TV-NP/VUK

Fieldbus Technology Overview -

I/O-Fieldbus
Advanced Fieldbus
Industrial Ethernet
Process Automation
Extended Version
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IO fieldbus (and related) systemtechnologies
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Positioning and potential of individual bus systems at the field level
Plant/machine
design
[dimensions & structure]
Complexity
of application
[sensors & actuators]
> 90% Digital
> 20% analogue
Pre-
processing
> 20% closed loop
Compact
manually
operating
workspaces
Automation
Cell
Linked,
station-orianted
machines
Automation
plants
Fieldbus
Communication
Motion Control
EtherNet TCP/IP
Drive-Bus
I/O Bus
Industrial EtherNet
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Development of bus systems in the last decade
AS-interface as the market leader world-wide. Late market entrance of the others.
I/O-Bus in the past
was synonym to
AS-Interface
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Network topology with I/O fieldbus (AS-Interface) [1] PC connection
[2] Multipin Wiring
[3] PLC cards for device control
3
2
1
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Network topology with I/O fieldbus (AS-Interface) [1] PC connection
[2] I/O Bus
[3] PLC cards for device control
3
2
Usually small slaves, longer distances, limited functionality. Focus on easy installation system.
1
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All about AS-Interface
Relevance
AS-interface dominates the I/O market with a
worldwide connectivity of over 80%
Compared to field bus systems, AS-interface hold
position 3 after Profibus and DeviceNet reg.
number of nodes installed
Fieldbus organisation
The Fieldbus club is ASI Association
http://www.as-interface.net/
Major suppliers
There are roughly 300 suppliers of AS-Interface
network and control devices. Leaders in Europe are
Siemens, ifm, Pepperl&Fuchs, Schneider, B&W.
Also many PLC and I/O suppliers integrate
platforms from Bihl&Wiedemann, KSK, Murr and
others.
Distribution AS-interface Regions
Asia/Japan: strong growth expected
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AS-Interface Benefits
Large amount of vendors and field devices
with AS-Interface connection in the market
available
Open system. EN and IEC standard.
Easy installation. Simple network rules.
Robust data transmission.
Small slaves allow perfect decentralisation.
Easy to maintain. Change slaves easily due to
autoprgamming
Good configuration integrated with STEP7 and
the hardware configuration tool by Siemens
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Some technical data
Single master system for control of simple functions
ASI-Slaves are passive inside the network
They just response
Up to 31 ASI addresses in one network (Spec. 2.0)
62 ASI addresses (Spec. 2.1 and 3.0)
Simple 4IO per slave (Spec. 2.0)
Up to 16DIO per slave by using profiles (Spec. 3.0)
Analogue and other advances slaves by using
profiles (Spec. 3.0)
Seamless integration of Safety Slaves
Cycle time up to 5 ms (Spec. 2.0) or 20 ms (Spec.
3.0)
Network length 100 (200 m), expanders up to 600 m
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Configuration, Parameters and Diagnostics
Configuration
Auto-Configuration makes ASI easy
Offline addressing via addressing unit
Online addressing from master / config. software
Parameters:
Simple slaves usually not needed
Some (a few) slaves feature 4 bit for parameters
Diagnostics:
Common Communication/Periphery Fault (Spec.
2.0)
Module oriented per slave (as per Spec. 2.1)
Advanced options available (as per Spec. 3.0)
No slave (bus)
configuration
Necessary
No
Parametrisation
Module oriented
diagnostics
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AS-Interface common field devices and controllers
Typical field devices there is a huge variety .
PLC:
Siemens S7, Schneider, Mitsubishi, .,
within I/O Clamps (Wago, Phoenix, )
Small masters, mainly from B&W, ifm
Gateways:
- to all field bus systems and Ethernet protocols
- Main supplier: Bihl&Wiedemann, others label
I/O:
Siemens, ifm, P&F, Phoenix, KSK, Murr, Schneider,

Push-buttons (Idec, Schmersal)

Valve Terminal, Airbox, Process Valve (hats):
- Festo CPV, MPA, VTSA, Norgren VM10, VS26,
SMC.. Kuhnke, Parker Modulfex, Camozzi, BR
HF03/04
Safety Monitors: Leuze Lumiflex (others label),
new: Siemens Gateyway to ProfiSafe, B&W
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Festo Products
Festo products: units variants
CPV10 V, I/O 8
CPV14 V, I/O 8 > 1 Mio.
CPV18 V 2
MPA1 V, I/O 2
MPA2 V, I/O 2
VTSA18 V, I/O 2
VTSA26 V, I/O 2
VTSA42 V, I/O 2
CPA10 4
CPA14 4
I/O compact line 2 5
I/O valves ASI-EVA 3 10
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All about CompoNet
Relevance
Not recognised by any studies (until 2010)
No products available on odva homepage
Fieldbus organisation
The ODVA (Open DeviceNet Vendor Association)
- focuses the development and extension of
DeviceNet, ControlNet and Ethernet/IP
technology.
- CIP (Common Industrial Protocol) is the
consolidated application layer
- Other topics: CIPMotion, CIP Safety, DeviceNet,
EthernetIP, details: www.odva.org
Major suppliers
Omron developed the technology and will focus on
networks in the Asian region
Rockwell Automation (Allen-Bradley) currently
does not support CompoNet with devices
Regional CompoNet distribution
Major vendors Rockwell Automation and Omron
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Technical data
Communication
Speed
Thick cable
length
Thin cable
length
Drop line
length
4300 kbit/s 30 m 30 m ? ?
1500 kbit/s m ? ?
93,75 kbit/s 1500 m ? ?
CompoNet attributes
Line topology with drop lines
Max. 256 bit devices, 2 bit / bit slave
Max. 128 word slaves, 16 bit / word slave
Single master network
Network communication
CIP protocol is routed directly from upper levels
(DeviceNet, EthernetIP) to low-end CompoNet
device
Acyclic communication with Explicit Messaging
possible for parameters and diagnostics (44 bytes
per frame)
Cycle time depending on number of devices, data
size and connection setup. It is said that < 1ms is
possible (best case)
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Configuration, Parameters and Diagnostics
Same configuration tools can be
used for all CIP protocols.
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Strengths and weaknesses
Fast data transmission, short cycle time < 1 ms
possible
CIP protocol for seamless integration into
Rockwell/Omron networks
Easy to install 4-wire flat cable, alternative round
cable
Aimed to be cheap
Not yet in the market
Late market entry
Low acceptance in Europe

No Festo products
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All about CC-Link LT
Relevance
Cc-Link/LT Not recognised by any studies
Only very few products in Mitsubishi catalogue
Fieldbus organisation
Die CC-Link Partner Association (CLPA) besteht aus
derzeit rund 500 Mitgliedsfirmen, die inzwischen
mehr als zwei Millionen Netze installiert haben.
CC-Link +LT organisation http://www.cc-link.org/
Major suppliers
Spec. 2005 finished and published
Mitsubishi
Regional CompoNet distribution not yet visible
Major vendors Rockwell Automation and Omron
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Technical data
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Technical data
T-branch connection by using the popular CC-Link
"one-touch" connector.
Introduction of 4point / 8point / 16point modes
Link scan time is 1.2ms (at 2.5Mbps / 4point modes
/ when the 64 modules are connected)
Max. number of link points is 1024
(when the 16point mode is used)
Up to 500 m network length
Highly reliable communication results from the
same technology used in the field-tested, well-
known CC-link field network.
CC-Link/LT can seamlessly communicate with CC-
Link through a bridge.
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Object Model
1. Mitsubishi supports the following networks:
Ethernet
CC-Link
Profibus
DeviceNet
AS-Interface
MELSECNET/10/10H
CANopen
SSCNet
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Strengths and weaknesses
Seamless integration into CC-Link
Short cycle time 1.2 ms
1024 I/O points
Low acceptance of CC-Link
No market relevance of CC-Link LT
IP20 devices only
Mitsubishi decided to cooperate
with AS-interface on I/O bus level
( letter of understanding 2006)

No Festo products
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All about IO-Link
IO-Link Brings Intelligence to Simple Devices
IO-Link is not an industrial network, but rather a
simple protocol that adds communication
capabilities to devices connected to existing
industrial networks. A point-to-point connection
Former named by Siemens: IQ sense
IO-Link uses the existing 24 VDC point-to-point
wiring between field devices and I/O channels to
transmit additional data via a UART-based pulse
modulation over distances of up to 15 meters.
Driven mainly by sensor companies. Own field
bus organisation:
http://www.io-link.com/
Distribution not yet visible
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IO-Link Beneftis
Peer-to-peer connection no fieldbus
technology
Standard sensor / actuator cable
Serial communication
making sensors communicative
Mixed operation possible
Use of intelligence given in the sensor /
actuator
Reducing the variety of interfaces by means of
standardisation
Convenient parameter setting and storage
Central diagnosis of the whole plant
Service data
Parameter data
Diagnostic data
Process data
Binary signals
Analogue signals
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Technical data
Technical characteristics
Standard I/O connection techniques, unscreened,
20 m cable length
Cyclical, deterministic process data typ. 2 ms
with parallel service data transmission
Integrated, differentiated diagnostic messages
Communication by means of 24 V pulse
modulation, standard UART protocol
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Customer benefits
Customer benefits
Reducing the projection and installation costs by
means of a standardised interface
Reducing the commissioning and set-up times by
means of transparent parameter storage
Reducing machine downtimes by means of
differentiated diagnosis
Sound investment due to the compatibility with the
installed base and field bus neutrality
Point to ponder:
Today unknown costs for IO-Link master and
therefore overall system costs.
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First Products
Products available 2007
Sick cylinder sensor
IO-Link Technologie: Parametrierung, Schaltpunkte,
Hysterese, Ausgang, Tastensperre Diagnose:
Sensorfunktion, Magnetfeldstrke
Halbierter Verkabelungsaufwand
Nur eine Nut ist belegt
Kompakte Bauform, einfache Montage von oben
Einfaches 2-Punkt-Teach-Verfahren
Gateyways zu Feldbus/Ethernet
Gateyway zu AS-Interface
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Strengths and weaknesses
Using existing connection technology, e.g. M12
Standard point-to-point wiring
Compatible to existing traditional sensors
Configured sensors exchange plug-and-work
No price premium within sensor
Plenty of companies support IO-Link
Costs for master system not transparent (yet)
No strategy for output devices (valves)
e.g. Emergency OFF
Short distance (1020 m)
Late market entry, additional technical system to
already existing systems

No Festo products yet
(e.g. SMAT planned 2008)
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Just to remember: the Festo CP/CPI system
Festo CP and CPI system
First decentral I/O system IP65 for valve terminals
Started 1996 for CPV and CPA terminals
Redesigned after 10 years doubled performance
USPs:
3 master platforms (CPX, CPI and FB Direct terminals)
3 I/O module platforms (robust, compact and ecoline)
3 pneumatic platforms (CPV, CPV-SC and MPA)
[CPA phase-out planned]
Competes against many field bus I/O systems from
manufactures like Phoenix, Beckhoff, B&R, Murr,
SMC, Norgren: but they all have multipin VT only !
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Just to remember: the Festo CPI system
Festo CPI system for decentralized I/O
I/O bus comparable system, based on CAN field
bus
Up to 128 resp. 512 I/O
Radius 10 m around field bus node
Digital I/O and valve terminals only
Module oriented diagnostics
Granularity:
- 8IN, 16IN, 32IN modules
- 4OUT, 8OUT modules
- CPV: 4/8 16 OUT/valves per CPI slave
- MPA: 232 OUT/valves per CPI slave
Cycle time 2 ms (CPI slaves only), 4 ms CP slave(s)
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Advanced Fieldbus technologies
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What is new with advanced fieldbus systems
Modular hardware configuration
Optimal and easy hardware configurations of complex and modular products may help to map
I/O data to the plc projects and to locate easily parameters and diagnostic data
Device and module parameterization
Need of setting up diagnostics and configuration of decentral field devices
Integrated diagnostics
Helps to identify failures very fast and to visualize them transparently. Reduction of down-time
Bandwidth for process data and devices
Control of mixed signals like analogue and digital signals
Acyclic data access
Change of parameters and validation of advanced diagnostics during the run-time of the PLC
program
TV-NP/VUK
Positioning and potential of individual bus systems at the field level
Plant/machine
design
[dimensions & structure]
Complexity
of application
[sensors & actuators]
> 90% Digital
> 20% analogue
Pre-
processing
> 20% closed loop
Compact
manually
operating
workspaces
Automation
Cell
Linked,
station-orianted
machines
Automation
plants
Fieldbus
Communication
Motion Control
EtherNet TCP/IP
Drive-Bus
I/O Bus
Industrial EtherNet
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Development of bus systems in the last decade
Clear consolidation to open communication fieldbus systems
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Network topology with I/O Fieldbus [1] PC connection
[2] I/O Bus
[3] PLC cards for device control
3
1
2
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Network topology with Fieldbus [1] Corporate network / Intranet
[2] I/O Bus
[3] Field device network / Fieldbus
[4] Fieldbus to I/O bus gateway
1
2
4
3
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All about Profibus
Relevance
Profibus dominates the market with a worldwide
connectivity of over 40%
Profibus is the number 1 and major fieldbus
technology and will keep dominance
Fieldbus organisation
The Fieldbus club is PNO (Profibus User
Organization) which administrates Profibus and
ProfiNet technologies for 1400 member
companies.
- More details: www.profibus.com
Major suppliers
The major supplier of Profibus network and control
devices is Siemens.
Some other PLC suppliers integrate Profibus
platforms like Hilscher Sycon (e.g. Schneider
Electric).
Regional Profibus distribution
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Some technical data
Baudrate
[kBaud]
Kabellnge
[m]
Stichleitungslnge
[m]
9.6 1200 500
19.2 1200 500
93.75 1200 100
187.5 1000 33,3
500 400 20
1500 200 6.6
3000-12000 100 -
Fieldbus attributes
Line topology , multi-master
Max. 126 field devices
Max. 512 I/O for each device
Network communication
Multi-master system for control and visualisation
Profibus slaves are passive inside the network
They just response
Acyclic communication with DPV1 possible for
parameters and diagnostics
Cycle time depending on number of devices, data
size and connection setup
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Configuration, Parameters
Hardware configuration
Module oriented configuration and network
configuration is done in a Hardware Configurator
including module/device parameter setting and
start up parameterization. All relevant information
about the device is captured in a generic station
description file (GSD)
Software tools for network configuration
Siemens: SIMATIC Step 7
Hilscher: Sycon Configurator
Parameterization
Usually parameters are downloaded to the filed
device during the start-up routine. Some field
devices support the function start with local
parameters. Alternatively parameters can be set
via DPV1 with the PLC program.
2
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Diagnostic integration
Diagnostics
Diagnostic data and parameters are usually also
integrated into the GSD files and are read out in
online mode of configuration tools like Step7 or
can be interpreted by PLCs.
16 pre-defined failure types.
Advanced diagnostics may be integrated into the
PLC with the use of OB82 and OB86 function
blocks.
Diagnostic information is structured in
Device oriented diagnostic
Module oriented diagnostic
Channel oriented diagnostic
OB82
:BE
Device
specific
failure
OB86
:BE
Communi-
cation
failure
Byte 0 - Station-Status 1
1 1 0 1 0 0 0 0
0 1 2 3 4 5 6 7
OB1
CALL SFC13
cyclic
Program
SFC13
#3 -> DBn
DP
Diagnose
DBn
Diagnostic-
Data
BE =Block End
->OB is interpreted
and SPS stays in
RUN-Mode
1
2 3
3
2 1
4 5
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Strengths and weaknesses
Large amount of vendors and field devices with
Profibus connections in the market available
Good configuration and parameterization
integrated with STEP7 and the hardware
configuration tool
Very good diagnostic concept as Profibus standard
automatic integration into Step7 environment
Good integration of non-Siemens vendor device
data with GSD into Profibus configuration
environment
Limited amount of parameters hinders to build up
parameter-intensive complex modular field devices.

TV-NP/VUK
Profibus common field devices and controllers
Generally all valve terminal & Remote I/O
manufacturers provide fieldbus devices with
Profibus
Many PLC suppliers integrate Profibus masters
PLC:
Siemens S7-300 [1], S7-400 [2]
I/O:
Siemens ET200 families [3] [4]
Phoenix Contact Inline
Wago 750 [5]
Beckhoff Bus Terminal
Valve Terminal:
Bosch valve terminals
Norgren valve terminals
SMC valve temrinals
7
6
1 2
3 4
5
8
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Festo products
CPX Terminal: CPX-FB13 Profibus DP
with MPA, VTSA, CPA, Typ03
CPI-System with CPX Fieldbus
CPV DI01 and CPV DI02 (summer 2007)
CP-FB13-E, CP-FB9-E
CPV-SC and CPA-SC
FB13-03, FB9-03, FB13-02
SPC200 (pneumatic controller)
SFC-DC PB
MTR-DCI PB
SFC-LAC PB
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All about DeviceNet
Relevance
Number 2 network in the world market
Expected to keep place 2 in 2010
Fieldbus organisation
The ODVA (Open DeviceNet Vendor Association)
- focuses the development and extension of
DeviceNet, ControlNet and Ethernet/IP
technology.
- CIP (Common Industrial Protocol) is the
consolidated application layer
- Other topics: CIPMotion, CIP Safety, CompoNet
- More details: www.odva.org
Major suppliers
Rockwell Automation (Allen-Bradley) is the major
supplier for PLC and field devices
Omron focuses DeviceNet networks in the Asian
region
Regional DeviceNet distribution
Major vendors Rockwell Automation and Omron
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Some technical data
Communication
Speed
Thick cable
length
Thin cable
length
Drop line
length
500 kbit/s 100 m 100 m 6 m
250 kbit/s 250 m 100 m 6 m
125 kbit/s 500 m 100 m 6 m
Fieldbus attributes
Line topology with drop lines
Max. 64 field devices
Max. 512 I/O for each device
Network I/O data limited by DeviceNet scanner
Network communication
Devices are specified as clients or servers, multiple
masters in one network are possible
Acyclic communication with Explicit Messaging
possible for parameters and diagnostics
Process data connection variants:
Master-to-Slave with: Polled, Bit-Strobed
Slave-to-Master with: Cyclic and Change-of-State
Cycle time depending on number of devices, data
size and connection setup
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Configuration and parameters
Hardware configuration
Field devices are mapped to PLC registers with
DeviceNet scanner modules. Type of connection
mode and I/O size is edited in the Scanlist [1]
Software tools for network configuration
Rockwell Automation: RSNetworx for DeviceNet
Omron: DeviceNet Configurator
Omron PLCs support also the Auto-Config mode
without using a software tool
Parameterization
Usually parameters are stored decentral in the field
devices. Some PLC scanners support ADR Auto-
Address Recovery. This functions stores
parameter sets locally and enables start-up
parameterization.
Alternatively parameters can be set with Explicit
Messaging via the PLC program
EDS files
1 2
RSNetWorx for DeviceNet
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Diagnostic integration
Diagnostics
Diagnostic data and parameters are usually also
integrated into the EDS files and are read out in
online mode of configuration tools like
RSNetWorx
Basic diagnostics can be integrated by mapping
Status Bits registers into the device I/O data
Advanced diagnostics may be integrated into the
PLC program by using Explicit Messaging
commands
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Strengths and weaknesses
Large amount of vendors and field devices for
DeviceNet networks in the market available
Easy maintenance, configuration and
parameterization with additional network tools
based on EDS files and Explicit Messaging
Good integration of non-Rockwell vendor devices
with EDS files
Acyclic device data access via fieldbus with
Explicit Messaging functionality
Drop line concept enables network availability also
with multiple defective devices
Device diagnostics are not automatically integrated
into controller program concept.
A manual programming based on Explicit
Messaging is necessary
Cycle time reduction with large networks

TV-NP/VUK
Common field devices and controllers
PLC:
Allen Bradley
ControlLogix [1] , SLC500 and CompactLogix [2]
Omron CJ1 [4]
I/O:
Allen Bradley 1734 Point I/O (IP20) [3]
AB 1738 Armorpoint I/O (IP65)
Valve Terminals:
Norgren VM series [5]
SMC EX250 with several valve families [6]
Numatics G2 with several valve families [7]
1 2
3
7
5
4
6
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Festo products
CPV-DN2, CPV-DN3 (3rd q. 2007)
CPA-SC, CPV-SC
CDVI
Typ03
CPX Terminal
with MPA, VTSA, CPA, Typ03
CPI-System with CPX Fieldbus
SPC 200
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All about Interbus
Relevance
Interbus is a common fieldbus in the European
automotive industry. The protocol was released in
1987 but it will just survive as niche application in
some branches.
Fieldbus organisation
The Interbus Club focuses actually to the
adaptation and integration of Interbus systems
into Profinet host systems
- More details: www.interbusclub.com
Major suppliers
The major supplier of Interbus network and control
devices is Phoenix Contact.
Regional Interbus distribution
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Some technical data
Communication Speed Bus cable length (m)
500 kbit/s (Copper) 12,8 km
2000 kbit/s (Fibre Optics) 80 km
Fieldbus attributes
Ring topology with single master
Max. 256 field devices
Typical 256 I/O for each
Network size is reduced to 8192 I/O
Network communication
Every device has a repeater functionality
The bus-ring must be a closed chain
Cycle time: 1ms (1 I/O) linear 7,8 ms(1096 I/O)
The technology is focused to bus functionalities as
redundancy, deterministic and bus diagnostics
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Configuration and parameters
Hardware configuration
Field devices are bus settings are configured by the
CMD tool. The set-up is then stored to the fieldbus
master
Software tools for network configuration
Phoenix Contact: IBS CMD enables the
configuration, monitoring and diagnostics of a
Interbus network.
Parameterization and Diagnostics
The acyclic communication via the PCP channel
enables configuration and parameterization of field
devices. But it has to be setup in the PLC project
with high expense. This enables a start-up
parameterization
Interbus has no integrated device diagnostic
concept
Interbus configuration tool IBS CMD
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Strengths and weaknesses
Deterministic cycle time
Good bus-diagnostic functions with detection of
failure location
Regulated fibre-optics communication
Fast bus cycle time which is independent of cable
length
Large network dimensions due to repeater
functionality
Good integration into ProfiNet environment
No device diagnostics integrated in fieldbus concept
No easy parameterization possible
Network breakdown in case of single device failures

TV-NP/VUK
Common field devices and controllers
PLC:
Phoenix Contact Inline Controllers [1]
I/O:
Phoenix Contact Inline I/O [1]
Lumberg ISL [2]
Phoenix Contact Fieldline [3]
Valve Terminal:
Bosch Rexroth HF02/03 [4]
EX245 with several valve families [5]
1
2
4
3
5
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Festo products
Festo products:
CPV-DN2
Typ03 Midi Maxi
- FB6 Interbus Standard
- FB21 Interbus Fibre Optics
CPX Terminal
with MPA, VTSA, CPA, Typ03
CPI-System with CPX Fieldbus
SPC 200
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All about CANopen
Relevance
CANopen was designed for motion-oriented
machine control networks, such as handling
systems.
Often used with PC based control system.
The main market is in Europe.
Fieldbus organisation
The CiA (CAN in Automation)
- focuses the development and extension of
CANopen and CAN technology.
- Integration of branch specific adaptations and
generic device profiles
- Other topics: General CAN, DeviceNet
- More details: www.can-cia.org
Major suppliers
CANopen is driven by a group of small- and middle
sized companies in central Europe
Regional CANopen distribution
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Some technical data
Comm.
Speed
1000
kbit/s
500
kbit/s
250
kbit/s
125
kbit/s
62,5
kbit/s
Cable
length
30 m 100 m 250 m 500 m 1000 m
Fieldbus attributes
Line topology with drop lines
Max. 124 field devices
Remote I/O devices are defined to have 4 PDO
connection pairs with totally 256 I/O (CiA DS 401)
Max. 512 network PDO connections (each 8 byte)
Network communication
PDO connections for cyclic I/O data exchange
SDO connections for acyclic parameter and
diagnostic data exchange
NMT (Network Management) for setting up
operational modes and network failure behaviours
Cycle time depending on number of devices, data
size and connection setup
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Configuration and parameters
Hardware configuration
Field devices are mapped directly to the PLC
registers via PDO connections. By default Remote
I/O devices
have 1 PDO pair for digital data and 3 PDO pairs for
analogue data. An alternative setup is possible.
Software tools for network configuration
Vector: ProCANopen
Hilscher: Sycon configuration tool also available
as OEM tool
Parameterization
Parameters are set up via SDO directly inside the
PLC program. This enables start-up
parameterization.
But also dynamic handling during the run-time.
Configuration tools are alternatives. More
transparency is possible with the integration of
EDS files.
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Diagnostic integration
Diagnostics
Advanced diagnostic data are integrated by the use
of SDO connections within the PLC program
Heartbeat is a method to integrate the network
status of a field device
Emergency messages may be triggered by field
devices. Diagnostic message will be sent to the
CANopen master.
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Strengths and weaknesses
Ideal for closed control chains
With SDO parameter access optimal for dynamic
application as motion control
Many functionalities as Heartbeat and
Emergency Messages integrated in field bus
definition
Many solutions with embedded CANopen masters
available in the market
Branch optimized device profiles

Maintenance of CANopen networks is difficult due
to non-transparent parameters and configurations
Users have to deal with bit & byte based registers to
access and to configure parameters and diagnostics
Many different configuration and maintenance tools
available
Cycle time reduction with large networks
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Common field devices and controllers
PLC:
Schneider Electric Modicon Premium
Panel PCs with embedded CANopen Master
I/O:
Beckhoff Bus Terminal
Wago 750 series
Valve Terminal:
Bosch Rexroth HF 02/03
Camozzi Y series
1
3
2
6
4
5
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Festo products
Valve terminals
CPV-DN2, CPV-DN3 (3rd q. 2007)
CPX Terminal
with MPA, VTSA, CPA, Typ03
CPI-System with CPX Fieldbus
Motor controller
SFC
SEC-AC
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All about CC-LINK
Relevance
CC-Link focuses regionally in Asia and especially
Japan.
Forecasts show that CC-Link looses market share.
An Industrial Ethernet adaptation is not available
Fieldbus organisation
The CC-Link Partner Association (CLPA) supports
CC-Link vendors from the head-office in Japan
- More details: www.cc-link.org
Major suppliers
The major supplier of CC-Link network and control
devices is Mitsubishi Electric
Regional CC-Link distribution
TV-NP/VUK
Technical data
Communication Speed Bus cable length (m)
10 Mbps 100
5 Mbps 160
2.5 Mbps 400
625 kbps 900
156 Kbps 1200
Fieldbus attributes
Max. 128 I/O for each device
1 to 4 stations assignable
Max. 64 stations (Vers. 1.10)
or max. 64 field devices (Vers. 2.00)
Network limited to 2048 I/O points (Vers. 1.10)
or 8192 I/O (Vers. 2.00)
Network communication
Single master system
Multi drop wiring with bus end resistors
Usage of T-branches is possible
TV-NP/VUK
Configuration, Parameters and Diagnostics
Hardware configuration
Up to 4 stations are linked to one field device.
The number of stations depends on size of bit
(digital) and word (analogue & status) data.
One station is able to reference 16 digital or 4
analogue channels
Software tools for network configuration
Mitsubishi Electric: CC-Link Configurator
Mitsubishi PLC software GX Developer
Parameterization & diagnostics
Uploading, downloading and monitoring of
network parameters via CC-Link configuration tools
Field device parameters and diagnostics are not
available on the fieldbus
TV-NP/VUK
Strengths and weaknesses
Easy hardware configuration
Network diagnostics available

No device diagnostics integrated in fieldbus concept
No device parameterization via fieldbus
Limited device I/O size
No acyclic data exchange for parameters available
TV-NP/VUK
CC-Link: Common field devices and controllers
PLC:
Mitsubishi MELSEC System Q
I/O:
Mitsubishi MELSEC ST
Valve Terminal:
SMC EX12*, EX140, EX180, EX250
CKD OPP-1G OPP2OPP6
1 2
3 4
TV-NP/VUK
Festo products
Valve terminals
CPV-DN2
CPX Terminal
with MPA, VTSA, CPA, Typ03
CPI-System with CPX Fieldbus
SA fieldbus modules for Typ03 and CPA
TV-NP/VUK
All about ControlNet
Relevance
Number 3 network in the North American market
ControlNet actually looses relevance, many
customer switch to Ethernet/IP
With redundancy and determinism ControlNet is
established as niche fieldbus
Fieldbus organisation
ControlNet International
- Sub organization of the ODVA
- More details: www.controlnet.org
Major suppliers
Rockwell Automation (Allen-Bradley) is the major
supplier for PLC and field devices Regional ControlNet distribution
TV-NP/VUK
Technical data
Communication Speed Bus cable length (m)
5000 kbit/s (Coax) 5000 m (Coax w.
repeater)
5000 kbit/s (Fibre optics) 30 km (Fibre optics w.
repeater)
Fieldbus attributes
Line, tree, star technologies and mixed
Max. 99 field devices
Network communication
Producer/Consumer model helps that devices and
controllers are synchronized at the same time
Communication modes as Master/Slave, Multi
master and peer-to-peer
Acyclic communication possible
Process data connection variants:
Polled, Cyclic and Change-of-State
Deterministic cycle time selectable between 2 and
100msec
Time critical data is configured with priority in the
network update time (NUT) intervals
TV-NP/VUK
Configuration, Parameters and Diagnostics
Hardware configuration
Field devices are mapped to PLC registers with
ControlNet scanner modules. Type of connection
mode and I/O size is edited in the Scanlist.
Additionally the setup of timing parameters and
network schedule is possible.
Software tools for network configuration
Rockwell Automation RSNetWorx for ControlNet
or directly in PLC program RSLogix
Parameterization & diagnostics
Parameters and diagnostics are reduced to
network status and settings
Field device parameters and diagnostics are not
available on the fieldbus
TV-NP/VUK
Strengths and weaknesses
Good network efficiency
Many topologies possible:
trunk, tree, star, ring, long distance
Fast data exchange between PLCs
Media redundancy
Good determinism and time interlocking
High bandwidth
Field device diagnostics not integrated inside
fieldbus concept
Network and infrastructure mostly supplied just by
Rockwell Automation

TV-NP/VUK
ControlNet common field devices and controllers
PLC:
Allen Bradley ControlLogix [1] , SLC500
I/O:
Allen Bradley 1734 Point I/O (IP20) [2]
Valve Terminal:
SMC EX250 with several valve families [3]
Numatics G2 with several valve families [4]
Gateway:
ControlNet to DeviceNet Linking Device
Allen Bradley 1788-CN2DN
1
2
4 3
5
TV-NP/VUK
Festo products
No products
TV-NP/VUK
Industrial Ethernet Fieldbus systems
TV-NP/VUK
Introduction to Ethernet and Industrial Ethernet
TV-NP/VUK
What is Ethernet?
With the term Ethernet many elements of a typical
office network structure are referenced
The official standard of ethernet defined by
the IEEE (Institute of Electrical and Electronics
Engineers) is IEEE 802.3 CSMA/CD (Carrier
Sense Multiple Access with Collision
Detection)
Ethernet is a definition of the group physical
LAN (Local Area Network) IEEE 802
Ethernet is a group of defined protocols on
defined hardware interfaces
Ethernet is an electronic medium for software
based transportation, communication and
application protocols
Ethernet ??
HTTP ??
SMTP ??
TCP/IP ??
UDP ??
TV-NP/VUK
Ethernet in the ISO/OSI network model
Ethernet is defined in the levels 1 and 2 of the
ISO/OSI network model
The upper level of the OSI model can also work
with other network access definitions then
ethernet
Ethernet describes cables, communication
media and hardware interfaces in level 1. Data
access via CSMA/CD and the Ethernet Frame are
described in level 2
Ethernet is common in office and home
networks. PCs, printers and servers use typically
ethernet
OSI
Level
Name Protocols
7
6
5
4
3
2 Data Link Layer Ethernet
Token Ring
WLAN
Fieldbus
1 Physical Layer
TV-NP/VUK
Ethernet standards
Ethernet has different definitions for speed, cables
and network topologies
1. 10 Mbit/s Ethernet
2. 100 Mbit/s Fast Ethernet
3. 1000 Mbit/s Gigabit Ethernet
4. 10 Gbit/s 10 Gigabit Ethernet
IEEE-
Standard Bezeichnung Jahr Datenrate Kabel
802.3 10Base-5 1983 10 MBit/s Koaxialkabel
(DIX/AUI), 500 m
802.3a 10Base-2 1988 10 MBit/s Koaxialkabel (BNC),
185 m
802.3i 10Base-T 1990 10 MBit/s Twisted-Pair-Kabel
(RJ-45), 100 m
802.3j 10Base-FL 1992 10 MBit/s Glasfaserkabel
802.3u 100Base-TX 1995 100 MBit/s Twisted-Pair-Kabel
(RJ-45), 100 m
802.3u 100Base-FX 1995 100 MBit/s Glasfaserkabel
1000Base-SX
1000Base-LX
802.3ab 1000Base-T 1999 1 GBit/s Twisted-Pair-Kabel
(RJ-45)
10GBase-SR
10GBase-SW
10GBase-LR
10GBase-LW
10GBase-ER
10GBase-EW
10GBase-LX4
802.3z 1998 1 GBit/s Glasfaserkabel
802.3ae 2002 10 GBit/s Glasfaserkabel
TV-NP/VUK
Ethernet address
Every ethernet device has a worldwide
unique ethernet address
(also called MAC address or MAC-ID)
In the levels of the network access of ethernet,
devices just communicate with each other via
the MAC-IDs
Via ethernet the devices of a network can
communicate with each other.
To communicate with other networks one device
(e.g. network router) has to use other network
access medias (Telephone network) and
protocols of the upper level
00 OE F0 - 00 - 02 08
The first 3 bytes are specified to
the manufacturer. The last 3 to the
production.
Festo - MAC numbers:
00 OE F0 xx xx xx
TV-NP/VUK
TCP/IP stack
The TCP/IP stack is the core of IT technology
The logical communication, between devices in
one or more networks, is handled at level 3 and
4 of the network model witch is referenced
by the term TCP/IP
Level 5 and 6 (Session management) are not
used in the ethernet environment
Level 7 describes the application protocols,
which are used between programs
(e.g. Web browser and web server)
The set of protocols of level 3 to 7 is often
described as TCP/IP stack or TCP/IP suite
OSI
Level
Name Protocols
7 Application HTTP, FTP, ...
6
5
4 Transport TCP UDP
3 Network IP
2 Network access Ethernet
Token Bus
WLAN
Field bus
1
TV-NP/VUK
Internet Protocol (IP) The network protocol
Internet Protocol
Via the Internet Protocol devices of different
networks can communicate with another
Logical IP addresses define the network
structure
With the use of network-masks IP-address
ranges can be defined for sub-networks
IP address
An IP-address is defined in 4 numbers of the
Dotted Decimal Notation. Every number can
have a value between 0 and 255
Up to 4.3 million address are so available
Various address ranges are defined for
institutions and companies. Others are open
for corporate (10.x.x.x) and private use
(192.168.x.x)
Ethernet network 1
with Router
192.168.1.56
Ethernet network 2
with Router
212.45.33.26
Telephone network
TV-NP/VUK
TCP and UDP The transportation protocols
TCP Transfer Control Protocol
TCP creates a virtual connection. The data is
divided into packets. This packets are sent to
the receiver. If packets get lost the addressor
sends them again.
Typically used for file transfer.
UDP User Datagram Protocol
UDP sends packets without acknowledgments to
the receiver.
It is used for fast applications.
TV-NP/VUK
Application protocols
Application protocols are used to transfer data
between programs
Examples of application protocols are
HTTP (Hyper Text Transfer Protocol)
used for the transfer of web-pages or web-files
(PDF) between a web-server and a we-browser
FTP (File Transfer Protocol)
used to transfer files between a local and a
server-based file system
SMTP (Simple Mail Transfer Protocol)
used to send emails between local email-
programs and email-server
Internet
FTP
Email
Telnet
TV-NP/VUK
Dictionary
Hub Active network device to connect IO devices. A hub routes frames to all field devices
Switch Active network device. A switch routes frames only to the addressed field device(s)
Router Netware component to ensure the gateway from one communication physics to another
Proxy Representative of a fieldbus in the Profinet environment (acts like a router)
IP Internet Protocol: allows data transfer from point to point in the ethernet
IP Address Internet Protocol address, assigned by IO controller to allow data communication
MAC Address Media Access Control Address, unique address (6 bytes) assigned by IEEE
MAC Media Access Control: defines the access to communication medium
RT / IRT Real Time / Isochrone Real Time
TCP Transmission Control Protocol: to ensure a coordinated and controlled data exchange
UDP User Datagram Protocol unsecured multicast/broadcast protocol
XML Extensible Markup Language: standardized description language for most interpreters
SNMP
Simple Network Management Protocol: standard internet protocol
TV-NP/VUK
What is Industrial Ethernet?
Industrial Ethernet describes:
The adaptation of ethernet components into
the rough industrial environment
Fieldbus based communication protocols for
use with or inside the TCP/IP stack
The possibility of information access and
engineering advantages through the local
network and IT-technology
TV-NP/VUK
Industrial Ethernet hardware components
Typical components in ethernet networks are hubs
and switches with RJ45 connectors
The industrial environment defines higher
conditions in the field:
- High protection rates, e.g. IP65/67
- Temperature
- Vibration
- Reliability,
Typical office components cannot fulfill
such conditions
New definitions for special business
orientations define special components
The prices of industrial ethernet components
are much more expensive
Example of standard office components
Example of Industrial Ethernet components
TV-NP/VUK
Industrial Ethernet Fieldbus concepts
To adopt the conditions of industrial networks, like real-
time and availability, to ethernet based installations,
new communication protocols have been created
Ethernet/IP
ProfiNet
MODBUS/TCP
EtherCAT
Ethernet Powerlink
TV-NP/VUK
What is new with advanced fieldbus systems
Modular hardware configuration
Optimal and easy hardware configurations of complex and modular products may help to map
I/O data to the plc projects and to locate easily parameters and diagnostic data
Device and module parameterization
Need of setting up diagnostics and configuration of decentral field devices
Integrated diagnostics
Helps to identify failures very fast and to visualize them transparently. Reduction of down-time
Bandwidth for process data and devices
Control of mixed signals like analogue and digital signals
Acyclic data access
Change of parameters and validation of advanced diagnostics during the run-time of the PLC
program
TV-NP/VUK
What is new with industrial ethernet fieldbus system
Higher bandwidth
Enables communication between controllers.
Integration of more complex products with large I/O size
Expansion of network technology
More devices may be integrated into the fieldbus networks due to IP addressing technology with
sub-networks.
Network peripheries like WLAN routers, switches, proxy and gateway servers may be included.
Integration of IT-Technology
More diagnostic tools which are able to communicate to the field devices via ethernet from any
point inside the control architecture.
TV-NP/VUK
Industrial Ethernet vs. fieldbus competition or co-existence?
Target situation Current situation
One industrial Ethernet protocol > 5 relevant industrial Ethernet protocols
Use of hardware from PCs and consumer products results in uniform,
standardised products.
Didnt happen: necessity for individualised hardware and designs for
each system, few usable electronic components from PC technology
Reduced hook-up costs per device thanks to large quantities and
inexpensive hardware. Vision: industrial Ethernet in the individual
sensor/actuator
Mission botched: price increase for hook-up costs per node due to
quantity splitting, high performance electronics and individual design
Utilisation of IT functions in the front-end automation device provides a
transparent link to master systems, as well as increased data
communication.
Not previously utilised: IT functions are usually only used as of the
control level; few projects with IT at the field level.
High performance communication with regard to data width, speed and
synchronisation allows for the integration of motion control applications
into an network with other field devices.
Mission accomplished: variants with fast, synchronous data
communication in co-existence with standard communications on a single
bus.

TV-NP/VUK
Positioning and potential of individual bus systems at the field level
Plant/machine
design
[dimensions & structure]
Complexity
of application
[sensors & actuators]
> 90% Digital
> 20% analogue
Pre-
processing
> 20% closed loop
Compact
manually
operating
workspaces
Automation
Cell
Linked,
station-orianted
machines
Automation
plants
Fieldbus
Communication
Motion Control
EtherNet TCP/IP
Drive-Bus
I/O Bus
Industrial EtherNet
TV-NP/VUK
Trend review 2006-2002: Industrial Ethernet
2006: industrial Ethernet will co-exist with fieldbus driven by complex applications
TV-NP/VUK
Network topology with Fieldbus [1] Corporate network / Intranet
[2] Automation network / Ind. Ethernet
[3] Field device network / Fieldbus
[4] Ethernet gateway server
4
4
1
2
3
TV-NP/VUK
Network topology with Industrial Ethernet [1] Corporate network / Intranet
[2] Automation network / Ind. Ethernet
[3] Field device network / Fieldbus
[4] Ethernet gateway server
[5] Fieldbus gateway devices
[6] Industrial network peripherals
4
4
5
1
2
3
6
TV-NP/VUK
Technology: TCP/IP based
Tunneling of process data
TCP/IP based concept uses standard, unmodified
Ethernet hardware as well as standard TCP/IP stacks
for process communication.
The real time performance is limited by
- Network components like switches
- The standard TCP/IP stacks which are not real time
optimzed
Bus cycle = ca. 10ms
Standard Ethernet Controller
IP
TCP/UDP
IT-Tech.
HTTP
SMTP
FTP
DHCP
Automation protocol
Process data (I/O)
Parameter data
Hardware
Software
CBA
TV-NP/VUK
Technology: Real-Time Access
Standard, unmodified hardware but the process data
communication is not based on the TCP/IP stack.
The access of real-time data and the parallel TCP/IP
data is coordinated by devices.
Bus cycle < 10ms
Standard Ethernet Controller
IP
TCP/UDP
IT-Tech.
HTTP
SMTP
FTP
DHCP
Automation protocol
Process data (I/O)
Parameter data
Hardware
Software
Real-Time
access
RT
TV-NP/VUK
Technology: Real-Time Hardware
Performance solution with focus on network speed.
Special Ethernet controller which enables optimized
real-time access
TCP/IP data is just tunneled with lower priority
Cycle time < 1ms
Real-Time Ethernet Controller
IP
TCP/UDP
IT-Tech.
HTTP
SMTP
FTP
DHCP
Automation protocol
Real-Time Data (I/O)
Parameter Data
Hardware
Software
Real-Time
access
IRT
TV-NP/VUK
All about Ethernet/IP
Relevance
Ethernet/IP (Ethernet Industrial Protocol)
Part of Rockwell Automation network architecture
Expected to win market share in the next years
Fieldbus organisation
The ODVA (Open DeviceNet Vendor Association)
- focuses the development and extension of
DeviceNet, ControlNet and Ethernet/IP technology.
- CIP (Common Industrial Protocol) is the
consolidated application layer
- Other topics: CIPMotion, CIP Safety, CompoNet
- More details: www.odva.org
Major suppliers
Rockwell Automation (Allen-Bradley) is the major
supplier for PLC and field devices
Regional Ethernet/IP distribution
TV-NP/VUK
Technical data
Communication
Speed
Recommended
network
periphery
Cable length
between
connections
10 Mbit/s Manageable
switches
100 m
100 Mbit/s 100 m
1000 Mbit/s Depending on
periphery
Fieldbus attributes
Switched Ethernet topology
Device identification based on IP-addresses
Number of slave connections limited by Ethernet/IP
bridging modules. Typically 64 connections.
Network communication
Acyclic communication with Explicit Messaging
possible for parameters and diagnostics
Cycle time depending on number of connections
and bandwidth which is used for other TCP/IP
applications
Communication based on TCP (Explicit) and UDP
(Implicit) messages. Also usage of broadcast
messages.
TV-NP/VUK
Configuration and parameters
Hardware configuration
Field devices are mapped directly inside the PLC
project
Software tools for network configuration
Rockwell Automation:
PLC project software RSLogix 5000
No diagnostic solution
Parameterization & diagnostics
Parameters are set up via vendor based software
tools
Parameter integration with EDS files is not yet
possible in Rockwell environments
Usage of IT-technology to access device data with
vendor specific tools
TV-NP/VUK
Strengths and weaknesses
Uses available infrastructure components as
switches
Acyclic device data access via fieldbus with
Explicit Messaging functionality
IT functionality supported with the same network
Device diagnostics are not automatically integrated
into controller program concept.
A manual programming based on Explicit
Messaging is necessary
Limited real time capabilities
Bad integration of non-Rockwell vendor devices into
Allen-Bradley products.
No parameters and diagnostics with the EDS file
No line topology integrated, big invest into
infrastructure (switches)

TV-NP/VUK
Ethernet/IP common field devices and controllers
PLC:
Allen Bradley
ControlLogix [1] and CompactLogix [2]
I/O:
Allen Bradley 1734 Point I/O (IP20) [3] ,
1738 Armorpoint I/O (IP65)
Valve Terminal:
Numatics G2-2 with 2002, 2005, 2012, 2035 [4]
Parker IsysNet with AB ArmorPoint [5]
Gateway:
Ethernet/IP to DeviceNet network gateway
AB 1788-EN2DN [6]
1 2
3
4
5
6
TV-NP/VUK
Festo products
CPX Terminal:
CPX-FB32 Ethernet/IP [1]
with MPA, VTSA, CPA, Typ03
CPI-System with CPX Fieldbus [2]
1
2
TV-NP/VUK
All about ProfiNet
Relevance
ProfiNet is supposed to dominate the market of
industrial ethernet within the next years.
Fieldbus organisation
The Fieldbus club is PNO (Profibus User
Organization) which administrates Profibus and
ProfiNet technologies.
- More details: www.profibus.com
Major suppliers
The major supplier of ProfiNet network and control
devices is Siemens.
Also Phoenix Contact provides a broad portfolio of
ProfiNet controllers and field devices as well as
active network devices.
Expected regional ProfiNet distribution
TV-NP/VUK
Some technical data
Fieldbus attributes
Star, Tree, Line topology by integrated
switches , multi-master
Max. 255 field devices per segment
Max. 512 I/O for each device
Parameters unlimited
Max cable length 100m
Network communication
Multi-master system for control and
visualisation
Cyclic communication and update time
configurable for each field device
Differentiation between ProfiNet RT, IRT
and NRT
TV-NP/VUK
Configuration and parameters
Hardware configuration
Module oriented configuration and network
configuration is done in a Hardware Configurator
including module/device parameter setting and start
up parameterization. All relevant information about
the device is captured in a generic station description
file (GSDML)
Configuration very similar to Profibus DP
Software tools for network configuration
Siemens: SIMATIC Step 7
Parameterization
Usually parameters are downloaded to the filed
device during the start-up routine. Some field
devices support the function start with local
parameters.
TV-NP/VUK
Diagnostic integration
Diagnostics
Access to process data with standard office tools
Diagnostic concept very similar to Profibus DP
Usage of IT-technology to access device data with
vendor specific tools
OB82
:BE
Device
specific
failure
OB86
:BE
Communi-
cation
failure
Byte 0 - Station-Status 1
1 1 0 1 0 0 0 0
0 1 2 3 4 5 6 7
OB1
CALL SFC13
cyclic
Program
SFC13
#3 -> DBn
DP
Diagnose
DBn
Diagnostic-
Data
BE =Block End
->OB is interpreted
and SPS stays in
RUN-Mode
1
2 3
3
2 1
4 5
TV-NP/VUK
Strengths and weaknesses
Excellent market reputation of Profibus and good
migration strategy to ProfiNet.
Good configuration, parameterization integrated
with STEP7 and the hardware configuration tool
Very good diagnostic concept as ProfiNet standard
automatic integration into Step7 environment
Good integration of non-Siemens vendor device
data with GSDML into ProfiNet configuration
environment

Limited amount of field devices available so far
therefore technology still in the start-up.
Prize of field devices still higher than other fieldbus
interfaces
No nominal-actual comparison on module level of
field device.
TV-NP/VUK
Common field devices
PLC:
Siemens S7-300 [1], S7-400 [2]
Phoenix Contact Inline Master [5]
I/O:
Siemens ET200s (IP20) [4],
ET200pro (IP65) [3]
Phoenix Contact Inline (IP20) [5]
Valve Terminal:
Norgren VS26 with Siemens ET200pro [6]
Gateways:
ProfiNet to ProfiBus
ProfiNet to Interbus
1 2
3 4
5
6
TV-NP/VUK
Festo products
CPX Terminal: CPX-FB33, -FB34,-FB35
with MPA, VTSA, CPA, Typ03 [1]
CPI-System with CPX Fieldbus [2]
1
2
TV-NP/VUK
All about Modbus/TCP
Relevance
Modbus TCP is actually strong in Schneider Electric
host environments but also often integrated in PC
based control
Expected to win market share in the next years
Fieldbus organisation
The Modbus-IDA
- focuses the development and extension of the
Modbus protocols for serial and ethernet
communication
- More details: www.modbus.org
Major suppliers
Schneider Electric is the major supplier for PLC and
field devices
Regional Modbus/TCP distribution
TV-NP/VUK
Technical data
Communication
Speed
Recommended
network
periphery
Cable length
between
connections
10 Mbit/s Switches 100 m
100 Mbit/s 100 m
1000 Mbit/s Depending on
periphery
Fieldbus attributes
Switched Ethernet topology
Device identification based on IP-addresses
Number of slave connections limited by
Modbus/TCP master
Network communication
Modbus/TCP is a simple protocol which is
encapsulated inside TCP/IP message via the port
502
A predefined register set is used for I/O and
parameter data access
Many PC software tools support drivers for
Modbus/TCP field device access
No special hardware is needed
TV-NP/VUK
Configuration, parameters & diagnostics
Hardware configuration
Field devices I/O are mapped to Bit or 2Byte
registers directly inside the PLC project
Additionally to the I/O register the service type has
to be chosen (read, write, read/write)
Software tools for network configuration
Schneider Electric PLC software Unity Pro
Several software tools for simulation as
Modbus/TCP master are available as freeware
Parameterization & diagnostics
Parameters are set up by vendor based software
tools or via Modbus/TCP registers within the PLC
program
Parameter integration with device description files
is not possible
Schneider Electric Unity Pro
TV-NP/VUK
Strengths and weaknesses
Uses available infrastructure components as
switches and PC ethernet ports
Easy configuration possible
IT functionality supported with the same network
No device profiles defined
No network failure functionalities integrated
Device diagnostics are not automatically integrated
into controller program concept.
A manual programming is necessary
Limited real time capabilities
Handling with a lot of bit and byte based data
Bad integration of vendor devices into configuration
tools.
No device description files available.
No line topology integrated, big invest into
infrastructure (switches)

TV-NP/VUK
Modbus/TCP common field devices and controllers
PLC:
Schneider Electric Premium family
Generic PC based control with integrated
Modbus/TCP drivers
I/O:
Schneider Electric Advantys family
Beckhoff Bus Terminal
Valve Terminal:
Norgren VM series [5]
1 2
3
4
5
TV-NP/VUK
Festo products
CPX Terminal:
CPX-FEC in Remote I/O mode [1]
with MPA, VTSA, CPA, Typ03
CPI-System with CPX Fieldbus [2]
1
2
TV-NP/VUK
All about EtherCAT
Relevance
EtherCAT is a solution optimized for closed control
chains in machines. With the fast cycle-time it is
ideal for motion control
Expected to win market share especially in Germany
in the next years
Fieldbus organisation
The EtherCAT technology group focuses the
development and extension of the EtherCAT
- More details: www.ethercat.org
Major suppliers
Beckhoff is the core supplier for EtherCAT control
and I/O systems
Expected regional EtherCAT distribution
TV-NP/VUK
Technical data
Fieldbus attributes
2 Ethernet ports integrated on EtherCAT chip
Line, Ring, Tree, Star topologies possible
Automatic network addressing
Network communication
EtherCAT is a network down to the I/O level
(Beckhoff bus I/O modules have EtherCAT
integrated)
Key principle: Frame processing on the fly
EtherCAT masters use standard Ethernet ports.
Slaves need a special EtherCAT ASIC
No additional ethernet hardware needed
CANopen over EtherCAT (CoE) used for device
profiles and parameters
Bus cycle time up to < 0.5 ms
TV-NP/VUK
Configuration, parameters & diagnostics
Hardware configuration
Device I/O are mapped with cyclic PDO
connections
The EtherCAT tools enable the scanning of
hardware
Hardware must not be addressed manually
because the network creates a ring-bus
Software tools for network configuration
Beckhoff PLC software TwinCAT enables with the
System Manager the configuration of EtherCAT
networks
Parameterization & diagnostics
Parameterization and diagnostic is similar to
CANopen networks. Via SDO device objects may be
accessed.
Device data are integrated by the use of XML files
Beckhoff TwinCAT
TV-NP/VUK
Strengths and weaknesses
Very fast bus cycle time up to < 0,5ms
Good synchronicity behaviour
Easy configuration with TwinCAT tool possible
Device description with XML files
Acyclic data access with CoE
CANopen over EtherCAT
Parameters and diagnostics are visualized on a bit&
byte level. Bad maintenance aspects.
Bad integration of IT-technology. Just indirectly with
special Ethernet modules. The core modules dont
supply those functions.

TV-NP/VUK
EtherCAT common field devices and controllers
PLC:
Beckhoff CX series [1]
PC based control with Beckhoff TwinCAT Software
I/O:
Beckhoff Bus Terminal
Valve Terminal:
Prototypes of:
SMC and Bosch Rexroth valve terminals available
1 2
3
4
TV-NP/VUK
Festo products
(Planned in 2008)
CPX Terminal:
CPX-FB38 node [1]
with MPA, VTSA, CPA, Typ03
CPI-System with CPX Fieldbus [2]
1
2
TV-NP/VUK
Generic ethernet cables and connectors
Suppliers of Industrial Ethernet accessories:
Phoenix Contact
PLUSCON Series VARIOSUB
- Ethernet M12 & RJ45 connectors
- Cables sets IP20 to IP65, and other
Harting
- Cables and connectors
Belden
- Cables
TV-NP/DEIC

Fieldbus in process automation

1
TV-NP/DEIC

2
Installation Type
[Dimension & Structure]
Complexity of Application
[Sensors and Actuators]
>90% Digitale
Signale
>40% Analog
Drives and
Remote I/O
Package Units Utilities/Batch Plants
Continuous/
Large Plants
Enterprise
Communication
Plant
Communication
Process-Fieldbus (z.B. Profibus PA, FF-H1)
HART
I/O Bus (AS-i)
TV-NP/DEIC

Process IO Bus - HART

HART-Signal is modulated on an
analog signal like a modem!
Analog: Main Process Value
HART: Parameters, Secondary
Process Values and Diagnostics
3
I/O
Field
Device
4..20mA
TV-NP/DEIC

Process IO Bus HART Access to HART-Data

[1] Handheld Terminal
One-to-One Access
[2] Central Access to all HART-
Devices
HART on Profibus
Asset Management Tools
[3] HART Mapping
I/O Device maps special
HART Data into Process
Data
Accessible from normal
PLC
4
Profibus
Remote I/O
Asset
Management
Tool
HART on Profibus
2
1
3
TV-NP/DEIC

2.1 Process Fieldbus Profibus PA and Foundation Fieldbus H1

Requirements:
Connect all field devices to a bus system
Easy and robust installation in IP65
2-wire installation, power and data on the
same 2 wires
Suitable for large number of analog signals
Allows long cable length for use in large
outdoor plants
Optional Intrinsic Safety for Explosion
Protection
5
TV-NP/DEIC

2.1 Process Fieldbus Profibus PA and Foundation Fieldbus H1

Power and Data on 2 wires how it works
Manchester Coding, Bus Powered (MBP):
Each Fieldbus Segment can be connected to up to 10 Field Devices
6
TV-NP/DEIC

2.1 Process Fieldbus Network Topology Original Concept

7
Control Room
Plant
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2.1 Process Fieldbus Network Topology Modern Concept

8
Control Room
Plant
TV-NP/DEIC

Relevance
Profibus PA is dominant in Europe, worldwide it
plays a smaller role
Fieldbus organisation
The Fieldbus organization is PNO (Profibus User
Organization) which administrates Profibus and
ProfiNet technologies for 1400 member companies.
- More details: www.profibus.com
Major suppliers
As with Profibus DP, the major supplier of host
systems is Siemens.
Special Profibus PA Network Components are
supplied by Pepperl&Fuchs, MTL-Relcom, Stahl.
All about Profibus PA
Regional Profibus PA distribution
TV-NP/DEIC

Relevance
Foundation Fieldbus is the worldwide dominant
Fieldbus for Process Automation
Fieldbus organisation
Fieldbus Foundation www.fieldbus.org.
Major suppliers
Host Systems:
Emerson Process, Yokogawa, Honeywell, ABB
Field Devices: Emerson Process, Yokogawa,
Honeywell, ABB , Endress+Hauser, Siemens
Network Components:
Pepperl&Fuchs, MTL-Relcom, Stahl, Siemens.
All about Foundation Fieldbus H1
Regional FF H1 distribution
TV-NP/DEIC

2.1 Profibus PA and Foundation Fieldbus H1 where is the difference?

Profibus PA
Distribution mainly in Europe
Technically close to Profibus DP
transparent coupling
Supported by Siemens, ABB an any other
manufacturer who supports Profibus
DCS integration is GSD-Based (like Profibus
DP)
Foundation Fieldbus H1
Distribution mainly in NA and Asia
Developed purposely for PA
Offers additional functions: Control in the
Field
Supported by Emerson, Yokogawa,
Honeywell, ABB
DCS integration is EDD based
11
TV-NP/DEIC

2.1 Process Fieldbus - Field Devices

Most Manufacturers offer Field Devices alternatively
with 4..20mA/HART, FF H1, Profibus PA
In Europe, less than 10% of shipped devices are with
PA or FF, 90% are 4..20mA/HART
Price difference 4..20mA/HART to Fieldbus Device:
typically 50 to 100 EUR
12
TV-NP/DEIC

13
Installation Type
[Dimension & Structure]
Complexity of Application
[Sensors and Actuators]
>90% Digitale
Signale
>40% Analog
Drives and
Remote I/O
Package Units Utilities/Batch Plants
Continuous/
Large Plants
Enterprise
Communication
Plant
Communication
EtherNet TCP/IP
Industrial EtherNet
Process-Fieldbus (z.B. Profibus PA, FF-H1)
Plant-Fieldbus (z.B. Profibus DP, DP-IS, DeviceNet)
I/O Bus (AS-i)
TV-NP/DEIC

2.2 Control Architecture of large process plant

OS:
Operator Station Monitoring
and Operation of the plant
ES:
Engineering Station
Comparable to Programming
Device
AS:
Automation System the
control element
14
Ethernet
Plant Bus
IO-Bus
Process Fieldbus
Remote I/O Intelligent Valve Terminal
AS
OS ES
Frequency
Converter
TV-NP/DEIC

3 DCS Systems and Fieldbus Integration

Example: Pharma plant with Emerson Delta V
15
Festo offering: Replace
Remote I/O and Valve
Terminal
TV-NP/DEIC

3 DCS Systems and Fieldbus Integration

Example: Pharma plant with Siemens SIMATIC PCS7
16
Festo offering: Replace
Remote I/O and Valve
Terminal