Steps To A Successful Profibus Project

Practical Steps to a Successful
PROFIBUS Project
Slides by Dr. Xiu Ji - MMU
Presentation today by Richard Needham Hi-Port Controls
Outline of this presentation
Presentation objective
Introduction to PROFIBUS and associated benefits
Connection options and rules
Other cabling issues : grounding and interference
Design Considerations
Implementation issues
Essential training
Practical steps to a successful project, The PROFIBUS Group Seminars, Dr Xiu Ji
Slide 2
Introduction to PROFIBUS
Fieldbus is widely used in many automation systems.
PROFIBUS solutions for Factory Automation (FA) and
Process Automation (PA)
Applications also involving drives, instruments, servos,
robotics, functional safety, redundancy, and explosive
environments etc.
Extensive diagnostic functions available to operators and
maintenance engineers
Diagnostic tools available for engineering, commissioning,
maintenance, and fault finding
Excellent support from PROFIBUS International, regional
events and competence and training centres.
Slide 3
More Information
More adjustable settings and parameters (e.g. scaling,
linearization and calibration).
Diagnostic data to inform if measurement is valid.
Slide 4
Extensive Diagnostics
Controller
SCADA/HMI
2
Engineering
Station
PA Software
2
Analyser
Slide 5
PROFIBUS Applications
Factory
automation
Process
automation
Vehicle
manufacture
Bottling plants
Warehousing
systems
Switchgear
Hollow glass
production
Chemical
industry
Petrochemical
industry
Paper and
textile industry
Foodstuffs
Power stations
Sewage plants
Drive
technology
Machine tools
Packaging
machines
Pressing plants
Paper production
Safety
applications
Vehicle
assembly
Machine tool
building
Slide 6
The PROFIBUS Family

PROFIBUS DP (Decentralised Periphery)
Low cost, simple, fast for general automation applications

Within short distances, in large quantities, mainly in-door, in dry
areas, in cabinets
Parameters, options and capabilities can be defined using a
simple, text GSD file.
Physical layer uses RS485 or fiber optic
Slide 7
The PROFIBUS Family
PROFIBUS PA (Process Automation)
Developed specifically for the process industry to replace 4-20mA

transmission
Two-wire connection carrying both power and data
Spread over long distances, in low quantities, mainly out-doors,
in wet and exposed sites
Parameters, options and capabilities are defined in additional to a
GSD file, in EDD or FDT/DTM
Large number of parameters, options and diagnostic events
Cyclic and acyclic communications
PA equipment is often used in explosive environments
Slide 8
Transmission Technologies
PROFIBUS supports different transmission technologies
HART on
PROFIBUS
LabAutomation
XY
Weighing &
Dosage
PROFIsafe, I&M, iPar-Server,

Time Stamp, Redundancy,
Communication
Technology
Transmission
Technologies
....
PROFIBUS DP (DP-V0, -V1, -V2)
Wired
Optical
RS485 / RS485-IS
MBP / MBP-IS
Glass, PC F, Plastic
Engineering Technologies
GS D, EDD, FDT / DTM, TCI
Common
Application
Profiles
Encoder
Ident Systems
PA Devices
Specific
Application
Profiles
PRO FIdrive
Wired, Optical, and Wireless
Wireless
Slide 9
Connection technologies
1
0
PROFIBUS DP uses 2-core shielded and twisted RS485 wiring.

9-pin sub-D or M12 connectors extensively used.
DP can also use plastic or glass fibre optic cabling.

ST/BFOC connectors widely used
PROFIBUS PA uses Manchester Bus Powered (MBP) cabling

over 2 cores.
Glanded screw or M12 connection normally used
Slide 10
Optical transmission
The implementation of a fibre optic cable network involves the
use of electro optical converters (OBT and OLM):
for long distance, between buildings, and
to solve grounding problem (grounds with un-even earth
potential).
OLM (Optical Link Module)
OBT (Optical
Bus Terminal)
FO
Coupler
FO
Coupler
Fibre to Copper
Slide 11
Control System Architecture
Slide 12
From DP (RS485) to PA (MBP)
4
To
7
volts
0
PROFIBUS PA, MBP
PROFIBUS DP, RS485

Current/mA
+9mA
10 mA
-9mA
time
Slide 13
DP & PA Segments
One PROFIBUS network can host up to 126 stations (masters and slaves)
capacity of a PROFIBUS DP master
Limitation of RS485 and MBP 32 loads and total cable length per segment
Segment
1 RS485
M
Repeater
Segment 2
RS485
S
Segment 3
Fibre Optic
R
S
DP/PA
Coupler S
S
S
Segment 4
RS485
Fibre optic
links
Each RS485 segment are best laid

out as a linear bus daisy-chaining
from device to device.
Segment 5
MBP
MBP segments can be laid out in a

more flexible manner using Tee
junctions to create spur lines.
Slide 14
DP Segment Cable Length

When using best quality PROFIBUS RS485 (Type-A) cables, the
segment cable length is limited according to the network speed.
Baud rate
Maximum segment length
9.6 kbit/s
1 200m
19.2 kbit/s
1 200m
45.45 kbit/s
1 200m
93.75 kbit/s
1 200m
187.5 kbit/s
1 000m
500.0 kbit/s
400m
1.5 Mbit/s
200m
3.0 Mbit/s
100m
6.0 Mbit/s
100m
12.0 Mbit/s
100m
Low
speeds
Middle
speeds
High
speeds
Slide 15
PA Segment Cable Length

PA baud rate is fixed at 31.25 kbit/s.
The maximum segment cable length is 1900 meters for nonintrinsically safe applications, and.
1000 meters for intrinsically safe applications
Slide 16
Segmentation, PA
The maximum number of devices on a PA segment is the same
as the maximum on a DP segment, which is 32.
However, how many slaves can be connected to a PA segment
depends primarily on the power supplied to the segment.
Segment Coupler
V = 13.4 VDC, I = 100 mA
Maximum number of
PA slaves = 100 / 14 = 7
I actual = 5 x 14 = 70 mA
14 mA
14 mA
14 mA
#13
14 mA
14 mA
#16
#17
#15
#14
Slide 17
Reflections
When electrical signals travel down a cable, any electrical
discontinuity can cause reflections to occur
The end of the cable in particular is a major discontinuity, which
can cause severe reflections, particularly with fast changes
Just like an echo, the reflected signal can cause multiple signals
or corrupted telegrams to appear on the line
Slide 18
Reflections
Reflection caused by
missing terminator
missing terminator
missing terminator
Analysis of PROFIBUS system behaviour is covered in PROFIBUS in

Practice system engineering, troubleshooting and maintenance.
Slide 19
Termination - Rules
To avoid reflections from ends of the cable it is essential
that each segment is terminated at both ends and
nowhere else
Both terminators in each segment must be powered at all
times
Terminator switches and resisters are normally include in
9-pin PROFIBUS connectors for this purpose, with plug-in
terminators used for M12 schemes
+5 volt power is needed for these terminators to work
properly. This is normally supplied from the connected
device
Slide 20
Termination
Standalone termination boxes are also available
for DP
and for PA
Termination on Repeaters
Slide 21
Termination
#10
#0
#1
#11
T
DP/PA
coupler
Power supply for PA segment

T
T
1 network with 2
segments.
#13
#15
#14
#16
#17
Slide 22
Causes of Reflections
Missing terminator
Un-powered terminator
Terminator switch - faulty
Extra terminator
Reflection can also be caused by:
Un-certified devices
Cable length between two devices is too short
Spurs are used in high speed networks
Wrong types of cables are used
Cores are sharply bent
Slide 23
Allowance of RS485 Spurs
Bit rate
Total allowable spur

capacitance
Total Spur cable

length/segment*
>1.5 Mbit/s
None
None
1.5 Mbit/s
0.2 nF One spur @ 6.7m or 6.7 m
500 kbit/s
0.6 nF 6 spurs @ 1.1m each 20 m
187.5 kbit/s
1.0 nF
33 m
93.75 kbit/s
3.0 nF
100 m
19.2 kbit/s
15 nF
500 m
It is much more flexible @ low speed.

* Calculated for PROFIBUS cable type A at 30pF/m
Slide 24
Allowance of MBP Spurs

The length of the individual spur-lines on a PA segment depends
upon the total number of spurs used:
Number of
spur-lines
Maximum spur length

non-intrinsically safe
Maximum spur length

intrinsically safe
25 to 32
1m
1m
19 to 24
30 m
30 m
15 to 18
60 m
60 m
13 to 14
90 m
60 m
1 to 12
120 m
60 m
Note that the maximum cable length of 1900m includes

cable used for spurs. E.g. 18 x 60 = 1080m spurs + 810m trunk line.
Slide 25
Interference
2
6
Interference is picked up from adjacent equipment or

connected equipment with poor Electromagnetic Compatibility
(EMC) rating.
Interference can be caused by:
Inadequate earthing of equipment,

Poor or incorrect earthing of cable shield,
Insufficient segregation of power and bus cables,
Routing cables through electrically noisy areas, and
Heavy earth currents on the cable screen.
Slide 26
Equipotential Bonding
Slide 27
Installation: Shielding and Grounding

intern
2
8
Shielding and Grounding

The recommended grounding practices:
Connect all PROFIBUS interfaces and cable shields to ground.
Use a grounding cable to go from cabinet to cabinet
in the same segment equipotential bonding.
Types of grounding:
Direct grounding (at any connecting point)
Capacitive grounding
Slide 28
Equipotential Bonding at a Device

Connect the PROFIBUS cable shield to the equipotential
bonding at every PROFIBUS station assuming local potentials
are equal!
Connector
Shielded, twisted-pair cable
Red = +
Green = Rx
Cable shield route

to ground
Rx
Tx
Tx
Device
Device
Slide 29
Connector wiring problems

Which connectors are incorrectly wired?
D
Slide 30
Cable Segregation
All channels and partitions must be properly earthed.
Use flexible bonding links are protected against corrosion.
Braided straps are better than solid metal.
Slide 31
Cable Segregation Distance

In general, the greater the spacing between the cables and the
shorter the paths run parallel, the lower the risks of
interference.
Recommended cable segregation distances:
20 cm
Cable
Category I
50 cm
10 cm
Cable
Category II
10 cm
Cable
Category III
50 cm
Cable
Category IV
50 cm
Slide 32
Cable Segregation ?
An example: variable frequency drives
Can you spot the error here?
Power cable route
Slide 33
Spot the errors
Slide 34
Spot the errors
Slide 35
Spot the errors
Slide 36
Standard connections PROFIBUS DP
3
7
Slide 37
Standard connections PROFIBUS PA
3
8
Trunk
PROFIBUS DP
Link/
Coupler
PROFIBUS PA
Spur lines
Devices
PROFIBUS DP
Link/
Coupler
Junction
Box
PROFIBUS PA
Junction
Box
Trunk
Spur lines
Devices
Slide 38
Spot the errors
Slide 39
Design considerations - details
Limitations of segment loads and total cable length

Standalone terminations for DP, redundant power supply to
terminators
Network drawings node addresses, mark of termination
position, cable routes, cable length between connectors and
junction boxes, trunk cable and drop cable length
Piggyback connectors spare connection into EVERY segment
for voltage measurements and troubleshooting
Slide 40
Design considerations - architecture
4
1
Which network to use PROFIBUS, PROFINET, DP, PA, AS-i?

Designation of safe and hazardous areas
Production and functional safety systems
Cable routes fibres, copper cables, earthing systems,
equipotential bonding cable in place?
Cabinet or field assembly
Connection of devices via remote IO or integrated fieldbus?
Use of redundancy at difference levels
Network and device access for engineering, monitoring and
maintenance
Slide 41
Installation Checklists
4
2
Checklist to determine network topology and obtain the

network drawing
Checklist for PROFIBUS DP (RS485) Grounding
Checklist for PROFIBUS PA (MBP) Grounding
Checklist for PROFIBUS DP (RS485) Cabling
All above are included in PROFIBUS in Practice installing
PROFIBUS devices and cables as templates for a Factory
Acceptance Test document.
Slide 42
Practical steps to a successful PROFIBUS project
4
3
The very first step to a successful project should be
Training
PROFIBUS training courses are available for:
Installers,
System Designers,
Commissioning Engineers, and
Maintenance staff.
Many industry sectors specify that their staff, contractors and

sub contractors must be appropriately trained.
Competence Centre - Manchester Metropolitan University
Training Centre Verwer Training and Consultancy
Slide 43
Certified PROFIBUS Installer Training
4
4
This training is widely accepted as the minimum standard of

training for anyone who is working in PROFIBUS systems at a
technical level.
Available as a one-day training course in house or on-site.
It teaches the basic principles of PROFIBUS and covers the basic
layout, installation and testing of DP and PA networks.
It is also essential basic training for system designers,
maintenance and all engineering staff.
Background details are covered in the series of PROFIBUS in
Practice, the orange and blue textbook.
Extra days can be added to extend the training for maintenance,
design and engineering staff.
Slide 44
PROFIBUS System Design Training
4
5
Good overall design, with good documentation and clear

specifications of required wiring, installation, testing,
commissioning and final setting-to-work practices are
recommended. Production of final as installed drawings are
also recommended (to assist with subsequent maintenance)
Designer training will allow companies to ensure that their
designers are aware of the common design pitfalls and able to
produce systems that are cost effective, efficient and
maintainable.
Designer course at MMU is 3 days covering installation,
maintenance, and design.
Slide 45
Summary: Steps to a successfully project
4
6
1. Design staff should be trained before the design starts.

2. Everyone involved in the project at a technical level is trained to
an adequate level, at the least to the designer or installer level
3. Make sure that designers are fully aware of the methods for
diagnosing and locating faults, before start of design
4. Ensure that health checking and performance monitoring
facilities are incorporated into the network
5. Follow the extensive guidance that is available from PI and from
competency and training centres, for example, incorporating
the checklists in to your installation acceptance tests
Slide 46

Steps To A Successful Profibus Project

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Practical Steps to a Successful

Outline of this presentation

Practical steps to a successful project, The PROFIBUS Group Seminars, Dr Xiu Ji

Practical steps to a successful project, The PROFIBUS Group Seminars, Dr Xiu Ji

Practical steps to a successful project, The PROFIBUS Group Seminars, Dr Xiu Ji

Practical steps to a successful project, The PROFIBUS Group Seminars, Dr Xiu Ji

Practical steps to a successful project, The PROFIBUS Group Seminars, Dr Xiu Ji

The PROFIBUS Family

Low cost, simple, fast for general automation applications

Practical steps to a successful project, The PROFIBUS Group Seminars, Dr Xiu Ji

The PROFIBUS Family

PROFIBUS PA (Process Automation)

Developed specifically for the process industry to replace 4-20mA

Practical steps to a successful project, The PROFIBUS Group Seminars, Dr Xiu Ji

PROFIsafe, I&M, iPar-Server,

PROFIBUS DP (DP-V0, -V1, -V2)

Practical steps to a successful project, The PROFIBUS Group Seminars, Dr Xiu Ji

Wired, Optical, and Wireless

PROFIBUS DP uses 2-core shielded and twisted RS485 wiring.

DP can also use plastic or glass fibre optic cabling.

PROFIBUS PA uses Manchester Bus Powered (MBP) cabling

Practical steps to a successful project, The PROFIBUS Group Seminars, Dr Xiu Ji

OLM (Optical Link Module)

Practical steps to a successful project, The PROFIBUS Group Seminars, Dr Xiu Ji

Control System Architecture

Practical steps to a successful project, The PROFIBUS Group Seminars, Dr Xiu Ji

From DP (RS485) to PA (MBP)

PROFIBUS PA, MBP

PROFIBUS DP, RS485

Practical steps to a successful project, The PROFIBUS Group Seminars, Dr Xiu Ji

Each RS485 segment are best laid

MBP segments can be laid out in a

Practical steps to a successful project, The PROFIBUS Group Seminars, Dr Xiu Ji

DP Segment Cable Length

Maximum segment length

Practical steps to a successful project, The PROFIBUS Group Seminars, Dr Xiu Ji

PA Segment Cable Length

Practical steps to a successful project, The PROFIBUS Group Seminars, Dr Xiu Ji

Practical steps to a successful project, The PROFIBUS Group Seminars, Dr Xiu Ji

Practical steps to a successful project, The PROFIBUS Group Seminars, Dr Xiu Ji

Analysis of PROFIBUS system behaviour is covered in PROFIBUS in

Practical steps to a successful project, The PROFIBUS Group Seminars, Dr Xiu Ji

Practical steps to a successful project, The PROFIBUS Group Seminars, Dr Xiu Ji

Power supply for PA segment

Practical steps to a successful project, The PROFIBUS Group Seminars, Dr Xiu Ji

Practical steps to a successful project, The PROFIBUS Group Seminars, Dr Xiu Ji

Allowance of RS485 Spurs

Total allowable spur

Total Spur cable

0.2 nF One spur @ 6.7m or 6.7 m

0.6 nF 6 spurs @ 1.1m each 20 m

It is much more flexible @ low speed.

Allowance of MBP Spurs

Maximum spur length

Maximum spur length

Note that the maximum cable length of 1900m includes

Interference is picked up from adjacent equipment or

Inadequate earthing of equipment,

Practical steps to a successful project, The PROFIBUS Group Seminars, Dr Xiu Ji

Practical steps to a successful project, The PROFIBUS Group Seminars, Dr Xiu Ji

Installation: Shielding and Grounding

Shielding and Grounding