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© Chevron 2005
Foundation FieldbusTechnical Training
Ryan KellyChevron Energy Technology Company (ETC)
June 2008
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Welcome & Introductions
Ryan Kelly
Instrumentation & Controls Engineer
Chevron ETC – Process Automation Unit
Vincent Palughi
Snr Instrumentation & Controls Engineer
Chevron ETC – Process Automation Unit
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Welcome & Introductions
Please tell us about yourself:
Name
Role on the project
Experience (if any) with Foundation Fieldbus or
other types of smart instrumentation
Your expectations of the course – what you hope
to learn from it
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Safety Moment – Hazardous Areas
The Fire Triangle
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Safety Moment – Hazardous Areas
Area Classification (NEC Article 500.5 / API RP 500)
Class I - flammable gases, flammable liquid–
produced vapors, or combustible liquid–produced
vapors
Class II – combustible dust
Class III - easily ignitible fibers or materials
producing combustible flyings
For full text of the standard, please see NEC Article 500.5
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Safety Moment – Hazardous Areas
Area Classification (NEC Article 500.5 / API RP 500)
Class I, Division 2 is a location in which volatileflammable gases, flammable liquid–produced vapors, orcombustible liquid–produced vapors are handled,processed, or used, but in which the liquids, vapors, orgases will
normally be confined within closed containers or closedsystems from which they can escape only in case ofaccidental rupture or breakdown of such containers orsystems or in case of abnormal operation of equipment,or
normally prevented by positive mechanical ventilation
and which might become hazardous through failure orabnormal operation of the ventilating equipment, or
the area is adjacent to a Class I, Division 1 location
For full text of the standard, please see NEC Article 500.5
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Safety Moment – Hazardous Areas
Protection Techniques (NEC Article 500.7)
Intrinisically Safe Equipment (IS) - Class I, Div
1&2
"Intrinsically safe" devices produce or consume electrical power at levels belowwhat is required to cause an ignition in a hazardous area. The electrical energygoing to the device is limited, and the devices are incapable of storing enoughenergy to create a spark when disconnected.
For full text of the standard, please see NEC Article 500.7
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Safety Moment – Hazardous Areas
Protection Techniques (NEC Article 500.7)
Non-Incendive Equipment (NI) - Class I, Div 2
“Non-Incendive” equipment works on the same principle as Intrinsically Safe,that is by limiting the amount of energy going to and stored in a device. Thedifference is that Non-Incendive is only permitted for use in Division 2 areas,and as such has a reduced safety factor which allows more energy to the fielddevices (but still not enough to create a spark).
For full text of the standard, please see NEC Article 500.7
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Safety Moment – Hazardous Areas
Protection Techniques (NEC Article 500.7)
Purged and Pressurized – Class I, Div 1&2
Hermetically Sealed – Class I, Div 2
Combustible Gas Detection – Class I, Div 1&2
Oil Immersed – Class I, Div 1
Used more in electrical systems than instrumentation
The above techniques are more commonly used for electrical equipment thaninstrumentation.
For full text of the standard, please see NEC Article 500.7
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Agenda – Day 1
Introduction to Foundation Fieldbus
History, Basics, Benefits
Fieldbus System Components
Power, Devices, Wiring
Key Fieldbus Concepts
Tags/Addresses, Blocks, DDs
R00#1 Segment Design and Specifications
Fieldbus and Yokogawa Centum CS3000
Hardware, Software, HMI example
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Agenda – Day 2
Yokogawa Plant Resource Manager (PRM)
Device configuration and troubleshooting
Foundation Fieldbus Commissioning
Segment and Loop Checks
Maintenance of Fieldbus Systems
Physical Layer diagnostics (inc. P+F modules)
Device troubleshooting
Adding/removing/replacing devices
Fieldbus device calibration
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Introduction to Foundation Fieldbus
Image Source:http://www.fieldbus.org/index.php?option=com_content&task=view&id=45&Itemid=195
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What is Foundation Fieldbus?
“Foundation Fieldbus is an open, nonproprietary
architecture that provides a communications protocol
for control and instrumentation systems in which
each device has its' own "intelligence" and
communicates via an all-digital, serial, two-way
communications system.”
More accurate(no 4-20mA)
More functionality
More vendors,interoperable
From equipment upto user interface
Definition fromhttp://www.fieldbus.org/index.php?option=com_content&task=view&id=23&Itemid=308
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History of Foundation Fieldbus
Development of proprietary digital bus protocols during
the 1980s Formation of the Fieldbus Foundation in 1994 to
develop an industry standard
Focused on development of open and interoperable
standards with input from suppliers and users
Future development includes DD enhancements and
safety systems
1995FF Standardsfirst introduced
20081,000,000 devices12,000 systems
1998First registeredFF devices
2001FF HSElinking devices
2003First ChevronFF installations
2002First majorFF plant
Currently for use in process control systems only, not safety systems.
Shell Deer Park was the first major plant to use Foundation Fieldbus.
Foundation Fieldbus Standards:
ANSI/ISA 50.02 (USA)
IEC 61158 (World)
CENELEC EN 50170 (Europe)
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The Fieldbus Foundation
Non-profit consortium formed by members of
various supplier and user organizations
Develops and administers the standards for
Foundation Fieldbus which are open and non-
proprietary
Provides reference material such as user guides
and engineering guides.
Useful website as a resource
for Fieldbus information
http://www.fieldbus.org/
Examples of Chevron participation:
•Deon Rae’s contribution to the Fieldbus Engineering Guideline and standarddevelopment
•Vincent Palughi’s participation in groups developing device coupler test andwiring standards
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Industry Acceptance
Users:
Major oil & gas companies
Other industries – manufacturing, pharmaceutical
Over 12,000 systems and 1 million devices*
68% of projects are selecting FF
Examples of Chevron installations:
El Segundo blending & shipping, California
Al Jubail petrochemical plant, Saudi Arabia
SJVBU tank farm, California
TGPP and TL platforms, Angola offshore
(*) Data from ARC report
Examples of Chevron projects using FF:
•Takula Gas Processing Platform (TGPP) – Angola offshore
•Tombua Landana Production Platform (TL) – Angola offshore
•Cabinda Gas Plant (CGP) – Angola onshore
•Escravos Gas To Liquids plant (EGTL) – Nigeria onshore
•R00#1 SLC VGO unit – Salt Lake City, Utah
•R00#1 Pascagoula Crude 2 unit upgrade – Pascagoula, Mississippi
•R00#1 Burnaby – Burnaby, Canada
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Suppliers – Control Systems & Field Devices
Suppliers – Power Supplies & Connecting
Equipment
Industry Acceptance
Emerson – includes Fisher, Rosemount, Micro Motion, etc.
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Comparison with Analog Systems
Fieldbus uses a digital signal (1s and 0s) rather than
reading analog values (milliamps) Digital data provides an actual measurement value
(e.g. 80 psi) rather than an analog value that has to
be interpreted (e.g. 12 mA)
Digital signal
Actual waveform
Reading analog values requires correct setup of scaling at either end of thecontrol loop.
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Comparison with Analog Systems
Fieldbus devices are also bus-powered (9-30 VDC)
Fieldbus uses a bus topology rather than requiring apair of wires to every device
Host
Marshalling
Host
Marshalling
Field Devices
Device Coupler
Field Devices
Bus-powered means that the device obtains power and communicates on thesame pair of wires (i.e. 2-wire device).
The above examples show field devices with Intrinsic Safety (IS) barriers –these may or may not be required depending on equipment location and thefacility’s choice of hazardous area protection.
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Comparison with Analog Systems
Smarter field devices
Setup of inputs in the device (range, units, etc.)
Built-in device diagnostics (e.g. impulse line plugging)
Additional functionality (mathematical functions, PID)
H1
Image Source: Fieldbus 101 Presentation (Dale Perry, Emerson)
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Comparison with HART
HART uses analog 4-20mA for process values and
superimposes a digital signal on top
Devices have some parameters built into them,
but not to the level and functionality of FF
Devices are polled by the controller (on demand)
rather than transmitting autonomously
Much slower data rate (FF is >25 times faster)
FF is not approved for safety systems, so HART is
generally used
Fieldbus for Safety Instrumented Systems (FF-SIS) is currently undergoingdevelopment and testing.
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FF Topology
Host Interface
(DCS I/O card)
PowerConditioner
Surge Protector DeviceCoupler
Trunk Cable
Field Devices
Spur Cables
T
T = Terminator
T
Key components in an FF segment:
•Host interface (I/O card)
•Power Conditioner
•Device Coupler (Brick)
•Field Devices
•Terminators (one at each end)
•Trunk and Spur wiring
•Surge Protectors
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FF Design Limits
Up to 32 devices per segment
Usually up to 12 devices connected
Also depends on power available
Up to 1900m (6200ft) total field wiring
Includes total of both trunk & spurs
Individual spurs up to 120m (390ft) long
Should be individual shielded twisted pair (STP)
Requires 9-32 VDC at field device
Consider voltage drop on long segments
The R00#1 segment design will be covered later.
Devices called “repeaters” can be used to extend the network length andincrease the number of devices. However the facility design is usually such thatrepeaters are not required, and they are generally not used in Chevroninstallations.
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FF Protocol
Communications protocol includes:
Physical layer (H1)
31.25 kbit/s digital signal
9-32 VDC bus powered
Data link layer
Defines what the bits/bytes mean
Specifications for messages (packets)
User layer
Function blocks
Virtual Communication Relationships (VCRs)
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FF Benefits
Digital protocol
No analog conversion, includes digital error correction,less susceptible to noise
Bi-directional communication between host & device
More data is available from the field device
PV status, health/diagnostics, extra PVs, asset mgmt.
More powerful field devices
Special function blocks, alarming, output scaling,
mathematical functions
More power at field devices enables additionalfunctionality (HART/analog were limited to <4mA)
Mathematical Functions – Integrator/totalizer, Signal Characterizer, Arithmetic
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FF Benefits
Fully digital communications from the sensor to the
control system without D/A conversion
D/A conversion reduces accuracy and the electronics are more susceptible tocurrent drift over time than fully digital electronics. This is the main reason thatanalog and HART instrumentation require more frequent field calibration thanFF devices. For example, the EJX pressure transmitter guarantees error < 0.1%of URL for 10 years.
Image Source: http://www.yokogawa.com/fld/3D/EJX/p03.html
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FF Benefits
Less field wiring/terminations and more physical layer
diagnostics available Faster field commissioning (no field/bench calibration,
configure multiple devices simultaneously)
Many projects are seeing a lower total lifecycle cost
Open standards
Devices tested and approved
Interoperability required
Lower total lifecycle cost is contributed to by saving in commissioning time andadditional info/diagnostics that can alert to device problems and avoiddowntime.
The Fieldbus Foundation check mark shown indicates that a device has passed
the Foundation’s testing
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Fieldbus System Components
Image Source: Fieldbus Book – A Tutorial (Yokogawa Corporation)
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FF Components – Host Interface Card
Yokogawa CS3000 DCS
ALF111 Card Redundant I/O cards
mounted in the Field
Control Station
Interface between the
control system and field
devices
4 segments per card
Special cable (AKB336)
between card and power
conditioner
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FF Components – Power Conditioner
MTL-Relcom
F880 hub w/F801 modules
Special power hub for
Yokogawa connectors
8 segments per hub
Supplies power to field
devices (24 VDC)
Special power supplies
required for FF
Redundant power
conditioner modules
F809f Diagnostic module inthe center
Built-in terminator
Redundant modules are hot swappable
Dual 24 VDC feeds from bulk power supply
The F809f diagnostic module is actually a fieldbus device on the segment(either segment 1 or 8). It can also be connected to an external segment.
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FF Components – Surge Protector
Pepperl+Fuchs
DB-LB w/ DP-LBF-1.34
Installed on all trunks in
the marshalling panel
Surge protection is required
on all pairs due to potential
voltage surge coupling from
the affected wire to any
adjacent wiring in the tray.
DB-LB base allows removal
of the protection module
without interruption of the
signal
Surge protection devices are also available that can be placed at the instrumentend (not part of the R00#1 spec)
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FF Components – Div 2 Device Coupler
Moore Hawke
Trunksafe TG20W (12-spur) Connects trunk to field
spurs
Installed in field junction
box rated for Div 2
Built-in auto terminator
Short-circuit protection
Spurs are classified
Div 2 Non-Incendive
The bottom two connectors on the device coupler are for trunk connections only(only one is used). The others are for the spurs to devices and contain energylimiting circuitry. The device coupler must be connected in accordance with itscontrol drawing (TG200-FM)
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FF Components – Div 1 Device Coupler
Turck
MBD49-T415/Ex (4-spur) Connects trunk to field
spurs
Complete with enclosure
rated for Div 2
Switchable terminator
Short-circuit protection
Spurs are classified
Div 1 Intrinsically Safe
Also known as a
“Multibarrier”
Switchable terminator enables a second multibarrier to be connected on thesegment. The terminator should only be switched on in the final multibarrier onthe segment so that there are exactly 2 terminators per segment (the other isin the power conditioner).
The bottom two connectors on the device coupler are for trunk connectionsonly. The others are for the spurs to devices and contain energy limitingcircuitry. The device coupler must be connected in accordance with its controldrawing (IS-2.502)
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FF Components – Field Devices
Pressure: Yokogawa EJX
Temp: Yokogawa YTAValve: Fisher DVC6000f
Vortex: Yokogawa DY
Radar: Vegaflex 62
Look the same as 4-
20mA and HART devices
but NOT interchangeable
Contains special FF
microprocessor
FF tick of compliance
Can be polarity sensitive
All devices will have + and – terminals – some devices require correct polaritywhile some are able to operate correctly if the polarity is reversed. The bestsolution is to assume all devices are polarity sensitive and always connect thedevices according to the polarity indicated on the terminals. + to brown, - toblue.
Models used for R00#1 specified in:
YR-PAS-DSP-201 Instrumentation Design
YR-PAS-DSP-214 Yokogawa Instrumentation
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FF Components – Wiring
Trunks: 16AWG (1.5mm2)
Spurs: 18AWG (1mm2)
Similar to analog
instrument wiring
Two pair with shield
Jacket : orange
Positive : brown
Negative : blue
Turck Minifast
connectors are used
for field devices(hand tighten only!)
16AWG trunk wire was selected to eliminate the need for volt drop calculations.Trunk wire is generally run in multipair (8 pair) cables.
For the Turck Minifast connectors, ensure you hand tighten only, don’t use awrench!
Field wiring has a drain wire which is used to connect the shield to instrument
ground at the control room end.
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FF Components – Terminators
Resistor and capacitor in
series. Two required on a
segment, one at each
end of the trunk
Power Conditioner
Device Coupler
Stops reflections of the
digital signal at each end
Any number of
terminators other than 2
causes signal problems
< 2 terminators results in signal reflections
> 2 terminators attenuates the fieldbus signal
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FF System Grounding
Similar to analog instrument grounding:
Connect the shield to instrument ground at one point only(where the trunk cable enters the marshalling cabinet)
Ensure that only the signal wires (+ and -) are connected tothe field device
Signal wires should NEVER be grounded or allowed to comeinto contact with the shield.
More than one ground point on a segment creates ground loops which canintroduce noise onto the network.
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FF Hazardous Areas
The R00#1 project requires the ability to connect
and disconnect Fieldbus devices in hazardouslocations under power
This requires Fieldbus spurs to be classified either:
Class I Division 2 Non-Incendive
Class I Division 1 Intrinsically Safe
IMPORTANT
Fieldbus trunk cables are NOT rated
for live connection/disconnection andmust be de-engergized first
The guiding industry standards for hazardous areas are:
Divisions (Non-Incendive): NEC Article 500, API RP 500, ANSI/ISA-12.12.01 /FM 3611
Zones (Energy Limited): NEC Article 505, API RP 505, IEC 60079-15
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FF Hazardous Areas: Division 2
Equipment rating requirements (FM/IEC)
Field devices
Non-Incendive (NI)
Device couplers (associated apparatus)
Non-Incendive (NI) and
Non-Incendive Associated Apparatus (ANI)
Length of spur cable ≤ 120 meters (393 ft)
This does NOT meet the requirements for Division
1 areas (which requires the device coupler contain
an approved Intrinsically Safe barrier)
Generally most equipment will have equivalent ratings for both NEC and IECstandards. Always view the actual approval certificate/drawing, since somemanufacturers may say the approval is “in progress” which can take a while.
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FF Hazardous Areas: Division 2
Surge Protector
Field Devices(NI)
Spur Cables
T
Device Coupler(NI & ANI)
Div 2
PowerConditioner
T
Junction Box
NotRated
Remember, only the spurs can be disconnected under power. Fieldbus trunkcables are NOT rated for live connection/disconnection and must be de-engergized first.
Refer to the FF Hazardous Area Verification Drawings document for furtherinformation
Higher rated equipment (e.g. intrinsically safe devices) can be used in thisconfiguration, but will still only be allowed for used in Division 2 areas.
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FF Hazardous Areas: Division 1
Equipment rating requirements (FM/IEC)
Field devices
Intrinsically Safe (IS)
Device couplers (associated apparatus)
Non-Incendive (NI) and
Intrinsically Safe Associated Apparatus (AIS)
Length of spur cable ≤ 120 meters (393 ft)
Device couplers can NOT be placed in Division 1
areas
Generally most equipment will have equivalent ratings for both NEC and IECstandards. Always view the actual approval certificate/drawing, since somemanufacturers may say the approval is “in progress” which can take a while.
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FF Hazardous Areas: Division 1
SurgeProtector
Field Devices(IS)
Spur Cables
T
Device Coupler(NI & AIS)
PowerConditioner
T
Div 1Div 2Not Rated
Remember, only the spurs can be disconnected under power. Fieldbus trunkcables are NOT rated for live connection/disconnection and must be de-engergized first.
Refer to the FF Hazardous Area Verification Drawings document for furtherinformation
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Key Fieldbus Concepts
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FF Concepts – Tags & Addresses
Each device on the segment (host cards,
instruments, valves, handheld communicators) has atag, address and Device ID.
Tags for identification of an instrument by the DCS
PT101 – pressure transmitter
CV101 – control valve
Addresses for managing segment communications
Between 10 and 255
Device IDs are unique serial numbers, e.g. 5945430005S0010968
Tags and addresses can be assigned by engineering software and fieldcommunicators.
Device IDs are fixed and cannot be changed. Needs to be updated if devices arereplaced
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FF Concepts – Address Range
0-15 Reserved Addresses (do not use)
16-247 Permanent Addresses
Host system card and permanent field devices
248-251 Default Addresses
Used by system and assigned to unconfigured field
devices
252-255 Temporary Addresses
Used by tools such as handheld configurators and
diagnostics tools
See: FF address range.xls
Similar to IP addresses on computers
Refer to FF address range spreadsheet for decimal to hexadecimal conversion
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FF Concepts – LAS
Link Active Scheduler (LAS) – the device on the
segment that controls communications
Without a LAS there is no segment communication
The LAS is the host interface card (ALF111)
Redundant ALF111 card is the backup LAS
Two “device types”
Basic Device (does not have LAS capability)
Link Master (can become LAS)
Link Master capable devices can also become the LAS, but the R00#1 fieldbusdesign specification dictates that the LAS shall be the primary ALF111 card andthe backup LAS shall be the redundant ALF111 card.
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FF Concepts – Blocks
There are three types of blocks in a FF field device –
Resource, Transducer and Function.
Resource Block (RB)
Device Name
DD Information
Manufacturer
Serial Number
Only one per device
The user application layer is based on blocks which perform different applicationfunctions
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FF Concepts – Blocks
Transducer Block (TB)
Transmitter range
Measurement setup
Calibration data
Sensor type
Can be more than one per device (e.g. one for
sensor measurement and one for an LCD display)
Unique for each device (specified by the
manufacturer)
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FF Concepts – Blocks
Function Blocks
Provide input, output and control functions
Can communicate to the control system and
between each other
Executed every scan period
Many different types (input, output, PID,
mathematical function)
Multiple function blocks in a device
Function blocks are always identical (standardized
by the Fieldbus Foundation)
Common types of function blocks and their abbreviations:
Analog Input (AI)
Analog Output (AO)
Discrete Input (DI)
Discrete Output (DO)
PID Control Block (PID)
Signal Characterizer (SC)
Integrator/Totalizer (IT)
Input Selector (IS)
Multiple Analog Input (MAI)
Multiple Analog Output (MAO)
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FF Concepts – Block Modes
Each block has a mode (MODE_BLK) that determines
its response to inputs or user action.
AUTO (Automatic) – Normal operation
MAN (Manual) – Manual operation
CAS (Cascade) – Set by another function block
O/S (Out of Service) - When downloading or
configuring blocks they may be temporarily
unavailable.
Remember the difference between “Target” and“Actual” block modes.
Each block has three categories:
•Actual – mode that the block is currently in (if not equal to target, then thereis a problem in the device)
•Target – desired mode as set by the user
•Allowed – modes that the block is permitted to be in
If you set the “target” mode and the “actual” does not change to match, thenthere may be a problem in the device preventing it from moving to the “target” mode.
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FF Concepts - Parameters
The data inside each
block is organized intoparameters.
Each parameter has a
name, format and value.
Allowable formats with
examples
String: “PT101”
Bit: “1” or “0”
Integer: “243”
Floating: “25.6234”
Similar to the way HART uses parameters inside the field device to storeinformation.
Each Parameter can have several Elements, which are individual pieces of datathat make up a parameters (e.g. range, units, decimal point)
The allowable format will depend on what the parameter is used for. Examples
of different types of parameters:•String: TAG_NAME
•Bit: CHANNEL
•Integer: ADDRESS
•Floating: AI1_OUT
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FF Concepts – Resource Block
1Revision number of DD fileDD_REV
2Revision number of the deviceDEV_REV
0X000CModel number of the deviceDEV_TYPE
0x00594543ID number of the device manufacturerMANUFAC_ID
15 (O/S)Error code associated with the blockBLOCK_ERR
AUTOActual/Target/Permitted block modesMODE_BLK
ExampleExplanationParameter
The above example shows the Resource Block
parameters in a Yokogawa EJX pressure transmitter,
device revision 2 and DD revision 1.
Anytime that “0x” is seen in front of a number, it means that it is inhexadecimal format.
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FF Concepts – Transducer Block
22 (I/O failure)Error code in the transducerXD_ERROR
Pt100Type of RTD or thermocouple connected
(for temp. transmitters)
SENSOR_CONNEC
TION
1000Highest calibrated valueCAL_POINT_HI
-328 to 2192
deg F
High and Low range limit values and
engineering units of the sensor (e.g.
thermocouple or RTD)
SENSOR_RANGE
2Damping time constant for the primary
value (in seconds)
PRIMARY_VALUE_F
TIME
-100 to 100 kPaHigh and Low range limit values and
engineering units of primary value
(generally set at factory)
PRIMARY_VALUE_
RANGE
107 (DP)Type of measurement represented by theprimary value (recommended to keep as
default)
PRIMARY_VALUE_TYPE
ExampleExplanationParameter
Examples of important parameters in a sensor transducer block. Theparameters will vary considerably depending on the type of device (e.g.pressure transmitter, temperature transmitter).
Valve positioners have a different set of parameters – it is generallyrecommended to use the Setup Wizard in ValveLink to set these up.
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FF Concepts – Analog Input Block
DirectSelects if value from the transducer is
output as is (direct), with scaling (indirect)
or with square root function (indirect sqrt)
L_TYPE
1 (Primary
Value)
Logical hardware channel that is connected
to this I/O block
CHANNEL
0-100 %High/Low scale values and engineering
units for output (used for indirect output,
e.g. level or flow)
OUT_SCALE
0-100 kPaHigh/Low scale values and engineering
units from transducer
XD_SCALE
72.34 kPaOutput from the AI blockOUT
ExampleExplanationParameter
Important parameters – remember that the AI block is the same for everyfieldbus device, regardless of instrument type or manufacturer.
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FF Concepts – Analog Output Block
42 %Back calculation provided to BKCAL_IN of
the controller (PID). This provides
bumpless transfer on mode changes and
windup protection in the upstream block.
BKCAL_OUT
50 %Setpoint of the AO block (Equals CAS_IN in
cascade and tracks valve position in
manual)
SP
46 %The AO block output and status – limited by
allowed rate of change
OUT
0-100 %High/Low scale values and engineering
units from transducer
XD_SCALE
42 %Actual valve positionREADBACK
50 %Remote setpoint value from the controllerblock (PID)
CAS_IN
ExampleExplanationParameter
Important parameters – remember that the AO block is the same for everyfieldbus device, regardless of instrument type or manufacturer.
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FF Concepts – VCRs
Virtual Communication
Relationships (VCRs) arethe links between function
blocks which enable data to
be exchanged.
The type of communication
is known as
“Publisher/Subscriber”.
Devices always transmit
information rather than only
doing so when polled.
Difference between publisher/subscriber and master/slave.
Can be one-to-many communications if PVs are required by more than onedevice.
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FF Concepts - Macrocycle
Cycle of communications between devices
Executed once per scan period (e.g. 1 second)
Controlled by the LAS
Two types of communications
Scheduled – communication between function
blocks that occur at the same time every cycle
(each FB has an execution time)
Unscheduled – asynchronous communication (e.g.
configuration, downloads) that are executed afterthe scheduled communications.
Scheduled communications are for control data – occur at the same time everymacrocycle (deterministic).
Unscheduled communications are non-critical and will occur when spare time isavailable (like ethernet).
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FF Concepts - Macrocycle
It is required that the macrocycle contains at least 30%
unscheduled time (i.e. the cycle time for schedule
communications should not exceed 700 msec)
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FF Concepts - DDs
Device Descriptors (DDs) are files that describe the
functionality of a device so that other devices andcontrol systems can interface with it correctly.
The revision of the DD file on the host computer
must match the DD revision in the device.
Updated DD files are available from the Fieldbus
Foundation or vendor’s websites:
http://www.fieldbus.org/index.php?option=com_mtree&Itemid=324
http://www.yokogawa.com/fbs/fbs-download2-en.htm
Similar to the way that a computer uses drivers so it knows how to interfacewith hardware such as printers.
Recommend getting updated DD files from the host’s website (Yokogawa)because they have undergone the HIST (Host Interoperability Systems Test)
Copies of DD files are stored in the following locations:•CS3000 project database on the engineering workstation
•PRM Server
•PRM Field Communication Server (if on a different machine)
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FF Concepts - CFFs
Capabilities files (CFF - Common File Format) describe the
functionality of the devices to enable engineering and
configuration of the devices.
DD = Device revision number
RR = DD revision number
FF = Capabilities file revision number
Device Descriptor (DD)
DDRR.ffo / DDRR.sym
Capabilities File (CFF)
DDRRFF.cff
DDs and CFFs will be located under a directory for the supplier and then devicetype.
•Yokogawa = 594543
•Fisher = 005100
•Rosemount = 001151
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FF Concepts - Interoperability
All devices must be tested to get approval from
the Fieldbus Foundation (check mark)
Control systems perform the Host Interoperability
Systems Test (HIST) based on the Foundation’s
guidelines. Lists of devices that have undergone
the HIST are available on the vendor’s website
http://www.yokogawa.com/fbs/Interoperability/fbs-hist-en.htm
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R00#1 FF Segment Design
The defining document for R00#1 is the FOUNDATION Fieldbus Segment
Design (YR-PAS-DSP-203) which is an addendum to the CVX standard
ICM-DU-5161
Key requirements:
Redundant ALF111 modules (which is also the backup LAS)
16AWG (1.5 mm2) segment trunk wiring with orange jacket
Maximum of 12 devices for Div 2 segments
Last 2 spurs reserved for owner use (spare)
Maximum of 10 devices connected during system design
Maximum of 8 devices for Div 1 segments
Last 2 spurs reserved for owner use (spare)
Maximum of 6 devices connected during system design
A maximum of three control valves are permitted on a segment
during system design (On-Off actuated valves are not considered
control valves)
This presents a summary of the key requirements in the R00#1 projectsegment design.
Devices should NOT be daisy-chained, but this introduces more connectionsonto the trunk and hence additional points of failure.
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R00#1 FF Segment Design
Only one device shall be connected to a device coupler spur
Device spur wiring shall not exceed 120 meters (393 ft)
Segment trunk wiring plus all device spurs shall not exceed a
cumulative length of 1660 meters (5446 ft)
Control segments shall have a 1 second macrocycle with a
minimum of 30% spare (unscheduled) time
All control functions shall reside within the Process Control
System (PCS) and not in the field device
Multi-variable transmitters (i.e., compensated flow
transmitter) may use only one variable for control
The aim is to build in reliability, expandability and make it easierto perform maintenance.
For segment wiring length limit of 1660 meters:
a. 1900 meters is the maximum length for a FF segment per FF Guidelines AG-181.
b. The two owner reserved spurs may be up to 120 meters each for a reservedlength of 240 meters
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R00#1 Segment Topology
Devices
Multipair JB
Device CouplerJunction Box
PowerConditioner
MarshallingPanel
Figure 8 from ICM-DU-5161 Foundation Fieldbus Segment Design
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R00#1 Device Coupler Junction Boxes
One Device Coupler
Four Device Couplers
Device Coupler
Wiring Diagram
YR-PAS-DWG-203 (One Brick JB Schematic)
YR-PAS-DWG-204 (Four Brick JB Schematic)
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Fieldbus and Yokogawa Centum CS3000
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FF and Yokogawa Centum CS3000
System Hardware:
Field Control Station (FCS)
Fieldbus I/O Card (ALF-111)
Special cables to FF Power Conditioner (AKB336)
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FF and Yokogawa Centum CS3000
System Software – System View
Main system “explorer”
Used for overall project configuration
Add ALF111 I/O cards to controllers
Launches other builders:
Fieldbus Builder
Control Drawing Builder
Generally used by control system engineers. For further learning, recommendthe Yokogawa-run CS3000 engineering course.
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System View - Screenshot
FCS0101 > Node 1 > Slot 1 > Segment 1
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FF and Yokogawa Centum CS3000
System Software – Fieldbus Builder
Interface for fieldbus data in the project database
Add/remove and configure devices
Set up device tags and addresses
Download parameters and control logic to the
field devices
Field DeviceProject Database
Upload
Download
Generally used by control system engineers. For further learning, recommendthe Yokogawa-run CS3000 fieldbus course.
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Fieldbus Builder - Screenshot
DeviceBlocks
Linked blocks (i.e. those that are in the control drawing builder and used forprocess control) are indicated with a star (*)
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Fieldbus Builder – Parameter Edit
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FF and Yokogawa Centum CS3000
System Software – Device Panel
Interface for fieldbus data in the field devices
View live devices connected to segment
Change tag, address and other parameters in
connected field devices
Equalize parameters between the project
database and the field device
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Device Panel - Screenshot
Devices inengineeringdatabase
“Live List” Devices currently
attached to segment
TagAddress
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FF and Yokogawa Centum CS3000
Faceplate for the device
(e.g. TL-TIT-7935B) Viewing block mode
Viewing error status (e.g.
IOP, OOP, CNF)
Faceplate for the indicator or
PID (e.g. TL-TI-7935B)
Setting alarm ranges
Setting calibration mode
AI PVI AO
feedback
output
from PID
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FF and Yokogawa Centum CS3000
Alarms occur on the banner and alarm screen in a similar
way to analog devices Process alarms (e.g. low, high) will occur with the
indicator or PID tag
Device errors (e.g. IOP, OOP, CNF) will occur with the
device tag
Live demonstration if possible
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Yokogawa Plant Resource Manager
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Plant Resource Manager (PRM)
PRM is Yokogawa’s plant asset management
application. It can be used for:
Setting up and modifying field devices
Management of field device configuration
Diagnostic alarms and troubleshooting
Launching specialized plug-in applications
Instrument calibration and recording
It is used for both Fieldbus and HART devices.
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PRM – Network View
Segment
Device StatusGreen = Device Ok
Red = Device ErrorYellow ! = Unacknowledged Alarm
Network view displays all the fieldbus devices and which segment they areconnected to.
Plant view can be configured to group the devices based on geographic area,unit number, equipment number.
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Plant Resource Manager (PRM)
Key functions used in PRM:
Device Status – indicates if a device is OK
Device Viewer – more detail on errors
Maintenance History – alarm/event history
DD Menu (Methods) – use to perform tasks such
as device setup and calibration
Parameter Manager – save/restore parameters
Plug-Ins – launches specialized applications
Explained in more detail in the ‘Maintenance’ section
The DD menu (methods) is similar to the device menus on a Rosemount275/375 communicator.
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PRM – Device Viewer
Alarm Code
CurrentParameters
Cause of Alarm
Red = Alarm
Yellow = Warning
Green = Ok
Mandatory – alarms which must be fixed to return the device to normal
operation (device status will be red until fixed)
Optional – alarms which may not affect the operation of a device (doesn’t affectdevice status)
The trend tab allows you to trend the values in the parameter list.
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PRM – Maintenance Alarm
•Problem•Cause•Action
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PRM – DD Menu
e.g. Configuring
temperature sensor type
DD menu maps are normally available in the device’s user manual.
The problem with using PRM for configuration is that these changes are notreflected in the engineering database (Fieldbus Builder).
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PRM – Parameter Manager
Current Saved
Saving device parameters in PRM:
Select the desired device on the left and click on the “Parameter” tab
Select the desired block tag (resource, transducer or function blocks)
The column on the left displays the current parameters in the device – click “Update” to refresh
The column on the right displays historical parameters – right-click and select “Save All Parameters”
The arrow in the middle is used to change a device’s parameters back to asaved configuration – click “Set” to execute
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Yokogawa Fieldmate
Can be used for:
Segment LAS
Device Viewer
DD Menu
Parameter save
HART (with modem)
Can’t be used for:
Plug-ins (e.g. ValveLink)
Fieldmate is a device configuration tool that connects
to a live segment and has many of the functions ofPRM in a portable format.
Fieldmate can be installed in a Panasonic Toughbook that is rated for Class 1,Div 2 hazardous areas (e.g. TB-19 or TB-30). However these are only rated foruse in hazardous areas when it is inside the supplied leather case and all portflaps are closed. The only way to make a connection to a device in a hazardousarea is to use a bluetooth HART modem (no such bluetooth or wireless deviceexists for fieldbus). If you need to connect locally to a fieldbus device, then the
375 field communicator can be used as it is Class 1, Div 1 rated.
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Yokogawa Fieldmate
Device Status
Green = Device OkYellow = Error (optional)Red = Error (mandatory)
DCS ALF111 card(s) areat the top of the list
Right-click on a device top open the various tools:
•Tag/Address assignment
•Device Viewer
•DD Menu
•Parameter Manager
•DTM
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FDT/DTM Technology
FDT = Field Device Tool
(the program that runs DTMs)
DTM = Device Type Manager
(the file for each type of device)
Standardizes the interface between control system
and the field device.
Makes it easier to view the device parameters and
perform maintenance and configuration functions.
DTMs exist for both Foundation Fieldbus and HART
devices.
Chevron is a participating member of the FDT group.
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FDT/DTM Technology
Parameter Manager
Text Based DD language
Harder to navigate
DTM
More visual Intuitive naming
Easier functions
Example of the difference between looking at a device through DD parameterview, and through a device’s DTM.
DDs use more complicated parameter names, DTMs have a better description ofwhat they are.
DTMs use graphics and alarm colors to better convey the device’s status to the
user.Commonly used functions (e.g. changing a block mode) are easily accessiblefrom the first screen in a DTM.
DTMs are supported in PRM v3.02 and Fieldmate v1.03
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Fisher ValveLink
ValveLink software is a tool for Fisher valve
positioners (e.g. DVC6000)
Launched from the “Plug-In” menu in PRM
Valve and positioner configuration management
Displays current status and troubleshooting info.
Setup wizard and travel calibration
Valve partial stroke testing
Step response and valve signature analysis
Used for both Fieldbus and HART devices
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Fisher ValveLink
Select the device in PRM and click on the “Plug-In” tab. Double click on “FisherValveLink” to launch the application.
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Fisher ValveLink - Status
Red tabsindicate errors
Live datafrom device
Click “Start Monitoring” to obtain valve information, then end and “SaveDataset” to record the values.
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Fisher ValveLink – Total Scan
Example of a Valve Signature obtained through the ValveLink “Total Scan” function which can be used to identify and diagnose valve problems. ValveLinkcan also run a step response as a performance test for the valve.
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Foundation Fieldbus Commissioning
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FF Commissioning
Commissioning Foundation Fieldbus devices typically
consists of three main steps:
Physical Inspection – check of field device
installation, instrument air lines, etc.
Segment Check (unique to fieldbus) – checks the
physical layer components and performs initial
segment configuration.
Loop Check - checking of control loops in a similar
way to analog instrumentation.
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FF Segment Check
Segment Check
Tag/Address Assignment
(Device Panel)
Segment Config./
Download(inc. PRM save)
Cable/NetworkTest
(F809f module)
Sign-off SegmentCheck Sheet
Segment Check (unique to fieldbus) – checks the physical layer componentsand performs initial segment configuration.
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FF Loop Check
Loop Check
Check Inputs(AI/DI blocks)
Sign-off LoopCheck Sheet
Check Outputs(AO/DO blocks)
Check PID Blocks
Loop Check - checking of control loops in a similar way to analoginstrumentation (check instruments read correct values and final controlelement action is correct)
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Maintenance of Fieldbus Systems
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Maintenance of FF Systems
Typical maintenance tasks in a Fieldbus system:
Fieldbus Physical layer troubleshooting
Fieldbus device troubleshooting
Replacing fieldbus devices
Adding/removing fieldbus devices
Calibrating fieldbus devices
Other potential problems
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Physical Layer Maintenance
Examples of physical layer problems that can occur:
Damage of field wiring or devices (mechanical damage,water damage)
Accidental shorts or grounding
Faulty components
Improper termination of segments
Noise from Electromagnetic Interference (EMI)
Degradation of device electronics over time
Use physical layer diagnostic devices for troubleshooting
These should generally not be a problem if proper installation and maintenanceprocedures are followed.
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Physical Layer Maintenance
Expected segment measurements:
< 300 nF> 20 MΩShield to Ground
< 300 nF> 20 MΩNegative to Ground
< 300 nF> 20 MΩPositive to Ground
< 300 nF> 20 MΩNegative to Shield
< 300 nF> 20 MΩPositive to Shield
0.8 to 1.2 μF*> 50 kΩPositive to Negative
CapacitanceResistanceMeasurement
These values come from the Fieldbus Foundation System EngineeringGuidelines.
(*) Note that these measurements are taken from the control system end withthe trunk cable disconnected from the power conditioner (so that there is only
one terminator present on the segment). The capacitance between positive andnegative signal wires may be less that stated if active terminators are used inthe device coupler.
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Physical Layer Maintenance
Tools for physical layer
troubleshooting: F809f diagnostic
modules on power
conditioners (fixed)
FBT-6 handheld
diagnostic tool (portable)
Multimeter for
measuring resistance
and capacitance
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Physical Layer Maintenance: FBT-6
Portable diagnostics unit:
• Connect FBT-6 at devicecoupler or device
• Should read “ALL
MEASUREMENTS OK”
• If not, errors will be
displayed
• Press “FUNC” to view
other segment
diagnostics
• Scroll to save menu and
hold “SEL” to save
The FBT-6 comes with a USB cable and software for exporting measured data toa PC as an excel .csv file.
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Physical Layer Maintenance: FBT-6
Connect the FBT-6 to a laptop and launch the FBT-6
Assistant software. Click “Transfer Reports from FBT-6” to transfer the
reports to the laptop.
By default they will be saved with the report slot
number - rename the files with the segment number
for easy identification.
Need to remember which slot the measurements were saved into
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Physical Layer Maintenance: F809f
Fixed on the power hub,
continuously monitors all
8 segments
Communicates through
the fieldbus segment
(selectable on module)
The F809f is actually a
fieldbus device on the
segment (with a tag and
an address)
Diagnostic
measurements are madeavailable as parameters
in transducer blocks
F809F
The F809f can be configured to communicate on segment 1 or 8 of the powerhub by the “comb” on the corner of the module (flip it over to change betweensegments). The “comb” can also be removed so that the F809f can beconnected to an external segment.
Image Source: MTL - F809F Integration for Yokogawa (MTL)
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Physical Layer Maintenance: F809f
The F809f modules have a number of features to
assist with maintenance activities:
Segment measurement
Diagnostics and alarm logging
Historical data viewing and export
Oscilloscope for viewing waveforms
Automated commissioning function
See: MTL - F809F User Manual.pdf
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F809f: Fieldbus Block Structure
F809f onFieldbus seg.
Resource Block
System Transducer Block
SegmentTransducer Blocks
Segment AlarmDI Blocks
Alarm DI BlockSystem Alarm DI Block
RESRC: Resource block, defines the physical resources of the device includingtype of measurement, memory, etc.
DITB_S: System transducer block (SysTB), allows the user to view system andself-test alarms together with the system power feed voltages and temperature.
DITB_1 – DITB_8: Segment transducer blocks (SegTB), provide all the
measured parameters and associated alarms for each fieldbus segment and itsdevices.
DIFB_1: Alarm DI block, set to 1 if any of the System Alarm, Segment / DeviceAlarm or Self Test Fault Alarm bits is set.
DIFB_2: System alarm DI block, set to 1 if any System Alarm and Self TestFault Alarm bits are set.
DIFB_3 – DIFB_10: Segment alarm DI blocks, set to 1 if any of the Segment / Device Alarm bits is set for the respective segment.
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F809f: Device Alarm
•Problem•Cause•Action
Maintenance alarms for the diagnostics module are logged the same way asfield devices. Note that in general, the recommended actions are notparticularly useful, so it is recommended to look at the segment transducerblock parameters to determine the cause of the alarm.
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F809f: System Transducer Block
Current Saved
The above example shows the system transducer block parameters when thesecondary power feed to the power hub is disconnected. Note theSYSTEM_ALARMS parameter shows the description “Power feed B voltage lowalert” – use this parameter to determine the cause of the alarm. Looking at theparameters that have changed since last save (highlighted in yellow) we cansee that the secondary power feed voltage decreased from 27.8V to 0.1V,
indicating it has either been disconnected or the bulk power supply is faulty.
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F809f: Segment Transducer Block
Current Saved
The screenshot above shows typical segment parameters viewed in thesegment transducer block, including:
•Segment Voltage
•Average and Peak Noise (The peak is recorded over the previous hour, andmay be caused by connecting/disconnecting devices. In general, average noise
is a more useful measurement and is the one specified in the FieldbusFoundation System Engineering Guidelines)
•Lowest device signal level
•Retransmissions
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F809f: Segment Transducer Block
Current Saved
The screenshot above shows typical device parameters viewed in the segmenttransducer block, including:
•Device address
•Device tag (This has to be entered manually and is stored in volatile memory,so it will be lost if power fails. It is recommended to save all parameters to the
PRM database so the tags can be reloaded into the module in the event of apower failure.)
•Device signal level
•Device retransmissions
•Device jitter
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F809f: Know Issues
The hardwired contact on the power hub is the only indicator
of primary or secondary power module failure (contacts are
closed when normal, and open when there is a fault). This
contact should be wired to a DI card in the DCS to provide an
alarm if there is a problem.
The Alarm DI Block should be configured in a DCS control
drawing to provide a path for the F809F diagnostic module
system alarm on an operator station. This will change to 1 on
all F809f diagnostic alarms.
For segments containing F809f modules, a manual change
had to be made to the NM folder in the common section of
Fieldbus Builder. The maximum response delay setting should
be changed from 4 to 5 in the NM folder.
For detailed instructions on how to make the change of maximum responsedelay setting, see SLR VGO SYSTEMS INTEGRATION FAT.doc in the suppliedflash drive.
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F809f: Forthcoming DTM Interface
This screenshot is from a prototype DTM (Device Type Manager) which willmake it easier to view the diagnostic measurements and performtroubleshooting. It will also have the ability to generate a commissioning report
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Device Troubleshooting
Examples of device problems that can occur:
Incorrect setup of a device
Block left out of service
Alarms requesting maintenance
Out of range alarm
Problems with temperature sensor connection
Problems with instrument air supply
Advanced diagnostics (e.g. impulse line plugging)
Use PRM Device Viewer or DTM for troubleshooting
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Device Troubleshooting
Example of a “Device Status” screen on a DTM for the YTA temperaturetransmitter. The alarm indicates that there is a problem with Sensor 1 (eitherfaulty or not connected).
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375 Field Communicator
The 375 is a field
communicator for both FFand HART devices
Change tags & addresses
View & write parameters
Link Master capability
View device alarms
Basic physical layer
diagnostics (voltage,
signal level)
Intrinsically Safe for use
in hazardous areas
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Replacing Fieldbus Devices
1.Decommission device to be replaced (Device Panel)
2.Install and connect new device
3.Assign correct tag & address (Device Panel)
4.Download configuration (Fieldbus Builder)
5.Check for correct operation (call up faceplate)
6.Commission for use
It is important to check that all the blocks go to
normal operating mode (typically AUTO) and
communications are re-established.
Remember that Foundation Fieldbus devices are INTEROPERABLE (differentdevices work together) but not INTERCHANGEABLE (cannot replace a devicewith one of a different type). You need to use the exact same manufacturer,model and DD revision when replacing devices. If a different device is requiredto be used, then some minor re-engineering is required in Fieldbus Builder.
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Adding Fieldbus Devices
1. Add new device into engineering database
(Fieldbus Builder)
2. Configure control drawing and device parameters
(Control Drawing Builder)
3. Install and connect new device
4. Assign correct tag & address (Device Panel)
5. Download configuration (Fieldbus Builder)
6. Loop check for correct operation
7. Commission for use
8. Device plug & play in PRM
Suggest following steps of the project’s fieldbus commissioning procedure
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Removing Fieldbus Devices
1.Decommission device to be removed
2.Disconnect and remove device
3.Remove device tag from engineering database and
control drawings
Decommissioning the device in Device Panel will
remove it’s tag and address so it is ready to be
installed in a different location.
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Fieldbus Device Calibration
With analog devices, calibration compensates for
inaccuracies in two parts of the device:
Sensor or actuator
Digital/Analog conversion
Fieldbus devices have no analog communications
signal, eliminating that source of error.
The sensor or actuator can still develop an error over
time (although this is very low in modern devices) so
calibration may still be required.
With an analog device, such as a transmitter, the output is scaled so that theexpected operating range uses the entire 16 mA of a 4-20 mA signal. Thisminimizes the effect of error in both the transmitter analog output and the hostanalog input. However, it's common to see errors resulting from a mismatchbetween the scaling of the field device and the host.
With digital fieldbus devices, output scaling isn't required — so there's no suchmismatch. Fieldbus does require that the unit of measure be the same in boththe device transducer block and the function blocks.
http://www.yokogawa.com/fld/3D/EJX/p03.html
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Fieldbus Device Calibration
1. Add calibration record in PRM and enter settings
2. Open up Calibration method in DD Menu or DTM(PRM/Fieldmate)
3. Record the “As Found” results on calibration record
4. Follow instructions from the manual or calibration
wizard to calibrate the transmitter using a suitable
reference source (it will first ask you to set the
transducer block to O/S mode)
5. Record the “As Left” results on the calibration record
6. Return block mode to normal operation (AUTO)
7. Check device status returns to good and the PV reads
correctly
Calibration of a fieldbus device is similar to that of a smart (HART) transmitter.A number of tools can perform this function:
•Yokogawa PRM
•Yokogawa Fieldmate
•375 Communicator
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Calibration Data in PRM
Add new calibration record
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Calibration Data in PRM
Set up calibration
The input/output values are set based on the individual device’s range settings.
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Calibration with DD Menu - YTA
Start by setting CAL_STATEto “Calibration Exec”
O/S
Follow the steps in the Yokogawa YTA manual to calibrate the transmitter –start by setting CAL_STATE to “Calibration Exec”.
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Calibration with DD Menu - EJX
Click on “PressureCalibration” and follow the
steps to calibrateO/S
The Yokogawa EJX has a “Calibration Wizard” that helps automate thecalibration steps.
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Calibration with DTM - EJX
Use the “Sensor Calibration
Wizard” and follow steps
The Yokogawa EJX has a “Calibration Wizard” that helps automate thecalibration steps.
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Calibration Data in PRM
Record calibration results
“Input” is the simulated value from the reference source (such as a pressurepump, temperature element simulator or Fluke 744 calibrator).
“Output” is the value measured by the transmitter – suggest using DeviceViewer to read the current value.
Remember, a calibration is only as accurate as the reference source! Use a highaccuracy calibrator or send the device out to be factory/bench calibrated.
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Calibration Data in PRM – Fluke 744
The Fluke 744 is capable of HART communication only. The only calibratorcurrently available that supports Fieldbus is the Beamex MC5 (a plug-in for theMC5 does not exist yet, but is under consideration/development)
Create a new entry in the “Calibration Data” tab and select “Fluke 74X” as the
Calibrator. Add details as appropriate into the Fluke 74X tab at the bottom ofthe screen.
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Calibration Data in PRM – Fluke 744
First click “AddGroup” to add
the instrumenttags to becalibrated.
Then click “Detect” and “Download” to load
calibration data to theFluke 744. Performcalibration and thenUpload the results
Go to the PRM menu: Option > Cal. Data > Download
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Troubleshooting DD/CFF files
These files need to be in the following locations:
On the engineering station in:
C:\CS3000\eng\BKProject\TOMBUA\Fieldbus\CFDDFILE\ In the PRM server and Field Communication Server in:
C:\PRM\DD
DD/CFF problems – occasionally a new type of device might not work orbehave unexpectedly.
Check device has FF tick and passed the Host Interoperability System Test
Contact the manufacturer for any known issues
Try connecting the device on a segment of it’s own
Try using a previous revision of the DD files
Sometimes capabilities files (CFF) have several options for the samedevice – e.g. linkmaster capability, PID blocks, advanced diagnostics.
Check that you have selected the right option for a particular device.
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Calibrating devices
Troubleshooting devices
Troubleshooting physical layer
Downloading to devices
Changing tags & addresses
FF Tools Summary
Device Panel
Fieldbus Builder
375
744
FBT-6
375
Note that for calibrating devices, the Fluke 744 is required as a referencesource (for temperature and pressure) while PRM to write calibration data to thedevice and record the results.
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Key Resources
Check out the “References” folder on your flash drive:
FF Web Links
Fieldbus Foundation - System Engineering Guidelines
Fieldbus Foundation - Wiring and Installation Guide
Yokogawa - Fieldbus Book
Yokogawa - Fieldbus Technical Information
Relcom - Fieldbus Wiring Guide
MTL - Fieldbus Physical Layer Troubleshooting Guide
Pepperl+Fuchs - FF Troubleshooting Manual
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The end of the theory…
… now for the practice
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R00#1 Foundation Fieldbus Training Exercises
Exercise 1 – Using Device Panel & Fieldbus Builder
Part 1 – Assigning Tags & Addresses (Device Panel)
Part 2 – Downloading To Devices (Fieldbus Builder)
Exercise 2 – Using Fieldmate
Exercise 3 – Using Plant Resource Manager (PRM)
Exercise 4 – Physical Layer Diagnostics
Part 1 – Using the Relcom FBT-6 handheld tool
Part 2 – Using the MTL F809f diagnostics module
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Exercise 1 – Using Device Panel & Fieldbus Builder
Part 1 – Assigning Tags & Addresses (Device Panel)
This step provides an introduction to Device Panel, a software package that is part of CS3000and used to view and set up fieldbus devices. In this exercise, you will learn how to set the tagand address of fieldbus devices.
1. From System View, open the Device Panel application by selecting the segment and clickingin the menu: Tools > Fieldbus > Display Device Information
2. The Device Panel screen is split, with the devices in the project database shown on the left,and the actual devices connected to the segment shown on the right (known as the live list).
3. Locate the following items on the Device Panel screen:
a. Tag Name
b. Address
c. Device ID
d. Device Revision information
4. If device tags and addresses have not been assigned, the system will assign temporaryaddresses in the range 248-251 (0xF8-0xFB). Note that only 4 unconfigured devices can bedisplayed at a time. If the desired device does not appear on the live list, then the devices willneed to be connected to the segment (and the addresses assigned) one at a time.
5. Identify the instrument tag and matching Device ID as shown on the instrument’scommissioning tag.
6. Locate the instrument on the live list with the desired Device ID, right click and select “Tag Assignment”. De-select “Assign Automatically” and input the instrument tag and address thatmatches the values in the database on the left.
Device ID
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7. Repeat steps 5 & 6 for every device on the segment.
8. Click on the [+] next to the devices to explore the devices and their block structure.
Part 2 – Downloading To Devices (Fieldbus Builder)
This step provides an introduction to Fieldbus, a software package that is part of CS3000 and
used for engineering and downloading of configuration to fieldbus devices. In this exercise, youwill learn how to download configuration to as segment and check that it is working.
1. From System View, locate the segment and double-click on it to open Fieldbus Builder.
2. This screen shows the devices configured in the engineering database (same as the left partof the screen in Device Panel). Locate the following items on the Fieldbus Builder screen:
a. Tag Name
b. Address
c. Device ID
d. Device Revision information
e. Polled address range for the segment (this setting dictates which addresses the ALF111 looks for – if this range doesn’t include a device it will be invisible!)
3. Select the ALF111 card and select: File > Download (ensure all boxes are ticked)
Matching
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4. Confirm that there are no errors and verify that all the devices were downloaded successfullyby checking that the “Device ID” column has been filled in for each tag. If there are anyerrors, view the “Message” window at the bottom of the screen for details and rectify theproblem.
5. From Fieldbus Builder, open the Device Panel application by selecting the segment and
clicking in the menu: Tools > Display Device Information 6. If any of the devices have a yellow lightning bolt icon next to them, then they have not been
equalized successfully. Sometimes parameters such as software revision are notsuccessfully imported to the database by Fieldbus Builder so this has to be correctedmanually.
7. Double-click on the device to launch the “Device Information Display” and perform thefollowing steps:
a. Click on “Update” to show the current parameters.
Device IDs
No Errors
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b. Select “Equalization Mode” and “Difference” to see the parameters that are not yetequalized.
c. Tick “Equalization of block parameters is executed”
d. Select “Equalization” and execute.
e. Select “Update” and check that the parameters are now equalized
f. Close the equalization window and check that the yellow lightning bolt next to thedevice icon has disappeared.
8. Right-click on each device and select “Commission”. This will remove the commissioning tagicon from each device. The Device Panel should now look as shown below, with no questionmark or lightning bolt icons.
9. Close Device Panel and return to Fieldbus Builder.
10. From a HIS, open the faceplate for each instrument on the segment to ensure it is workingcorrectly (click the “NAME” button and type the instrument tag). The status should be NR
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(normal) with no errors (note that since the instrument is not yet in service, the faceplate maydisplay a LL or HH alarm – this should be normal depending on the alarm settings). Thefaceplate should NOT display an IOP (input open), OOP (output open), CNF (connection fail)or O/S (block out of service) status. Faceplates for input blocks (AI/DI) should be in AUT andoutput blocks (AO/DO) should be in CAS.
11. Experiment with the instrument by making the following changes and observing the effect ithas on the instrument faceplate (and associated indicator or PID faceplate):
a. Change the process value (e.g. test pump on a pressure transmitter)
b. Change the process value outside of alarm limits (PL/PH)
c. Change the process value outside of range limits (LL/HH)
d. Disconnect the device and then reconnect it
e. Disconnect the temperature element (temperature transmitters only)
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Exercise 2 – Using Fieldmate
This exercise provides an introduction to Fieldmate, a portable software tool that is used toconfigure fieldbus devices. In this exercise, you will learn how to connect Fieldmate to a segmentand set the tag and address of fieldbus devices, and troubleshoot using Device Viewer.
1. Open the NI-FBUS Interface Configuration utility from the start menu:Start > National Instruments > NI-FBUS > Utilities > Interface Configuration Utility
2. Select each port and click edit to configure only the first port with the following settings:
When there is no other LAS on the segment (i.e. no ALF111 card connected) and you wantFieldmate to become the LAS:
• Device Address: 0x10
• Device Type: Link Master Device
• Usage: NI-FBUS
When another LAS is already connected to the segment:
• Device Address: Visitor
• Device Type: Basic Device
• Usage: NI-FBUS
3. Connect one port of the NI-FBUS card to the segment to a spare device coupler terminal.
4. Start up the Yokogawa Fieldmate application and select “FF-H1” as the default scansegment. Click “Ok” to start up NI-FBUS Communications Manager which will pop up thefollowing window once it has started successfully.
5. Ensure the “Segment Viewer” tab and “Foundation Fieldbus” are selected on the left panel.The actual devices connected to the segment are shown on the right (known as the live list).Note that there is no panel on the left showing the devices in the engineering database – thisfeature is only available in Device Panel on an engineering workstation.
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6. Locate the following items on the Fieldmate screen:
a. Tag Name
b. Address
c. Device ID
d. Device Revision information
7. If device tags and addresses have not been assigned, the system will assign temporaryaddresses in the range 248-251 (0xF8-0xFB). Note that only 4 unconfigured devices can bedisplayed at a time. If the desired device does not appear on the live list, then the devices will
need to be connected to the segment (and the addresses assigned) one at a time.
8. Identify the instrument tag and matching Device ID as shown on the instrument’scommissioning tag.
9. In Fieldmate, locate the instrument on the live list with the desired Device ID, right click andselect “Tag/Address Assignment”. Input the instrument tag and address that matches thevalues in the project database print-out generated from Fieldbus Builder and click “Set”.
Device ID
Live List
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10. Repeat steps 8 & 9 for every device on the segment.
11. Check the Device Status for all devices on the segment (the colored oval next to the deviceicon). The Device Status should be good (green) for every device on the segment.
12. Right-click on the device and select “Device Viewer” to see more detailed status of thedevice.
13. Since the devices have not yet been configured by the DCS, Device Viewer may see someerrors such as “AI FB not scheduled”. This is expected and can be ignored as it will beresolved once the instruments are connected to the DCS and downloaded.
Matching
DeviceStatus
FieldbusBuilderprint-out
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14. Experiment with the instrument by making the following changes and observing the effect ithas on Device Viewer (Right-click on the instrument and select “DD Menu” or “AssignedDTM” to launch the application used to make these changes)
a. Change the block mode of AI1 to out of service (O/S)
b. Click on the “Trend Information” tab to observe trended parameters
DD Menu Screen DTM Screen
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Exercise 3 – Using Plant Resource Manager (PRM)
This exercise provides an introduction to PRM, the application used for management ofFoundation Fieldbus and HART instrumentation. It shows how to set up PRM for a segment andintroduces its device troubleshooting tools.
1. Open up the PRM application select the “Network” tab.
2. Under “Foundation Fieldbus” locate the segment, right-click on it and select “Plug & Play” toautomatically recognize the devices connected to the segment.
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3. Check the Device Status for all devices on the segment (the colored oval next to the deviceicon). The Device Status should be good (green) for every device on the segment.
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4. Experiment with the instrument by making the following changes and observing the effect ithas on Device Viewer (Right-click on the instrument and select “DD Menu” or “AssignedDTM” to launch the application used to make these changes)
a. Change the block mode of AI1 to out of service (O/S)
b. Click on the “Trend Information” tab to observe trended parameters
DD Menu Screen DTM Screen
5. Click on the “History” then “Maintenance” tab of the device to view the alarm generated –read the message regarding problem, cause and action. Right-click on the alarm and select“Acknowledge” – enter a reason and you should see the yellow exclamation point icondisappear from the device.
DeviceStatus
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6. Right-click on the device and select “Device Viewer” to launch. The following screenshotshows an example of a device viewer warning that states “AI1 FB is in O/S mode”. Thismeans that the analog input block is out of service, so the process value is not beingtransmitted to the control system.
7. Fix the problem using DD Menu or the DTM and observe the device return to normal.
8. Right click on the segment and select “Save All Parameters”. Type ‘Commissioning’ into the“Reason” box, tick the “Read details from the field devices” box and select ok. This will savethe current set of parameters in the device.
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9. In the following steps you will compare previously saved parameters to the currentparameters read from the device:
a. Select a device on the segment and click on the “Parameter” tab
b. Select the desired block tag (resource, transducer or function blocks)
c. The column on the left displays the current parameters in the device – click “Update”
to read in current parameters from the device
d. The arrow in the middle is used to change a device’s parameters back to a savedconfiguration – click “Set” to execute
Current Saved
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Exercise 4 – Physical Layer Diagnostics
Part 1 – Using the Relcom FBT-6 handheld tool
The FBT-6 is a handheld fieldbus monitor that can detect physical layer problems on thesegment. It is bus-powered and rated for use in hazardous areas. This exercise will show you
how to use the FBT-6 to check a segment and identify common problems.
1. Connect the FBT-6 Fieldbus Monitor to the segment at the device coupler and wait for it tocheck (approximately 20 seconds). The FBT-6 should display “ALL MEASUREMENTS OK” ifthere are no problems. Press the “FUNC” button to scroll through the various measurementsfor the segment.
2. With the FBT-6 still connected, introduce the following faults onto the segment and observethe reading on the FBT-6 to see whether the changes are identified.
a. Disconnect a device and then reconnect it
b. Place a short between the shield wire and one of the signal wires
c. Switch off the terminator at the power supply end
3. Press “FUNC” to scroll through to the save function. Hold down the “SEL” button to save thesegment measurements into one of the empty slots (there are 8 slots available). Make surethe number of the slot is noted on the check sheet as this will be needed for the next step.
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4. Connect the FBT-6 to a laptop and launch the FBT-6 Assistant software. Click “TransferReports from FBT-6” to transfer the reports to the laptop. By default they will be saved withthe report slot number - rename the files with the segment number for easy identification.
Part 2 – Using the MTL F809f diagnostics module
The MTL F809f is a physical layer diagnostics module that mounts on the segment power hub forcontinuous monitoring. This exercise will show you how to use the module to check a segment
and identify common problems.
1. Open up the PRM application select the “Network” tab.
2. Under “Foundation Fieldbus” locate the segment and select the F809f module.
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3. Click on the “Parameter” tab, then right-click on <Show actual parameter> and select“Parameter Manager”. This will enable you to read the current parameters in the F809f.
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4. The parameters in the F809f display the measured values from the segment, and any activealarms that are present. Read through the parameters for the two types of transducer blocksto see what the current status is (TB01 is the system transducer block, and TB02-TB09 arethe segment transducer blocks). Consult the F809f user manual on your flash drive if you arenot sure what a parameter means.
5. Generate a print-out of the current parameter values – this can be useful as a commissioningreport to document the measurements taken.
6. Right-click on the F809f module and select “Save all parameters” to save all the currentparameters in the device to the PRM database. In Parameter Manager you will then be ableto view the saved values alongside current measurements taken from the segment.
7. Introduce the following faults onto the segment and observe the measurements by updatingthe current parameters in Parameter manager. Compare these to the saved parameters inthe previous step to see whether the changes are identified.
a. Unplug the secondary 24VDC power connector from the power hub
b. Place a short between the shield wire and one of the signal wires
c. Switch off the terminator at the power supply end
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8. Click on the “History” then “Maintenance” tabs of the device to view the alarms generated,and read the message regarding problem, cause and action. Right-click on the alarm and
Current Saved