Foundation Fieldbus Training Book

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© Chevron 2005

Foundation FieldbusTechnical Training

Ryan KellyChevron Energy Technology Company (ETC)

June 2008



2ETC-PA: Foundation FieldbusTraining© Chevron 2005

Welcome & Introductions

Ryan Kelly

Instrumentation & Controls Engineer

Chevron ETC – Process Automation Unit

[email protected]

Vincent Palughi

Snr Instrumentation & Controls Engineer

Chevron ETC – Process Automation Unit

[email protected]




Welcome & Introductions

Please tell us about yourself:

Name

Role on the project

Experience (if any) with Foundation Fieldbus or

other types of smart instrumentation

Your expectations of the course – what you hope

to learn from it




Safety Moment – Hazardous Areas

The Fire Triangle





Area Classification (NEC Article 500.5 / API RP 500)

Class I - flammable gases, flammable liquid–

produced vapors, or combustible liquid–produced

vapors

Class II – combustible dust

Class III - easily ignitible fibers or materials

producing combustible flyings

For full text of the standard, please see NEC Article 500.5





Area Classification (NEC Article 500.5 / API RP 500)

Class I, Division 2 is a location in which volatileflammable gases, flammable liquid–produced vapors, orcombustible liquid–produced vapors are handled,processed, or used, but in which the liquids, vapors, orgases will

normally be confined within closed containers or closedsystems from which they can escape only in case ofaccidental rupture or breakdown of such containers orsystems or in case of abnormal operation of equipment,or

normally prevented by positive mechanical ventilation

and which might become hazardous through failure orabnormal operation of the ventilating equipment, or

the area is adjacent to a Class I, Division 1 location






Protection Techniques (NEC Article 500.7)

Intrinisically Safe Equipment (IS) - Class I, Div

1&2

"Intrinsically safe" devices produce or consume electrical power at levels belowwhat is required to cause an ignition in a hazardous area. The electrical energygoing to the device is limited, and the devices are incapable of storing enoughenergy to create a spark when disconnected.







Non-Incendive Equipment (NI) - Class I, Div 2

“Non-Incendive” equipment works on the same principle as Intrinsically Safe,that is by limiting the amount of energy going to and stored in a device. Thedifference is that Non-Incendive is only permitted for use in Division 2 areas,and as such has a reduced safety factor which allows more energy to the fielddevices (but still not enough to create a spark).







Purged and Pressurized – Class I, Div 1&2

Hermetically Sealed – Class I, Div 2

Combustible Gas Detection – Class I, Div 1&2

Oil Immersed – Class I, Div 1

Used more in electrical systems than instrumentation

The above techniques are more commonly used for electrical equipment thaninstrumentation.





Agenda – Day 1

Introduction to Foundation Fieldbus

History, Basics, Benefits

Fieldbus System Components

Power, Devices, Wiring

Key Fieldbus Concepts

Tags/Addresses, Blocks, DDs

R00#1 Segment Design and Specifications

Fieldbus and Yokogawa Centum CS3000

Hardware, Software, HMI example




Agenda – Day 2

Yokogawa Plant Resource Manager (PRM)

Device configuration and troubleshooting

Foundation Fieldbus Commissioning

Segment and Loop Checks

Maintenance of Fieldbus Systems

Physical Layer diagnostics (inc. P+F modules)

Device troubleshooting

Adding/removing/replacing devices

Fieldbus device calibration




Introduction to Foundation Fieldbus

Image Source:http://www.fieldbus.org/index.php?option=com_content&task=view&id=45&Itemid=195




What is Foundation Fieldbus?

“Foundation Fieldbus is an open, nonproprietary

architecture that provides a communications protocol

for control and instrumentation systems in which

each device has its' own "intelligence" and

communicates via an all-digital, serial, two-way

communications system.”

More accurate(no 4-20mA)

More functionality

More vendors,interoperable

From equipment upto user interface

Definition fromhttp://www.fieldbus.org/index.php?option=com_content&task=view&id=23&Itemid=308




History of Foundation Fieldbus

Development of proprietary digital bus protocols during

the 1980s Formation of the Fieldbus Foundation in 1994 to

develop an industry standard

Focused on development of open and interoperable

standards with input from suppliers and users

Future development includes DD enhancements and

safety systems

1995FF Standardsfirst introduced

20081,000,000 devices12,000 systems

1998First registeredFF devices

2001FF HSElinking devices

2003First ChevronFF installations

2002First majorFF plant

Currently for use in process control systems only, not safety systems.

Shell Deer Park was the first major plant to use Foundation Fieldbus.

Foundation Fieldbus Standards:

ANSI/ISA 50.02 (USA)

IEC 61158 (World)

CENELEC EN 50170 (Europe)




The Fieldbus Foundation

Non-profit consortium formed by members of

various supplier and user organizations

Develops and administers the standards for

Foundation Fieldbus which are open and non-

proprietary

Provides reference material such as user guides

and engineering guides.

Useful website as a resource

for Fieldbus information

http://www.fieldbus.org/

Examples of Chevron participation:

•Deon Rae’s contribution to the Fieldbus Engineering Guideline and standarddevelopment

•Vincent Palughi’s participation in groups developing device coupler test andwiring standards




Industry Acceptance

Users:

Major oil & gas companies

Other industries – manufacturing, pharmaceutical

Over 12,000 systems and 1 million devices*

68% of projects are selecting FF

Examples of Chevron installations:

El Segundo blending & shipping, California

Al Jubail petrochemical plant, Saudi Arabia

SJVBU tank farm, California

TGPP and TL platforms, Angola offshore

(*) Data from ARC report

Examples of Chevron projects using FF:

•Takula Gas Processing Platform (TGPP) – Angola offshore

•Tombua Landana Production Platform (TL) – Angola offshore

•Cabinda Gas Plant (CGP) – Angola onshore

•Escravos Gas To Liquids plant (EGTL) – Nigeria onshore

•R00#1 SLC VGO unit – Salt Lake City, Utah

•R00#1 Pascagoula Crude 2 unit upgrade – Pascagoula, Mississippi

•R00#1 Burnaby – Burnaby, Canada




Suppliers – Control Systems & Field Devices

Suppliers – Power Supplies & Connecting

Equipment

Industry Acceptance

Emerson – includes Fisher, Rosemount, Micro Motion, etc.




Comparison with Analog Systems

Fieldbus uses a digital signal (1s and 0s) rather than

reading analog values (milliamps) Digital data provides an actual measurement value

(e.g. 80 psi) rather than an analog value that has to

be interpreted (e.g. 12 mA)

Digital signal

Actual waveform

Reading analog values requires correct setup of scaling at either end of thecontrol loop.





Fieldbus devices are also bus-powered (9-30 VDC)

Fieldbus uses a bus topology rather than requiring apair of wires to every device

Host

Marshalling

Host

Marshalling

Field Devices

Device Coupler

Field Devices

Bus-powered means that the device obtains power and communicates on thesame pair of wires (i.e. 2-wire device).

The above examples show field devices with Intrinsic Safety (IS) barriers –these may or may not be required depending on equipment location and thefacility’s choice of hazardous area protection.





Smarter field devices

Setup of inputs in the device (range, units, etc.)

Built-in device diagnostics (e.g. impulse line plugging)

Additional functionality (mathematical functions, PID)

H1

Image Source: Fieldbus 101 Presentation (Dale Perry, Emerson)




Comparison with HART

HART uses analog 4-20mA for process values and

superimposes a digital signal on top

Devices have some parameters built into them,

but not to the level and functionality of FF

Devices are polled by the controller (on demand)

rather than transmitting autonomously

Much slower data rate (FF is >25 times faster)

FF is not approved for safety systems, so HART is

generally used

Fieldbus for Safety Instrumented Systems (FF-SIS) is currently undergoingdevelopment and testing.




FF Topology

Host Interface

(DCS I/O card)

PowerConditioner

Surge Protector DeviceCoupler

Trunk Cable

Field Devices

Spur Cables

T

T = Terminator

T

Key components in an FF segment:

•Host interface (I/O card)

•Power Conditioner

•Device Coupler (Brick)

•Field Devices

•Terminators (one at each end)

•Trunk and Spur wiring

•Surge Protectors




FF Design Limits

Up to 32 devices per segment

Usually up to 12 devices connected

Also depends on power available

Up to 1900m (6200ft) total field wiring

Includes total of both trunk & spurs

Individual spurs up to 120m (390ft) long

Should be individual shielded twisted pair (STP)

Requires 9-32 VDC at field device

Consider voltage drop on long segments

The R00#1 segment design will be covered later.

Devices called “repeaters” can be used to extend the network length andincrease the number of devices. However the facility design is usually such thatrepeaters are not required, and they are generally not used in Chevroninstallations.




FF Protocol

Communications protocol includes:

Physical layer (H1)

31.25 kbit/s digital signal

9-32 VDC bus powered

Data link layer

Defines what the bits/bytes mean

Specifications for messages (packets)

User layer

Function blocks

Virtual Communication Relationships (VCRs)




FF Benefits

Digital protocol

No analog conversion, includes digital error correction,less susceptible to noise

Bi-directional communication between host & device

More data is available from the field device

PV status, health/diagnostics, extra PVs, asset mgmt.

More powerful field devices

Special function blocks, alarming, output scaling,

mathematical functions

More power at field devices enables additionalfunctionality (HART/analog were limited to <4mA)

Mathematical Functions – Integrator/totalizer, Signal Characterizer, Arithmetic




FF Benefits

Fully digital communications from the sensor to the

control system without D/A conversion

D/A conversion reduces accuracy and the electronics are more susceptible tocurrent drift over time than fully digital electronics. This is the main reason thatanalog and HART instrumentation require more frequent field calibration thanFF devices. For example, the EJX pressure transmitter guarantees error < 0.1%of URL for 10 years.

Image Source: http://www.yokogawa.com/fld/3D/EJX/p03.html




FF Benefits

Less field wiring/terminations and more physical layer

diagnostics available Faster field commissioning (no field/bench calibration,

configure multiple devices simultaneously)

Many projects are seeing a lower total lifecycle cost

Open standards

Devices tested and approved

Interoperability required

Lower total lifecycle cost is contributed to by saving in commissioning time andadditional info/diagnostics that can alert to device problems and avoiddowntime.

The Fieldbus Foundation check mark shown indicates that a device has passed

the Foundation’s testing




Fieldbus System Components

Image Source: Fieldbus Book – A Tutorial (Yokogawa Corporation)




FF Components – Host Interface Card

Yokogawa CS3000 DCS

ALF111 Card Redundant I/O cards

mounted in the Field

Control Station

Interface between the

control system and field

devices

4 segments per card

Special cable (AKB336)

between card and power

conditioner




FF Components – Power Conditioner

MTL-Relcom

F880 hub w/F801 modules

Special power hub for

Yokogawa connectors

8 segments per hub

Supplies power to field

devices (24 VDC)

Special power supplies

required for FF

Redundant power

conditioner modules

F809f Diagnostic module inthe center

Built-in terminator

Redundant modules are hot swappable

Dual 24 VDC feeds from bulk power supply

The F809f diagnostic module is actually a fieldbus device on the segment(either segment 1 or 8). It can also be connected to an external segment.




FF Components – Surge Protector

Pepperl+Fuchs

DB-LB w/ DP-LBF-1.34

Installed on all trunks in

the marshalling panel

Surge protection is required

on all pairs due to potential

voltage surge coupling from

the affected wire to any

adjacent wiring in the tray.

DB-LB base allows removal

of the protection module

without interruption of the

signal

Surge protection devices are also available that can be placed at the instrumentend (not part of the R00#1 spec)




FF Components – Div 2 Device Coupler

Moore Hawke

Trunksafe TG20W (12-spur) Connects trunk to field

spurs

Installed in field junction

box rated for Div 2

Built-in auto terminator

Short-circuit protection

Spurs are classified

Div 2 Non-Incendive

The bottom two connectors on the device coupler are for trunk connections only(only one is used). The others are for the spurs to devices and contain energylimiting circuitry. The device coupler must be connected in accordance with itscontrol drawing (TG200-FM)




FF Components – Div 1 Device Coupler

Turck

MBD49-T415/Ex (4-spur) Connects trunk to field

spurs

Complete with enclosure

rated for Div 2

Switchable terminator

Short-circuit protection

Spurs are classified

Div 1 Intrinsically Safe

Also known as a

“Multibarrier”

Switchable terminator enables a second multibarrier to be connected on thesegment. The terminator should only be switched on in the final multibarrier onthe segment so that there are exactly 2 terminators per segment (the other isin the power conditioner).

The bottom two connectors on the device coupler are for trunk connectionsonly. The others are for the spurs to devices and contain energy limitingcircuitry. The device coupler must be connected in accordance with its controldrawing (IS-2.502)




FF Components – Field Devices

Pressure: Yokogawa EJX

Temp: Yokogawa YTAValve: Fisher DVC6000f

Vortex: Yokogawa DY

Radar: Vegaflex 62

Look the same as 4-

20mA and HART devices

but NOT interchangeable

Contains special FF

microprocessor

FF tick of compliance

Can be polarity sensitive

All devices will have + and – terminals – some devices require correct polaritywhile some are able to operate correctly if the polarity is reversed. The bestsolution is to assume all devices are polarity sensitive and always connect thedevices according to the polarity indicated on the terminals. + to brown, - toblue.

Models used for R00#1 specified in:

YR-PAS-DSP-201 Instrumentation Design

YR-PAS-DSP-214 Yokogawa Instrumentation




FF Components – Wiring

Trunks: 16AWG (1.5mm2)

Spurs: 18AWG (1mm2)

Similar to analog

instrument wiring

Two pair with shield

Jacket : orange

Positive : brown

Negative : blue

Turck Minifast

connectors are used

for field devices(hand tighten only!)

16AWG trunk wire was selected to eliminate the need for volt drop calculations.Trunk wire is generally run in multipair (8 pair) cables.

For the Turck Minifast connectors, ensure you hand tighten only, don’t use awrench!

Field wiring has a drain wire which is used to connect the shield to instrument

ground at the control room end.




FF Components – Terminators

Resistor and capacitor in

series. Two required on a

segment, one at each

end of the trunk

Power Conditioner

Device Coupler

Stops reflections of the

digital signal at each end

Any number of

terminators other than 2

causes signal problems

< 2 terminators results in signal reflections

> 2 terminators attenuates the fieldbus signal




FF System Grounding

Similar to analog instrument grounding:

Connect the shield to instrument ground at one point only(where the trunk cable enters the marshalling cabinet)

Ensure that only the signal wires (+ and -) are connected tothe field device

Signal wires should NEVER be grounded or allowed to comeinto contact with the shield.

More than one ground point on a segment creates ground loops which canintroduce noise onto the network.




FF Hazardous Areas

The R00#1 project requires the ability to connect

and disconnect Fieldbus devices in hazardouslocations under power

This requires Fieldbus spurs to be classified either:

Class I Division 2 Non-Incendive

Class I Division 1 Intrinsically Safe

IMPORTANT

Fieldbus trunk cables are NOT rated

for live connection/disconnection andmust be de-engergized first

The guiding industry standards for hazardous areas are:

Divisions (Non-Incendive): NEC Article 500, API RP 500, ANSI/ISA-12.12.01 /FM 3611

Zones (Energy Limited): NEC Article 505, API RP 505, IEC 60079-15




FF Hazardous Areas: Division 2

Equipment rating requirements (FM/IEC)

Field devices

Non-Incendive (NI)

Device couplers (associated apparatus)

Non-Incendive (NI) and

Non-Incendive Associated Apparatus (ANI)

Length of spur cable ≤ 120 meters (393 ft)

This does NOT meet the requirements for Division

1 areas (which requires the device coupler contain

an approved Intrinsically Safe barrier)

Generally most equipment will have equivalent ratings for both NEC and IECstandards. Always view the actual approval certificate/drawing, since somemanufacturers may say the approval is “in progress” which can take a while.





Surge Protector

Field Devices(NI)

Spur Cables

T

Device Coupler(NI & ANI)

Div 2

PowerConditioner

T

Junction Box

NotRated

Remember, only the spurs can be disconnected under power. Fieldbus trunkcables are NOT rated for live connection/disconnection and must be de-engergized first.

Refer to the FF Hazardous Area Verification Drawings document for furtherinformation

Higher rated equipment (e.g. intrinsically safe devices) can be used in thisconfiguration, but will still only be allowed for used in Division 2 areas.





Equipment rating requirements (FM/IEC)

Field devices

Intrinsically Safe (IS)

Device couplers (associated apparatus)

Non-Incendive (NI) and

Intrinsically Safe Associated Apparatus (AIS)

Length of spur cable ≤ 120 meters (393 ft)

Device couplers can NOT be placed in Division 1

areas

Generally most equipment will have equivalent ratings for both NEC and IECstandards. Always view the actual approval certificate/drawing, since somemanufacturers may say the approval is “in progress” which can take a while.





SurgeProtector

Field Devices(IS)

Spur Cables

T

Device Coupler(NI & AIS)

PowerConditioner

T

Div 1Div 2Not Rated

Remember, only the spurs can be disconnected under power. Fieldbus trunkcables are NOT rated for live connection/disconnection and must be de-engergized first.

Refer to the FF Hazardous Area Verification Drawings document for furtherinformation




Key Fieldbus Concepts




FF Concepts – Tags & Addresses

Each device on the segment (host cards,

instruments, valves, handheld communicators) has atag, address and Device ID.

Tags for identification of an instrument by the DCS

PT101 – pressure transmitter

CV101 – control valve

Addresses for managing segment communications

Between 10 and 255

Device IDs are unique serial numbers, e.g. 5945430005S0010968

Tags and addresses can be assigned by engineering software and fieldcommunicators.

Device IDs are fixed and cannot be changed. Needs to be updated if devices arereplaced




FF Concepts – Address Range

0-15 Reserved Addresses (do not use)

16-247 Permanent Addresses

Host system card and permanent field devices

248-251 Default Addresses

Used by system and assigned to unconfigured field

devices

252-255 Temporary Addresses

Used by tools such as handheld configurators and

diagnostics tools

See: FF address range.xls

Similar to IP addresses on computers

Refer to FF address range spreadsheet for decimal to hexadecimal conversion




FF Concepts – LAS

Link Active Scheduler (LAS) – the device on the

segment that controls communications

Without a LAS there is no segment communication

The LAS is the host interface card (ALF111)

Redundant ALF111 card is the backup LAS

Two “device types”

Basic Device (does not have LAS capability)

Link Master (can become LAS)

Link Master capable devices can also become the LAS, but the R00#1 fieldbusdesign specification dictates that the LAS shall be the primary ALF111 card andthe backup LAS shall be the redundant ALF111 card.




FF Concepts – Blocks

There are three types of blocks in a FF field device –

Resource, Transducer and Function.

Resource Block (RB)

Device Name

DD Information

Manufacturer

Serial Number

Only one per device

The user application layer is based on blocks which perform different applicationfunctions





Transducer Block (TB)

Transmitter range

Measurement setup

Calibration data

Sensor type

Can be more than one per device (e.g. one for

sensor measurement and one for an LCD display)

Unique for each device (specified by the

manufacturer)





Function Blocks

Provide input, output and control functions

Can communicate to the control system and

between each other

Executed every scan period

Many different types (input, output, PID,

mathematical function)

Multiple function blocks in a device

Function blocks are always identical (standardized

by the Fieldbus Foundation)

Common types of function blocks and their abbreviations:

Analog Input (AI)

Analog Output (AO)

Discrete Input (DI)

Discrete Output (DO)

PID Control Block (PID)

Signal Characterizer (SC)

Integrator/Totalizer (IT)

Input Selector (IS)

Multiple Analog Input (MAI)

Multiple Analog Output (MAO)




FF Concepts – Block Modes

Each block has a mode (MODE_BLK) that determines

its response to inputs or user action.

AUTO (Automatic) – Normal operation

MAN (Manual) – Manual operation

CAS (Cascade) – Set by another function block

O/S (Out of Service) - When downloading or

configuring blocks they may be temporarily

unavailable.

Remember the difference between “Target” and“Actual” block modes.

Each block has three categories:

•Actual – mode that the block is currently in (if not equal to target, then thereis a problem in the device)

•Target – desired mode as set by the user

•Allowed – modes that the block is permitted to be in

If you set the “target” mode and the “actual” does not change to match, thenthere may be a problem in the device preventing it from moving to the “target” mode.




FF Concepts - Parameters

The data inside each

block is organized intoparameters.

Each parameter has a

name, format and value.

Allowable formats with

examples

String: “PT101”

Bit: “1” or “0”

Integer: “243”

Floating: “25.6234”

Similar to the way HART uses parameters inside the field device to storeinformation.

Each Parameter can have several Elements, which are individual pieces of datathat make up a parameters (e.g. range, units, decimal point)

The allowable format will depend on what the parameter is used for. Examples

of different types of parameters:•String: TAG_NAME

•Bit: CHANNEL

•Integer: ADDRESS

•Floating: AI1_OUT




FF Concepts – Resource Block

1Revision number of DD fileDD_REV

2Revision number of the deviceDEV_REV

0X000CModel number of the deviceDEV_TYPE

0x00594543ID number of the device manufacturerMANUFAC_ID

15 (O/S)Error code associated with the blockBLOCK_ERR

AUTOActual/Target/Permitted block modesMODE_BLK

ExampleExplanationParameter

The above example shows the Resource Block

parameters in a Yokogawa EJX pressure transmitter,

device revision 2 and DD revision 1.

Anytime that “0x” is seen in front of a number, it means that it is inhexadecimal format.




FF Concepts – Transducer Block

22 (I/O failure)Error code in the transducerXD_ERROR

Pt100Type of RTD or thermocouple connected

(for temp. transmitters)

SENSOR_CONNEC

TION

1000Highest calibrated valueCAL_POINT_HI

-328 to 2192

deg F

High and Low range limit values and

engineering units of the sensor (e.g.

thermocouple or RTD)

SENSOR_RANGE

2Damping time constant for the primary

value (in seconds)

PRIMARY_VALUE_F

TIME

-100 to 100 kPaHigh and Low range limit values and

engineering units of primary value

(generally set at factory)

PRIMARY_VALUE_

RANGE

107 (DP)Type of measurement represented by theprimary value (recommended to keep as

default)

PRIMARY_VALUE_TYPE


Examples of important parameters in a sensor transducer block. Theparameters will vary considerably depending on the type of device (e.g.pressure transmitter, temperature transmitter).

Valve positioners have a different set of parameters – it is generallyrecommended to use the Setup Wizard in ValveLink to set these up.




FF Concepts – Analog Input Block

DirectSelects if value from the transducer is

output as is (direct), with scaling (indirect)

or with square root function (indirect sqrt)

L_TYPE

1 (Primary

Value)

Logical hardware channel that is connected

to this I/O block

CHANNEL

0-100 %High/Low scale values and engineering

units for output (used for indirect output,

e.g. level or flow)

OUT_SCALE

0-100 kPaHigh/Low scale values and engineering

units from transducer

XD_SCALE

72.34 kPaOutput from the AI blockOUT


Important parameters – remember that the AI block is the same for everyfieldbus device, regardless of instrument type or manufacturer.




FF Concepts – Analog Output Block

42 %Back calculation provided to BKCAL_IN of

the controller (PID). This provides

bumpless transfer on mode changes and

windup protection in the upstream block.

BKCAL_OUT

50 %Setpoint of the AO block (Equals CAS_IN in

cascade and tracks valve position in

manual)

SP

46 %The AO block output and status – limited by

allowed rate of change

OUT

0-100 %High/Low scale values and engineering

units from transducer

XD_SCALE

42 %Actual valve positionREADBACK

50 %Remote setpoint value from the controllerblock (PID)

CAS_IN


Important parameters – remember that the AO block is the same for everyfieldbus device, regardless of instrument type or manufacturer.




FF Concepts – VCRs

Virtual Communication

Relationships (VCRs) arethe links between function

blocks which enable data to

be exchanged.

The type of communication

is known as

“Publisher/Subscriber”.

Devices always transmit

information rather than only

doing so when polled.

Difference between publisher/subscriber and master/slave.

Can be one-to-many communications if PVs are required by more than onedevice.




FF Concepts - Macrocycle

Cycle of communications between devices

Executed once per scan period (e.g. 1 second)

Controlled by the LAS

Two types of communications

Scheduled – communication between function

blocks that occur at the same time every cycle

(each FB has an execution time)

Unscheduled – asynchronous communication (e.g.

configuration, downloads) that are executed afterthe scheduled communications.

Scheduled communications are for control data – occur at the same time everymacrocycle (deterministic).

Unscheduled communications are non-critical and will occur when spare time isavailable (like ethernet).




FF Concepts - Macrocycle

It is required that the macrocycle contains at least 30%

unscheduled time (i.e. the cycle time for schedule

communications should not exceed 700 msec)




FF Concepts - DDs

Device Descriptors (DDs) are files that describe the

functionality of a device so that other devices andcontrol systems can interface with it correctly.

The revision of the DD file on the host computer

must match the DD revision in the device.

Updated DD files are available from the Fieldbus

Foundation or vendor’s websites:

http://www.fieldbus.org/index.php?option=com_mtree&Itemid=324

http://www.yokogawa.com/fbs/fbs-download2-en.htm

Similar to the way that a computer uses drivers so it knows how to interfacewith hardware such as printers.

Recommend getting updated DD files from the host’s website (Yokogawa)because they have undergone the HIST (Host Interoperability Systems Test)

Copies of DD files are stored in the following locations:•CS3000 project database on the engineering workstation

•PRM Server

•PRM Field Communication Server (if on a different machine)




FF Concepts - CFFs

Capabilities files (CFF - Common File Format) describe the

functionality of the devices to enable engineering and

configuration of the devices.

DD = Device revision number

RR = DD revision number

FF = Capabilities file revision number

Device Descriptor (DD)

DDRR.ffo / DDRR.sym

Capabilities File (CFF)

DDRRFF.cff

DDs and CFFs will be located under a directory for the supplier and then devicetype.

•Yokogawa = 594543

•Fisher = 005100

•Rosemount = 001151




FF Concepts - Interoperability

All devices must be tested to get approval from

the Fieldbus Foundation (check mark)

Control systems perform the Host Interoperability

Systems Test (HIST) based on the Foundation’s

guidelines. Lists of devices that have undergone

the HIST are available on the vendor’s website

http://www.yokogawa.com/fbs/Interoperability/fbs-hist-en.htm




R00#1 FF Segment Design

The defining document for R00#1 is the FOUNDATION Fieldbus Segment

Design (YR-PAS-DSP-203) which is an addendum to the CVX standard

ICM-DU-5161

Key requirements:

Redundant ALF111 modules (which is also the backup LAS)

16AWG (1.5 mm2) segment trunk wiring with orange jacket

Maximum of 12 devices for Div 2 segments

Last 2 spurs reserved for owner use (spare)

Maximum of 10 devices connected during system design

Maximum of 8 devices for Div 1 segments

Last 2 spurs reserved for owner use (spare)

Maximum of 6 devices connected during system design

A maximum of three control valves are permitted on a segment

during system design (On-Off actuated valves are not considered

control valves)

This presents a summary of the key requirements in the R00#1 projectsegment design.

Devices should NOT be daisy-chained, but this introduces more connectionsonto the trunk and hence additional points of failure.




R00#1 FF Segment Design

Only one device shall be connected to a device coupler spur

Device spur wiring shall not exceed 120 meters (393 ft)

Segment trunk wiring plus all device spurs shall not exceed a

cumulative length of 1660 meters (5446 ft)

Control segments shall have a 1 second macrocycle with a

minimum of 30% spare (unscheduled) time

All control functions shall reside within the Process Control

System (PCS) and not in the field device

Multi-variable transmitters (i.e., compensated flow

transmitter) may use only one variable for control

The aim is to build in reliability, expandability and make it easierto perform maintenance.

For segment wiring length limit of 1660 meters:

a. 1900 meters is the maximum length for a FF segment per FF Guidelines AG-181.

b. The two owner reserved spurs may be up to 120 meters each for a reservedlength of 240 meters




R00#1 Segment Topology

Devices

Multipair JB

Device CouplerJunction Box

PowerConditioner

MarshallingPanel

Figure 8 from ICM-DU-5161 Foundation Fieldbus Segment Design




R00#1 Device Coupler Junction Boxes

One Device Coupler

Four Device Couplers

Device Coupler

Wiring Diagram

YR-PAS-DWG-203 (One Brick JB Schematic)

YR-PAS-DWG-204 (Four Brick JB Schematic)




Fieldbus and Yokogawa Centum CS3000




FF and Yokogawa Centum CS3000

System Hardware:

Field Control Station (FCS)

Fieldbus I/O Card (ALF-111)

Special cables to FF Power Conditioner (AKB336)





System Software – System View

Main system “explorer”

Used for overall project configuration

Add ALF111 I/O cards to controllers

Launches other builders:

Fieldbus Builder

Control Drawing Builder

Generally used by control system engineers. For further learning, recommendthe Yokogawa-run CS3000 engineering course.




System View - Screenshot

FCS0101 > Node 1 > Slot 1 > Segment 1





System Software – Fieldbus Builder

Interface for fieldbus data in the project database

Add/remove and configure devices

Set up device tags and addresses

Download parameters and control logic to the

field devices

Field DeviceProject Database

Upload

Download

Generally used by control system engineers. For further learning, recommendthe Yokogawa-run CS3000 fieldbus course.




Fieldbus Builder - Screenshot

DeviceBlocks

Linked blocks (i.e. those that are in the control drawing builder and used forprocess control) are indicated with a star (*)




Fieldbus Builder – Parameter Edit





System Software – Device Panel

Interface for fieldbus data in the field devices

View live devices connected to segment

Change tag, address and other parameters in

connected field devices

Equalize parameters between the project

database and the field device




Device Panel - Screenshot

Devices inengineeringdatabase

“Live List” Devices currently

attached to segment

TagAddress





Faceplate for the device

(e.g. TL-TIT-7935B) Viewing block mode

Viewing error status (e.g.

IOP, OOP, CNF)

Faceplate for the indicator or

PID (e.g. TL-TI-7935B)

Setting alarm ranges

Setting calibration mode

AI PVI AO

feedback

output

from PID





Alarms occur on the banner and alarm screen in a similar

way to analog devices Process alarms (e.g. low, high) will occur with the

indicator or PID tag

Device errors (e.g. IOP, OOP, CNF) will occur with the

device tag

Live demonstration if possible




Yokogawa Plant Resource Manager




Plant Resource Manager (PRM)

PRM is Yokogawa’s plant asset management

application. It can be used for:

Setting up and modifying field devices

Management of field device configuration

Diagnostic alarms and troubleshooting

Launching specialized plug-in applications

Instrument calibration and recording

It is used for both Fieldbus and HART devices.




PRM – Network View

Segment

Device StatusGreen = Device Ok

Red = Device ErrorYellow ! = Unacknowledged Alarm

Network view displays all the fieldbus devices and which segment they areconnected to.

Plant view can be configured to group the devices based on geographic area,unit number, equipment number.




Plant Resource Manager (PRM)

Key functions used in PRM:

Device Status – indicates if a device is OK

Device Viewer – more detail on errors

Maintenance History – alarm/event history

DD Menu (Methods) – use to perform tasks such

as device setup and calibration

Parameter Manager – save/restore parameters

Plug-Ins – launches specialized applications

Explained in more detail in the ‘Maintenance’ section

The DD menu (methods) is similar to the device menus on a Rosemount275/375 communicator.




PRM – Device Viewer

Alarm Code

CurrentParameters

Cause of Alarm

Red = Alarm

Yellow = Warning

Green = Ok

Mandatory – alarms which must be fixed to return the device to normal

operation (device status will be red until fixed)

Optional – alarms which may not affect the operation of a device (doesn’t affectdevice status)

The trend tab allows you to trend the values in the parameter list.




PRM – Maintenance Alarm

•Problem•Cause•Action




PRM – DD Menu

e.g. Configuring

temperature sensor type

DD menu maps are normally available in the device’s user manual.

The problem with using PRM for configuration is that these changes are notreflected in the engineering database (Fieldbus Builder).




PRM – Parameter Manager

Current Saved

Saving device parameters in PRM:

Select the desired device on the left and click on the “Parameter” tab

Select the desired block tag (resource, transducer or function blocks)

The column on the left displays the current parameters in the device – click “Update” to refresh

The column on the right displays historical parameters – right-click and select “Save All Parameters”

The arrow in the middle is used to change a device’s parameters back to asaved configuration – click “Set” to execute




Yokogawa Fieldmate

Can be used for:

Segment LAS

Device Viewer

DD Menu

Parameter save

HART (with modem)

Can’t be used for:

Plug-ins (e.g. ValveLink)

Fieldmate is a device configuration tool that connects

to a live segment and has many of the functions ofPRM in a portable format.

Fieldmate can be installed in a Panasonic Toughbook that is rated for Class 1,Div 2 hazardous areas (e.g. TB-19 or TB-30). However these are only rated foruse in hazardous areas when it is inside the supplied leather case and all portflaps are closed. The only way to make a connection to a device in a hazardousarea is to use a bluetooth HART modem (no such bluetooth or wireless deviceexists for fieldbus). If you need to connect locally to a fieldbus device, then the

375 field communicator can be used as it is Class 1, Div 1 rated.




Yokogawa Fieldmate

Device Status

Green = Device OkYellow = Error (optional)Red = Error (mandatory)

DCS ALF111 card(s) areat the top of the list

Right-click on a device top open the various tools:

•Tag/Address assignment

•Device Viewer

•DD Menu

•Parameter Manager

•DTM




FDT/DTM Technology

FDT = Field Device Tool

(the program that runs DTMs)

DTM = Device Type Manager

(the file for each type of device)

Standardizes the interface between control system

and the field device.

Makes it easier to view the device parameters and

perform maintenance and configuration functions.

DTMs exist for both Foundation Fieldbus and HART

devices.

Chevron is a participating member of the FDT group.




FDT/DTM Technology

Parameter Manager

Text Based DD language

Harder to navigate

DTM

More visual Intuitive naming

Easier functions

Example of the difference between looking at a device through DD parameterview, and through a device’s DTM.

DDs use more complicated parameter names, DTMs have a better description ofwhat they are.

DTMs use graphics and alarm colors to better convey the device’s status to the

user.Commonly used functions (e.g. changing a block mode) are easily accessiblefrom the first screen in a DTM.

DTMs are supported in PRM v3.02 and Fieldmate v1.03




Fisher ValveLink

ValveLink software is a tool for Fisher valve

positioners (e.g. DVC6000)

Launched from the “Plug-In” menu in PRM

Valve and positioner configuration management

Displays current status and troubleshooting info.

Setup wizard and travel calibration

Valve partial stroke testing

Step response and valve signature analysis

Used for both Fieldbus and HART devices




Fisher ValveLink

Select the device in PRM and click on the “Plug-In” tab. Double click on “FisherValveLink” to launch the application.




Fisher ValveLink - Status

Red tabsindicate errors

Live datafrom device

Click “Start Monitoring” to obtain valve information, then end and “SaveDataset” to record the values.




Fisher ValveLink – Total Scan

Example of a Valve Signature obtained through the ValveLink “Total Scan” function which can be used to identify and diagnose valve problems. ValveLinkcan also run a step response as a performance test for the valve.




Foundation Fieldbus Commissioning




FF Commissioning

Commissioning Foundation Fieldbus devices typically

consists of three main steps:

Physical Inspection – check of field device

installation, instrument air lines, etc.

Segment Check (unique to fieldbus) – checks the

physical layer components and performs initial

segment configuration.

Loop Check - checking of control loops in a similar

way to analog instrumentation.




FF Segment Check

Segment Check

Tag/Address Assignment

(Device Panel)

Segment Config./

Download(inc. PRM save)

Cable/NetworkTest

(F809f module)

Sign-off SegmentCheck Sheet

Segment Check (unique to fieldbus) – checks the physical layer componentsand performs initial segment configuration.




FF Loop Check

Loop Check

Check Inputs(AI/DI blocks)

Sign-off LoopCheck Sheet

Check Outputs(AO/DO blocks)

Check PID Blocks

Loop Check - checking of control loops in a similar way to analoginstrumentation (check instruments read correct values and final controlelement action is correct)




Maintenance of Fieldbus Systems




Maintenance of FF Systems

Typical maintenance tasks in a Fieldbus system:

Fieldbus Physical layer troubleshooting

Fieldbus device troubleshooting

Replacing fieldbus devices

Adding/removing fieldbus devices

Calibrating fieldbus devices

Other potential problems




Physical Layer Maintenance

Examples of physical layer problems that can occur:

Damage of field wiring or devices (mechanical damage,water damage)

Accidental shorts or grounding

Faulty components

Improper termination of segments

Noise from Electromagnetic Interference (EMI)

Degradation of device electronics over time

Use physical layer diagnostic devices for troubleshooting

These should generally not be a problem if proper installation and maintenanceprocedures are followed.





Expected segment measurements:

< 300 nF> 20 MΩShield to Ground

< 300 nF> 20 MΩNegative to Ground

< 300 nF> 20 MΩPositive to Ground

< 300 nF> 20 MΩNegative to Shield

< 300 nF> 20 MΩPositive to Shield

0.8 to 1.2 μF*> 50 kΩPositive to Negative

CapacitanceResistanceMeasurement

These values come from the Fieldbus Foundation System EngineeringGuidelines.

(*) Note that these measurements are taken from the control system end withthe trunk cable disconnected from the power conditioner (so that there is only

one terminator present on the segment). The capacitance between positive andnegative signal wires may be less that stated if active terminators are used inthe device coupler.





Tools for physical layer

troubleshooting: F809f diagnostic

modules on power

conditioners (fixed)

FBT-6 handheld

diagnostic tool (portable)

Multimeter for

measuring resistance

and capacitance




Physical Layer Maintenance: FBT-6

Portable diagnostics unit:

• Connect FBT-6 at devicecoupler or device

• Should read “ALL

MEASUREMENTS OK”

• If not, errors will be

displayed

• Press “FUNC” to view

other segment

diagnostics

• Scroll to save menu and

hold “SEL” to save

The FBT-6 comes with a USB cable and software for exporting measured data toa PC as an excel .csv file.




Physical Layer Maintenance: FBT-6

Connect the FBT-6 to a laptop and launch the FBT-6

Assistant software. Click “Transfer Reports from FBT-6” to transfer the

reports to the laptop.

By default they will be saved with the report slot

number - rename the files with the segment number

for easy identification.

Need to remember which slot the measurements were saved into




Physical Layer Maintenance: F809f

Fixed on the power hub,

continuously monitors all

8 segments

Communicates through

the fieldbus segment

(selectable on module)

The F809f is actually a

fieldbus device on the

segment (with a tag and

an address)

Diagnostic

measurements are madeavailable as parameters

in transducer blocks

F809F

The F809f can be configured to communicate on segment 1 or 8 of the powerhub by the “comb” on the corner of the module (flip it over to change betweensegments). The “comb” can also be removed so that the F809f can beconnected to an external segment.

Image Source: MTL - F809F Integration for Yokogawa (MTL)




Physical Layer Maintenance: F809f

The F809f modules have a number of features to

assist with maintenance activities:

Segment measurement

Diagnostics and alarm logging

Historical data viewing and export

Oscilloscope for viewing waveforms

Automated commissioning function

See: MTL - F809F User Manual.pdf




F809f: Fieldbus Block Structure

F809f onFieldbus seg.

Resource Block

System Transducer Block

SegmentTransducer Blocks

Segment AlarmDI Blocks

Alarm DI BlockSystem Alarm DI Block

RESRC: Resource block, defines the physical resources of the device includingtype of measurement, memory, etc.

DITB_S: System transducer block (SysTB), allows the user to view system andself-test alarms together with the system power feed voltages and temperature.

DITB_1 – DITB_8: Segment transducer blocks (SegTB), provide all the

measured parameters and associated alarms for each fieldbus segment and itsdevices.

DIFB_1: Alarm DI block, set to 1 if any of the System Alarm, Segment / DeviceAlarm or Self Test Fault Alarm bits is set.

DIFB_2: System alarm DI block, set to 1 if any System Alarm and Self TestFault Alarm bits are set.

DIFB_3 – DIFB_10: Segment alarm DI blocks, set to 1 if any of the Segment / Device Alarm bits is set for the respective segment.




F809f: Device Alarm

•Problem•Cause•Action

Maintenance alarms for the diagnostics module are logged the same way asfield devices. Note that in general, the recommended actions are notparticularly useful, so it is recommended to look at the segment transducerblock parameters to determine the cause of the alarm.




F809f: System Transducer Block

Current Saved

The above example shows the system transducer block parameters when thesecondary power feed to the power hub is disconnected. Note theSYSTEM_ALARMS parameter shows the description “Power feed B voltage lowalert” – use this parameter to determine the cause of the alarm. Looking at theparameters that have changed since last save (highlighted in yellow) we cansee that the secondary power feed voltage decreased from 27.8V to 0.1V,

indicating it has either been disconnected or the bulk power supply is faulty.




F809f: Segment Transducer Block

Current Saved

The screenshot above shows typical segment parameters viewed in thesegment transducer block, including:

•Segment Voltage

•Average and Peak Noise (The peak is recorded over the previous hour, andmay be caused by connecting/disconnecting devices. In general, average noise

is a more useful measurement and is the one specified in the FieldbusFoundation System Engineering Guidelines)

•Lowest device signal level

•Retransmissions




F809f: Segment Transducer Block

Current Saved

The screenshot above shows typical device parameters viewed in the segmenttransducer block, including:

•Device address

•Device tag (This has to be entered manually and is stored in volatile memory,so it will be lost if power fails. It is recommended to save all parameters to the

PRM database so the tags can be reloaded into the module in the event of apower failure.)

•Device signal level

•Device retransmissions

•Device jitter




F809f: Know Issues

The hardwired contact on the power hub is the only indicator

of primary or secondary power module failure (contacts are

closed when normal, and open when there is a fault). This

contact should be wired to a DI card in the DCS to provide an

alarm if there is a problem.

The Alarm DI Block should be configured in a DCS control

drawing to provide a path for the F809F diagnostic module

system alarm on an operator station. This will change to 1 on

all F809f diagnostic alarms.

For segments containing F809f modules, a manual change

had to be made to the NM folder in the common section of

Fieldbus Builder. The maximum response delay setting should

be changed from 4 to 5 in the NM folder.

For detailed instructions on how to make the change of maximum responsedelay setting, see SLR VGO SYSTEMS INTEGRATION FAT.doc in the suppliedflash drive.




F809f: Forthcoming DTM Interface

This screenshot is from a prototype DTM (Device Type Manager) which willmake it easier to view the diagnostic measurements and performtroubleshooting. It will also have the ability to generate a commissioning report




Device Troubleshooting

Examples of device problems that can occur:

Incorrect setup of a device

Block left out of service

Alarms requesting maintenance

Out of range alarm

Problems with temperature sensor connection

Problems with instrument air supply

Advanced diagnostics (e.g. impulse line plugging)

Use PRM Device Viewer or DTM for troubleshooting




Device Troubleshooting

Example of a “Device Status” screen on a DTM for the YTA temperaturetransmitter. The alarm indicates that there is a problem with Sensor 1 (eitherfaulty or not connected).




375 Field Communicator

The 375 is a field

communicator for both FFand HART devices

Change tags & addresses

View & write parameters

Link Master capability

View device alarms

Basic physical layer

diagnostics (voltage,

signal level)

Intrinsically Safe for use

in hazardous areas




Replacing Fieldbus Devices

1.Decommission device to be replaced (Device Panel)

2.Install and connect new device

3.Assign correct tag & address (Device Panel)

4.Download configuration (Fieldbus Builder)

5.Check for correct operation (call up faceplate)

6.Commission for use

It is important to check that all the blocks go to

normal operating mode (typically AUTO) and

communications are re-established.

Remember that Foundation Fieldbus devices are INTEROPERABLE (differentdevices work together) but not INTERCHANGEABLE (cannot replace a devicewith one of a different type). You need to use the exact same manufacturer,model and DD revision when replacing devices. If a different device is requiredto be used, then some minor re-engineering is required in Fieldbus Builder.




Adding Fieldbus Devices

1. Add new device into engineering database

(Fieldbus Builder)

2. Configure control drawing and device parameters

(Control Drawing Builder)

3. Install and connect new device

4. Assign correct tag & address (Device Panel)

5. Download configuration (Fieldbus Builder)

6. Loop check for correct operation

7. Commission for use

8. Device plug & play in PRM

Suggest following steps of the project’s fieldbus commissioning procedure




Removing Fieldbus Devices

1.Decommission device to be removed

2.Disconnect and remove device

3.Remove device tag from engineering database and

control drawings

Decommissioning the device in Device Panel will

remove it’s tag and address so it is ready to be

installed in a different location.




Fieldbus Device Calibration

With analog devices, calibration compensates for

inaccuracies in two parts of the device:

Sensor or actuator

Digital/Analog conversion

Fieldbus devices have no analog communications

signal, eliminating that source of error.

The sensor or actuator can still develop an error over

time (although this is very low in modern devices) so

calibration may still be required.

With an analog device, such as a transmitter, the output is scaled so that theexpected operating range uses the entire 16 mA of a 4-20 mA signal. Thisminimizes the effect of error in both the transmitter analog output and the hostanalog input. However, it's common to see errors resulting from a mismatchbetween the scaling of the field device and the host.

With digital fieldbus devices, output scaling isn't required — so there's no suchmismatch. Fieldbus does require that the unit of measure be the same in boththe device transducer block and the function blocks.

http://www.yokogawa.com/fld/3D/EJX/p03.html




Fieldbus Device Calibration

1. Add calibration record in PRM and enter settings

2. Open up Calibration method in DD Menu or DTM(PRM/Fieldmate)

3. Record the “As Found” results on calibration record

4. Follow instructions from the manual or calibration

wizard to calibrate the transmitter using a suitable

reference source (it will first ask you to set the

transducer block to O/S mode)

5. Record the “As Left” results on the calibration record

6. Return block mode to normal operation (AUTO)

7. Check device status returns to good and the PV reads

correctly

Calibration of a fieldbus device is similar to that of a smart (HART) transmitter.A number of tools can perform this function:

•Yokogawa PRM

•Yokogawa Fieldmate

•375 Communicator




Calibration Data in PRM

Add new calibration record





Set up calibration

The input/output values are set based on the individual device’s range settings.




Calibration with DD Menu - YTA

Start by setting CAL_STATEto “Calibration Exec”

O/S

Follow the steps in the Yokogawa YTA manual to calibrate the transmitter –start by setting CAL_STATE to “Calibration Exec”.




Calibration with DD Menu - EJX

Click on “PressureCalibration” and follow the

steps to calibrateO/S

The Yokogawa EJX has a “Calibration Wizard” that helps automate thecalibration steps.




Calibration with DTM - EJX

Use the “Sensor Calibration

Wizard” and follow steps

The Yokogawa EJX has a “Calibration Wizard” that helps automate thecalibration steps.





Record calibration results

“Input” is the simulated value from the reference source (such as a pressurepump, temperature element simulator or Fluke 744 calibrator).

“Output” is the value measured by the transmitter – suggest using DeviceViewer to read the current value.

Remember, a calibration is only as accurate as the reference source! Use a highaccuracy calibrator or send the device out to be factory/bench calibrated.




Calibration Data in PRM – Fluke 744

The Fluke 744 is capable of HART communication only. The only calibratorcurrently available that supports Fieldbus is the Beamex MC5 (a plug-in for theMC5 does not exist yet, but is under consideration/development)

Create a new entry in the “Calibration Data” tab and select “Fluke 74X” as the

Calibrator. Add details as appropriate into the Fluke 74X tab at the bottom ofthe screen.




Calibration Data in PRM – Fluke 744

First click “AddGroup” to add

the instrumenttags to becalibrated.

Then click “Detect” and “Download” to load

calibration data to theFluke 744. Performcalibration and thenUpload the results

Go to the PRM menu: Option > Cal. Data > Download




Troubleshooting DD/CFF files

These files need to be in the following locations:

On the engineering station in:

C:\CS3000\eng\BKProject\TOMBUA\Fieldbus\CFDDFILE\ In the PRM server and Field Communication Server in:

C:\PRM\DD

DD/CFF problems – occasionally a new type of device might not work orbehave unexpectedly.

Check device has FF tick and passed the Host Interoperability System Test

Contact the manufacturer for any known issues

Try connecting the device on a segment of it’s own

Try using a previous revision of the DD files

Sometimes capabilities files (CFF) have several options for the samedevice – e.g. linkmaster capability, PID blocks, advanced diagnostics.

Check that you have selected the right option for a particular device.




Calibrating devices

Troubleshooting devices

Troubleshooting physical layer

Downloading to devices

Changing tags & addresses

FF Tools Summary

Device Panel

Fieldbus Builder

375

744

FBT-6

375

Note that for calibrating devices, the Fluke 744 is required as a referencesource (for temperature and pressure) while PRM to write calibration data to thedevice and record the results.




Key Resources

Check out the “References” folder on your flash drive:

FF Web Links

Fieldbus Foundation - System Engineering Guidelines

Fieldbus Foundation - Wiring and Installation Guide

Yokogawa - Fieldbus Book

Yokogawa - Fieldbus Technical Information

Relcom - Fieldbus Wiring Guide

MTL - Fieldbus Physical Layer Troubleshooting Guide

Pepperl+Fuchs - FF Troubleshooting Manual




The end of the theory…

… now for the practice



136

R00#1 Foundation Fieldbus Training Exercises

Exercise 1 – Using Device Panel & Fieldbus Builder

Part 1 – Assigning Tags & Addresses (Device Panel)

Part 2 – Downloading To Devices (Fieldbus Builder)

Exercise 2 – Using Fieldmate

Exercise 3 – Using Plant Resource Manager (PRM)

Exercise 4 – Physical Layer Diagnostics

Part 1 – Using the Relcom FBT-6 handheld tool

Part 2 – Using the MTL F809f diagnostics module



137

Exercise 1 – Using Device Panel & Fieldbus Builder

Part 1 – Assigning Tags & Addresses (Device Panel)

This step provides an introduction to Device Panel, a software package that is part of CS3000and used to view and set up fieldbus devices. In this exercise, you will learn how to set the tagand address of fieldbus devices.

1. From System View, open the Device Panel application by selecting the segment and clickingin the menu: Tools > Fieldbus > Display Device Information

2. The Device Panel screen is split, with the devices in the project database shown on the left,and the actual devices connected to the segment shown on the right (known as the live list).

3. Locate the following items on the Device Panel screen:

a. Tag Name

b. Address

c. Device ID

d. Device Revision information

4. If device tags and addresses have not been assigned, the system will assign temporaryaddresses in the range 248-251 (0xF8-0xFB). Note that only 4 unconfigured devices can bedisplayed at a time. If the desired device does not appear on the live list, then the devices willneed to be connected to the segment (and the addresses assigned) one at a time.

5. Identify the instrument tag and matching Device ID as shown on the instrument’scommissioning tag.

6. Locate the instrument on the live list with the desired Device ID, right click and select “Tag Assignment”. De-select “Assign Automatically” and input the instrument tag and address thatmatches the values in the database on the left.

Device ID



138

7. Repeat steps 5 & 6 for every device on the segment.

8. Click on the [+] next to the devices to explore the devices and their block structure.

Part 2 – Downloading To Devices (Fieldbus Builder)

This step provides an introduction to Fieldbus, a software package that is part of CS3000 and

used for engineering and downloading of configuration to fieldbus devices. In this exercise, youwill learn how to download configuration to as segment and check that it is working.

1. From System View, locate the segment and double-click on it to open Fieldbus Builder.

2. This screen shows the devices configured in the engineering database (same as the left partof the screen in Device Panel). Locate the following items on the Fieldbus Builder screen:

a. Tag Name

b. Address

c. Device ID


e. Polled address range for the segment (this setting dictates which addresses the ALF111 looks for – if this range doesn’t include a device it will be invisible!)

3. Select the ALF111 card and select: File > Download (ensure all boxes are ticked)

Matching



139

4. Confirm that there are no errors and verify that all the devices were downloaded successfullyby checking that the “Device ID” column has been filled in for each tag. If there are anyerrors, view the “Message” window at the bottom of the screen for details and rectify theproblem.

5. From Fieldbus Builder, open the Device Panel application by selecting the segment and

clicking in the menu: Tools > Display Device Information 6. If any of the devices have a yellow lightning bolt icon next to them, then they have not been

equalized successfully. Sometimes parameters such as software revision are notsuccessfully imported to the database by Fieldbus Builder so this has to be correctedmanually.

7. Double-click on the device to launch the “Device Information Display” and perform thefollowing steps:

a. Click on “Update” to show the current parameters.

Device IDs

No Errors



140

b. Select “Equalization Mode” and “Difference” to see the parameters that are not yetequalized.

c. Tick “Equalization of block parameters is executed”

d. Select “Equalization” and execute.

e. Select “Update” and check that the parameters are now equalized

f. Close the equalization window and check that the yellow lightning bolt next to thedevice icon has disappeared.

8. Right-click on each device and select “Commission”. This will remove the commissioning tagicon from each device. The Device Panel should now look as shown below, with no questionmark or lightning bolt icons.

9. Close Device Panel and return to Fieldbus Builder.

10. From a HIS, open the faceplate for each instrument on the segment to ensure it is workingcorrectly (click the “NAME” button and type the instrument tag). The status should be NR



141

(normal) with no errors (note that since the instrument is not yet in service, the faceplate maydisplay a LL or HH alarm – this should be normal depending on the alarm settings). Thefaceplate should NOT display an IOP (input open), OOP (output open), CNF (connection fail)or O/S (block out of service) status. Faceplates for input blocks (AI/DI) should be in AUT andoutput blocks (AO/DO) should be in CAS.

11. Experiment with the instrument by making the following changes and observing the effect ithas on the instrument faceplate (and associated indicator or PID faceplate):

a. Change the process value (e.g. test pump on a pressure transmitter)

b. Change the process value outside of alarm limits (PL/PH)

c. Change the process value outside of range limits (LL/HH)

d. Disconnect the device and then reconnect it

e. Disconnect the temperature element (temperature transmitters only)



142

Exercise 2 – Using Fieldmate

This exercise provides an introduction to Fieldmate, a portable software tool that is used toconfigure fieldbus devices. In this exercise, you will learn how to connect Fieldmate to a segmentand set the tag and address of fieldbus devices, and troubleshoot using Device Viewer.

1. Open the NI-FBUS Interface Configuration utility from the start menu:Start > National Instruments > NI-FBUS > Utilities > Interface Configuration Utility

2. Select each port and click edit to configure only the first port with the following settings:

When there is no other LAS on the segment (i.e. no ALF111 card connected) and you wantFieldmate to become the LAS:

• Device Address: 0x10

• Device Type: Link Master Device

• Usage: NI-FBUS

When another LAS is already connected to the segment:

• Device Address: Visitor

• Device Type: Basic Device

• Usage: NI-FBUS

3. Connect one port of the NI-FBUS card to the segment to a spare device coupler terminal.

4. Start up the Yokogawa Fieldmate application and select “FF-H1” as the default scansegment. Click “Ok” to start up NI-FBUS Communications Manager which will pop up thefollowing window once it has started successfully.

5. Ensure the “Segment Viewer” tab and “Foundation Fieldbus” are selected on the left panel.The actual devices connected to the segment are shown on the right (known as the live list).Note that there is no panel on the left showing the devices in the engineering database – thisfeature is only available in Device Panel on an engineering workstation.



143

6. Locate the following items on the Fieldmate screen:

a. Tag Name

b. Address

c. Device ID


7. If device tags and addresses have not been assigned, the system will assign temporaryaddresses in the range 248-251 (0xF8-0xFB). Note that only 4 unconfigured devices can bedisplayed at a time. If the desired device does not appear on the live list, then the devices will

need to be connected to the segment (and the addresses assigned) one at a time.

8. Identify the instrument tag and matching Device ID as shown on the instrument’scommissioning tag.

9. In Fieldmate, locate the instrument on the live list with the desired Device ID, right click andselect “Tag/Address Assignment”. Input the instrument tag and address that matches thevalues in the project database print-out generated from Fieldbus Builder and click “Set”.

Device ID

Live List



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10. Repeat steps 8 & 9 for every device on the segment.

11. Check the Device Status for all devices on the segment (the colored oval next to the deviceicon). The Device Status should be good (green) for every device on the segment.

12. Right-click on the device and select “Device Viewer” to see more detailed status of thedevice.

13. Since the devices have not yet been configured by the DCS, Device Viewer may see someerrors such as “AI FB not scheduled”. This is expected and can be ignored as it will beresolved once the instruments are connected to the DCS and downloaded.

Matching

DeviceStatus

FieldbusBuilderprint-out



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14. Experiment with the instrument by making the following changes and observing the effect ithas on Device Viewer (Right-click on the instrument and select “DD Menu” or “AssignedDTM” to launch the application used to make these changes)

a. Change the block mode of AI1 to out of service (O/S)

b. Click on the “Trend Information” tab to observe trended parameters

DD Menu Screen DTM Screen



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Exercise 3 – Using Plant Resource Manager (PRM)

This exercise provides an introduction to PRM, the application used for management ofFoundation Fieldbus and HART instrumentation. It shows how to set up PRM for a segment andintroduces its device troubleshooting tools.

1. Open up the PRM application select the “Network” tab.

2. Under “Foundation Fieldbus” locate the segment, right-click on it and select “Plug & Play” toautomatically recognize the devices connected to the segment.

.

3. Check the Device Status for all devices on the segment (the colored oval next to the deviceicon). The Device Status should be good (green) for every device on the segment.



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4. Experiment with the instrument by making the following changes and observing the effect ithas on Device Viewer (Right-click on the instrument and select “DD Menu” or “AssignedDTM” to launch the application used to make these changes)

a. Change the block mode of AI1 to out of service (O/S)

b. Click on the “Trend Information” tab to observe trended parameters

DD Menu Screen DTM Screen

5. Click on the “History” then “Maintenance” tab of the device to view the alarm generated –read the message regarding problem, cause and action. Right-click on the alarm and select“Acknowledge” – enter a reason and you should see the yellow exclamation point icondisappear from the device.

DeviceStatus



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6. Right-click on the device and select “Device Viewer” to launch. The following screenshotshows an example of a device viewer warning that states “AI1 FB is in O/S mode”. Thismeans that the analog input block is out of service, so the process value is not beingtransmitted to the control system.

7. Fix the problem using DD Menu or the DTM and observe the device return to normal.

8. Right click on the segment and select “Save All Parameters”. Type ‘Commissioning’ into the“Reason” box, tick the “Read details from the field devices” box and select ok. This will savethe current set of parameters in the device.



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9. In the following steps you will compare previously saved parameters to the currentparameters read from the device:

a. Select a device on the segment and click on the “Parameter” tab

b. Select the desired block tag (resource, transducer or function blocks)

c. The column on the left displays the current parameters in the device – click “Update”

to read in current parameters from the device

d. The arrow in the middle is used to change a device’s parameters back to a savedconfiguration – click “Set” to execute

Current Saved



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Exercise 4 – Physical Layer Diagnostics

Part 1 – Using the Relcom FBT-6 handheld tool

The FBT-6 is a handheld fieldbus monitor that can detect physical layer problems on thesegment. It is bus-powered and rated for use in hazardous areas. This exercise will show you

how to use the FBT-6 to check a segment and identify common problems.

1. Connect the FBT-6 Fieldbus Monitor to the segment at the device coupler and wait for it tocheck (approximately 20 seconds). The FBT-6 should display “ALL MEASUREMENTS OK” ifthere are no problems. Press the “FUNC” button to scroll through the various measurementsfor the segment.

2. With the FBT-6 still connected, introduce the following faults onto the segment and observethe reading on the FBT-6 to see whether the changes are identified.

a. Disconnect a device and then reconnect it

b. Place a short between the shield wire and one of the signal wires

c. Switch off the terminator at the power supply end

3. Press “FUNC” to scroll through to the save function. Hold down the “SEL” button to save thesegment measurements into one of the empty slots (there are 8 slots available). Make surethe number of the slot is noted on the check sheet as this will be needed for the next step.



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4. Connect the FBT-6 to a laptop and launch the FBT-6 Assistant software. Click “TransferReports from FBT-6” to transfer the reports to the laptop. By default they will be saved withthe report slot number - rename the files with the segment number for easy identification.

Part 2 – Using the MTL F809f diagnostics module

The MTL F809f is a physical layer diagnostics module that mounts on the segment power hub forcontinuous monitoring. This exercise will show you how to use the module to check a segment

and identify common problems.

1. Open up the PRM application select the “Network” tab.

2. Under “Foundation Fieldbus” locate the segment and select the F809f module.



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3. Click on the “Parameter” tab, then right-click on <Show actual parameter> and select“Parameter Manager”. This will enable you to read the current parameters in the F809f.



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4. The parameters in the F809f display the measured values from the segment, and any activealarms that are present. Read through the parameters for the two types of transducer blocksto see what the current status is (TB01 is the system transducer block, and TB02-TB09 arethe segment transducer blocks). Consult the F809f user manual on your flash drive if you arenot sure what a parameter means.

5. Generate a print-out of the current parameter values – this can be useful as a commissioningreport to document the measurements taken.

6. Right-click on the F809f module and select “Save all parameters” to save all the currentparameters in the device to the PRM database. In Parameter Manager you will then be ableto view the saved values alongside current measurements taken from the segment.

7. Introduce the following faults onto the segment and observe the measurements by updatingthe current parameters in Parameter manager. Compare these to the saved parameters inthe previous step to see whether the changes are identified.

a. Unplug the secondary 24VDC power connector from the power hub

b. Place a short between the shield wire and one of the signal wires

c. Switch off the terminator at the power supply end



8. Click on the “History” then “Maintenance” tabs of the device to view the alarms generated,and read the message regarding problem, cause and action. Right-click on the alarm and

Current Saved

Foundation Fieldbus Training Book

Documents

Transcript of Foundation Fieldbus Training Book