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TechnicalInformation

Fieldbus Technical Information

TI 38K03A01-01E

TI 38K03A01-01ECopyright Mar. 19983rd Edition Sep. 2002

Yokogawa Electric Corporation2-9-32, Nakacho, Musashino-shi, Tokyo, 180-8750 JapanTel.: 81-422-52-5634 Fax.: 81-422-52-9802

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IntroductionFieldbus is an innovative technology for creating field information networks, and isattracting much interest among users and manufacturers of process control systems.

This manual describes how users can introduce Fieldbus into their process control sys-tems, and also describes Yokogawas Fieldbus solutions and Yokogawas Plant ResourceManager (PRM) software package for managing plant assets in the field network era.

Structure of This Manual

This manual gives an overview of Yokogawas Fieldbus Solutions, and explains the ben-efits of adopting them. For the detail specifications for ordering, refer to the relevant Gen-eral Specifications. For engineering, installation, operation, and maintenance of theFieldbus system and products described in this manual, refer to the relevant InstructionManuals.

This manual consists of three parts. Part A outlines Fieldbus prescribed by the FieldbusFoundation and Yokogawas Fieldbus-ready products, Part B explains Fieldbus engineer-ing, installation, operation, and maintenance, and Part C outlines the Plant ResourceManager (PRM) software developed by Yokogawa.

Part A consists of four sections. An overview of the functions and progress of internationalstandardization of Fieldbus is given in Section A1, the features of Fieldbus in Section A2,Fieldbus-ready field devices in Section A3, and Yokogawas Fieldbus-ready systems inSection A4.

Part B consists of five sections. Managing Fieldbus engineering is described in Section B1,

design considerations in Section B2, construction considerations in Section B3, startupconsiderations in Section B4, and maintenance considerations in Section B5.

Part C consists of four sections. An overview and glossary of Plant Resource Manager(PRM) are described in Section C1, the system configuration in Section C2, an overview offunctions in Section C3, and the interface to the computerized maintenance managementsystem in Section C4.

Sep.01,2002-00Media No. TI 38K03A01-01E (MO) 3rd Edition : Sep. 2002 (YK)All Rights Reserved Copyright 1998, Yokogawa Electric Corporation

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Target Readership for This Manual

This manual is mainly intended for:

Managers who are planning to purchase a control system, Fieldbus, and PlantResource Manager (PRM).

Instrumentation, electricity, maintenance, and computer engineers who are evaluatingprocess control systems, Fieldbus, and maintenance management systems forpurchase or who will be in charge of installing these systems.

Trademarks

CENTUM is a registered trademark of Yokogawa Electric Corporation.

Ethernet is a registered trademark of Xerox Corporation.

Microsoft and Windows are registered trademarks or trademarks of MicrosoftCorporation in the United States and/or other countries.

FOUNDATION in FOUNDATION Fieldbus is a registered trademark of the FieldbusFoundation.

NI-FBUS Monitor is a registered trademark of National Instruments Corporation.

HART is a registered trademark of the HART Communication Foundation.

Oracle is a registered trademark of Oracle Corporation.

MAXIMO is a registered trademark of MRO Software, Inc.

Other product and company names may be registered trademarks of their respectivecompanies (the TM or mark is not displayed).

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Part A Overview of Fieldbus and

Yokogawas Fieldbus-ready Products

CONTENTS

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TI 38K03A01-01E 3rd Edition

A1. Progress of International Standardization of Fieldbus .......................A1-1

A1.1 What is Fieldbus? ......................................................................................... A1-1

A1.2 Progress of Fieldbus Standardization ......................................................... A1-2

A1.3 Fieldbus Standard Specifications................................................................A1-4

A1.4 Yokogawas Efforts for Fieldbus Standardization .......................................A1-5A2. Features of Fieldbus............................................................................. A2-1

A2.1 Comparison with Conventional Communication ........................................ A2-2

A2.2 Reduced Wiring Cost ....................................................................................A2-4

A2.3 Improved Transmission Accuracy ............................................................... A2-6

A2.4 Enhanced Data Transmission ...................................................................... A2-8

A2.5 Distributed Functions ...................................................................................A2-9

A2.6 Interoperability ............................................................................................ A2-10

A3. Fieldbus-ready Field Devices ...............................................................A3-1

A3.1 Changes in Transmitters ..............................................................................A3-3

A3.1.1 Accuracy Improvement due to Digitalization.................................... A3-4

A3.1.2 Multi-sensing Function Equipment .................................................. A3-6

A3.1.3 Multifunction Equipment ................................................................. A3-7

A3.2 Actuator ......................................................................................................... A3-8

A3.3 Using Self-diagnostics Function................................................................ A3-10

A3.4 Yokogawas Fieldbus-ready Field Devices Line-up .................................. A3-11

A4. Yokogawas Fieldbus-ready Systems ..................................................A4-1

A4.1 Fieldbus Support in Yokogawas CENTUM Control Systems..................... A4-1

A4.1.1 Fieldbus Support in FCS for FIO of CENTUM CS 3000................... A4-2

A4.1.2 Fieldbus Support in FCS for RIO and Compact FCS ofCENTUM CS 3000 ......................................................................... A4-4

A4.1.3 Fieldbus Support in CENTUM CS 1000 .......................................... A4-6

A4.1.4 Fieldbus Support in CENTUM CS ................................................... A4-8

A4.2 Connection of FF Devices from Other Vendors toYokogawas CENTUM Control Systems .................................................... A4-10

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A1. Progress of InternationalStandardization of Fieldbus

This section describes what is Fieldbus, the progress of standardization of Fieldbus,Fieldbus standard specifications, and Yokogawas efforts toward standardization ofFieldbus.

A1.1 What is Fieldbus?The Fieldbus Foundation gives the following definition: Fieldbus is a digital, two-way, multi-drop communication link among intelligent measurement and control devices. Fieldbus isgradually replacing 4 to 20 mA standard instrumentation signals used to transfermeasurement and control data between control room and plant floor. It is one of severallocal area networks dedicated for industrial automation.

Modern industries in the 21st century could not survive without information technologiesand networks. From production line to enterprise level, digital communication supports alleconomic and social activities with powerful modern technologies. Fieldbus is one suchtechnology and cannot be separated from others. Fieldbus is at the lowest level in thehierarchy and exchanges information with higher-level databases.

IEC (International Electrotechnical Commission) prescribes the following seven definitionsstandardized by the standard organizations (shown by their trademarks) as internationalstandards of Fieldbus:

FOUNDATION Fieldbus and HSE

ControlNet

PROFIBUS and PROFInet

P-NET

WorldFIP

INTERBUS

SwiftNet

FOUNDATION Fieldbus, which is one of the seven definitions, is a standard defined by theFieldbus Foundation. Yokogawa, a member of the board of directors of the FieldbusFoundation since its inception, has participated closely in developing the Fieldbusspecifications.

Unfortunately, the Fieldbus standards of IEC list the definitions of many standard organiza-tions. In practice, all major makers and users are now participating in the Fieldbus Founda-tion, and many products based on the FOUNDATION Fieldbus specifications are devel-oped and marketed.

Yokogawa considers that FOUNDATION Fieldbus will be used as widely as the fieldbus forprocess control systems in industry. Yokogawas CENTUM CS 3000, CENTUM CS 1000,and CENTUM CS support FOUNDATION Fieldbus.

FOUNDATION Fieldbus H1 (Low Speed Voltage Mode) is called FOUNDATIONFieldbus, Fieldbus, H1 Fieldbus, FF, or FF-H1 in this manual.

The sophisticated communication functions of Fieldbus allow distributed control via

Fieldbus devices and optimal control by interfacing with a field control station (FCS).

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A1.2 Progress of Fieldbus StandardizationThe international standards of Fieldbus have been unified by IEC/TC65/SC65C WG6(International Electrotechnical Commission/Technical Committee 65/Sub-Committee 65C/Working Group 6), ISA (The International Society for Measurement & Control) SP50

Committee (which defined 4 to 20 mA analog signals as the standard electronicinstrumentation signal), and the Fieldbus Foundation.

Recently, the Fieldbus Foundation, a private organization formed to promote Fieldbus, issupporting the international unification of Fieldbus standards. Yokogawa, a member of theboard of directors of the Fieldbus Foundation since its inception, is also promotingFOUNDATION Fieldbus worldwide.

Recognition as a Standardization Work Item

In 1984, the standardization concept for the next-generation digital communication protocolfor field devices was first proposed to the IEC, which is to replace the 4 to 20 mA analogtransmission. In 1985, IEC/TC65/SC65C recognized the digital communication protocol asa new standardization work item and named it Fieldbus. IEC/TC65/SC65C WG6, and theISA SP50 Committee, which had already commenced discussions on Fieldbus standard-ization, consented to jointly standardize Fieldbus.

Establishment of the Fieldbus Foundation

The standardization of Fieldbus will have a great effect on industry. Many views werepresented at the ISA SP50 Committee, delaying the standardization of Fieldbus.

To make up for lost time and promote the production of Fieldbus, ISP (Interoperable Sys-tems Project) was organized by Yokogawa, Fisher Control, Rosemount, and Siemens inAugust 1992. In February 1993, ISP became ISP Association.

In March 1993, WorldFIP (Factory Instrumentation Protocol) was jointly created byHoneywell, A-B (Allen-Bradley), CEGELEC, Telemechanique, and several othercompanies.

A consensus was then obtained amongst customers that Fieldbus should conform to theinternationally unified standard. In September 1994, in accordance with this decision, theISP Association and WorldFIP North America were combined to form the Fieldbus Founda-tion.

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Process of Standardization

IEC/TC65/SC65C WG6 and the ISA SP50 Committee started Fieldbus standardization. Byestablishing the Fieldbus Foundation, a structure has been built to develop internationallyunified instrumentation specifications.

The process of Fieldbus standardization is shown below.

1984The standardization concept of digital communication protocol for field devices was proposed to IEC.

1985In IEC/TC65/SC65C, the new standardization work item was recognized and named Fieldbus.

1990The ISA SP50 Committee and IEC/TC65/SC65C/WG6 decided to collaborate on Fieldbus standardization.

August, 1992ISP was organized.

March, 1993WorldFIP was established.

September, 1994The ISP Association and WorldFIP North America were combined into The Fieldbus Foundation.Since then, The Fieldbus Foundation has developed the internationally unified instrumentation specifications.The Fieldbus standardization structure is configured by IEC, ISA, and The Fieldbus Foundation.

August, 1996Fieldbus Foundation defined and published FOUNDATION Fieldbus H1 standard (low speed voltage mode).

1985 1990 1992.8 1993.3 1994.9 1996.8

ISASP50

Committee

IEC

1984

WorldFIPNorth

America

ISP

The FieldbusFoundation

A010201E.EPS

FF-H1 standard isdefined and published.

Figure Process of Fieldbus Standardization

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A1.3 Fieldbus Standard SpecificationsThere are two kinds of Fieldbus physical layer specifications standardized by IEC61158-2and ISA S50.02: low-speed and high-speed Fieldbus specifications. But the high-speedFieldbus specification is not adopted and High Speed Ethernet (HSE) specification is

added as additional type.

IEC/ISA Standard Specifications

The low-speed and high-speed Fieldbus specifications are standardized as shown in thetables below.

Table Fieldbus Specifications (Standard)

ItemLow-Speed Fieldbus

FF-H1High-speed Fieldbus

FF-H2

Transmission Speed 31.25 kbps1.0 Mbps (in 1 Mbps mode orhigh-speed current mode)2.5 Mbps (in 2.5 Mbps mode)

Number of Connectabledevices

Max. 32 devices/segmentMax. 32 devices/segment(Using repeaters increase thenumber of connectable devices.)

Cable Twisted pair cable (shielded) Optical Fiber

Twisted pair cable (shielded)

Power supply toconnected devices

Enabled Enabled

Intrinsic safety Enabled Enabled

Redundancy No (*1) Enabled

Example of connecteddevices

Transmitter, control valve,field multiplexer, etc.

Multicomponent analyzer,PLC, remote I/O, etc.

High-speed FieldbusFF-HSE (High Speed Ethernet)

100 Mbps

Positioning Field device integration Subsystem integrationSubsystem integrationData Server integration

Number of connectable devicesdepend on the subsystemintegrated by FF-HSE.

Twisted pair cable (shielded) Optical Fiber

No

No

Enabled

Multicomponent analyzer,PLC, remote I/O, etc.

A010301E.EPS

*1: Yokogawa has developed dual-redundant configuration of ALF111 Fieldbus Communication Module for FF-H1.

Table Type of Low-speed Fieldbus Cables and Transmissible Length

Type of cable Cable specificationsMax. length of cable

(reference value)

Type A: Individually-shielded twisted pair cable #18AWG (0.82 mm2) 1,900 m

Type B: Overall-shielded twisted pair cable #22AWG (0.32 mm2) 1,200 m

Type C: Unshielded twisted pair cable #26AWG (0.13 mm2

) 400 mType D: Overall-shielded non-twisted cable #16AWG (1.25 mm2) 200 m

A0130302E.EPS

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.

SEE ALSO

For the cable specifications, refer to Section B2 of Part B.

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A1.4 Yokogawas Efforts for Fieldbus StandardizationYokogawa, a member of the board of directors of the Fieldbus Foundation, has played aleading role in the international standardization of Fieldbus standards.

Services for Fieldbus Support Devices

Yokogawa has worked hard to promote Fieldbus, and provided the following services to addvalue for customers:

Product Development

Yokogawa has developed and provided a variety of products that support Fieldbus, rangingfrom various field devices to an integrated production control system, CENTUM CS 3000.

Development of Field Device Management and Diagnostics Packages

Yokogawa has developed and provided field device management and diagnostics pack-ages which support enhanced field information.

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A2. Features of FieldbusFieldbus is a bidirectional digital communication protocol for field devices. Fieldbustechnology drastically changes process control systems and is gradually replacing

the standard 4 to 20 mA analog transmission that most current field devices employ.Fieldbus has the following features:

Because multiple devices can be connected, and multivariables can be trans-mitted on a single cable, thus reducing the number of cables, wiring costs arereduced.

A digital transmission protocol ensures accurate information processing andhence strict quality control.

Multiplex communications allow other information as well as process variables(PVs) and manipulated variables (MVs) to be transmitted from field devices.

Communication between field devices allows truly distributed control.

Interoperability enables devices from different manufacturers to be combined.

A broad choice of devices from any manufacturer permits flexible systemconstruction.

Instrumentation systems, electrical devices, FAs, BAs, OAs, and analyzers canbe integrated.

Some adjustments and inspections of field devices can be performed from thecontrol room.

The following sections explain the advantages of Fieldbus and the effect of Fieldbuson process control systems.

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A2.1 Comparison with Conventional CommunicationThe Fieldbus communication protocol is superior to analog transmissions and hybridcommunications in information accuracy, transmission speed, and transmission amount. Italso offers superiority to those transmissions and communications in functionality, including

the ability to communicate between connected devices and to communicate bidirectionally.

Analog Transmission

An analog transmission is an information transmission technique using analog signals witha direct current of 4 to 20 mA. The topology, which is a one-to-one system, allows only onefield device to be connected to a single cable. The transmission direction is one-way.Therefore, two different cables must be provided: one to acquire information from the fielddevice, and the other to transmit control signals to the field device.

Hybrid Communication

A hybrid communication is a communication technique in which field device information issuperimposed as digital signals on the conventional 4 to 20 mA analog signal. In addition toanalog transmission capabilities, it is possible to remotely set up the field device range andzero-point adjustment. Also, maintenance information such as self-diagnostics of the fielddevice can be obtained using a dedicated terminal.

Hybrid communication protocols were developed independently by each manufacturer, andso devices from different manufacturers cannot communicate with each other. With theYokogawa BRAIN system or the hybrid communication systems of other manufacturers, theself-diagnostics information cannot be exchanged between field devices from differentmanufacturers. A hybrid communication mainly supports 4 to 20 mA analog transmission,though it also allows digital data communication. The digital data communication speedthrough the hybrid communication is slower than that through the Fieldbus communication.

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Fieldbus Communication

The Fieldbus communication protocol, which is different from analog transmissions orhybrid communications, supports a perfect digital signal communication system. In addi-tion, the Fieldbus communication supports bidirectional communication, thus allowing more

types and a larger amount of data to be transmitted in comparison to analog transmissionand hybrid communication.

This communication removes the restriction which allows only one field device to be con-nected to a single cable in an analog transmission system. Multiple field devices can beconnected to a single Fieldbus cable. Also, since this communication is internationallystandardized, interoperability of field devices is guaranteed.

Fieldbus solves the problems of hybrid communications, such as slow digital transmissionspeeds and lack of interoperability.

A comparison between the conventional 4 to 20 mA analog transmission, hybrid communi-cation, and Fieldbus communication protocols is shown below.

Table Comparison of Communication Protocols

Fieldbus Hybrid Analog

A020101E.EPS

Topology Multi-drop One-to-one One-to-one

Transmissionmethod

Digital signal

4 to 20 mA DCanalog signal

+digital signal

4 to 20 mA DCanalog signal

Transmissiondirection

Bidirectional

One-way(analog signal),

bidirectional(digital signal)

One-way

Type of signal Multiplex signalPartially multiplex

signalSingle signal

Standard Standardized in 1996. Differs dependingon manufacturers

Standardized

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A2.2 Reduced Wiring CostThe introduction of Fieldbus reduces wiring cost by means of multi-drop connections andmultivariable transmission.

Multi-drop Connections

Connecting multiple field devices to a single cable is known as multi-drop connections, andthe reduction in the number of cables has many advantages. An example of multi-dropconnections is shown below.

Field device Field device

To the system

A020201E.EPS

Multi-drop connectionFieldbus

Figure Multi-drop Connections

In a conventional analog transmission system, only one field device can be connected to asingle cable that leads to a system. Multi-drop connections connect multiple field devices toa single cable, and so allow additional field devices to be connected to a cable which hasalready been laid.

In the past, it was costly to connect multiple field devices. Using a Fieldbus communicationsystem, it is possible to connect a large number of field devices to the Fieldbus because oflow wiring cost by multi-drop connections. This expands the scale of process controlsystems and promotes a higher level of plant automation.

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Multivariable Detection and Transmission

Multivariable means multiple measured variables, and multivariable detection means thatone field device can detect multiple measured variables, which is also called multi-sensing.

A conventional analog transmission system requires one cable for each measured variable.

Fieldbus supports multivariable transmission. Therefore, a field device can transmit allmeasured variables detected by the field device via a single cable.

The difference in wiring a control valve between analog and Fieldbus communicationsystems is shown below.

Conventional Analog Transmission System Fieldbus Communication System

Positioner Positioner

Control valve

Positioner control signal Valve opening signal

Upper/lower limit signalTotal

Control valve

Number of cables

Fieldbus : 1 pair

Number of cables

: 1 pair: 1 pair

: 2 pairs: 4 pairs

A020202E.EPS

Positioner control signalLower limit signalValve opening signalUpper limit signal

Positioner control signal

Lower limit signal

Valve opening signal

Upper limit signal

Fieldbus

Figure Difference in Detection and Transmission between Analog Transmission and FieldbusCommunication Systems

In the conventional analog transmission system, the control output signal to the positioneris usually transmitted. In a Fieldbus communication system, multiple pieces of informationsuch as control signals, limit signals, and valve opening signals can all be detected andtransmitted.

Multivariable detection and transmission can be used for:

Monitoring the condition of the steam heat tracing of differential pressure transmittersby ambient temperature information.

Detecting clogging in impulse lines by static pressure information.

Many other pieces of information will also be used to expand measurement and controlcapabilities.

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A2.3 Improved Transmission AccuracyFieldbus improves transmission accuracy by eliminating errors that occur during datatransmission in the conventional analog transmission system.

Removing Error Factors

The following three factors cause errors in the conventional analog transmission system.

D/A conversion in the field device

Analog signal transmission

A/D conversion in the system

For example, if data is transmitted from a field device with a microprocessor in the conven-tional analog transmission system, an error may result during A/D and D/A data conversion.Fieldbus eliminates transmission errors and conversion errors during data transmission.

The difference in transmission accuracy between the conventional analog transmissionsystem and the Fieldbus communication system is shown below.

Upgrade to Fieldbus

Data transmission direction

Data transmission direction

4 to 20 mA analog signal

Digital signal

PVs with transmission errors

Sensor P ModemModem

Conventional Analog Transmission System

Fieldbus Communication System

System

PVs without transmission errors

System

Sensor P A/DD/A

A020301E.EPS

Error due to data conversionError due to data conversion

Error due to analog signal transmission

Figure Difference in Transmission Accuracy between Analog Transmission and FieldbusCommunication Systems

Fieldbus transmits data using digital signals. Signal transmission errors rarely occur indigital signal transmission, unlike analog signal transmission. In addition, Fieldbus does notneed A/D and D/A conversions because data is always transmitted digitally. Fieldbusremoves these three error factors, improving transmission accuracy.

System reliability also improves as a result of higher transmission accuracy, which allowsstricter quality control and greater production efficiency.

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Making the Most of Field Device Accuracy

Improved data transmission means accurate transmission of data which is detected by fielddevices. Especially, digital field devices reduce transmission errors and conversion errors ofdigital signals detected by sensors. Therefore, a Fieldbus communication system can take

advantage of the performance of high-accuracy field devices.

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A2.4 Enhanced Data TransmissionIn a Fieldbus communication system, many pieces of field information as well as PVs andMVs can be exchanged between field devices. Fieldbus can transmit many kinds of databidirectionally, so the system offers more advanced functionality than a conventional

analog transmission system.

Various Types of Data Transmission

Fieldbus can transmit various types of data.

The conventional analog transmission system cannot transmit data other than PVs andMVs. Although hybrid communication, an analog communication protocol with a digital datatransmission function, allows various types of data transmission, the hybrid communicationprotocol has the following problems:

The transmission speed is slow.

Only one-to-one communication between a system and a field device is possible.

Fieldbus solves the problems associated with hybrid communication.

The transmission speed is fast.

Multiple pairs of devices can simultaneously communicate among a system and fielddevices, and between field devices.

Transmission of various types of data allows the following advanced functionalities.

Since past maintenance information can be easily acquired, maintenance efficiencyimproves.

Device management such as field device master file creation can be automated.

Bidirectional Communication

Fieldbus transmits multiplexed digital information. This enables the system to performbidirectional communication, which is not possible with the conventional analog transmis-sion system.

Data Exchange between Field Devices

Distribution of control to field devices is made possible by exchanging data between them.

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A2.5 Distributed FunctionsThe use of Fieldbus implements integrated control over the entire plant and autonomousdistributed control.

Installing Advanced Functions in Field Devices

Fieldbus allows the exchange of field information used for control in addition to PVs andMVs.

Field devices with a calculation function and other functions can thus be adjusted from asystem. Although some functions such as correction computation have been installed incurrent field devices, various functions that use more information are expected to beincluded in future field devices.

By doing this, a field device such as a positioner will be able to field-adjust valve controlcharacteristics.

Distributing Functions to the Field

Depending on the requirements of the processes to be controlled, field devices areequipped with advanced functions that provide some control functionality that used to beprovided by a system.

Distribution of control to field devices will change system functions.

Functions of Field Devices and System

By increasing the functionality of field devices and distributing control functions, the func-tions will vary between field devices and system.

For example, the user can install the PID function for each control object in a field device ora system.

If the relation between loops is tight and they cover a wide range in a large-scale plant, thePID function will be generally installed in the system. Conversely, if the loops are relativelyindependent in a small-scale plant, the PID function may be installed in a field device.

In an oil refinery or a petrochemical, for example, the PID function is closely related tocomplex control, advanced control, optimized control, and integrated control over the entireplant. Therefore, excluding some independent control loops, the PID function will be in-stalled in the system.

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A2.6 InteroperabilityConventional hybrid communications can transmit digital signals, but information exchangebetween devices of different manufacturers is difficult because each device uses itsmanufacturers protocol.

In Fieldbus communication, international standardization of the protocol ensures theInteroperability between FF devices including FF interface card in host system. FF devicesallow digital data to be exchanged between devices from different manufacturers. There-fore, the freedom to configure the process control system increases since there is no needto choose one device manufacturer.

The Fieldbus Foundation prescribes the interoperability test procedure calledInteroperability Test (IT) to ensure the Interoperability for the FF devices, and the FF de-vices that passed the IT are registered to the Foundation, and published on the FieldbusFoundations web site (http://www.fieldbus.org/). Yokogawa registered EJA series transmit-ter as the worlds first vendor.

Fieldbus Foundation started the Host Interoperability Support Test (HIST) for host com-puter in September 2000. On September 14, 2000, Yokogawas CENTUM series werecertified as the system able to execute the Host Interoperability Support Test (HIST),becoming the worlds first vendor to carry out the HIST. The HIST is to prove theinteroperability between the host computer and devices. The various devices from differentmanufacturers has been tested by the CENTUM series with the HIST procedure, and theinteroperability has been proved.

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A3. Fieldbus-ready Field DevicesWhen Fieldbus is introduced, the type and amount of transmissible information willdrastically increase. Also, bidirectional communication of digital information can

take place between a field device and a system, and between field devices. To makethe most of communication improvements and to satisfy more advanced needs, bigchanges are taking place with field devices. This section explains the differences infield devices when Fieldbus is introduced in a communication system.

Difference between Analog Transmission and Fieldbus CommunicationSystems

The Fieldbus communication system transmits information differently from the conventionalanalog transmission system. It has the following capabilities:

A large amount of information can be transmitted.

There are many types of transmissible information, both control and non-controlinformation.

Digital information can be transmitted.

Bidirectional communication is possible between a field device and a system.

Bidirectional communication is possible between field devices.

According to those differences, the information handled by field devices (field information)changes significantly.

The differences between analog transmission and Fieldbus communication systems isshown below.

One variableOne way

Controller

Sequencer

Fieldbus

Control bus

A030001E.EPS

Remote I/O card,terminal board

MultivariableBidirectional

Sequencergateway

Controlstation

Fieldjunction box

Computergateway

Conventional Analog Transmission System Fieldbus Communication System

4 to 20 mA analogcommunicationcable

Control valve

Control valve

Flowmeter

Flowmeter

Bidirectional communicationis possible between thecontrol valve and flowmeters.

Figure Difference between Analog Transmission and Fieldbus Communication Systems

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Advanced Functionality of Field Devices

By making the most of Fieldbus communication system features, it is possible to have moreadvanced control over the system. As a result, more advanced functionality is required infield devices.

For example, by transmitting self-diagnostics information from a field device to the system,with the appropriate timing, the system can control the field device according to its statusand can predict a problem in the field device. Also, by exchanging data (PV, MV, etc.)between field devices, autonomously distributed control of multiple field devices will bepossible.

Once the main power to the process control systems was changed from air to electricity,new electric-powered field devices appeared on the market. Similarly, when processcontrol systems are changing from analog transmission to Fieldbus communication, newfield devices that support Fieldbus communication capabilities are appearing on the mar-ket.

Field devices are primarily categorized into transmitters and actuators. Fieldbus will bringabout changes in both components. The following sections describe what changes willoccur in transmitters and actuators.

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A3.1 Changes in TransmittersThe Fieldbus communication system can transmit digital information in a single line. There-fore, the function of a transmitter is changing greatly.

In a conventional analog transmission system, transmitters are primarily designed totransmit the PV value to be measured to the system. This is because the analog transmis-sion system performs one-way communication, from a field device to a system, or viceversa.

By using the Fieldbus communication system, the type and amount of information beingtransmitted through a single cable will increase drastically, and will be far greater than thatof a conventional analog transmission system. In addition, bidirectional communication canbe performed between a field device and a system, and between field devices. Since digitalinformation can be transmitted to field devices without conversion, information will be muchmore reliable.

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A3.1.1 Accuracy Improvement due to DigitalizationSince the Fieldbus communication system transmits information digitally, it can transmit themeasured data from a transmitter to the system with minimum error. Many transmitters withdrastically higher accuracy come to market.

Improvement of Transmission Accuracy

A transmitter with the conventional analog transmission handled a PV value as a percent-age (0 to 100 % relative value) of the measuring range, and transmitted this value to thesystem after converting to a 4 to 20 mA analog signal. The system converted the 4 to 20mA analog signal that was transmitted to the digital signal in engineering unit, and used it.

Errors occur during these signal conversion.

In contrast, a transmitter with the Fieldbus communication handles a PV value in engineer-ing units and transmits this value, without conversion, to the system as a digital signal. The

system uses the digital signal as it was transmitted. The Fieldbus communication systemdoes not require signal conversion, thereby eliminating conversion errors that occur duringtransmission of measured data.

The Fieldbus communication system provides for higher data transmission accuracycompared to the analog transmission system.

Using the example of the orifice flowmeter which uses a differential pressure transmitter,the difference in transmission accuracy between the analog transmission and Fieldbuscommunication systems is described below.

In a conventional analog transmission system, the differential pressure generated at theorifice, proportional to the square of the flow rate, was measured by a differential pressure

transmitter and transmitted to the system after converting to a 4 to 20 mA signal. If thedifferential pressure, P at the orifice is 2 kPa when the flow rate is 20 Nm3/h, the outputsignal of the differential pressure transmitter will be as shown in the table below. Theanalog transmission system generates an error when this output signal is converted to adigital signal in the system side.

If the differential pressure is converted to a flow rate on the system side, the transmissionerror will be changed by the flow rate because this conversion is not linear as shown inFigure below.

Table Analog Signal Data

OutputDifferentialpressure

Flow rate

4 mA 0 kPa 0 Nm3

m3

/h

20 mA 2 kPa 20 N /h

A030101E.EPS

Differential

pressure

Flow rate

A030102E.EPS

Figure Relationship between Differential Pressure and Flow Rate

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In contrast, the Fieldbus communication system transmits the flow signal in engineeringunits as a digital signal. Therefore, there is no error during transmission. In this example,the differential pressure generated by the orifice is calculated and converted to a flow rateby the microprocessor of the differential pressure transmitter. The flow signal in engineeringunit is transmitted to the system as a digital signal without conversion.

Improvement of Transmitter Measuring Accuracy

If the transmission accuracy is improved by the Fieldbus communication, the improvementof transmitter measuring accuracy will be a factor in improving the accuracy of the entireprocess control system. To perform measurements at higher accuracy, field devices thatemploy a superior measurement principle will be widely used.

For example, conventional mechanical flow meters and level meters will be replaced byelectric flow meters and level meters that employ digital technology.

Since the Fieldbus communication system transmits the measured data in engineering

units, without dependence on measuring range, a transmitter with a wide measuring rangewill show the original measuring performance. The width of the measuring range is one ofthe most important factors in determining the quality of transmitters.

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A3.1.2 Multi-sensing Function EquipmentThe function used to measure multiple variables with a single transmitter is known as themulti-sensing function.

In a Fieldbus communication system, it is possible to transmit multiple pieces of information

over a single cable. To make the most of this Fieldbus feature, users will demand transmit-ters equipped with a multi-sensing function.

In a conventional analog transmission system, a transmission cable with a pair of wires isrequired to transmit one measured value. For example, a transmitter that can performmultiple measurements, such as the Coriolis flowmeter, requires multiple cables to transmitmultiple measurement variables.

The Fieldbus communication system allows the Coriolis flowmeter to transmit multiplemeasurement variables via a single cable.

Transmitters that have been used to perform only one measurement are enhanced toperform the multi-sensing function using the Fieldbus communication system.

For example, the differential pressure transmitter is able to measure process pressure,ambient temperature, etc., in addition to flow rate, which was the transmitters originalfunction. If a temperature sensor for measuring the process temperature is combined withthis differential pressure transmitter, all flow rate, pressure, and temperature variablesnecessary for process control will be measurable by the transmitter alone.

Possible data that will be gained by multi-sensing function for the main transmitters areshown below.

Differential pressure flowmeter: Mass flow, volume flow, pressure, temperature

Magnetic flowmeter: Volume flow, conductivity, temperature

Vortex flowmeter: Mass flow, volume flow, temperature, pressure

Coriolis flowmeter: Mass flow, volume flow, density, temperature

Differential pressure level meter: Liquid level, density and specific gravity, tankinternal pressure, temperature

Ultrasonic level meter: Liquid level, temperature

Temperature transmitter: Humidity, ambient temperature, vibration

pH meter: pH, temperature

Conductivity meter: Conductivity, temperature

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A3.1.3 Multifunction EquipmentA Fieldbus communication system can transmit other information in addition to the PVvalue. To make the most of this feature, the transmitter is expected to calculate the multiplevalues and process them into the required information for control.

A transmitter that incorporates multiple functions, such as the calculation function, is knownas a multifunction transmitter. Multifunction transmitters increase for a Fieldbus communi-cation system.

The main function of transmitters used in a conventional analog transmission system is tomeasure a PV value at high-accuracy and transmit it. To do this, additional devices areused for converting the measured PV value into the information necessary for control.

A multifunction transmitter can calculate the PV value in engineering units required by theuser and transmit it to the system.

If a multifunction transmitter is used in combination with the above multi-sensing function, itis possible to drastically simplify the process control system.

For example, assume that there is a differential pressure transmitter which can multi-sensethe flow rate, pressure, and temperature. If a calculation function is added to this differentialpressure transmitter, it allows the transmitter to calculate the mass flow rate after tempera-ture-pressure compensation using the measured flow rate, pressure, and temperature, andbefore executing transmission.

To attain the above functions, a conventional analog transmission system would requirethree transmitters, one each for flow rate, pressure, and temperature, and an additionalcalculator for temperature-pressure compensation. A single multifunction transmitter withmulti-sensing can process all of this.

This will not only drastically reduce the instrumentation cost, but will also improve thereliability.

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Features of Control Valves with the Fieldbus Communication

Improvement of valve controllability (detects stroke cycle, open-close time, etc. topredict clogging, sticking, leakage, etc.)

Remote monitoring of control valves

Modification and improvement of valve characteristics

Stabilized control together with operability and complete closure of valves

Improved valve stability

Ease-to-operate adjustment and stabilization of valve characteristics

Reduction of valve accessories

The following figure shows the compensation curves of valve flow characteristics. By usingthe control valve with the Fieldbus communication, the following valve flow characteristicswill be change easily. In addition, it is possible to adopt the customized characteristics.

Flow rate

Valve openingA030201E.EPS

Intrinsic flow characteristics (from ISA Hand Book of Control Valve)

Quick

open

Squa

reroot

Equalp

erce

nt

Line

ar

Hype

rboli

c

Figure Modification of Valve Flow Characteristics

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A3.3 Using Self-diagnostics FunctionThe Fieldbus communication system can predict a problem in a field device using the self-diagnostics function.

Integration of Instrumentation and Self-diagnostics Functions

The conventional analog transmission system can handle only one signal on a singlecable. The system handles the PV or MV value and the self-diagnostics information ascompletely different data, even if it is information from the same field device.

The Fieldbus communication system can handle multiple signals on a single cable. Thesystem can handle the PV or MV value and the self-diagnostics information in the sameenvironment. Instrumentation and self-diagnostics will be performed under the sameenvironment by integrating work in the field into a single network.

This idea is far different from the conventional one which has separated instrumentationfrom self-diagnostics.

Problem Prediction Function

Since Fieldbus handles the measured values in engineering units, it allows the system toaccurately measure slight changes in pressure and temperature, other than the PV value.This enables the system to detect the symptoms of problems that were difficult to predict.

For example, suppose the system cannot judge whether the self-diagnostics result of afield device is abnormal or normal. The conventional analog transmission system cantransmit a self-diagnostics result as either abnormal or normal. Therefore, if a result cannotbe judged as being abnormal or normal, the system always handles it as abnormal for

safety. If a minor abnormality is generated in field devices, a number of alarms will bedisplayed on the panel in the control room. However, if minor abnormalities in field devicesare handled as normal to reduce alarms in the control room, the symptom of a majorproblem may not be detected.

If a self-diagnostics result cannot be judged as abnormal or normal, Fieldbus communica-tion system can transmit the status information to the system. In addition, Fieldbus com-munication system will be able to monitor the information which influences measurementand control, such as clogging, vibration, etc. The use of this information allows the systemto chronologically analyze changes in field devices and predict their problems.

Using the dedicated package software will make the maintenance work easier.

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A3.4 Yokogawas Fieldbus-ready Field Devices Line-up

Differential Pressure/Pressure Transmitter DPharp EJA Series (suffix codefor output: F)

Function Block: Two (2) AI function blocks

One (1) PID function block (option: /LC1)

Link Master function (option: /LC1)

Hazardous area certification for FM, CENELEC, CSA, or JIS is available. FISCO model forFM or CENELEC intrinsically safe is also available.

(See GS 01C22T02-00E for the detail.)

Vortex Flowmeter YF100 (YEWFLO*E) (suffix code for output: F)

Function Block: One (1) AI function block



(See GS 01F02F04-00E for the detail.)

Magnetic Flowmeter ADMAG AE (with option code /FB)

Function Block: One (1) AI function block


Link Master function (option: /LC1)Hazardous area certification for CENELEC ATEX is available.

(See GS 01E07F01-00E for the detail.)

Temperature Transmitter YTA320 (suffix code for output: F)

Function Block: Four (4) AI function blocks

One or two (1 or 2) PID function block(s) (option: /LC1 or /LC2)

Link Master function: with one (1) PID function block (option: /LC1)

with two (2) PID function blocks (option: /LC2)

Hazardous area certification for FM, CENELEC, CSA, SAA, or JIS is available. FISCOmodel for CENELEC intrinsically safe is also available.

(See GS 01C50T02-00E for the detail.)

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Advanced Valve Positioner YVP110

Function Block: One (1) AO function block

Two (2) DI function block

One (1) OS (Output Splitter) function block



Signature Function:(option: /BP)

Hazardous area certification for FM, CENELEC, CSA, or JIS is available. FISCO model forFM or CENELEC intrinsically safe is also available.

(See GS 21B04C01-01E for the detail.)

YVP Management Software

This software package offers a variety of functions to help users to easily set up and tune

YVP110.

This software needs National Instruments FBUS fieldbus communication interface card.

(See GS 21B04C50-01E for the detail.)

Paperless Digital Recorder DAQSTATION (with option code /CF1)

Function Block: Eight (8) AI function block (1-channel each)

One (1) MAO function block (8-channel)

Link Master function

(See GS 04L01A01-00E for the detail.)

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A4. Yokogawas Fieldbus-ready SystemsThe control system that uses Fieldbus communication handles more advancedinformation than the conventional analog transmission system. Information recep-

tion, display and record management are more important factors in control systems.This section describes the Yokogawa systems that support Fieldbus.

The H1 Fieldbus Communication Protocol and H1 Fieldbus indicated in thissection and Part B are the FOUNDATION Fieldbus H1 (Low Speed Voltage Mode)of the Fieldbus Foundation.

A4.1 Fieldbus Support in Yokogawas CENTUMControl Systems

The CENTUM CS 3000 Integrated Production Control System, CENTUM CS 1000 Produc-tion Control System, and CENTUM CS Integrated Production Control System supportFieldbus.

This section describes a typical system configuration for each CENTUM Fieldbus system.

These systems are connected to field devices via I/O modules which support 1-5 V DC/4-20 mA I/Os, thermocouple and resistance temperature detector inputs, digital I/O, andcommunication. The Fieldbus Communication Module can also be combined with suchconventional analog I/O modules.

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A4.1.1 Fieldbus Support in FCS for FIO of CENTUM CS 3000Fieldbus support in FCS for FIO of CENTUM CS 3000 is shown below. FCS for FIO can beconnected via an ALF111 Fieldbus Communication Module installed in a node unit to FFtransmitters and FF valve positioners.

A040101E.EPS

HIS

V net

Ethernet

ALF111(in service)

ALF111(stand-by)

EB401(dual

redundant)

SB401(dual

redundant)

FCU

ESB bus

Fieldbuspower supply unit (optional)

Local Node

ER bus

Terminator

FCS

IS barrier orlightning arrester

(optional)H1 fieldbus segment

Terminator(optional)

ALF111(in service)

ALF111(stand-by)

EB501(dual

redundant)

Fieldbuspower supply unit (optional)

Remote NodeTerminator

IS barrier or

lightning arrester(optional)

H1 fieldbus segment


ACB41

HIS: Human Interface station

PRM: Plant Resource Manager

FCS: Field control station

FCU: Field control unit

SB401: ESB-bus interface (in Local Node)

EB401: ER-bus interface (in Local Node)

EB501: ER-bus interface (in Remote Node)ALF111: Foundation Fieldbus communication module

ACB41: I/O expansion cabinet for FIO

PRM

Operation andmonitoring functionEngineering function(system generation)Fieldbus tools:

Engineering tool Device management

tool

Figure Fieldbus Support in FCS for FIO of CENTUM CS 3000

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ALF111 Fieldbus Communication Module Specifications

Number of ALF111s per FCS:

Standard FCS control function: Max. 16 (*1) modules (8 pairs for a dual-redundant configuration) per FCS

Enhanced FCS control function: Max. 32 (*2) modules (16 pairs for a dual-redundant configuration) per FCS

Number of ALF111 ports: Max. 4 ports per ALF111 (One port is connectedto one segment (*3).)

Number of field devices per segment (*3): Max. 32 units per segment (including anALF111 as one unit)

Number of FF faceplate blocks: Max. 250 blocks for Standard FCS (general-purpose database)Max. 600 blocks for Enhanced FCS (general-purpose database)

ALF111 dual-redundant support: Dual-redundant configuration possible with twoadjacent ALF111s in a node

Link active scheduler (LAS) function: Available

Time master function: Available

The number of field devices per segment varies significantly depending on the cablelength, power supply capacity, existence of a barrier, etc. For details, refer to Section B2.2of Part B.

Other Fieldbus specifications are in accordance with the specifications for the FOUNDA-TION Fieldbus.

*1: For the standard FCS control function, the maximum number of ALF111s may be two depending on the

database type selected as the FCS database. For details, refer to GS, Control Function for Standard FieldControl Station (for FIO) (GS 33Q03K30-31E).

*2: For the enhanced FCS control function, when remote node expanded is selected as the database type, themaximum number of ALF111s is 32. In the other database type, the maximum number of ALF111s is 16. Fordetails, refer to GS, Control Function for Enhanced Field Control Station (for FIO) (GS 33Q03K31-31E).

*3: A segment is an engineering unit consisting of several Fieldbus devices and ALF111 port to be connected toone H1 Fieldbus.

SEE ALSO

For details of the ALF111 Fieldbus Communication Module, refer to GS 33Q03L60-31E.

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A4.1.2 Fieldbus Support in FCS for RIO and Compact FCS ofCENTUM CS 3000Fieldbus support in FCS for RIO and Compact FCS of CENTUM CS 3000 is shown below.FCS for RIO and Compact FCS can be connected via an ACF11 Fieldbus Communication

Module installed in an I/O module nest to FF transmitters and FF valve positioners.

A040102E.EPS

V net

HIS: Human Interface StationPRM: Plant Resource ManagerLFCS: Standard FCSSFCS: Compact FCSRIO bus: Remote I/O busNIU: Node Interface UnitACF11: Fieldbus Communication Module

NIU ACF11

LFCS SFCS

RIO bus

ACF11

Externalpower supply

(optional)Intrinsic safety barrier /

arrester(optional)

Field devices

HIS

Ethernet

PRM



tool


CouplerH1 Fieldbus

Fieldbus

Coupler

Terminator

Figure Fieldbus Support in FCS for RIO and Compact FCS of CENTUM CS 3000

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ACF11 Fieldbus Communication Module Specifications of CENTUM CS3000

The main specifications of the ACF11 Fieldbus Communication Module of CENTUM CS3000 are shown below.

For LFCS (FCS for RIO)

Number of ACF11s per FCS: Max. 80 modules per FCS

Number of ACF11s per AMN33 nest: Max. two modules per nest

Number of segments (*1) per ACF11: Max. one segment

Number of field devices per segment (*1): Max. 32 units per segment (including anACF11 as one unit)



Fieldbus power supply: Available (supply current: max. 80 mA)

For SFCS (Compact FCS)





Link active scheduler (LAS) function: AvailableTime master function: Available


*1: A segment is an engineering unit consisting of several Fieldbus devices and ACF11 to be connected to one H1Fieldbus.

SEE ALSO

For details of the ACF11 Fieldbus Communication Module of CENTUM CS 3000, refer to GS 33Q03L50-31E.

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A4.1.3 Fieldbus Support in CENTUM CS 1000Fieldbus support in CENTUM CS 1000 is shown below. FCS can be connected via anACF11 Fieldbus Communication Module installed in an I/O module nest to FF transmittersand FF valve positioners.

VL net

HIS: Human Interface StationPRM: Plant Resource ManagerPFCS: Control StationACF11: Fieldbus Communication Module

ACF11

Externalpower supply

(optional)Intrinsic safety barrier /

arrester(optional)

Field devices

PFCS

A040103E.EPS

HIS

Ethernet

PRM



tool


CouplerH1 Fieldbus

Coupler

Terminator

Figure Fieldbus Support in CENTUM CS 1000

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ACF11 Fieldbus Communication Module Specifications of CENTUM CS1000

The main specifications of the ACF11 Fieldbus Communication Module of CENTUM CS1000 are shown below.








*1: A segment is an engineering unit consisting of several Fieldbus devices and ACF11 to be connected to one H1Fieldbus.

SEE ALSO

For details of the ACF11 Fieldbus Communication Module of CENTUM CS 1000, refer to GS 33S03L50-31E.

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A4.1.4 Fieldbus Support in CENTUM CSFieldbus support in CENTUM CS is shown below. FCS can be connected via an ACF11Fieldbus Communication Module installed in an I/O module nest to FF transmitter and FFvalve positioners.

A040104E.EPS

V net

ICS: Information and Command StationACG: Communication Gateway UnitFCS: Field Control StationFCU: Field Control UnitRIO bus: Remote I/O busNIU: Node Interface UnitACF11: Fieldbus Communication Module

NIU

FCU

ACF11External

power supply(optional)

Intrinsic safety barrier / arrester(optional)

PC

FCS

Field devices

Ethernet

ACG

ICS EWS

RIO bus


CouplerH1 Fieldbus

Terminator

Coupler

Fieldbus tools Engineering tool Device Management tool

System generation function

Operation and monitoring function

Figure Fieldbus Support in CENTUM CS

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ACF11 Fieldbus Communication Module Specifications of CENTUM CS

The main specifications of the ACF11 Fieldbus Communication Module of CENTUM CSare shown below.








*1: A segment is an engineering unit consisting of several Fieldbus devices and ACF11 to be connected to one H1

Fieldbus.

SEE ALSO

For details of the ACF11 Fieldbus Communication Module of CENTUM CS, refer to GS 33G6K40-01E.

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A4.2 Connection of FF Devices from Other Vendorsto Yokogawas CENTUM Control SystemsFF devices from other vendors can be connected to CENTUM under the following condi-

tions:

Use devices registered by the Fieldbus Foundation

The Fieldbus Foundation prescribes the interoperability test procedure calledInteroperability Test (IT) to ensure interoperability between the FF devices. The FF devicesthat passed the IT are registered to the Foundation, and information about them is pub-lished on the Fieldbus Foundations web site (http://www.fieldbus.org/).

The field devices from other vendors, which are registered to Fieldbus Foundation, can beconnected to CENTUM. Yokogawa recommends to use the IT4.0 (or later version) registra-tion devices including the Capabilities File and Device Description (DD) File.

For the Fieldbus accessories (e.g. cables, external bus power supply units, barriers, and

arresters), there is no system of registering to the Fieldbus Foundation; these accessoriesshould be used according to the conditions provided by their vendors.

Yokogawa informs users of field-proven Fieldbus accessories as recommended devices.Contact Yokogawa sales for the Fieldbus accessories if necessary.

Use devices as instructed

Use devices according to the conditions provided by their vendors. The vendors assumeresponsibility for the quality, performance and warranty of their field devices.

Test devices

A user who uses field devices from other vendors is responsible for testing them.

Yokogawa, if required, will provide assessment information on connecting other vendorsdevices to CENTUM, to assist users in device selection.

Yokogawa supports only standard Fieldbus specifications, not manufac-turer-specific extensions

Yokogawas systems support information and functions that meet the standard specifica-tions prescribed by the Fieldbus Foundation. They may not support another manufacturersproprietary functions.

The Fieldbus standardization facilitates operation and maintenance of field devices fromdifferent manufacturers. Yokogawa can meet a variety of user needs, including startup andmaintenance work on process control systems including products (components) from othervendors, based on accumulated know-how about devices and their usage.

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Part B Fieldbus Engineering

CONTENTS

Sep.01,2002-00

TI 38K03A01-01E 3rd Edition

B1. Managing Fieldbus Engineering ..........................................................B1-1

B1.1 Fieldbus Engineering Process ..................................................................... B1-1

B1.2 Difference between Fieldbus and Analog Signal Process ControlSystems......................................................................................................... B1-4

B1.3 Software Packages for Fieldbus .................................................................. B1-5

B2. System Design Considerations ...........................................................B2-1

B2.1 Considerations in Basic and Overall Design............................................... B2-2

B2.2 Detail Design Considerations ...................................................................... B2-3

B2.2.1 Investigation of Number of Field Devices connected toan H1 Segment............................................................................... B2-4

B2.2.2 Selection of Fieldbus Cable and Wiring Method .............................. B2-5

B2.2.3 Design of FF Device Grouping per Segment ................................... B2-8

B2.2.4 Expansion and Modification of Existing System .............................. B2-8

B3. System Construction Considerations .................................................B3-1

B3.1 New Construction of Fieldbus Process Control System ............................ B3-1

B3.1.1 Mounting Terminators ..................................................................... B3-3

B3.1.2 Mounting Couplers ......................................................................... B3-3

B3.1.3 Cabling ........................................................................................... B3-4

B3.1.4 Installing an Intrinsic Safety Barrier ................................................. B3-4

B3.1.5 Handling the Shield Mesh ............................................................... B3-4

B3.1.6 Connecting the Fieldbus Cable and Handling the Shield Mesh forFieldbus Communication Module.................................................... B3-4

B3.2 Reusing Existing Cables ..............................................................................B3-5

B4. System Startup Considerations ...........................................................B4-1

B4.1 Tool Necessary for Startup...........................................................................B4-1

B4.2 Technologies and Expertise Necessary for Startup ................................... B4-2

B4.3 Labor Savings in Startup Work .................................................................... B4-3

B5. System Maintenance Considerations ..................................................B5-1

B5.1 Daily Maintenance.........................................................................................B5-1

B5.2 Inspection and Maintenance ........................................................................B5-2

B5.3 Maintenance Management (Maintenance Plan, Device Management,Audit Trail) ..................................................................................................... B5-3

B5.4 Evolution of Maintenance.............................................................................B5-3

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B1. Managing Fieldbus EngineeringIn a process control system that uses Fieldbus, the engineering process differs fromthat of a process control system that uses conventional analog signals. This section

explains the engineering process in a process control system using the H1 (31.25kbps) Fieldbus.

B1.1 Fieldbus Engineering ProcessThe engineering of a process control system that employs Fieldbus is divided into fivesteps: design, production, construction, startup, and maintenance. Each step has multipletask processes and each task process includes detailed task items.

The example of engineering process for the process control system using Fieldbus tech-nology is shown below.

START

Basic design

Overall design

Detail design

Hardware production

Witness inspection

Shipping

Delivery

Acceptance inspection

Installation work

Unit startup

Production

Witness inspection

Shipping

Delivery

Acceptance inspection

Installation work

Unit startup

FF parameterconfirmation

System startup

Trial operation

Plant operation

System Field devices

Startup

Design

Production

Construction

Maintenance

Performed by contractor,system integrator or user.

Maintenance

Software production

B010101E.EPS

Figure Example of Engineering Process Using Fieldbus

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Design

The specifications of the process control system are verified by completing the basicdesign, overall design, and detail design for the system.

SEE ALSO

For detailed information about designing the process control system using Fieldbus, refer to Section B2,System Design Considerations.

Production

According to the specifications that are confirmed in the design process, the system andfield devices are produced. Production work is completely performed by Yokogawa. Noother work needs to be performed by the user.

Construction

The manufactured system and field devices are delivered to the users site. Then, accord-ing to the system layout that has been clarified in the design step, wiring such as Fieldbuscabling is installed.

Acceptance inspection is performed for the field devices before installation. The processcontrol system using Fieldbus needs to be closely inspected. The following items requireespecially close inspection.

Parameter settings (PD tag names (*1), node addresses (*1)) required for Fieldbuscommunication

Parameter settings specific to field devices

After inspection, the system is installed in the control room, and field devices in the field.The system and field devices are connected to the Fieldbus.

*1: For PD tag name and node address, refer to Section C1.1 Glossary.

SEE ALSO

For detailed information about constructing a process control system using Fieldbus, refer to Section B3,System Construction Considerations.

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Startup

In the startup step, unit startup, system startup and the trial operation are performed.

Startup (Unit and System)

The following checks are required.

Unit identification for all field devices

Confirmation of data input/output between system and field devices(The input/output definition on the system side must be completed by this time.)

Adjustment of various control constants and parameters of FF devices by devicemanagement package on a system computerThese parameters are for the built-in function blocks in field devices and for thefunction blocks managed by control function in a system computer.

Trial Operation

This includes adjustment of control parameters such as P, I, D constants of the built-in PIDfunction blocks in FF devices.

SEE ALSO

For detailed information about starting up the process control system using Fieldbus, refer to Section B4,System Startup Considerations.

MaintenanceDuring plant operation, the field device status is managed using a device managementfunction which is supported by the Plant Asset Management (PAM) system such asYokogawas Plant Resource Manager (PRM see Part C Overview of Plant ResourceManager) from the control room or maintenance room.

Also, error generation is monitored using the self-diagnostics function of field devices if thefield device has such a self-diagnostics function.

With maintenance work, parameters can be confirmed by directly connecting field devicemanagement tools to field devices or by a field device management function on PAMsystem. The communication status can be checked by directly connecting the FieldbusMonitor (*1) to Fieldbus.

Some field devices may have a maintenance record function of their own. The mainte-nance record data on the field device is uploaded and managed them into the PAM system.

*1: Yokogawa recommends NI-FBUS Monitor Package from National Instruments Co. as Fieldbus Monitor.Contact National Instruments Co. (http://www.ni.com/).

SEE ALSO

For detailed information about maintaining the process control system using Fieldbus, refer to SectionB5, System Maintenance Considerations.

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B1.2 Difference between Fieldbus and Analog SignalProcess Control SystemsProcess control systems using Fieldbus differ greatly from those using a conventional

analog signal, in that the parameters for Fieldbus configuration definitions also need to beset.

Setting Parameters Specific to Field Devices

Various FF block parameters for field devices must be set up.

The following main parameters for FF function block (FFB) must be set:

Range parameters (XD_scale, OUT_scale and engineering unit for each scale)

Compensation parameters (Direct, Indirect, Indirect Sqr Root)

Input filter process parameters (PV_FTIME)

Setting Parameters for Fieldbus Communication and Its Functions

New parameters for Fieldbus communication and its functions have been added.

The following main parameters must be set:

PD tag name (*1)

Node address (*1)

FF function block definition

Link information (connecting block, output parameter, etc.)

*1: For PD tag name and node address, refer to Section C1.1 Glossary.

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B1.3 Software Packages for FieldbusYokogawa offers various packages that support engineering and maintenance for Fieldbusprocess control systems.

Fieldbus Package Types

Yokogawa offers the following types of packages for Fieldbus depending on the conditionsof use.

Fieldbus package type for desktop PC: Fieldbus engineering and maintenance pack-ages for field devices in the central control room

Fieldbus package type for portable PC: Field device maintenance package in the fieldsite.

An example of use of Fieldbus package types is shown below.

In practice, these packages can be run on the same PC.

B010301E.EPS

Fieldbus monitor

FF-H1 support tool

(includes device managementtool function and

device tool function)

Field device

Field device

Ethernet

V net

H1 Fieldbus

Supply air

HISHIS for builder(includes Fieldbusengineering function)

Remark

Desktop typeFieldbus package

Portable typeFieldbus package

Plant Resource Manager(PRM)

FCS

Figure Example of Use of Fieldbus Package Types

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Fieldbus Engineering and Field Device Maintenance in Central Control Room

The Fieldbus package for desktop PC is designed for Fieldbus engineering and field devicemaintenance work in the central control room.

Fieldbus engineering in integration with the system

This package, which is added to conventional system configuration function, registersdevices to Fieldbus segments and links FF function blocks. The Device ManagementTool (DMT) or Plant Resource Manager (PRM) also executes remote parametersetting (tuning), and remote diagnosis of field devices.

Parameter setting and tuning, and diagnosis for the field devicesDMT or PRM executes remote parameter setting and diagnosis for field devices.

Field Device Maintenance in the Field

The Fieldbus package for portable PC is designed for tuning Fieldbus devices in the field.

The FF-H1 support tool is installed in a portable PC (such as notebook PC), which isconnected to Fieldbus to monitor the statuses of field devices. It is also used to tune pa-rameters and check operation of field devices before actual plant operation.

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B2. System Design ConsiderationsWhen designing a process control system that uses the Fieldbus communicationprotocol, it is necessary to thoroughly understand the design considerations,

including Fieldbus. This section describes the design considerations of a processcontrol system that employs Fieldbus technology.

Importance of Process Control System Design

To design a process control system, the design procedure should follow these steps:

Basic design

Overall design for common specifications

Detail design for individual components

First perform the basic design, then the overall design for the specified system. If the basicand overall design have not been completed, inconsistencies with specifications may occurand require returning to an earlier step. The more sophisticated the process control systembecomes, the more important the basic and overall design will be.

During the detail design, the individual components to be designed are identified on thebasis of the basic and overall design.

Designing Process Control Systems with Fieldbus Technology

In designing Fieldbus process control systems, more items need to be considered than forsystems using conventional analog signals.

However, this does not mean that it is difficult to design Fieldbus process control systems.

Although Fieldbus-related items need to be added to the design items of conventionalprocess control systems, a conventional design method can be used.

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B2.1 Considerations in Basic and Overall DesignDuring the basic design of a process control system that uses Fieldbus, it is necessary toproperly consider the purpose of the system and its construction costs. Also, in the overalldesign, the process control system configuration and the integrating or grouping range and

extent must be carefully considered.

Basic Design Considerations

During the basic design of a process control system that uses Fieldbus, the following mustbe taken into consideration.

Purpose of the process control system

Cost of system implementation (total estimation including the construction cost)

Delivery period of the system implementation

Safety concept

Operation procedure

Maintenance procedure

Overall Design Considerations

During the overall design of the process control system that uses Fieldbus, includingcommon specifications, take the following into consideration.

Configuration of the process control system (hardware and software configuration)

Integrating or grouping range and scope

Safety design and reliability design

Measures under abnormal situations

Interface design

Future expansion

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B2.2 Detail Design ConsiderationsIn detail design, the contents of the basic design and overall design are realized. Thissection describes major considerations in designing individual components.

In detail design, the considerations for limit and restriction items depending on cable length,power supply capacity and so forth are also important.

There are also many items to be considered other than those described here.

Integrating or Grouping Range and Scope

Integration of buses between the process control system and other systems

Consistency of operation types between the process control system and other sys-tems

System integration through upper-level communication and lower-level communica-tion

Connectable number of field devices and their grouping

Clarification of hardware and software configuration with system configuration draw-ings

Safety Design and Reliability Improving Design

Selecting devices and construction in hazardous area (power supply method forintrinsic safety devices)

Assignment of Fieldbus I/O and conventional I/O for the system functionalityFor example, the emergency shutdown system should be assigned to the conven-

tional analog control system.

Selection of type of cables, field devices, and redundancy of FF power supply unit andFieldbus interface module

Fail-safe design, safety measurements using diagnostics technologies, and equip-ment diagnostics design

Selection of noise resistant devices and wiring route to minimize noise (affected byhigh voltage or motors)

Selection of fieldbus accessories such as FF power supply unit, terminator, barrierand arrester

Design of a Link Master (LM) device with Link Active Scheduler (LAS) capability andbackup LM devices with LAS capability.

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B2.2.1 Investigation of Number of Field Devices connected to anH1 SegmentThe number of field devices that can be connected to an H1 segment is restricted by thepower supply current capacity of the segment, macrocycle corresponding to the control

period, and Fieldbus cable length. For details of the restriction by Fieldbus cable length,refer to Section B2.2.2, Selection of Fieldbus Cable and Wiring Method.

Restriction by Power Supply Current Capacity

The sum of the current consumption of field devices connected to one Fieldbus segmentcannot exceed the current supply capacity of the power supply.

In an intrinsic safety system, the sum of the current consumption of field devices connectedto one Fieldbus segment can not exceed the current supply capacity of the power supply orlimitation value of the safety barrier unit.

Restriction by Macrocycle Corresponding to Control Period

The number of field devices that can be connected to an H1 segment should be decided bythe macrocycle corresponding to the control period.

A macrocycle is the period of the control or measurement and the unit is 1/32 ms (1 sec =32000 units). The scheduled control and communication on macrocycle is executed by theLM device with LAS capability.

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B2.2.2 Selection of Fieldbus Cable and Wiring MethodData on several types of cables are given below for reference only. Yokogawa recom-mends using Type A cable.

The Fieldbus cable specifications are important in Fieldbus system design. The voltage

drop restrictions of Fieldbus should also be considered.

Yokogawa investigates Fieldbus cable specifications in various aspects. Use the datadescribed in this manual for reference only.

Consideration of Voltage Drop Restrictions

The voltage drop limits are set so that the minimum output voltage of the power supply, lessthe voltage drop in the cable resistance, is not less that the minimum operating voltage ofthe device, even considering the voltage fluctuation. Yokogawa recommends minimum 9.5volts as operating voltage design.

Cable Type and its Resistance

The typical resistances per unit length of the various cable types that can be used forFieldbus are shown below. The following resistance values are for reference only. For actualvalues, contact the cable manufacturer.

Type A (individually shielded twisted-pair cable): 22 ohm/km

Type B (multi-pair twisted-pair cable, with outer shield): 56 ohm/km

Type D (multi-pair cable, no twist, with outer shield): 20 ohm/km

The following general formula is used to check whether the minimum supply voltage issecured.

Minimum Power Supply Voltage(resistance per unit length cable length) device currentminimum operating voltage

This calculation must be performed for each Fieldbus device.

Selection of Wiring Cables

Consider noise, cost, flexibility, and explosion-proof.

Insulating Material of Twisted Pair CableThe insulating material such as polyethylene is appropriate.

Selection of Bus Topology and Maximum Number of FF Devices perSegment

Consider the bus topology, such as serial link and tree link, and maximum number ofdevices per segment.

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Selection of Cable Type and Total Length

If using a twisted-pair cable for the main line, carefully consider the kind and total length ofcabling.

The total length of cabling for Fieldbus is as follows:

Type A (Individually-shielded twisted pair cable) 1900 m

Type B (Overall-shielded twisted pair cable) 1200 m

Type D (Overall-shielded non-twisted cable) 200 m

Some Type B cables attenuate signals largely. To secure sufficient signal amplitude, nomore than 20 field devices must be connected with a maximum total cable length of 600 m,or no more than 10 field devices must be connected with a maximum total cable length of1,200 m.

When using Type D cables, up to two pairs of cables must be used for Fieldbus

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