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Networks in Process

Automation

K.Vijaya Lakshmi, M.Tech (PhD)


Contents
• Communication hierarchy in factory automation
• I/O bus networks - Types, Network and protocol standards
• Networking at Various levels
• Highway Addressable Remote Transducer (HART)
• Introduction to HART protocol
• HART encoding and waveform - Frequency Shift Keying (FSK)
technique, HART character
• HART addressing - Short and long Address, Arbitration
• Communication modes – Master- Slave and Burst modes
• HART networks - Point-to-point, Multi drop configurations
• HART communication layers - Physical, Data link, Application Layer
Networks in Process Automation
• Traditional communication networks are used to enable data
communication between computers, computers and its peripherals and other
devices.
• On the other hand, industrial communication network is a special type of
network made to handle real-time control and data integrity in harsh
environments over large installations.
• The examples of industrial communication networks include
• Foundation Field Bus
• DeviceNet
• Modbus
• Profibus and so on.
Networks in Process Automation
• The three significant control mechanisms used in industrial automation
field include
• Programmable Logic Controllers (PLCs)
• Supervisory Control and Data Acquisition (SCADA) and
• Distributed Control System (DCS)
• All these elements deals with field instruments, supervisory control
PCs, distributed I/O controllers and HMI suits. smart field devices,
• In order to provide an interconnection between these devices and also
to enable communication in between them, a powerful and more
effective communication network or scheme is needed.
• These industrial networks form a communication path among field
devices, controllers and PCs.
Communication hierarchy in factory
automation
• Automation Pyramid consists of five levels namely
• Field Level
• I/O Level
• Control Level
• HMI (Human Machine Interface) Level
• Enterprise Level
Field Level
• It is the lowest level of the automation hierarchy which includes the
field devices like sensors and actuators.
• The main task of these field devices is to transfer the data of
processes and machines to the next higher level for monitoring and
analysis.
• Sensors convert the real time parameters like temperature, pressure,
flow, level, etc into electrical signals.
• This sensor data is further transferred to the controller so as to
monitor and analyze the real time parameters.
• Some of the sensors include thermocouple, proximity sensors, RTDs,
flow meters, etc.
I/O Level
• This level combines the inputs and outputs together.
• The sensor output via the I/O level, is directed to the controller, which
then generates an appropriate control signal, and is then feedback to
the actuator for control of the process.
• Actuators converts the electrical signals (from the controllers) into
mechanical means to control the processes.
• Flow control valves, solenoid valves, pneumatic actuators, relays, DC
motors and servo motors are the examples of actuators.
Control Level
• This level consists of various automation devices like PLCs, DCS etc.,
which generates control signals.
• These signals are sent to the field/actuator level where as per the
signal received, the control action is taken
• Opening or closing of valve
• Starting or stopping of motors etc.
• Programmable Logic Controllers (PLCs) are most widely used robust
industrial controllers which are capable of delivering automatic
control functions based on input from sensors.
HMI Level
• In this level, automatic devices and monitoring system
facilitates the controlling and intervening functions like
Human Machine Interface (HMI), supervising various
parameters, setting production targets, historical archiving,
setting machine start and shutdown, etc.
• This level ensures that any process variable value from any
place in the plant can be displayed on the operator console,
can warn the operator in case of any process value
undershoots/overshoots predefined set limits, can change
the device configurations etc.
Enterprise Level
• This is the top level of the industrial automation which manages the
whole automation system and the information flows in to the office
environment.
• The tasks of this level include production planning, customer and
market analysis, orders and sales, etc.
• So it deals more with commercial activities and less with technical
aspects.
• The communication network can be different one level to the other.
Some of these networks include RS485, CAN, DeviceNet, Foundation
Field bus, Profibus, etc.
Speed of data transmission, data
volume and data security are the
major concerns of these levels.
I/O Bus Networks
• I/O bus networks allow PLCs to communicate with I/O devices
through digital communication.
• The basic function of an I/O bus network is to communicate
information with, as well as supply power to, the field devices that
are connected to the bus.
• In an I/O bus network, the PLC drives the field devices directly,
without the use of I/O modules.
• The process bus network and device bus network are connected to a
PLC.
• Remote I/Os are connected to other PLCs.
I/O BUS NETWORK BLOCK DIAGRAM
I/O Bus Networks – Data & Status Information
• The field devices connected to I/O bus networks must be intelligent
(sensor with SC, Microcontroller, TX/RX network & Power module).
• These devices communicate not only the ON/OFF state of input and
output controls, but also diagnostic information about their operating
states.
• For example, a photoelectric sensor (switch) can report when its
internal gain starts to decrease because of a dirty lens, or a limit
switch can report the number of motions it has performed.
• This type of information can prevent I/O device malfunction and can
indicate when a sensor has reached the end of its operating life, thus
requiring replacement.
Connection between a PLC, a local area
network, and an I/O bus network
Connections for an I/O bus network
Intelligent field device
TYPES OF I/O BUS NETWORKS
• Device bus networks
 Interface with low-level information devices (e.g., push buttons,
limit switches, etc.), which primarily transmit data relating to the
state of the device (ON/OFF) and its operational status (e.g.,
operating OK).
 generally process only a few bits to several bytes of data at a time.
• Process bus networks
 connect with high-level information devices (e.g., smart process
valves, flow meters, etc.), which are typically used in process
control applications.
 handle large amounts of data (several hundred bytes), consisting
of information about the process, as well as the field devices
themselves.
I/O bus network classification
Device bus network
• The majority of devices used in process bus networks are analog,
while most devices used in device bus networks are discrete.
• However, device bus networks sometimes include analog devices,
such as thermocouples and variable speed drives, that transmit only a
few bytes of information.
• Device bus networks that include discrete devices, as well as small
analog devices, are called byte-wide bus networks.
• These networks can transfer between 1 and 50 or more bytes of data
at a time.
Device bus network
• Device bus networks that only interface with discrete devices are
called bit-wide bus networks.
• Bit-wide networks transfer less than 8 bits of data from simple
discrete devices over relatively short distances.
• Since device bus networks transmit only small amounts of data at a
time, they can meet the high speed requirements
Process bus network
• These networks work slower because of their large data packet size, so
they are more applicable for the control of analog I/O devices, which do
not require fast response times.
• They can transmit several hundred bytes of data at a time, they are suitable
for applications requiring complex data transmission.
• For example, an intelligent, process bus network–compatible pressure
transmitter can provide the controller with much more information than
just pressure; it can also transmit information about temperature, flow
rate and internal operation.
• Thus, this type of pressure transmitter requires a large data packet to
transmit all of its process information, which is why a process bus network
would be appropriate for this application.
• This amount of information just would not fit on a device bus network.
PROTOCOL STANDARDS
• In the process bus area, two main organizations are working to
establish network and protocol standards.
 The Fieldbus Foundation (which is the result of a merger
between the Interoperable Systems Project, ISP, Foundation
and the World FIP North American group) and
 The Profibus (Process Field Bus) Trade Organization
• Other organizations, such as the Instrument Society of America (ISA)
and the European International Electronics Committee (IEC), are also
involved in developing these standards.
Network and protocol standards
Network and protocol standards
• The device bus protocol standards are based on the control area
network bus (CANbus), developed for the automobile industry, which
uses the commercially available CAN chip in its protocol.
• Standards for the byte-wide device bus network is
 DeviceNet, originally from PLC manufacturer Allen-
Bradley
 SDS (Smart Distributed System) from Honeywell
 InterBus-S from Phoenix Contact
Network and protocol standards
• The de facto standards for low-end, bit-wide device bus networks
include
 Seriplex, developed by Square D
 ASI (Actuator Sensor Interface), a standard developed by a
consortium of European companies
 Inter Bus Loop
 Again, this is why I/O bus network and field device
manufacturers will specify compatibility with a particular
protocol (e.g., ASI, Seriplex, InterBus-S, SDS, or DeviceNet)
even though no official protocol standard exists.
Networking at I/O and Field Levels
• Field Bus – Bidirectional control of field devices
• Controls and I/Os are now embedded in the field devices.
• 4-20mA analog communication is currently in existence.
• Binary field devices such as limit switches, solenoids and two position
open-close valves, are integrated via the binary I/O cards of PLCs by a
point to point connection.
• Within a field bus controller, remote I/Os will be there to integrate
these signals.
Networking at I/O and Field Levels

• For MODBUS and AS-i, an appropriate interface must be present in


the controller for integrating such binary field devices.
• 4-20mA signals are connected through the analog I/O cards in the
PLCs in a point to point manner.
• Fig. shows the connection to PLC for simple 4-20mA analog signals
along with 4-20mA hybrid ie., HART signals.
• Field devices are connected to the control network via intelligent
I/Os.
Connections of analog and hybrid signals to a
PLC
Networking at I/O and Field Levels

• In Foundation Field Bus, the field devices are attached to foundation


field bus H1 segment.
• A linking device connects this bus segment to the High Speed
Ethernet (HSE) or H2.
• The linking device performs only protocol or baud rate conversion.
Connections of foundation field bus segment
to controller
Networking at I/O and Field Levels

• In case of Profibus, devices are connected via a profibus segment


(PROFIBUS-PA(Process Automation)), which is then taken to the
higher speed network (PROFIBUS-DP(Decentralized Periphery)) via a
segment coupler or link.
• The link acts as an interface between the two signals.
Connections of PROFIBUS segment to
controller
Networking at Control level
• Fieldbus HSE
With ControlNet
• Profibus-DP
• Foundation Fieldbus – Lower speed H1 is connected to the higher
speed HSE via a linking device.
• PROFIBUS – a segment coupler couples the PA network to the higher
speed DP.
Networking at Enterprise/Management level
• Ethernet TCP/IP network – internetworking and sharing data with the
outside world.
• For this, hubs, switches, routers etc., are used.
• Data exchange formats for intercompany data sharing, e-business etc.
• XML text
• CMG drawing
• Data exchange between enterprise and management levels
• SAP
• Microsoft Office
• Data exchange between management and control levels
• PLCs with Ethernet port connected to a supervisory station
HART- Highway addressable Remote Transducer

• It is an open source process control network that supports Hybrid


Communication.
• Provides bidirectional digital communication channel over the same
4-20 mA wiring in half duplex mode.
• It uses 1200 baud Frequency Shift Keying (FSK) based on the Bell 202
standard to superimpose digital information on the conventional 4-20
mA analog signal.
• Provide flexibility which is not available with any other
communication technology.
HART
• The HART (Highway Addressable Remote Transducer) Protocol is the
global standard for sending and receiving digital information across
analog wires between smart devices and control or monitoring
system or Handheld communicators.
• The digital signal contains information from the device including
device status, diagnostics, additional measured or calculated values,
etc.
• Together, the two communication channels provide a low-cost and
very robust complete field communication solution that is easy to use
and configure.
HART
• The HART protocol directly contributes to these business goals by
providing cost savings in:
 Commissioning and installation
 Plant operations and improved quality
 Maintenance
• Hand Held Communicators are often used to perform device set-up,
calibration, commissioning and periodic maintenance.
Benefits of HART
• Is supported by all of the major vendors of process field instruments
• Preserves present control strategies by allowing traditional 4-20 mA
signals to co-exist with digital communication on existing two wire
loops
• Is compatible with traditional analog devices
• Can support cabling savings through use of multidrop networks
HART ENCODING AND WAVEFORM
• Frequency Shift Keying
• The HART communication protocol is based on the Bell 202 telephone
communication standard and operates using the frequency shift keying
(FSK) principle.
• The digital signal is made up of two frequencies— 1,200 Hz and 2,200 Hz
representing bits 1 and 0, respectively.
• Sine waves of these two frequencies are superimposed on the direct
current (dc) analog signal cables to provide simultaneous analog and digital
communications.
• Because the average value of the FSK signal is always zero, the 4– 20 mA
analog signal is not effected.
• The digital communication signal has a response time of approximately 2–3
data updates per second without interrupting the analog signal.
HART digital signal superimposed on 4–20 mA
analog signal
HART CHARACTER
• Uses asynchronous mode for communication purpose
• One byte at a time with out any clock signal
• Composed of 11 bits
HART COMMUNICATION MODES
• HART is a master-slave communication protocol.
 Master Slave mode
 Burst mode
• Master Slave mode:
• During normal operation, each slave (field device) communication is
initiated by a master communication device.
• The slave, in turn, responds only to the query from the master.
• Two masters can connect to each HART loop.
Terminologies
• Primary master ----control system
• Secondary master ----A hand-held communicator or a maintenance
computer.
• Slave Transmitter, sensor, transducer, attenuator
Master Slave mode (“Poll-Response mode”)
• The primary master is generally a distributed control system (DCS),
programmable logic controller (PLC), or a personal computer (PC).
• The secondary master can be a handheld terminal or another PC.
• Slave devices include transmitters, actuators or valve positioners.
• A slave can never initiate communication.
Master Slave mode
• Master Slave Mode (Poll---Response Mode)
• Maximum communication speed ---2 messages/sec
• Configuration ----Point-to-point or Multi-point
• Master sends command (request) , slave responds (replies)
Burst (Broadcast) Mode
• Some HART devices support the optional burst communication mode.
• Burst mode enables faster communication (3–4 data updates per
second).
• In burst mode, the master instructs the slave device to continuously
broadcast a standard HART reply message (e.g., the value of the
process variable).
• The master receives the message at the higher rate until it instructs
the slave to stop bursting.
Burst (Broadcast) Mode
• Slave transmits messages continuously (e.g. values of a measurand)
• The communication speed ---3 message/sec.
• A slave device repeatedly sends a data message
• Used for fast updation of the value of a measured variable
HART ADDRESSING
 Polling Address
 Unique identifier
• Polling address is a single byte and is also known as short address.
Short address
• One bit of the short address distinguishes the two masters, while
another bit indicates burst mode telegrams.
• The remaining four bits distinguish the field devices (from 0 to 15)—0
for single-unit mode and 1–15 corresponds to multidrop mode.
• The polling address format is used with old HART devices that do not
support the long address format.
HART ADDRESSING
• Unique identifier is of 5 bytes and also called long address.
Long Address
• The 5-byte unique identifier is a hardware address that consists of
 1-byte manufacturer code
 1-byte device type code, and
 a 3-byte sequential number.
• This 5-byte ID is unique for each device.
• HCF (HART Communication Foundation) administers the
manufacturer code, which eliminates the possibility of address
duplication of any two HART devices.
• The master uses this unique long address to communicate with the
slaves.
Long Address
• In single mode, the master polls address 0 to get the unique slave ID.
• In multidrop mode, the master checks all the polling addresses 0 to
15 to check device presence.
• The master then presents a list of live devices on the network.
• A user can alternatively enter the tag of the intended device and the
master will broadcast the same.
ARBITRATION
• Arbitration ensures proper message transmission between master
and slave devices. (master-slave or burst mode)
• Arbitration between the two masters (primary and secondary) is
based on timing.
• In burst mode, data is updated at a faster rate since the slave goes on
transmitting without a request from the master.
• A frame, either from a master or a slave is transmitted only after
ensuring that no transmission is taking place on the network at that
point of time.
ARBITRATION
• It is the responsibility of the timer to allow access to the network to
the primary masters, secondary masters, slaves, or slaves in burst
mode.
• Both masters have equal priority in getting access to the bus. In case
both masters have to repetitively access the bus, they would do so
alternatively.
• Burst mode slaves wait longer than the masters to transmit, allowing
the masters to control such slaves either to continue or abort the
burst mode.
HART NETWORKS (Configurations)
• Point to point
• The traditional 4–20 mA signal is used to communicate one process
variable, while additional process variables, configuration parameters,
and other device data are transferred digitally using the HART
protocol.
• The 4–20 mA analog signal is not affected by the HART signal and can
be used for control in the normal way.
• The HART communication digital signal gives access to secondary
variables and other data that can be used for operations,
commissioning, maintenance, and diagnostic purposes.
Point to Point
MultiDrop
• Used when the devices are widely spaced.
• Only two wires are required to communicate with the master.
• If required, intrinsic safety barrier and auxiliary power supply for upto
15 devices can be incorporated.
• All process values are transmitted digitally.
• All polling addresses of the devices are set at greater than 0 and the
current through each device is limited to a typical value of 4mA.
MultiDrop
• They allow two wire devices to be connected in parallel.
• Information reading time from a signal variable is typical 500ms and
• with 15 devices connected to the network, Approx. 7.5s would be
required to completely go through the network cycle once.
MultiDrop
HART COMMUNICATION LAYERS
• The HART protocol follows the seven-layer OSI (Open Systems
Interconnection) protocol. But it uses only three layers.
• 1. Application layer
• 2. Data link layer
• 3. Physical layer.
Physical Layer
• It defines physical and mechanical properties of connectors and cables.
• Also it defines signal characteristics.
• It uses asynchronous transmission.
• Masters & slaves are connected in parallel.
• Twisted pair cable with single shielded cable length of 3000 m.
• FSK Digital signal communication through wire is based on Bell 202
communication standard.
• It defines
• SIMPLEX CHANNEL FOR 4-20mA ANALOG SIGNAL
• HALF DUPLEX FOR FSK DIGITAL SIGNAL
Physical Layer
• HART allows additional information to be carried on the
same pair of wires with the 4-20 mA Analog Signal
HART COMMUNICATION SIGNAL
 Channels Separated in Frequency
– Like Channels on a Television
– Physical Layer Specification
• » Ensures channel separation
• » Ensures simultaneous communication
 4-20mA "Analog" Channel
– One-way communication of one process value
– Simple Low Pass Filter isolates 4-20mA signal
 HART "Digital" Channel
– Two-way Communications
– Compliments 4-20mA
Data Link Layer
• Responsible for reliable transfer of message over network.
• Organizes data and control byte into frames, adds error detection
codes to data stream.
• Assures symmetric access to communication channel by both master
and slave.
• Each HART transaction consists of master command & slave response.
• HART telegram (message frame format)
• Short frame format uses 1byte
• Long frame format uses 5 bytes in address field of telegram
• Telegram contains min. of 10 control bytes & max. of 25 bytes
HART TELEGRAM
HART TELEGRAM
Application Layer
• Defines commands, responses, data type, and status reporting.
• HART commands enable a master device to send instruction to field
devices to return data.
• Field devices respond by sending acknowledgement telegram which
contains data or requested status.
Three types of Commands in HART protocol
• At the Application Layer HART uses Commands for Data Transfer.
• All the devices using HART protocol must recognize and support the
Universal Commands.
• These provide the access to information useful in normal operations.
• Common Practice commands provide functions implemented by
many, but not all the HART devices.
• Device Specific Commands are unique to each field device based on
the application.
Universal Commands Common Practice Commands Device-Specific Commands

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