Industrial Control

(EEPC45)

Lecture Notes 29

Unit III
Communication and Networking
 Back ground
Organization of a general purpose computer :
I / O devices Operator I/O

Operator I/O: Between CPU & plant devices

Operator I/O: Between CPU & peripheral devices

Bus interface for communication :

• Data bus
• Address bus
• Control & status lines.
Types:

• S-100 :8 bits
• ISA bus
• ISA AT : 16 bit , 12 MHz clk, 2 MB/sec. slow
• MCA bus
• EISA : up to 80846 , shared interrupts.
• NU bus : Apple
 Process related interface
• Analog
• Digital
• Pulse
• RTC
• Standard I/F RS 232
RS 422A : Digital voltage
RS 485 : < 32 receivers.
For process control application:
• Series & parallel
• Synchronous and Asynchronous
• LAN Bus topology
Ring
Ethernet /IEEE 802.3
Computer integrated processing (CIP) data communication
network in industries viz: Chemical , mineral, metals,
foodstuff involving batching , mixing, drying, conveying,
storing, all individual controlled.
Need optimization at each steps and process as a whole
model.
Ethernet - Screened coaxial cable to connect peripherals
has taps ; Supports communication at speeds w/o need to
decode message not directed to them.
 Corporate Storage Computer
Level -4
Company network 100Mbps , Response time < sec.

Prod. Manag.
PC -1 Computer Gateway PC - 2
Level -3

Facility network 100Mbps , Response time < sec.

Process control Peripheral PC-1 Gateway

Level -2

Process bus 100Kbps , Response time < 500 msec.

Field level control
PLC PC Peripheral O/P
Level -1
devices

Field bus 32Kbps

Field level sensing
Level -0
Contactors DVM /DPM
 Network Requirement
Demand of data different at each level e.g. At 0- level :
network frequently used. Response time and data strings
should be short.
At 3 - level Several network types present simultaneously
therefore standards needed.
ISO reference model for communication between open
system called Open system interconnection /OSI
models.
 Architecture : 7 layer model
Field bus user

Application layer 7
Presentation layer 6
Session layer 5
For process Transport layer 4
Network layer 3
control
Data- link layer 2
Physical layer 1
In process control application the most common:
• Physical layer
• Data link layer
• Network layer
Physical layer defines how the data is to be transferred
physically between devices. Specification: electrical
signals ,cables , connectors , network topology , transfer
speed.
Cables:
Twisted pairs - Economical , good for filed level
,Transmitter up to 375 Kbps up to 300 mtr, 31.25 Kbps
up to 1500 mtr. Shielded fro immunity to interference
Coaxial cables: expensive for carrier / Broadband
transmitter in higher level network.5 Mbps < 1000 mtr
over carrier , 10Mbps → kms over Broad band.
FOC - simple to lay and connect, transmitter capacity is
five times more than the coaxial , immune to electronic
magnetic interference. Transfer rate is of Gbps order.
Network layer:
• Addresses & routes messages
• Sets up communication ports
• Flow control
• Standards: USA DOD - IP X25 ,X75.
e.g. Tymnet ,Telenet ,ARPANET

Transport layer:
Provides end to end control of a communication session.
Allows process to exchange data reliability.
Standards; USA DOD -TCP ,IBM.SNA ,DEC DNA
Session layer:
Establishes and control-node-system dependent aspects,
Interfaces transport level to logical function in node
operating system.

Presentation layer:
Allows encoded data transmitters via communication path
to be presented in suitable formats for user manipulation.

Application layer:
Allows a user service to be supported e.g.. Resource
sharing , file transfer , remote file access ,DBM…..
 Data link layer:

Ensures exchange between devices. Governs network

access , data format and data security.
For regulating access:
Central bus control : A master assigns the right to one
station at a time . Failure is critical.
Decentralized bus control: With flying master right to
transfer conferred to many.
 Models:

(a) CSMA /CD model for bus access:

( Carrier sense multiple access with collision detection).
- All station on bus have right to transmit.
- Each station continuously sense / listens to the bus.
- If bus is free ,any station can transmit.
- If several station want to transmit simultaneously
collision is detected and all station withdraw.
- A random generator in each station then determines the
time interval before the station can renew attempt to
transmit.
 - Good for office /higher automation level, not for field
bus because short response time required for alarms can
not be guaranteed.

(b) Token passing method :

Token means right to transmit is passed from device tio
device.
-Passing sequence defined during planning of system.
- Each devices allowed to transmit within a preset period.
-Time taken to pass the token round the system determines
frequency of polling of each member.
- Used in control & field applications. Reaction to events in
process domain takes place within a specified time.
 -Token passing model (as per IEEE 802.2) accepted as
standard.
- Gateway / Intelligent interface required the link the
networks.

(c) Master -slave method:

-One bus device is assigned as master allowed to transmit.
- Master polls ( or addresses) each participant turn wise
supplies it with data and asks it to send data.
-Typically used for sensor /actuator applications.
 Industrial communication systems
Demands on communication system differ according to
function performed.
Communication management systems
For upper level of organization , international standards.
MAP protocol : (Manufacturing automation protocol)
-Suitable for medium large data volumes.
- cost / node is high.
- Support only token passing bus access method (IEEE
802.2).
-For communication between computer , Robot controller
, PLC , CNC , DNC.
- For time critical operations -MAP enhanced performance
architecture (MAP /EPA) is preferred.

TOP protocol:
-Used in technology / science & office automation
environment.
- Emphasizes exchange of documentation both CAD and
CAM.
- Supports a no. of transmitter media & access method
i.e. CSMA /CD , token passing.
 Field Buses:
-To link sensor actuators with system intelligence i.e.-
DCS system , PLC, controller….

- Advantages over hardwired installation:

* Bidirectional digital
* Simple cabling and wiring
* Easy expandability , retrofitting
* Reduces planning and maintenance cost
* higher safety through self monitoring
* Higher resolution of process variables.
Applications:
Factory automation - High transmit rates.
- Short reaction time.
- Bus length < 300 mtr.
Process control: - Average cycle time < 1000 msec.
- Bus length < 1500 mtr.
- power supply to field instrumentation.
Types of field buses
smart transmitter
- intelligence located in field instrument.
- 4 -20 mA and digital signal super imposed to transport
the data and configuration.
 - on site interrogation by plugging a handheld terminal into
supply line.

Rack bus:
- serial , character oriented bus to link smart transmitters to
external networks via gateway.
- Through bus the data is available to supervisory system
also, transmitters can be configured remotely.
- Operates on fixed master - slave principle : master is gate
way & transmitter slave. Each transmitter has unique
address.
- gateway interfaced to field bus in special module for RS
232 C , RS 422 , 4-20 mA current loop.
 - Used for reliable data transport in environment with
high interference potential.
- Uses twisted pair as transmitting medium realizes layer
1, 7,2 of OSI model.
MOD bus:
- transmission protocol for process control system.
- No transmission media is defined. User can chose any
RS 232 C , RS 422 , 4-20 mA .
- Accessed on Master /slave principle. Protocol provides
for one master & < 250 slaves.
- Some characteristics fixed : frame format , frame
sequence , handling of communication errors , exception
conditions function performed.
- User selectable: Transmission medium , transmission
characteristics , transmission mode RTU/ ASCII.
- All supported function are identified by index no . And
designed as control command for filed instrumentation
and actuators.
- Slow w.r.t. PROFI bus /FIP bus, but popular with
instrument manufactures /users.

PROFI bus: ( Process field bus)

- Specifies layers 1,2,7.
- For hi - performance communication system for simple
inexpensive equipment with immediate response, Master
-salve access with central polling & broad cast message.
 - Application layer with function corresponding to MMS
( manufacturing message standard).
- Interface between layer 2 & 7 designed such that field
bus function are imaged as MMS function.
- Uses MAP /EPA 3 layer protocol (Physical +Data+
Application layer).

FIP bus : ( Factory information protocol) French standard.

- Specifies protocol and interface.
- Very fast transmission rate and defines scanning interval.
- Central unit - ARBITRATOR - organizes broadcasting.
Data transmitted on bus: variable - identified by a name.
Trammeled by one but readable by many.
- Freedom in design of system architecture. Process
control faction can be distributed between various
devices on bus.