Virtual Field Devices for such individual applications. An identifier, given to a VCR, identifies the VFD. A Fieldbus device has at least two VFDs. One is Management VFD where network and system management applications reside. It is used to configure network parameters including VCRs as well as to manage devices in a Fieldbus system. The other is a Function Block VFD where Function Blocks exist. It is possible for a field device to have two or more Function Block VFDs.
Management VFD MIB OD SMIB NMIB RB TB Function Block VFD FB OD AI PID Link

VCR

VCR

VCR

VCR

VCR

VCR

FMS FAS DLL PHL SMSAP VFD OD SMIB NMIB SMSAP SM/NM Server FB RB TB VCR Publisher Subscriber Source

: Virtual Field Device : Object Dictionary : System Management Information Base : Network Management Information Base : System Management Service Access Point

: Function Block : Resource Block : Transducer Block : Virtual Communication Relationship

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Figure 2.16

Management VFD and Function Block VFD

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FMS Objects
Applications in a VFD are shown to other applications on the network using an object model, which consists of attributes, its behavior and access methods.

Object Examples
Function Blocks have parameter objects to which another application can have access. Alarms, Function Block Linkage are also objects. Their behavior is specified in the Function Block Application specification. Network behavior is managed through Network Management Information Base (NMIB) objects. System behavior is managed through System Management Information Base (SMIB) objects. Schedules and VCRs are also objects.

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Object Dictionary
An object is identified with a number called index, which is unique within the VFD. Additional information to describe an object is necessary for open systems. Such information is called the Object Dictionary (OD), which is an assembly of information called Object Descriptions to explain the objects. A Client application can read such explanations with Get OD service and read the value when the object is a variable. The most fundamental object is a variable to contain a value. It may be a simple variable, a record (structure) or an array. Function Block parameters, VCR, NMIB and SMIB are examples of record variables. Other objects are event, domain, and program. They are explained in the next sections. See Figure 2.17.
Object Dictionary Data Type Object Description Object Description Object Description Object Description Read Variable Variable Write Variable Variable Variable Variable Notify Event Event Event Download Domain Domain Start Program Program Program Domain Event Variable Object Description Object Description Object Description Object Description Object Description Object Description Object Description Object Description Object Description Object Description Object Description Object Description Object Description
F020405.EPS

Get

Figure 2.17

Object Descriptions and Object Dictionary

An object is accompanied with its Object Description sharing the same index. There are Object Descriptions without associated objects. Those Object Descriptions give other information such as object location, amount of objects, data type, data structure and so on.

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FMS Services
FMS provides services to access FMS objects. Table 2.8 to 2.11 summarize them with service classes.

Variable Access
A variable is storage of data. Its value can be read or written by another application. An application can send variable data without request from another application using Information Report service. Foundation Fieldbus uses this service in publishing data and reporting trends. It is possible to define a list of variables for an effective transfer. When a variable is a record or an array and consists of multiple variables, it is possible to transfer it as a whole or only one component assigned with sub index.
Table 2.8 Variable Access Services
Service Read Write Information report Define variable list Delete variable list Functionality Read value of a variable. Write value to a variable. Send value as Publisher or Source. Define a list of variables to send. Delete a list of variables.
T020402.EPS

Event Management
Event is used to notify that an application detects something important. Failure, data update and alarms are examples of events. An event is notified with the Source-Sink model repeatedly until it is acknowledged through the Client-Server model. Its notification can be enabled or disabled through another Event-related service.
Table 2.9 Event Services

Service Event Notification Acknowledge Event Notification Alter Event Condition Monitoring

Functionality Report an event as Source. Acknowledge an event. Disable or enable an event.

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Domain Management
Domain is a continuous memory area. It may be a program area or data area. A Client can download data to a domain or upload domain content through FMS services. Because a domain can be larger than the maximum size of FMS encoding, FMS allows uploading or downloading a domain in parts. Initiate and Terminate services are prepared to manage partial download and upload.
Table 2.10 Domain Services

Service Request Domain Download (Generic) Initiate Download Sequence (Generic) Download Segment (Generic) Terminate Download Sequence Request Domain Upload Initiate Upload Sequence Upload Segment Terminate Upload Sequence

Functionality Request download. Start downloading. Download. Stop downloading. Request upload. Start uploading. Upload. Stop uploading
T020404.EPS

Program Invocation
Program is a data processing functionality that can be managed from other applications. It was modeled for PLC ladder programs and can be used for Function Block Applications. When a program is downloaded, its invocation is tightly coupled with Domain management.
Table 2.11 Program Services

Service Create Program Invocation Delete Program Invocation Start Stop Resume Reset Kill

Functionality Create a Program object. Delete a Program object. Start a program. Stop a program. Resume a program execution. Reset the program. Disable the program.
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Other Services
FMS provides other services for Object Dictionary and Context management. An Object Description can be read by the Get OD service. When an object is downloadable, its object descriptions need to be downloaded too. A connection between applications is managed though Context. Initiate and Abort services are fundamental and the status information of the partner can be transferred by other services.
Table 2.12 Other FMS Services
Service Get OD OD management services Initiate Put OD Put OD Terminate Put OD Initiate Context management services Abort Reject Identity Functionality Read an object description. Start downloading OD. Download an OD. Stop downloading OD. Establish a FMS connection. Release a FMS connection. Reject an improper request. Ask VFD Identification (vendor, model).
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2.5

System Management Protocol

System Management needs additional protocols to manage Fieldbus systems. It must be operational even under abnormal situations such as system startup, wrong configuration, device failure and its replacement. Its protocol is called System Management Kernel Protocol (SMKP) and it directly uses Data Link Layer services without the Application Layer.

2.5.1

Tag and Address Assignment

A field device is identified with its PD tag as well as its node address as explained in Section 3.4.1 Device Management. SMKP provide services to assign them to a device. When a device changes it address, it disappears and comes back to the link with a different address. Therefore its behavior is complicated in the Data Link Layer. A special protocol is defined for this purpose.

2.5.2

Tag Location
Device Tag and Function Block Tag are useful for humans but need longer data for communication. SMKP provides services to replace Device Tag and Block Tag with node address and index to make further communications much simpler.

2.5.3

Application Time Synchronization

Fieldbus Applications need to be synchronized in the sense of time to interact each other. For example, an event message needs a time stamp to indicate when it is detected, because it is received sometime later depending on the token rotation and bus traffic. SMKP provides a mechanism for all Management VFDs to share the synchronized time.

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2.6

High Speed Ethernet

Though the Fieldbus specification allows faster media such as 1 Mbps and 2.5 Mbps, very few people are interested in using them. 31.25 kbps Physical Layer has its niche to replace 4 to 20 mA transmissions in plant floor and work in a hazardous area. Ethernet is getting its place by the state-of-art technologies.

2.6.1

Why Ethernet?
Ethernet is one of the most popular networks for office and business applications. Network components such as cables, hubs and switches are available with very low prices from the commercial off the shelf (COTS) environment. Its media are evolving very quickly. 100 Mbps Ethernet is replacing traditional 10 Mbps Ethernet, and a faster Ethernet of 1 Gbps is emerging. It is better to utilize those COTS components both in cost and availability.

2.6.2

TCP/IP Protocol Suite

Much more important thing for high-speed fieldbus is TCP/IP, which is the de facto standard in information technology (IT) world. When FOUNDATION Fieldbus goes over TCP/IP, it makes it possible to open the door to the IT world and build a total network from plant floor to enterprise level. Internet Protocol (IP) is used to transfer data to a desired station IP address. FOUNDATION Fieldbus utilizes IP version 4 today and will switch to much powerful IP v6 in the near future. Transfer Control Protocol (TCP) provides connection-oriented transport services that can be used for Client-Server communication. User Data Protocol (UDP) transfers an amount of data to a desired application and can be used for Source-Sink communication. PublisherSubscriber communication can use either TCP or UDP.

2.6.3

Field Device Access Protocol

It is desirable to have the same applications for measurement and control regardless of their physical location in a hierarchical network. FMS and SMKP services must be maintained for this goal. Field Device Access (FDA) protocol is designed for this purpose to allow all FMS and SMKP services go over TCP/IP.

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3.

Fieldbus Applications
This section explains Function Blocks and other applications running over FOUNDATION Fieldbus. Communication technologies supporting those applications are explained in Section 2 of this textbook. This section describes how measurement and control applications are implemented on FOUNDATION Fieldbus and how carefully such applications are designed to provide the plant secure control and the successful maintenance.

3.1

Virtual Field Devices

A Fieldbus device may have user applications, which are independent from each other and do not interact. A Fieldbus device consists of Virtual Field Devices (VFDs) for such individual applications. VFDs can be seen as different field devices from an application point of view. Communication services guarantee their independence. See Figure 2.16 for relationship between VFD and communication.

3.1.1

VFDs in a Fieldbus Device

A FOUNDATION Fieldbus device has at least two VFDs. One is the Management VFD where network and system management applications reside. It is used to configure network parameters including VCRs as well as to manage devices on a Fieldbus. The other is a Function Block VFD where Function Blocks exist. It is possible for a field device to have two or more Function Block VFDs.

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3.2

Function Block
This section focuses the most important concept of Function Block in FOUNDATION Fieldbus, especially its models and parameters, through which users can configure, maintain and customize users applications.

3.2.1

What is a Function Block?

A Function Block is a functional model common in measurement and control. It is a generalized concept of the functionality users have in field instruments and control system such as analog input and output as well as PID control. The FOUNDATION specification, Function Block Application Process - Part 1, gives fundamental concepts while Part 2 and later give various Function Blocks details. Function Block parameters are visible and accessible through communication services and the Block behavior depends on the values of parameters. A Function Block may reside in virtually any device on the network and a set of Function Blocks connected to each other to form an application can reside in one device or be distributed among devices. Fieldbus Foundations System Architecture document says: One of these models, the function block model, has been specified within the architecture to support low level functions found in manufacturing and process control. Function Blocks model elementary field device functions, such as analog input (AI) functions and proportional integral derivative (PID) functions. The function block model has been supplemented by the transducer block model to decouple function blocks from sensor and actuator specifics. Additional models, such as the exchange block model, are defined for remote input/output and programmable devices. The function block model provides a common structure for defining function block inputs, outputs, algorithms and control parameters and combining them into an Application Process that can be implemented within a single device. This structure simplifies the identification and standardization of characteristics that are common to function blocks. The Function Block VFD contains three classes of blocks: Resource Block, Function Block and Transducer Block.

Resource Block
A Resource Block shows what is in the VFD. It gives the manufacturers name, device name, DD and so on. If the VFD allows creating or downloading a Function Block, Resource Block shows how much resource (memory and CPU time) is available. Status of hardware is also visible. Resource Block controls the overall device hardware and Function Blocks within the VFD.

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Function Blocks
A Function Block is a generalized model of measurement and control. For example, the AI block conditions raw data from transducer(s) and outputs the measured value in a common format. Function Blocks are classified into three classes: (1) a Standard Block as specified by the Fieldbus Foundation, (2) an Enhanced Block with additional parameters and algorithm, and (3) an Open Block or a Vendor-specific Block designed by individual vendors. A Function Block has input, output and contained parameters. Data generated in a block is exposed in an output parameter, which can be linked to the input parameter of other Function Blocks. Figure 3.1 shows an example of Function Block (PID Block).

Inputs

Algorithm (Example : PID)

Outputs

Standard Block Parameters Mode,etc.

Block Specific Parameters Gain,etc.

F030201.EPS

Figure 3.1

Example of Function Block (PID Block)

Table 3.1 lists Function Blocks defined by the Fieldbus Foundation. The major functionality is implemented here. Part 2 blocks are the most fundamental ones for measurement and control. Part 3 blocks are for advanced control. Part 4 blocks provide I/O interface to other world such as 4 to 20 mA. Part 5 blocks can be tailored for users application like a PLC program.

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3-4

FOUNDATION Specification Part No.

Block name AI DI ML BG CS PD PID RA AO DO DC OS SC LL DT IT SPG IS AR TMR AAL MDI Analog input Discrete input Manual loader Bias/gain

Block function

Part 2 (*1): Major blocks in control and measurement

Control selector PD control PID control Ratio Analog output Discrete output Device control Output splitter Signal characterizer Lead lag Deadtime Integrator Setpoint ramp generator Input selector Arithmetic Timer Analog alarm Multiple discrete input Multiple discrete output Multiple analog input Multiple analog output Fixed OD Fixed programmable resource Variable OD Variable programmable resource Resource block for programmable resource
T030201.EPS

Part 3 (*2): Advanced control Blocks

Part 4 (*3): Multiple I/O Blocks

MDO MAI MAO FOD

Part 5 (*4): Flexible blocks

FPR VOD VPR VRB

*1: Refer to Fieldbus Foundation Document FF-891 for details. *2: Refer to Fieldbus Foundation Document FF-892 for details. *3: Refer to Fieldbus Foundation Document FF-893 for details. *4: Refer to Fieldbus Foundation Document FF-894 for details.

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Various measurement and control applications can be built by linking these Function Blocks. Figure 3.2 shows typical examples using Part 2 blocks.

AI

DI

AI

AI AI

AI

Input

ML DO AO Manual Control

PID

PD DI

PID

AO

AO

AO

AO Track, Feedforward Capability in Control

Output

Feedback Control

AI

AI

AI AI

AI AI PID

AI

PID

PID

RA

PID

SS

PID

PID

BG

BG

AO Override Control

AO Ratio Control

AO Cascade Control

AO

AO

Split Range Control

F030202.EPS

Figure 3.2

Example of Function Block Linkage Using FF Specification Part 2 Blocks

Transducer Block
A Transducer Block is a model of sensors and actuators. It is modeled to give a similar expression to Function Blocks. Traditional sensors like pressure transmitters can be mapped to a Transducer Block. A Transducer Block is linked to a Function Block through the CHANNEL parameter of the Function Block. A Function Block is a general idea while the Transducer Block is dependent on its hardware and principles of measurement. For example, pressure transmitter and magnetic flowmeter have different measurement principles but provide an analog measured value. The common part is modeled as an Analog Input (AI) block. The difference is modeled as Transducer Blocks that give the information on the measurement principle.

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3.2.2

Link and Schedule

A measurement or control application consists of Function Blocks connected to each other. Figure 3.3 shows an example of PID control consisting of AI, PID and AO blocks. They are connected through Link Objects in Function Block VFD. A Link Object connects two Function Block within a device, or a Function Block to a VCR for Publisher or Subscriber. A Function Block must get input parameters before its algorithm is executed. Its output parameters must be published after the algorithm execution. Therefore algorithm execution and Publisher-Subscriber communication must be orchestrated even when blocks are distributed among devices. The System Management and Data Link Layer cooperate to achieve this by using the Link Scheduling (LS) time distributed and synchronized by the Link Active Scheduler (LAS). The System Management in a field device starts Function Blocks according to the Function Block schedule. The LAS transmits the Compel Data (CD) PDU to a publishing device to force the output data to be transmitted, according to the LAS schedule. These two schedules (Function Block Schedule and LAS schedule) are defined as offsets in the control period called macro cycle, and must be configured to schedule Function Blocks and communication in a desired order. See Figure 3.3 as an example.
Application AI PID AO

Block Link over Communication Schedule Block Execution Internal Block Link

Device #1

AI

Device #2

PID

AO

Communication

Scheduled Communication

For other Communications

F030203.EPS

Figure 3.3

Example of Scheduling of Function Blocks and Communication

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3.2.3

Parameters
A block has a series of parameters, which are accessible by choosing one with a FMS index. Parameters of a block have continuous indices.

Parameter Classes
Block parameters are classified into three classes: input, output and contained parameters. Function Blocks can have all of them while the Resource Block and Transducer Blocks have only contained parameters.

Output Parameters
An output parameter is an output of a Function Block and can be connected to input parameter(s) of other Function Block(s). It is possible for two or more Function Blocks to share one output parameter from a Function Block. This is supported by periodic PublisherSubscriber communications. An output parameter is a record consisting of a value (analog or discrete) and its status (showing whether the value is useful).

Input Parameters
An input parameter is an input of a Function Block and can accept one output parameter of another Function Block. Its data type must be equal to that of the output parameter.

Contained Parameters
A contained parameter is neither input nor output. It is accessible only through on-demand Read or Write request. Its data type can be any of those defined by the Fieldbus Foundation.

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Parameter Attributes
Block parameters have several attributes that make their behavior complex.

Access Right
Function Block parameters can be readable (expressed as r) and/or writable (expressed as w). Even when a parameter is writable, there may be restrictions. For example, OUT parameter of AI block is writable when block mode is O/S or MAN. In other modes, a write request to this parameter is rejected. Vendor-specific range check for a write request is allowed. For example, many PID blocks reject a request to set proportional gain to zero.

Dynamic or Static
A dynamic parameter varies when the Function Block is executed, but its value is lost when the power is turned off. A static parameter does not vary according to block execution but may be written by an on-demand request, and its value is restored. A parameter whose value just before power-off is retained when the power is turned on again, this parameter is called non-volatile. Static parameters can be written only when block mode is O/S; e.g., the block mode should be changed before modifying static parameters. After modifying static parameters, the block mode should be restored to appropriate mode (AUTO or CAS).

Status of a parameter
Input parameters, output parameters and some of contained parameters are records with status. Status shows whether the value of this parameter is useful or not. If the value is useful, the status is GOOD. If the value is not useful, the status is BAD. The status can be UNCERTAIN when the block is not 100% confident that the value is useful. Blocks have an option to interpret UNCERTAIN as GOOD or BAD. Status has additional fields to show more details.

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3.2.4

Important Parameters
Several parameters are common to many blocks and are very important.

Block Mode
All blocks have their mode, expressed by the MODE_BLK parameter. It is a record of four components; Target, Actual, Permitted and Normal. Target is the mode into which an operator wants to bring this block. This component is writable. Actual shows the actual mode of the block and is read-only. When the necessary condition is satisfied, Actual mode becomes same as Target. There is a chance that Actual mode stays different from Target for some reason. Permitted mode shows which mode is allowed in Target of this Function Block. Normal mode is a reminder for the operator to record the mode that an operator expects in normal conditions. These two components are writable but it is not a good idea to change them without reason. Mode can be one of O/S, MAN, AUTO, CAS, RCAS and ROUT. In O/S (out of service) mode, the block does nothing but set parameter status to BAD. In MAN (Manual) mode, Function Block execution does not affect its output. In AUTO (Automatic) mode, the block works independently from upstream Function Blocks. In CAS (Cascade) mode, the Function Block receives the set point from an upstream Function Block. Actual mode of Function Blocks for output or control may become IMAN (initialize Manual) or LO (Local Override) according to the status of a downstream block or local operation. Permitted mode depends on the block. Resource Block has only O/S and AUTO modes. Transducer Block may have O/S, MAN and AUTO modes.

Scaling Parameters
Some Function Blocks need scaling of the data as 0 to 100%. A scaling parameter is a record of four components: EU@100%, EU@0%, Unit Code and Point Position. EU@100% and EU@0% are values of 100% and 0%, respectively, in the engineering units. Unit Code indicates the engineering units of the scaling or parameter. It could be GPM, psi, inches or something else. Point Position shows the position of the point that an operator wants to show the desired resolution of the floating-point value. Table 3.10 summarizes important unit codes.

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3.2.5

View Objects
Since a Function Block has many parameters, it is not practical to read them one by one for display purposes, especially for operators. Fieldbus Foundation utilizes the FMS Variable List concept for this purpose. A View Object is a predefined Variable List made of many block parameters. Four View Objects are defined for each block. They are VIEW 1: Operation Dynamic - List of dynamic parameters that are necessary to run the plant by operators. VIEW 2: Operation Static - List of static (configured) parameters that may be necessary to show operators along with the dynamic parameters. VIEW 3: All Dynamic - List of all dynamic parameters that may be used for detailed display or diagnosis. This list is bigger than VIEW 1 object. VIEW 4: Other Static - List of static parameters that may be useful for configuration and maintenance purpose. This list is bigger than VIEW 2 object and may or may not consist of all static parameters.

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3.3

Important Blocks
Fieldbus Foundation specified ten (10) standard function blocks in the Part 2 of its specification. More function blocks were added later. However, only five Function Blocks (AI, DI, PID, AO and DO) are of the most importance in most cases, and only three of them (AI, PID and AO) are in many cases. This section describes the information of three important Function Blocks (AI, AO and PID) as well as Resource and Transducer Blocks. It also provides recommended values of block parameters, which come from Yokogawas long experience of measurement and control. These values can be used in most of cases. If a parameter is a bit-string (unsigned integer with each bit having an assigned meaning), names of bit to be set are listed using names in Foundation Document. If a parameter is dynamic and users cannot set it, value field indicates it as dynamic.

3.3.1

AI block
Analog Input (AI) block is designed to allow users to enjoy standard model of generalized signal-conditioning function. An AI block receives data measured by Transducer Block and manipulates it for the followings. Scaling Square root calculation (for an orifice plate) Low-pass filter Alarm generation

Figure 3.4shows the internal structure of an AI block.

AI Block ARITHMETICS CHANNEL scaling square root low cut filter OUT

SIMULATE
F030301.EPS

Figure 3.4

AI Block

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Scaling and Square Root Calculation

Parameter L_TYPE controls scaling and square root. Value of a contained parameter PV (Process Value) of AI is determined by L_TYPE. When its value is direct, Channel value becomes OUT value. When its value is indirect, Channel value is scaled with XD_SCALE and OUT_SCALE. XD_SCALE gives 0% and 100% value of Channel value and its engineering unit, while OUT_SCALE gives those of the output value. When the value of L_TYPE is Square Root, the output value is square root of scaled value. The resulting value could be very unstable because of the nature of orifice plate. In that case, a cutoff function is used to force PV value to zero when it is less than the LOW_CUT value.

Low-pass Filter
PV can be made more stable by applying single-exponential low-pass filter. Its time constant is given by PV_FTIME in seconds. If its value is zero, no filter is applied.

Alarm Generation
When PV value is smaller than LO_LIM or LO_LO_LIM, a LO or LO_LO alarm is generated, respectively. When PV value is larger than HI_LIM or HI_HI_LIM, a HI or HI_HI alarm is generated, respectively. Following order is expected. LO_LO_LIM LO_LIM HI_LIM HI_HI_LIM

Permitted Modes
Permitted modes are O/S, MAN and AUTO. In MAN mode, OUT.value can be modified. In AUTO mode, PV.value and PV.status are copied to OUT.value and OUT.status respectively.

Channel Value
The CHANNEL parameter, 1 or greater (upper bound depends on Transducer Block), chooses one of the data values from Transducer Block. Channel value is visible in SIMULATE parameter (Transducer Value and Transducer Status).

Simulation
This functionality is very useful in starting up the plant. If users set SIMULATE.En/DisAble to Enabled, AI block uses Simulate Value and Simulated Status as Channel value instead of Transducer Value and Transducer Status. This function is active only when Simulation Switch (hardware) is ON. Do not forget to disable SIMULATE after using this function.

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Recommended Parameter Values

Recommended values for the following three applications in Table 3.2 are listed in the Table 3.3. Note that those values can be changed only when MODE_BLK.Target is Out-ofService.
Table 3.2 Three AI Block Applications
Description The Transducer Block gives measured value in the desired unit. AI block can be transparent. In case of Yokogawa device EJA, its transducer block gives differential pressure in the unit given in XD_SCALE of AI block and this application can be applied in most cases. Transducer Block gives measured value in a unit and AI block needs to convert it into another unit. In case of a level meter with pressure transmitter, transducer block gives pressure and AI block converts it into level with a linear equation. Two set of values are needed: 0% Level = L0 inches = P0 psi 100% Level = L1 inches = P1 psi Transducer Block gives measured differential pressure with an orifice plate and AI block converts it into flow rate by calculating square-root of differential pressure. Two set of values are needed: 0% flow = F0 GPM = P0 psi 100% flow = F1 GPM = P1 psi
T030301.EPS

Application Application AI1: Simple measurement

Application AI2: Scaling in AI

Application AI3: Orifice plate flowmeter

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<3. Fieldbus Applications> Table 3.3

1. ST_REV 2. TAG_DESC 3. STRATEGY 4. ALERT_KEY 5. MODE_BLK Target Actual Permitted Normal 6. BLOCK_ERR 7. PV 8. OUT 9. SIMULATE Simulate Status Simulate Value Transducer Status Transducer Value En/Disable 10. XD_SCALE EU@100% EU@0% Units Index Decimal Point 11. OUT_SCALE EU@100% EU@0% Units Index Decimal Point 12. GRANT_DENY 13. IO_OPTS 14. STATUS_OPTS 15. CHANNEL(*1) 16. L_TYPE 17. LOW_CUT 18. PV_FTIME 19. FIELD_VAL 20. UPDATE_EVT 21. BLOCK_ALM 22. ALARM_SUM Current Unacknowledged Unreported Disabled 23. ACK_OPTION 24. ALARM_HYS 25. HI_HI_PRI 26. HI_HI_LIM 27. HI_PRI 28. HI_LIM 29. LO_PRI 30. LO_LIM 31. LO_LO_PRI 32. LO_LO_LIM 33. HI_HI_ALM 34. HI_ALM 35. LO_ALM 36. LO_LO_ALM Direct 100 0 Output unit 1 L1 L0 inch any dynamic Low Cutoff Propagate Fault Forward Appropriate value starting from 1 to receive transducer block output Indirect 0 0 Dynamic Dynamic Dynamic Dynamic Dynamic Dynamic Dynamic 0 Auto Ack Enabled (1) 0.5 0 +Infinity 0 +Infinity 0 -Infinity 0 -Infinity dynamic dynamic dynamic dynamic
T030302.EPS

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Recommended Parameter Values of AI Block

Application AI1 Application AI2
dynamic Any text 1 1 AUTO dynamic O/S+MAN+AUTO AUTO dynamic dynamic dynamic dynamic dynamic dynamic dynamic Disable 100 0 Transducer unit 1 P1 P0 psi any P1 P0 psi any F1 F0 GPM any

Parameter Mnemonic

Application AI3

Indirect Sq Root

*1:

For the information about CHANNEL, refer to the device instruction manual or the device Capabilitties file (CF).

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IMPORTANT
The numbers in front of the parameter names of the recommended parameter values show the index offset from the block header. The parameters (or components) in the grayed columns are often initialized on shipping to useless values by some vendors, to prevent a Function Block from being operational. Such parameters must be set to meaningful values as listed in the table.

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3.3.2

AO block
The Analog Output (AO) block is designed to allow users to enjoy a standard model of output devices like a valve positioner. An AO block receives the control value from a control block and sends back the current control value so that the control block can calculate the next control value or track the current value if the AO block is not controlled by that control block. An AO block has bi-directional data flow. One (forward path) is the flow from control value input to Transducer Block; the other (backward path) is the flow from Transducer Block to the control value. Figure 3.5 shows the AO block structure.
AO Block CAS_IN RCAS_IN BKCAL_OUT Scaling RCAS_OUT SIMULATE Set point selection Scaling CHANNEL

CAS : Cascade RCAS : Remote Cascade BKCAL : Backward Calculation

F030302.EPS

Figure 3.5

AO Block

Forward path
The control value from the controller becomes the set point, SP. AO block has several paths to calculate SP, depending on the block mode. In CAS mode, it is calculated from CAS_IN, subscribed from the publishing controller. In AUTO mode, SP value is given by on-demand Write request to SP. In RCAS (remote cascade) mode, remote controller gives data to RCAS_IN. In CAS or RCAS mode, CAS_IN or RCAS_IN is scaled by PV_SCALE for the controller and then XD_SCALE for the Transducer Block. In most cases those parameters have the same unit, e.g., %, and those scales can be simply 0 and 100 for EU@0% and EU@100%. Before calculating SP, CAS_IN or RCAS_IN goes through limiting functions, boundary limit and rate limit. For boundary limit, the value is replaced with PV_HI_LIM (PV_LO_LIM) if the value is larger (smaller) than the limit. For rate limit, difference of current CAS_IN or RCAS_IN from the previous value is greater than SP_RATE_HI (or SP_RATE_LO to decrease); another value with limited rate is used to calculate PV. SP becomes OUT if the communication is going well. If the controller disappears, OUT does not change. Or it goes to the predefined fault-state and may be replaced with FSTATE_VAL if options are appropriately selected. OUT is given to the Transducer Block though CHANNEL.

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Backward Path
Current position of actuator, like control valve, is manipulated through the backward path. Current position is fed to READBACK in transducer block unit (XD_SCALE) and then converted into the same unit of SP (PV_SCALE). Thus PV shows the valve position in SP unit. BKCAL_OUT shows the current valve position (target or actual) to PID block. The value of SP (target position) is usually fed to BKCAL_OUT. It is possible to feed PV to BKCAL_OUT to include valve characteristics into the control loop (Note: this is not common in process automation).

Fault State
Fault State is prepared for very critical processes, where control valves need to be shut or open when the upstream block is unavailable (gives BAD status) for a pre-determined time interval.

Modes
An AO block can be in one of O/S, MAN, LO (Local Override), AUTO, CAS (cascade), RCAS (Remote cascade) and ROUT (Remote output).

IMPORTANT
It is necessary to bring the AO block into CAS mode to set both CAS and AUTO bits in MODE_BLK.Target.

Recommended Parameter Values

Recommended values for the following two applications in Table 3.4 are listed in Table 3.5. Note that those values can be changed only when MODE_BLK.Target is Out-of-Service.
Table 3.4 AO Block Applications Description Use AO block with PID Function Block. Tracking value from AO block gives current SP given by PID or local operation. Use AO block with PID Function Block. Tracking value from AO block gives current valve position, PV.
T030303.EPS

Application Application AO1: Control with current target position Application AO2: Control with current valve position

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<3. Fieldbus Applications> Table 3.5

Parameter Mnemonic 1. ST_REV 2. TAG_DESC 3. STRATEGY 4. ALERT_KEY 5. MODE_BLK Target Actual Permitted Normal 6. BLOCK_ERR 7. PV 8. SP 9. OUT 10. SIMULATE Simulate Status Simulate Value Transducer Status Transducer Value En/Disable 11. PV_SCALE EU@100% EU@0% Units Index Decimal Point 12. XD_SCALE EU@100% EU@0% Units Index Decimal Point 100 0 % 1 100 0 % 1 dynamic dynamic dynamic dynamic Disable CAS+AUTO dynamic O/S+MAN+AUTO+CAS+RCAS CAS+AUTO dynamic dynamic dynamic dynamic

3-18
Application AO2

Recommended Parameter Values of AO Block

Application AO1 Application AO2 Parameter Mnemonic 13. GRANT_DENY 14. IO_OPTS Application AO1 dynamic Any test 1 1 15. STATUS_OPTS 16. READBACK 17. CAS_IN 18. SP_RATE_DN 19. SP_RATE_UP 20. SP_HI_LIM 21. SP_LO_LIM 22. CHANNEL(*1) 23. FSTATE_TIME 24. FSTATE_VAL 25. BKCAL_OUT 26. RCAS_IN 27. SHED_OPT 28. RCAS_OUT 29. UPDATE_EVT 30. BLOCK_ALM NONE dynamic dynamic +Infinity +Infinity 100 0 Use 1 for experiment 0(*2) 0(*2) Dynamic Dynamic Normal Shed Normal Return (1) dynamic dynamic dynamic dynamic IO_OPTS SP-PV track in MAN +SP-PV track in LO(*1) +Use PV for BKCAL_OUT

T030304.EPS

*1: *2:

For the information about CHANNEL, refer to the device instruction manual or the device Capabilitties file (CF). This configuration is for typical applications where control valves should remain at the current position when the data from the controlling block becomes bad by communication error or block malfunction. If the process is very critical and the valve must come to a pre-defined position when the control data is not available, use Fault State option. Set Fault state to Value + Use Fault state Value in restart of IO_OPTS. Give the safety position to FSTATE_VAL and the time to go to Fault State in seconds to FSTATE_TIME. User must set the Fault State Supported bit in FEATURES_SEL of the Resource Block. See also note *1 for Resource Block in Table 3.8.

IMPORTANT
The numbers in front of the parameter names of the recommended parameter values show the index offset from the block header. The parameters (or components) in the grayed columns are often initialized on shipping to useless values by some vendors, to prevent a Function Block from being operational. Such parameters must be set to meaningful values as listed in the table.

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3.3.3

PID block
A PID Block is a standardized model of PID control function. The process value comes through the IN parameter and its control output is the OUT parameter. Other input/output parameters exist to provide various control schemes, for example cascade control. Figure 3.6 shows the PID block architecture.
PID Block BKCAL_IN ROUT_IN Bypass CAS_IN RCAS_IN BKCAL_OUT RCAS_OUT IN FF_IN Filter Feed Forward ROUT : Remote OUT FF : Feedforward Set point selection OUT Control Output ROUT_OUT

CAS : Cascade RCAS : Remote Cascade BKCAL : Backward Calculation

F030303.EPS

Figure 3.6

PID Block

Modes
A PID block can be in various modes, O/S, MAN, IMAN (Initialize Manual), LO (Local Override), AUTO, CAS (cascade), RCAS (Remote cascade) and ROUT (Remote output). Several new modes are important:

IMAN
A PID block comes to IMAN mode when the downstream AO block does not accept control from the PID (e.g., O/S, MAN or LO mode). The PID block tracks to BKCAL_OUT, which is the current output of AO block.

Normal Mode
Normally the mode of the PID block is AUTO (closed loop) or CAS (cascaded loop). O/S and MAN may be used for operation.

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Set Point
A PID block accepts the control set point via several methods depending on its mode. The following two parameters are important.

SP
The set point to SP parameter can be directly written when MODE_BLK.Target is AUTO, MAN or O/S.

CAS_IN
In CAS mode, the PID block receives set point through the CAS_IN parameter. It must come from an upstream Function Block and the current set point is returned through BKCAL_OUT parameter.

PID Parameters
GAIN, RESET, and RATE are the tuning constants for the P, I and D terms, respectively. Gain is a dimensionless number. RESET and RATE are time constants expressed in seconds. It has another PID parameter, BAL_TIME, which can be left zero (0).

Recommended Parameter Values

Recommended values for the following two applications in Table 3.6 are listed in the table 3.7. Note that those values can be changed only when MODE_BLK.Target is Out-of-Service.
Table 3.6 PID Block Applications
Description PID block gives OUT to AO or another PID. An operator gives SP to this PID. PID block receives OUT from another PID.
T030305.EPS

Application Application PID1: Single loop Application PID2: Cascaded loop

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<3. Fieldbus Applications> Table 3.7

Parameter Mnemonic 1. ST_REV 2. TAG_DESC 3. STRATEGY 4. ALERT_KEY 5. MODE_BLK Target Actual Permitted Normal 6. BLOCK_ERR 7. PV 8. SP 9. OUT 10. PV_SCALE EU@100% EU@0% Units Index Decimal Point 11. OUT_SCALE EU@100% EU@0% Units Index Decimal Point 12. GRANT_DENY 13. CONTROL_OPTS 100 0 % 1 dynamic No OUT limits in MAN +Obey SP limits if CAS or RCAS + 3 more(*1) 14. STATUS_OPTS 15. IN 16. PV_FTIME 17. BYPASS 18. CAS_IN 19. SP_RATE_DN 20. SP_RATE_UP 21. SP_HI_LIM 22. SP_LO_LIM 23. GAIN 24. RESET 25. BAL_TIME 26. RATE 27. BKCAL_IN 28. OUT_HI_LIM 29. OUT_LO_LIM 30. BKCAL_HYS Target to MAN if BAD IN(*2) dynamic 0 OFF (1) dynamic +Infinity +Infinity 100 0 1 10 0 0 dynamic 100 0 0.5 100 0 % 1 AUTO dynamic dynamic dynamic dynamic AUTO dynamic O/S+MAN+AUTO+CAS+RCAS+ROUT AUTO+CAS AUTO+CAS

3-21
Application PID2

Recommended Parameter Values of PID Block

Application PID1 Application PID2 Parameter Mnemonic 31. BKCAL_OUT 32. RCAS_IN 33. ROUT_IN 34. SHED_OPT 35. RCAS_OUT 36. ROUT_OUT 37. TRK_SCALE EU@100% EU@0% Units Index Decimal Point 38. TRK_IN_D 39. TRK_VAL 40. FF_VAL 41. FF_SCALE EU@100% EU@0% Units Index Decimal Point 42. FF_GAIN 43. UPDATE_EVT 44. BLOCK_ALM 45. ALARM_SUM Disabled 46. ACK_OPTION 47. ALARM_HYS 48. HI_HI_PRI 49. HI_HI_LIM 50. HI_PRI 51. HI_LIM 52. LO_PRI 53. LO_LIM 54. LO_LO_PRI 55. LO_LO_LIM 56. DV_HI_PRI 57. DV_HI_LIM 58. DV_LO_PRI 59. DV_LO_LIM 60. HI_HI_ALM 61. HI_ALM 62. LO_ALM 63. LO_LO_ALM 64. DV_HI_ALM 65. DV_LO_ALM 100 0 % 1 0 dynamic dynamic Other components are dynamic 0 Auto Ack Enabled (1) 0.5 0 +Infinity 0 +Infinity 0 -Infinity 0 -Infinity 0 +Infinity 0 -Infinity dynamic dynamic dynamic dynamic dynamic dynamic
T030306.EPS

Application PID1

dynamic Any test 1 1

dynamic dynamic dynamic Normal Shed Normal Return (1) dynamic dynamic 100 0 % 1 dynamic dynamic dynamic

*1: *2:

For Application PID2, add [SP-PV track in MAN+SP-PV track in LO or IMAN+SP-PV track in ROUT] to CONTROL_OPTS. Add [Target to next permitted mode if BAD CAS_IN] to STATUS_OPTS if users tool is able to show this new option (from FF 1.4).

IMPORTANT
The numbers in front of the parameter names of the recommended parameter values show the index offset from the block header. The parameters (or components) in the grayed columns are often initialized on shipping to useless values by some vendors, to prevent a Function Block from being operational. Such parameters must be set to meaningful values as listed in the table.

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3.3.4

Resource Block and Transducer Block

Detailed knowledge of Resource Block and Transducer Block is not always necessary. The only thing is their mode. Possible modes are O/S and AUTO. They affect the behavior of Function Blocks and must be set to AUTO for correct operation. Transducer Blocks may have various parameters depending on their functionality. Their definition and behavior need to be discussed individually. However several parameters are common through Transducer Blocks. Recommended values for Resource Block and Transducer Blocks are listed in Tables 3.8 and 3.9, respectively. Note that these values can be changed only when MODE_BLK.Target is Out-of-Service.
Table 3.8 Recommended Parameter Values of Resource Block
Value dynamic Any text 1 1 AUTO dynamic O/S+AUTO AUTO dynamic dynamic dynamic fixed fixed fixed fixed fixed dynamic fixed Do not write here fixed Copy from FEATURES(*1) fixed Copy from CYCLE_TYPE Parameter Mnemonic 21. MIN_CYCLE_T 22. MEMORY_SIZE 23. NV_CYCLE_T 24. FREE_SPACE 25. FREE_TIME 26. SHED_RCAS 27. SHED_ROUT 28. FAULT_STATE 29. SET_FSTATE 30. CLR_FSTATE 31. MAX_NOTIFY 32. LIM_NOTIFY 33. CONFIRM_TIME 34. WRITE_LOCK 35. UPDATE_EVT 36. BLOCK_ALM 37. ALARM_SUM Disabled 38. ACK_OPTION 39. WRITE_PRI 40. WRITE_ALM 41. ITK_VER Value fixed fixed fixed fixed fixed 640000 640000 dynamic OFF(1) OFF(1) fixed Bigger one from (3, MAX_NOTIFY) 640000 Unlocked(1) dynamic dynamic Other components are dynamic 0 Auto Ack Enabled(1) 0 dynamic fixed
T030307.EPS

Parameter Mnemonic 1. ST_REV 2. TAG_DESC 3. STRATEGY 4. ALERT_KEY 5. MODE_BLK Target Actual Permitted Normal 6. BLOCK_ERR 7. RS_STATE 8.TEST_RW 9. DD_RESOURCE 10. MANUFAC_ID 11. DEV_TYPE 12. DEV_REV 13. DD_REV 14. GRANT_DENY 15. HARD_TYPES 16. RESTART 17. FEATURES 18. FEATURE_SEL 19. CYCLE_TYPE 20. CYCLE_SEL

*1:

Do not set Fault State Supported bit of FEATURES_SEL unless user definitely needs Fault State. See also note *2 for AO block in Table 3.5.

IMPORTANT
The numbers in front of the parameter names of the recommended parameter values show the index offset from the block header. The parameters (or components) in the grayed columns are often initialized on shipping to useless values by some vendors, to prevent a Function Block from being operational. Such parameters must be set to meaningful values as listed in the table.

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<3. Fieldbus Applications> Table 3.9

1. ST_REV 2. TAG_DESC 3. STRATEGY 4. ALERT_KEY 5. MODE_BLK Target Actual Permitted Normal 6. BLOCK_ERR 7. UPDATE_EVT 8. BLOCK_ALM 9. TRANSDUCER_DIRECTORY 10. TRANSDUCER_TYPE 11. XD_ERROR 12. COLLECTION_DIRECTORY 13. PRIMARY_VALUE_TYPE AUTO dynamic O/S + AUTO AUTO dynamic dynamic dynamic fixed fixed dynamic fixed fixed

3-23
Value dynamic

Recommended Parameter Values of Transducer Block

Value dynamic Any text 1 1 Parameter Mnemonic 14. PRIMARY_VALUE 15. CAL_POINT_HI 16. CAL_POINT_LO 17. CAL_MIN_SPAN 18. CAL_UNIT 19. SENSOR_TYPE 20. SENSOR_RANGE 21. SENSOR_SN 22. SENSOR_CAL_METHOD 23. SENSOR_CAL_LOC 24. SENSOR_CAL_DATE 25. SENSOR_CAL_WHO 26. SENSOR_ISOLATOR_MTL 27. SENSOR_FILL_FLUID 28. SECONDARY_VALUE 29. SECONDARY_VALUE_UNIT

Parameter Mnemonic

Written by calibrator Written by calibrator fixed Written by calibrator fixed fixed fixed Written by calibrator Written by calibrator Written by calibrator Written by calibrator fixed fixed dynamic

T030308.EPS

Note: This table shows typical Transducer Block parameters. Since Transducer Block parameters depend on the physical principle, users Transducer Block may have different parameters. In any case, do not forget to set STRATEGY, ALERT_KEY and MODE_BLOCK to above values.

IMPORTANT
The numbers in front of the parameter names of the recommended parameter values show the index offset from the block header. The parameters (or components) in the grayed columns are often initialized on shipping to useless values by some vendors, to prevent a Function Block from being operational. Such parameters must be set to meaningful values as listed in the table.

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3.3.5

Unit Codes
Fieldbus Foundation has specified numeric codes for engineering units. Here is an extract of important ones. It is much better to manipulate units with their unit text provided by DD instead of numeric expressions like this. They are listed here for the convenience in case the human-machine interface provides raw data expressions only. Refer to the Foundation document for missing units.

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code 1130 1132 1133 1134 1135 1136 1137 1138 1139 1140 1141 1142 1143 1144 1145 1146 1147 1149 1150 code 1088 1089 1090 1092 1093 1094 density code 1097 1100 1102 1103 1106 1107 frequency code 1077 1079 1080 1081 1082 1083 1085 unit Hz GHz MHz kHz 1/s 1/min RPM unit kg/m3 g/cm3 t/m3 kg/l lb/in3 lb/ft3 mass unit kg g mg t oz lb code 1061 1062 1063 1064 1065 1066 1067 1068 1069 1070 1071 1072 1073 1074 1075

3-25

Major Unit Codes Defined by Fieldbus Foundation (FF-903)

pressure unit Pa MPa kPa mPa Pa hPa ba mbar torr atm psi psia psig g/cm2 kg/cm2 inH2O inH2O(4C) mmH2O mmH2O(4C) code 1034 1036 1037 1038 1039 1040 1517 1042 1043 1044 1046 1047 1048 1050 1051 velocity unit m/s mm/s m/h km/h knot in/s ft/s yd/s in/min ft/min yd/min in/h ft/h yd/h MPH code 1054 1057 1058 1059 1060 miscellaneous code 1342 1422 1423 1424 unit % pH ppm ppb
T030309.EPS

flow code 1322 1330 1351 1352 1353 1356 1357 1358 1363 volume unit m3 cm3 mm3 l cl ml kl in3 ft3 yd3 pint quart gallon bushel barrel unit kg/s lb/s l/s l/min l/h CFS CFM CFH GPM

temperature code 1000 1001 1002 length code 1010 1011 1012 1013 1018 1019 1020 1021 area code 1023 1024 1025 1027 1030 1031 1032 1033 electricity code 1209 1211 1234 1240 1242 1243 1281 1284 time unit s s min h d unit A mA V/m V kV mV k unit m2 km2 cm2 mm2 in2 ft2 yd2 mile2 unit m km cm mm feet inch yard mile unit K C F

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3.4
3.4.1

System Management
System Management is an important application for all Foundation devices. It manages device information and its behavior in a FOUNDATION Fieldbus system.

Device Management
A device on FOUNDATION Fieldbus can be identified from others by using one of three identifiers: Device Identifier (ID): A text string unique to the device in the world given by the manufacturer. It is burnt into the device and will never change.

Physical Device (PD) Tag: A unique name in the plant or a set of Fieldbus segments, assigned by the user. It is used to identify a device for a specific application purpose in the plant.

(Physical) Node Address: A number of eight-bit length, unique in a Fieldbus segment assigned by the user through network configuration.

Device ID is unique to the device and the same Device ID does not exist elsewhere in the world. It is given by the manufacturer and therefore good for management purposes. PD Tag is assigned by the user to identify usage of the device in the plant. It is a text field 32 characters long (*1). It is common practice to give the same PD Tag to a new device replacing old broken device. Since Device ID and PD Tag are very long (32 bytes (*1)), they should not be used in daily communication, especially in the 31.25 kbps low speed network. Instead, Node Address is used to identify devices in communication. Services to correlate these three identifiers are provided. For example, a pressure transmitter is shipped with a permanent Device ID 59454300031999DEC22001102344 and configured to have PD Tag FI1001 and node address 0xF5. System Management Agent in a field device responds to System Management Kernel Protocol (SMKP) requests from a manager to configure the device. Its functionality is: To know information on a device at a specific address, including Device ID, manufacturer, device name and type, To clear and set the node address of the device using a specific Device ID, To clear and give a PD Tag to a device, and To find a device of specific PD Tag.

Note that even when a node address of a device is cleared, it must be able to join communication. For that purpose, a special address range (0xF8 to 0xFB) is prepared and a device without address can join the network using one in this address range.
*1: In a CENTUM Fieldbus system, the name of Physical Device (PD) Tag can be up to 16 alphanumeric characters.

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3.4.2

Function Block Management

As explained in Section 3.2.2 of this textbook, the Function Block algorithm must start in a defined time. System Management Agent stores Function Block scheduling information and starts an assigned Function Block at the desired time. Macro Cycle is the period of overall application and the schedule is designed as an offset time from the start of macro cycle.

3.4.3

Application Time Management

All System Management Agents in a system keep an application time (or system time). It is used to record an event with a time stamp. System time and Link Scheduling (LS) time are not equal. LS-time is local in the Data Link layer and is used for communication and Function Block execution. System time is more universal and is the same in all devices in a system consisting of multiple Fieldbus segments.

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3.5

Device Information Files

Applications such as human-machine interface and Fieldbus configuration need more information of devices. Several files are standardized by the Fieldbus Foundation to make devices interoperable and help engineers.

3.5.1

Device Description
Device Description (DD) provides information on blocks. A function block parameter can be read by name and displayed properly according to its data type and display specification. This is very useful in handling enumerated parameters; for example, psi is used instead of its code value 1141. Whenever a new device is introduced, its full functionality can be used by simply installing its DD without updating host software. DD Method can be run for a dedicated procedure (sequence of communications) for calibration, diagnosis and so on. DD Menu shows a list of DD Methods. DD is useful for human-machine interface, system configuration and maintenance. Figure 3.7 shows an example of display using Device Description (DD). The features of DD function are as follows. Gives information on parameters especially non- standards parameters. - Name and explanation - Data structure and attribute - Access right - Help menu - Calibration methods, etc. Enables a standard screen show a new device.

Users can control process without the help of DD.

Number of digits to display Values are read from the device over the Fieldbus. 25.50 Fieldbus % Engineering unit Label of the value Measured_Value

Device Descriptions are provided from vendors and distributed from the Fieldbus Foundation
F030501.EPS

Figure 3.7

Example of Display Using Device Description

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What are DDL and DD?

DDL is the specification Device Description Language, with which a device designer can describe the device functionality and data semantics. This text is then compiled with tokenizer software to generate DD binary files. The DD binary consists of two files. One is DD binary with the extension .ffo while the other is DD symbol list with the extension .sym. Once they are installed in users machine, users will have full access of the device. It is not a good idea for device vendors to write full information individually. Instead, Fieldbus Foundation provides DD Library, which provides a common DD and dictionary. A device vendor has only to describe their special part with DDL. Because of this convention, DD binary files can be small. Figure 3.8 shows the hierarchical structure of DD. Fieldbus Foundation specifies the standard part of blocks and provides the DD library. Device profiles defines a common part of various devices such as temperature transmitter and flow meter. The vendor-specific part is specified in their DD files.

Foundation Specification Block formal model Resource block Transducer block AI AO PID

Device profile Flow Temp

Extension

Extension

Extension Individual DD

Extension

Extension

F030502.EPS

Figure 3.8

Hierarchical Structure of Device Description

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Device Description Service

Device Description Service (DDS) is a software for the human-machine interface. It retrieves information in DD binary by using a key DD Item ID stored in the FMS Object Description of a parameter. DD binary files are stored in the following directory structure: <DD home directory> +- Manufacturer ID +--- Device type Manufacturer ID is a unique code given to the manufacturer by the Fieldbus Foundation. Users can identify the device manufacturer by this ID. It is thee byte in length and is shown in a hexadecimal expression with six characters. Yokogawas manufacturer ID is 594543, which stands for YEC. Device type identifies the device from others of the same manufacturer by the two-byte data expressed in a four-character hexadecimal form. Yokogawas EJA has device type 0003.

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3.5.2

Capabilities File
Capabilities File gives the information about the device capability of both Network/System Management and Function Block. Though certain parts of the information reside in the device itself, this file is useful for offline configuration where a Fieldbus system is configured without having real devices. A Capabilities file has an extension .cff. Capabilities file is often called CFF, which stands for Common File Format. Figure 3.9 shows how common files are used during the system design and maintenance.

Uploaded value file Value file to download Handheld communicator Capabilities file for system design

A new device

Manufacturer site

Downloader

DD

User site

Off-line system design System builder

Network and system design

F030503.EPS

Figure 3.9

Use of Capabilities File

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4.

Managing Fieldbus Projects

This section gives an example of Fieldbus project management. Again, Fieldbus is an enabling technology and does not obviate the need for users expertise in projects. The major steps and procedures must remain as they were; only knowledge and experience of Fieldbus-based control and measurement should be added. The example project shown in Figure 4.1 is used to describe key items that should be considered when managing a Fieldbus project. This project is a portion of a distillation tower process control using Fielsbus, consisting of six transmitters and two control valves forming a single loop and a cascade loop. Of course, actual distillation process control projects will differ from this example in terms of the control and measurement points and devices used. Although the selection of devices is one of the most important tasks to be considered, it is often beyond the scope of technical consideration and so is described very briefly in this textbook.
OHD Gas PT-201 PT TT-205 TT LT-202 D101

LT

LIC-210 LIC

T101 Feed LT-101 LT LIC-110 FIC FT-203 FT

FIC FIC-210

Product CV-204

FT-103 FT BTM Product CV-102

F040001.EPS

Figure 4.1

Example of a Portion of Distillation Tower Process Control Using Fieldbus

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4.1

Planning Phase
When starting to plan this project, the initial cost minimization of the project may be wanted. However the plant will probably last for decades and so the overall cost of the plant must also be considered. Fieldbus is not an exception. It is preferable to create a design with sufficient margin to reduce the future risk. First, devices should be counted. Table 4.1 shows the number of devices in the example of a portion of distillation tower control using Fieldbus. Table 4.1 shows also Yokogawas device models and their maximum current consumption.
Table 4.1 Number of Devices in Example of a Portion of Distillation Tower Process Control Using Fieldbus Devices Device model (in case of Yokogawas device) EJA110 EJA110 EJA430 YTA310 YVP110 Average current of device (mA) (in case of Yokogawas device) 16.52 = 33 16.52 = 33 16.5 16.5 172 = 34 Total: 133 (average value)
T040101.EPS

Number

2 2 1 1 2 Total: 8

Flow transmitter Level transmitter Pressure transmitter Temperature transmitter Valve positioner (for control valve)

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4.1.1

Devices on a Bus
How many devices should be installed on a Fieldbus segment? Since this example project is a brand new plant, the installation of all devices on a segment may be wanted. Before reaching final decision, the conditions to limit the number of devices should be studied.

Communication Specifications
The Physical Layer restricts the number of devices as follows. The Data Link Layer specifies the address to 8-bit length. Because some of these are reserved for special purposes, the actual address range for field devices is 232. This value is still large enough and need not be considered.

Power Supply and IS Barrier

If a bus-powered device is hooked on the Fieldbus, the necessary power must be fed through the Fieldbus from a power supply somewhere on the network. The capacity of the power supply must be larger than the total average current consumption of all bus-powered devices on the Fieldbus. This example is an Intrinsic Safe (IS) installation and so the number of devices in the hazardous area is limited by the total energy supplied through the safety barrier. By using Table 4.1 as an example, the maximum current of devices is calculated as follows. Model KLD2-PR-Ex1.IEC1 from P & F is used as an example of IS barrier of a Fieldbus Intrinsically Safe Concept (FISCO) Model. Power supply capacity (average) of P&F KLD2-PR-Ex1.IEC1: 100 mA (*1) Total average current consumption of devices shown by Table 4.1: 133 mA (*2)

In this example, the total average current of devices cannot be supplied by one barrier, so that two Fieldbus (two segments (*3)) and two barriers are used.
*1: *2: *3: Some vendors show the maximum power supply capacity as the specification. In this case, confirm that the maximum power supply capacity is lager than the total average current consumption plus 10 mA (signal amplitude). Assume an average current consumption of 20 mA (actually 20 mA +/- 10 mA (signal ampletude)) for field devices whose types have not yet been decided. A segment is an engineering unit consisting of several Fieldbus devices and a host interface to be connected to one Fieldbus. A Fieldbus system consists of multiple Fieldbus segments.

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Application Interaction
Interacting Function Blocks should be placed on one segment to avoid Function Block linkage over a bridge. A control loop is an example. Application interaction needs communication services over the Fieldbus. The greater the interaction between Function Blocks, the higher the communication demand. If the communication throughput is not fast enough to transfer all the data, this would also limit the number of devices on the Fieldbus. A rough and safe estimation is as follows. Count the number of Function Block linkages in different devices (number of Publishers), NP. Count the number of blocks to communicate for human-machine interface, NC. Add two numbers to multiply 40 ms (*1). TLOAD = (NP + NC) 40 ms If the product in milliseconds is greater than 70% (*2) of the control period (macro cycle), this configuration is risky and some devices should be removed. A detailed throughput analysis should be performed in the system design phase (see Section 4.1.3). In the example project, there are 6 AI blocks, 2 AO blocks and 3 PID blocks. Assuming that a control valve has a PID block and a level transmitter has another PID for cascade control, 7 (5+2) for NP (5 AI blocks excluding one for cascade, and two-way communication between cascading PID blocks) and 11 for NC (6AI + 2 AO + 3 PID for human-machine interface) are obtained. TLOAD is 720 ms. Therefore, from the standpoint of application interaction, process control for this example should be performed by two Fieldbus (two segments) if control must be performed within one second.
*1: *2: 40 ms is the average value of the marketed Fieldbus devices. The actual values should be checked by the using devices. 70% is the example for the application using Publisher-Subscriber Communication in Yokogawa CENTUM Fieldbus system. When the applications using Client-Server Communication, there are cases designed under 70% (for example 50%) of the control period (macro cycle).

Risk Management
If a device on the Fieldbus fails, there is a slight possibility that it destroys the segment communications. In the worst case, no measured values can be accessible through the Fieldbus and the control activities may be interrupted. The same situation can happen by a loose wire or short circuits of the Fieldbus cable. It is highly recommended to limit the number of control loops on a Fieldbus segment to avoid a serious situation caused by this type of worst mode failure.

Study for Example Project

In the case of the example project, two segments are required by both reasons of the power supply capacity of the IS barrier and the application interaction, so two IS barriers and host interface modules are used. Also, as there are a cascade control loop and a single loop, it is better to put them in different segments for risk management. Risk management analysis suggests the same choice for two segments. Now all instruments including IS barriers and terminators except for the cables and accessories (conduit, mating connectors, etc.) can be ordered.

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4.1.2

Wiring Design
The next step is to design wiring. The wiring design rules should be reviewed first. Rule 1: The number of devices on a Fieldbus shall be between 2 and 32. Rule 2: Cable shall be individually-shielded twisted pair (type A) 18 AWG wires. Rule 3: The total cable length shall not exceed 1900 m (including total spur length). Rule 4: The maximum total spur length shall not exceed 120 m. Rule 5: When overall-shielded twisted pair (type B) 22 AWG wires are used, the total length shall not exceed 1200 m. Table 2.1 shows the Fieldbus cable type and the transmission length, and Table 2.2 shows the number of devices and recommended maximum total spur lengths (*1). In the case of the example project, type A cables for trunk are used. Measure the each spur length from the junction box to devices. Assign devices to the segment within the 120m limit of total spur length. Make sure that the devices used to form control loops are on the same segment. In the case of the example project, two segments (100 and 200 Tag numbers in Figure 4.1) are used. Now the cables and accessories (conduit, mating connectors, etc.) can be ordered. Assign field devices tags to identify to which segment they should be connected. Figure 4.3 shows the wiring for this example.
*1: Refer to note *1 in Section 2.2.3.

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4.1.3

System Design
Now devices and Function Blocks used on each segment are listed. Connect all AI Function Blocks except the ones on LI-101, LI-202 and FI-203 to the monitoring application on the host Control loops are combinations of AI, PID and AO blocks. Figure 4.2 shows their connection for cascade level control. The PID block in the valve controls the flow (FIC210) while that in the level transmitter controls the level (LIC210). Target modes are also shown.
AUTO (Target mode) CAS (Target mode)

LI-202 LIC210 LI202 BKCAL_OUT SP IN BKCAL_IN

AI

PID

OUT

OUT

CV-204 FC200 FI-203 FI203 FIC210 CAS_IN IN BKCAL_IN BKCAL_OUT

AO
CAS_IN BKCAL_OUT

AI

PID

OUT

OUT

Link via communication Internal link

F040101.EPS

Figure 4.2

Example of Function Block Connection of Cascade Level Control

Determine block parameters as explained in Section 3 of this textbook. The configuration software generates other parameters for communication. Display the generated schedule to see how busy the Fieldbus is.

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4.2

Installation Phase
The installation period can be decreased by using the remote-configuration feature of Fieldbus devices. Engineers do not have to go to the field as frequently as they did with traditional 4 to 20 mA devices.

4.2.1

Installation
Device installation is completely the same as for 4 to 20 mA devices using installation and wiring drawings. It is recommended to assign PD tags to the devices before installation so that the device of the correct tag is installed at the correct location in the plant. Trunk wiring is the cable with terminators in each end. The other part is called spur and should be within 120 m in total. Wiring from junction box to devices can be a tree (or chicken-foot) topology if the spur length is within this limit. Figure 4.3 shows the wiring plan example.
HMI

Host I/F Junction box Terminators PT-201 PT TT-205 TT LT-202 Barrier (with FF power conditioner) D101 T101 FIC FIC-210 FT-203 FT LT-101 LT LIC-110 FIC CV-204

LT

LIC-210 LIC

FT FT-103 CV-102
F040201.EPS

Figure 4.3

Example of Wiring for a Portion of Distillation Tower Process Control Using Fieldbus

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4.2.2

Commissioning
After connecting devices to the wire, turn on the power supply to check whether all devices are operational. If they dont have correct tag or address, assign them with the appropriate configuration software. Download the configuration to all devices as well as the host interface module. All input values should be visible on the host screen. The plant may not be operational yet at the time of commissioning. Simulation function is useful for this purpose. Turn on the simulation switch in a device. The location of the switch should be explained in the device instruction manual. Write Enable to Simulate.DisEnable parameter of AI and AO blocks, then the blocks will use values and statuses that users write in the simulation fields. Now it can be checked that the display and control loops indicate the correct value as designed. Do not forget to disable the simulate hardware switch after the commissioning.

4.2.3

Startup and Test Operation

The instrumentation system over Fieldbus is now operational. The plant can be run for a test. Input values may need damping for smooth recording. PID parameters of the loops can be tuned. After test operation and tuning, upload tuned block parameters so that users can use them if and when the device malfunctions.

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4.3
4.3.1

Operation Phase
The operation phase should not change from traditional system.

Control Operation
During the operation phase, operators must be able to watch the plant operation and take over the control if needed. Input monitoring, loop display, manual operations, and process alarm display are available through the host human-machine interface. There is no change from traditional control and the operators need no additional training.

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4.4

Maintenance Phase
Once the plant is in operation, it is in the maintenance phase at the same time. Users should be able to maintain the Fieldbus control system during plant operation. DD-based software is helpful for daily maintenance such as calibration and pH electrode cleaning.

4.4.1

Device Alarms
When a device detects a problem in its operation, it reports a device alarm to users. This might be the sensor burnt out, loss of air, a leak or something else. Before going to the device location, users can now see what the alarm is by opening the diagnosis window and see the reported alarms. The device may also provide more information in the Resource Block or Transducer Block. An electronic manual may be useful and the diagnostic software shows the details of the problem in text retrieved from the DD.

4.4.2

Replacing a Faulty Device

When replacing a faulty device replaced, follow this procedure. Make sure the plant is safely operating even when a device malfunctioned. Locate the replacing device in the stock. It must be the same device of the same revision. It is recommended to give it device tag and address before connecting it to the operating Fieldbus. This clears all communication configurations and prevents any surprise in adding a device of unknown configuration to the operating Fieldbus. Disconnect the faulty device from the bus. Be careful not to short-circuit the bus. When the wire is connected with screw terminals, remove the screws as quickly as possible to avoid chattering as it causes momentarily undesired interrupt on the communications. Replace the device and connect the wire again following the notes above. The device should start communications in seconds. When setting the tag and address before connecting the replacement, it joins the token rotation and stays inactive for control and measurement. Download the configuration as well as the tuned parameters to the device to recover the operating condition. The applications using this device will be operational. Make sure the whole plant comes back to the normal state.

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4.4.3

Asset Management
Acquiring information about devices in the field will be wished. When doing any maintenance, a record of what is done to the device should be kept. When a device malfunctioned, a replacement should be found. A software package is useful for managing such information concerning users assets, as well as for planning plant shutdown for preventive maintenance. Figure 4.4 shows an example of the display of Yokogawa Plant Resource Manager (PRM) software as an example of a Plant Asset Management (PAM) package.

Plant Resource Manager R2.03.00 - Logon User ID: ADMINISTORATOR File Edit View Register Option Window Help
Device Navigator 1

Plant

Network

Class

History

Details

Memo

Parts

Schedule

Doc

Parameter

Tool

PLUG-IN

PLANT Foundation Fieldbus BOILER-0101-10111-1 R302DME-103-10113-1 DAQSTATION(Ready) EJA001 (Ready) FI1002 (Ready) YHL001 (Ready) YTA001 (Ready) YVP001(Ready)
HART

Device Tag Name Bock Tag Name Block Type

YVP001 FV100_YVP Analog Output

YVP001 FV100_YVP Analog Output Update Set

Individual

All

View1

View2

View3

View4

Alarm

Tune

Operate

Service

Diagnosic

Current

...

<<

05/07/2002 14:02:48

...

HART MYPJT-01-9999(MODEM) EJAHART(Off-Service) MYPJT-01-9999(MODEM) TI1002(Spare) MYPJT2-01-0100(MUX:KFD) R302DME-0103-10116-1 MODBUS PROFIBUS

Reason Last Update User

ST_REV TAG_DESO STRATEGY ALERT_KEY MODE_BLK TARGET ACTUAL PERMITTED NORMAL BLOCK_ERR PV SP OUT SIMULATE SIMULATE_STATUS Good_NonCascade::NonSpecific: SIMULATE_VALUE 26.468300 Good_NonCascade::NonSpecific: 0.020508 Good_NonCascade::NonSpecific: 0.020508 Disabled Man Man RCas+Cas+Auto+Man+O/S Cas+Auto 0x0000 26.467800 26.467800 26.461900 Cas+Auto Cas RCas+Cas+Auto+Man+O/S Cas+Auto 0x0000 0.020508 0.024414 0.024414 % % 309 (0x0135) 0x59565020414f000000000000000 1 (0x0001) 1 (0x01) ADMINISTRATOR 235 (0x00eb) 0x59565020414f000000000000000 1 (0x0001) 1 (0x01)

TRANSDUCTER_STATUS Good_NonCascade::NonSpecific: TRANSDUCTER_VALUE ENABLE_DISABLE PV_SCALE EU_100 EU_0 100.000000 0.000000 26.468300 Disabled

100.000000 0.000000

% %

Ready

Rows 1of 1

2/17/2003
F040401.EPS

Figure 4.4

Example of Display (Parameter Comparison) of Yokogawas Plant Resource Manager (PRM)

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4.5
4.5.1

Renovation Phase
When planning to renovate the plant, the plant shutdown period can be shorten by using the online upgrade feature of Fieldbus.

Addition of Applications
Suppose addition of temperature measurement is planned at two points, the top and mid position of the tower T101. The IS barrier for 100 Tag numbers in Figure 4.3 has enough capacity for additional devices. Since wiring is designed with a good margin, two transmitters can be added to the existing Fieldbus segment of the 100 Tag numbers. Install them on the plant and connect them to the Fieldbus using additional spurs with the same care as for device replacement. Add them to the applications and download configurations to the devices. If the device addition does not change the control strategy, this addition does not affect other devices and therefore two transmitters can be added without disturbing the plant operation.

4.5.2

Device Upgrade
Suppose users wish to upgrade existing smart transmitters to Fieldbus-ready transmitters and to add them to the existing Fieldbus segments. If the device vendor provides upgrade kits for upgrading from smart to Fieldbus, the installed instruments need not be removed from the plant; users simply need to replace the necessary electronics parts for the upgrade, and can then add these devices as additional devices to the Fieldbus as explained in the previous section. Several Fieldbus devices support field software upgrade, providing greater upgrade functionality. Follow the instruction of the device vendor.

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Acronyms
AC AI AO AP APL ASN.1 AUTO AWG BG BNU CCITT CAS CD CEP CF CFF CL COTS CPU CS CT DC DC DC DCS DD DDL DDS Device ID DI DLCEP DLL DLSAP DT DT DO EC Alternating Current Analog Input Function Block Analog Output Function Block Application Process Application layer Abstract Syntax Notation 1 Automatic mode American Wire Gauge Bias/Gain Station Block Buffered Network-Scheduled Unidirectional International Telegraph and Telephone Consultative Committee Cascade mode Compel Data DLPDU Connection Endpoint Capabilities File Common File Format Claim LAS DLPDU Commercial off the Shelf Central Processing Unit Control Selector Function Block Compel Time DLPDU Direct Current Disconnect Connection DLPDU Device Control Block Distributed Control System Device Description Device Description Language Device Description Service Device Identifier Discrete Input Function Block Data Link Connection End Point Data Link Layer Data Link Service Access Point Data Transfer DLPDU Dead Time Function Block Discrete Output Function Block Establish Connection DLPDU

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EU EUC ETS FAS FB FB FCS FDA FF FMS Gbps (Gbit/s) HMI ID IEC IMAN IP IS ISA ISO IT IT kbps (kbit/s) kHz LAN LAS LL LM LO LS mA MAC MAI MAN MAO Mbps (Mbit/s) MDI MDO ML NM NMIB

Engineering Unit End User Council Enterprise Technology Solutions Fieldbus Access Sublayer Fieldbus Function Block Frame Check Sequence Field Device Access Fieldbus Foundation Fieldbus Message Specification Gigabit per second Human Machine Interface Identifier International Electrotechnical Commission Initialize Manual mode Internet Protocol Intrinsic Safety The Instrumentation, Systems and Automation Society International Organization of Standard Information Technology Integrator Function Block Kilobit per second Kilohertz Local Area Network Link Active Scheduler Lead Lag Function Block Link Master Local Override mode Time Link Scheduling Time Milliampere Medium Access Control Multiple Analog Input Block Manual mode Multiple Analog Output Block Megabit per second Multiple Discrete Input Block Multiple Discrete Output Block Manual Loader Function Block Network Management Network Management Information Base
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OD OS O/S OSI PC PCI PD PDU PD PHL (PHY) PID PLC PN PR PT PV QUB QUU RA RB RCAS RI ROUT RQ RR RT SC SDU SM SMIB SMKP SP SP50 TB TCO TCP TD TL UDP VCR

Object Dictionary Output Splitter Block Out of Service mode Open System Interconnect Personal Computer Protocol Control Information PD Control Function Block Protocol Data Unit Tag Physical Device Tag Physical Layer PID Function Block Programmable Logic Controller Probe Node DLPDU Probe Response DLPDU Pass Token DLPDU Process Value Queued User-Triggered Bidirectional Queued User-Triggered Unidirectional Ratio Station Block Resource Block Remote Cascade mode Request Interval DLPDU Remote Output mode Round-trip Time Query DLPDU Round-trip Time Response DLPDU Return Token DLPDU Signal Characterizer Block Service Data Unit System Management System Management Information Base System Management Kernel Protocol Set Point Standard and Practice committee 50 Transducer Block Total Cost of Ownership Transfer Control Protocol Time Distribution DLPDU Transfer LAS DLPDU User Data Protocol Virtual Communication Relationship
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VFD VIEW WAN

Virtual Field Device View Object Wide Area Network

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FOUNDATION Fieldbus Book - A Tutorial

TI 38K02A01-01E 2nd Edition

INDEX
Symbols
31.25 kbps Physical Layer .................................. 2-6 Device Description Service ............................... 3-30 Device Information Files .................................... 3-28 Device Management ......................................... 3-26 Device Upgrade ................................................ 4-12 Devices on a Bus ................................................ 4-3 Domain Management ....................................... 2-26 Dynamic or Static ................................................ 3-8

A
Access Right ....................................................... 3-8 Addition of Applications ..................................... 4-12 Addresses ........................................................ 2-12 AI block ............................................................. 3-11 Alarm Generation ............................................. 3-12 AO block ........................................................... 3-16 Application Interaction ......................................... 4-4 Application Layer .............................................. 2-18 Application Time Management .......................... 3-27 Application Time Synchronization ..................... 2-28 Asset Management ........................................... 4-11

E
Event Management ........................................... 2-25

F
Fault State ........................................................ 3-17 Field Device Access Protocol ............................ 2-29 Fieldbus Access Sublayer ................................. 2-18 Fieldbus Applications .......................................... 3-1 Fieldbus Benefits ................................................ 1-3 Fieldbus Communication Technologies ............... 2-1 Fieldbus Message Specification ........................ 2-22 FMS Objects ..................................................... 2-23 FMS Services ................................................... 2-25 Forward path ..................................................... 3-16 FOUNDATION Fieldbus ...................................... 1-5 Function Block .................................................... 3-2 Function Block Management ............................. 3-27 Function Blocks .................................................. 3-3

B
Backward Path .................................................. 3-17 Block Mode ......................................................... 3-9

C
Capabilities File ................................................ 3-31 CAS_IN ............................................................ 3-20 Channel Value .................................................. 3-12 Client-Server Model .......................................... 2-19 Commissioning ................................................... 4-8 Communication Models ...................................... 2-2 Communication Specifications ............................ 4-3 Communication through VCR .............................. 2-5 Contained Parameters ........................................ 3-7 Control Operation ............................................... 4-9

H
High Speed Ethernet ........................................ 2-29

D
Data Link Layer ................................................. 2-11 Data Link PDUs ................................................ 2-17 Device Alarms .................................................. 4-10 Device Description ............................................ 3-28

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R
Recommended Parameter Values ... 3-13, 3-17, 3-20 Renovation Phase .................................... 1-4, 4-12 Replacing a Faulty Device ................................. 4-10 Resource Block ................................................... 3-2 Resource Block and Transducer Block .............. 3-22 Risk Management ............................................... 4-4

I
IMAN ................................................................ 3-19 Important Blocks ............................................... 3-11 Important Parameters ......................................... 3-9 Input Parameters ................................................ 3-7 Installation .......................................................... 4-7 Installation Phase ....................................... 1-3, 4-7 Intrinsic Safe (IS) Consideration ........................ 2-10

S L
Link Active Scheduler ....................................... 2-14 Link and Schedule .............................................. 3-6 Link Maintenance .............................................. 2-17 Low-pass Filter ................................................. 3-12 Scaling and Square Root Calculation ................ 3-12 Scaling Parameters ............................................. 3-9 Scheduled Communication ............................... 2-15 Set Point ........................................................... 3-20 Signaling Method ................................................ 2-7 Simulation ......................................................... 3-12 Source-Sink Model ........................................... 2-21 SP .................................................................... 3-20 Startup and Test Operation ................................. 4-8 Status of a parameter .......................................... 3-8 Study for Example Project ................................... 4-4 System Design ................................................... 4-6 System Management ........................................ 3-26 System Management Protocol .......................... 2-28

M
Maintenance Phase .................................. 1-4, 4-10 Managing Fieldbus Projects ................................ 4-1 Medium Access Control .................................... 2-11 Modes .................................................... 3-17, 3-19

N
Normal Mode .................................................... 3-19

O
Object Dictionary .............................................. 2-24 Object Examples .............................................. 2-23 Operation Phase ......................................... 1-4, 4-9 OSI Reference Model ......................................... 2-2 Other Services .................................................. 2-27 Output Parameters .............................................. 3-7 Overview of Fieldbus .......................................... 1-1

T
Tag and Address Assignment ........................... 2-28 Tag Location ..................................................... 2-28 TCP/IP Protocol Suite ....................................... 2-29 Transducer Block ................................................ 3-5

U
Unit Codes ........................................................ 3-24 Unscheduled Communication ........................... 2-16

P
Parameter Attributes ........................................... 3-8 Parameter Classes ............................................. 3-7 Parameters ......................................................... 3-7 Permitted Modes ............................................... 3-12 Physical Layer ..................................................... 2-6 PID block .......................................................... 3-19 PID Parameters ................................................ 3-20 Planning Phase .......................................... 1-3, 4-2 Power Supply and IS Barrier ............................... 4-3 Program Invocation ........................................... 2-26 Protocol Data Unit ............................................... 2-4 Publisher-Subscriber Model .............................. 2-20

V
Variable Access ................................................ 2-25 VFDs in a Fieldbus Device .................................. 3-1 View Objects ..................................................... 3-10 Virtual Field Device (VFD) ................................. 2-22 Virtual Field Devices ........................................... 3-1

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W
What are DDL and DD? .................................... 3-29 What is a Function Block? ................................... 3-2 What is Fieldbus? ............................................... 1-1 Why Ethernet? .................................................. 2-29 Wiring Design ..................................................... 4-5 Wiring Rules ....................................................... 2-8

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Revision Information
Title : FOUNDATION Fieldbus Book A Tutorial Manual No. : TI 38K02A01-01E May 2001/1st Edition Newly published March 2003/2nd Edition Title Changed the title from Fieldbus Book A Tutorial to FOUNDATION Fieldbus Book A Tutorial For all sections Revised the section numbering and updated the contents Introduction Started with Introduction Added Structure and Target Readership of This Textbook Transferred the content of Introduction of 1st Edition into Structure and Target Readership of This Textbook 2.2.2 Revised the explanation about the electric equivalent circuit 2.2.3 Revised the description of wiring rules 3.2.1 Updated the list of Function Block (Table 3.1) 3.3.5 Corrected some unit codes 4 Revised the example project and the all descriptions related the example project 4.1.1 Added the consideration for the power supply capacity of Intrinsic Safe (IS) barrier in the Section Power Supply and IS Barrier Updated the description of the Section Application Interaction

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Written by

Product Marketing Dept. Industrial Automation Systems Business Division Yokogawa Electric Corporation Published by Yokogawa Electric Corporation 2-9-32 Nakacho, Musashino-shi, Tokyo 180-8750, JAPAN Printed by Yokogawa Graphic Arts Co., Ltd.

Subject to change without notice.