Profibus Basics
Profibus Basics
PROFIBUS is the most universal fieldbus for plantwide use accross all sectors of the
manufacturing and process industries. It is the fieldbus having world wide best economic
success. Independent market studies confirm market leadership for PROFIBUS today and
high growth rates for the future. Using PROFIBUS means to have great cost advantages
and improved flexibility.
First of all there are major cost savings in hardware and assembly. Here most
important is you need less hardware components as I/O, terminal blocks, and
barriers. The installation becomes easier, quicker and cheaper.
Very impressive are the cost savings in engineering and documentation, which
makes the configuration much easier (only one tool for all devices), which
improves the asset management of an automation system and which facilitates the
documentation of the of the production procedure(easy and up-to-date
documentation)
An important feature of PROFIBUS based automation is the greater
manufacturing flexibility. This feature covers a lot aspects, of which the most
important are: improved functionality increases plant productivity, improved
availability and reduced down time and optimized use of limited resources and
raw materials
One of the most important advantage of using fieldbusses in the automation is reduced
installation efforts. E.g., the cost savings estimated in process automation if PROFIBUS
is used instead of the conventional 4..20mA technology are sumed up to more than 40%.
PROFIBUS Basics
Fieldbuses are industrial communication systems that use a range of media such as
copper cable, fiber optics or wireless, with bit-serial transmission for coupling distributed
field devices (sensors, actuators, drives, transducers, analyzers etc.) to a central control or
management system. Fieldbus technology was developed in the 80s with the aim of
replacing the commonly used central parallel wiring and prevailing analog signal
transmission (4-20 mA- or +/- 10V interface) with digital technology. Due, in parts, to
the different industry-specific demands and preferred proprietary solutions of large
manufacturers, several bus systems with varying properties were established in the
market. The key technologies are now included in the standards IEC 61158 and IEC
61784. PROFIBUS is an integral part of these standards. Fieldbuses increase the
productivity and flexibility of automated processes compared to conventional technology
and they create the basic prerequisite for the configuration of distributed automation
systems. PROFIBUS is an open, digital communication system with a wide range of
applications, particularly in the fields of factory and process automation. PROFIBUS is
suitable for both fast, time-critical applications and complex communication tasks. The
application and engineering aspects are specified in the generally available technical
documents of PROFIBUS International. This fulfills user demand for manufacturer
independence and openness and ensures communication between devices of various
manufacturers. Building on a very efficient and extensible communications protocol,
coupled with the development of numerous application-oriented profiles and a fast
growing number of devices, PROFIBUS began its advance, initially in factory
automation and, since 1995, in process automation. Today, PROFIBUS is the fieldbus
world market leader.
PROFIBUS has a modular design (PROFIBUS Tool Box) and offers a range of
transmission and communication technologies, numerous application and system profiles,
as well as device management and integration tools. Thus PROFIBUS covers the diverse
and application-specific demands from the field of factory to process automation, from
simple to complex applications, by selecting the adequate set of components out of the
tool box.
Transmission Technologies
PROFIBUS provides five different transmission technologies, all of which are based on
international standards and are assigned to PROFIBUS in both IEC 61158 and IEC
61784: RS485 and MBP, RS485-IS and MBP-IS (both providing intrinsic safety
protection), and Fiber Optics. RS485 transmission technology is simple and cost-effective
and primarily used for tasks that require high transmission rates. Shielded, twisted pair
copper cable with one conductor pair is used. No expert knowledge is required for
installation of the cable. The bus structure allows addition or removal of stations or the
step-by-step commissioning of the system without influencing other stations. Subsequent
expansions (within defined limits) have no effect on stations already in operation.
Various transmission rates can be selected between 9.6 Kbit/s and 12 Mbit/s. One
uniform speed is selected for all devices on the bus when commissioning the system. Up
to 32 stations (master or slaves) can be connected in a single segment. For connecting
more than 32 stations repeaters may be used. The maximum permissible line length
depends on the transmission rate. Different cable types (type designation A - D) for
different applications are available on the market for connecting devices either to each
other or to network elements (segment couplers, links and repeaters). When using RS485
transmission technology, PI recommends the use of cable type A. RS485-IS transmission
technology responds to an increasing market demand to support the use of RS485 with its
fast transmission rates in intrinsically safe areas. A PROFIBUS document is available for
the configuration of intrinsically safe RS485 solutions with simple device
interchangeability. The interface specification details the levels for current and voltage
that must be adhered to by all stations in order to ensure safe functioning during
interconnection. An electric circuit permits maximum currents at a specified voltage
level. When connecting active sources, the sum of the currents of all stations must not
exceed the maximum permissible current. In contrast to the FISCO model (see below), all
stations represent active sources. Up to 32 stations are expected to be connected to the
intrinsically safe bus circuit. MBP type transmission technology ("Manchester Coding"
and "Bus Powered") is a new term that replaces the previously common terms for
intrinsically safe transmission such as "Physics in accordance with IEC 61158-2", "1158-
2", etc. The reason for this change is that, in its definitive version, the IEC 61158-2
(physical layer) describes several different connection technologies, MBP technology
being just one of them. MBP is synchronous transmission with a defined transmission
rate of 31.25 Kbit/s and Manchester coding and frequently used in process automation as
it satisfies the key demands of the chemical and petrochemical industries for intrinsic
safety and bus power using two-wire technology. MBP transmission technology is
usually limited to a specific segment (field devices in hazardous areas) of a plant, which
are then linked to a RS485 segment via a segment coupler or links (Fig. ). Segment
couplers are signal converters that modulate the RS485 signals to the MBP signal level
and vice versa. They are transparent from the bus protocol standpoint. In contrast, links
have their own intrinsic intelligence. They map all the field devices connected to the
MBP segment as a single slave in the RS485 segment. Tree or line structures (and any
combination of the two) are network topologies supported by PROFIBUS with MBP
transmission with up to 32 stations per segment and max. 126 per network. Fiber Optic
transmission technology is used for fieldbus applications that place restrictions on wire-
bound transmission technology, such as those in environments with very high
electromagnetic interference or when particularly large distances need to be covered. The
PROFIBUS guideline (2.021) for fiber optic transmission specifies the technology
available for this purpose including multimode and single mode glass fiber, plastic fiber,
and HCS® fiber. When determining these specifications, great care was naturally taken
to allow problem-free integration of existing PROFIBUS devices in a fiber optic network
without the need to change the protocol behavior of PROFIBUS. This ensures backward
compatibility with existing PROFIBUS installations. The internationally recognized
FISCO model (Fieldbus Intrinsically Safe Concept, developed in Germany by the PTB)
considerably simplifies the planning, installation and expansion of PROFIBUS networks
in potentially explosive areas. The model is based on the specification that a network is
intrinsically safe and requires no individual intrinsic safety calculations when the relevant
four bus components (field devices, cables, segment couplers and bus terminators) fall
within predefined limits with regard to voltage, current, output, inductance and capacity.
The corresponding proof can be provided by certification of the components through
authorized accreditation agencies, such as PTB and BVS (Germany) or UL and
FM(USA). If FISCO-approved devices are used, not only is it possible to operate more
devices on a single line, but the devices can be replaced during runtime by devices of
other manufacturers or the line can be expanded - all without the need for time-
consuming calculations or system certification. So simple plug & play is possible, even in
hazardous areas!
Communication Technologies
The Time Stamp application profile provides certain events and actions with a time
stamp, which enables precise time assignment. Precondition is a time-of-day management
in the slaves through a time-of-day master. An event can be given a precise system time
stamp and read out accordingly. A concept of graded messages is used. The message
types are summarized under the term "Alerts" and are divided into high-priority "alarms"
(these transmit a diagnostics message) and low-priority "events". In both cases, the
master acyclically reads the time-stamped process values and alarm messages from the
alarm and event buffer of the field device.
The Slave redundancy application profile provides a slave-redundancy mechanism: Slave
devices contain two different PROFIBUS interfaces that are called primary and backup
(slave interface). These may be either in a single device or distributed over two devices.
The devices are equipped with two independent protocol stacks with a special
redundancy expansion. A redundancy communication (RedCom) runs between the
protocol stacks, i.e. within a device or between two devices, that is independent of
PROFIBUS and whose performance capability is largely determined by the redundancy
reversing times.Only one device version is required to implement different redundancy
structures and no additional configuration of the backup slave is neccessary. The
redundancy of PROFIBUS slave devices provides high availability, short reversing times,
no data loss and ensures fault tolerance.
Specific Application Profiles
The PROFIdrive application profile defines device behavior and the access procedure to
drive data for electric drives on PROFIBUS, from simple frequency converters through to
highly dynamic servo-controls. The integration of drives in automation solutions is highly
dependent on the task of the drive. For this reason, PROFIdrive defines six application
classes, which cover the majority of applications. With standard drives (class 1), the drive
is controlled by means of a main setpoint value (e.g. rotational speed), whereby the speed
control is carried out in the drive controller. In case of standard drives with technological
function (class 2), the automation process is broken down into several subprocesses and
some of the automation functions are shifted from the central programmable controller to
the drive controllers. PROFIBUS serves as the technology interface in this case. Slave-to-
slave communication between the individual drive controls is a requirement for this
solution. The positioning drive (class 3) integrates an additional position controller in the
drive, thus covering an extremely broad spectrum of applications (e.g. the twisting on and
off of bottle tops). The positioning tasks are passed to the drive controller over
PROFIBUS and started. The central motion control (classes 4 and 5) enables the
coordinated motional sequence of multiple drives. The motion is primarily controlled
over a central numeric control (CNC). PROFIBUS serves to close the position control
loop as well as synchronize the clock. The position control concept (Dynamic Servo
Control) of this solution also supports extremely sophisticated applications with linear
motors. Distributed automation by means of clocked processes and electronic shafts
(class 6) can be implemented using slave-to-slave communication and isochronous
slaves. Sample applications include "electrical gears", "curve discs" and "angular
synchronous processes". In contrast to other drive profiles, PROFIdrive only defines the
access mechanisms to the parameters and a subset of approx. 30 profile parameters,
which include fault buffers, drive controllers, device identification, etc. All other
parameters (which may number more than 1,000 in complex devices) are manufacturer-
specific, which provide drive manufacturers great flexibility when implementing control
functions.
The PA Devices profile defines all functions and parameters for different classes of
process devices that are intrinsically intelligent and can execute part of the information
processing or even the overall functionality in automation systems. The profile includes
all steps of a typical signal flow - from process sensor signals through to the preprocessed
process value which is read out at the control system together with a measured value
status, see Fig. .... The PA Devices profile is documented in a general data sheet
containing the currently valid specifications for all device types and in device data sheets
containing the agreed specifications for specific device classes. The PA device profile
version 3.0 includes device data sheets for Pressure and differential pressure, level,
temperature, flow rate, valves and actuators, analyzers, and analog and digital inputs and
outputs. In process engineering it is common to use blocks to describe the characteristics
and functions of a sensor or actuator at a certain control point and to represent an
automation application through a combination of these types of blocks. Therefore, the
specification of PA Devices uses a function block model to represent functional
sequences. The blocks are implemented by the manufacturers as software in the field
devices and, taken as a whole, represent the functionality of the device. The following
three block types are used: A Physical Block (PB) contains the characteristic data of a
device, such as device name, manufacturer, version and serial number, etc. There can
only be one physical block in each device. A Transducer Block (TB) contains all the data
required for processing an unconditioned signal delivered from a sensor for passing on to
a function block. If no processing is required, the TB can be omitted. Multifunctional
devices with two or more sensors have a corresponding number of TBs. A Function
Block (FB) contains all data for final processing of a measured value prior to
transmission to the control system, or on the other hand, for processing of a setting before
the setting process. Different FB are available: Analog Input Block (AI, delivers the
measured value from the sensor/TB to the control system), Analog Output Block (AO,
provides the device with the value specified by the control system), Digital Input (DI,
provides the control system with a digital value from the device), and Digital Output
(DO, provides the device with the value specified by the control system).
Ident systems is a profile for barcode readers and transponder systems. These are
primarily intended for extensive use with the DP-V1 functionality. While the cyclic data
transmission channel is used for small data volumes to transfer status/control information,
the acyclic channel serves the transmission of large data volumes that result from the
information in the barcode reader or transponder. The definition of standard function
blocks has facilitated the use of these systems and paves the way for the application of
open solutions on completion of international standards, such as ISO/IEC 15962 and
ISO/IEC18000.
PROFIdrive The profile specifies the behavior of devices and the access procedure to
data for variable-speed electrical drives on PROFIBUS. PA Devices The profile specifies
the characteristics of devices of process engineering in process automation on
PROFIBUS. Robots/NC The profile describes how handling and assembly robots are
controlled over PROFIBUS. Panel Devices describes the interfacing of simple human
machine interface devices (HMI) to higher-level automation component s. Encoders
describes the interfacing of rotary, angle and linear encoders with single-turn or multi-
turn resolution. Fluid Power describes the control of hydraulic drives over PROFIBUS.
SEMI describes characteristics of devices for semiconductor manufacture on PROFIBUS.
Low-voltage Switchgear describes data exchange for low-voltage switchgear
(switchdisconnectors, motor starters, etc.) on PROFIBUS. Dosage and Weighing Devices
describes the implementation of weighing and dosage systems on PROFIBUS. Ident
Systems describes the communications between devices for identification purposes (bar
codes, transponders). Intelligent Pumps describes the implementation of liquid pumps on
PROFIBUS DP. Remote I/O for PA Devices describes a different device model (due to
the special place of RIO in bus operations).
Master Profiles for PROFIBUS describe classes of controller, each of which support a
specific "subset“ of all the possible master functionalities, such as Cyclic and Acyclic
Communications, Diagnostics, Interrupt handling, Time-of-day management, Slave-to-
slave communication, Isochronous mode, and Safety. System Profiles for PROFIBUS go
a step further and describe classes of systems including the master functionality, the
possible functionality of Standard Program Interfaces (FB in accordance with IEC 61131-
3, safety layer and FDT) and integration options (GSD, EDD and DTM). The figure
below shows the standard platforms available today. In PROFIBUS system, the master
and system profiles provide the counterpart to the application profiles. Master and system
profiles describe specific system parameters that are made available to the field devices,
application profiles require specific system parameters in order to simplify their defined
characteristics. By using these profiles the device manufacturers can focus on existing or
specified system profiles and the system manufacturers can provide the platforms
required by the existing or specified device application profiles.
Integration Technologies
Modern field devices in both Factory and Process Automation provide a wide range of
information and also execute functions that were previously executed in PLCs and
control systems. To execute these tasks, the tools for commissioning, maintenance,
engineering, and parameterization of these devices require an exact and complete
description of device data and functions, such as the type of application function,
configuration parameters, range of values, units of measurement, default values, limit
values, identification, etc. The same applies to the controller/control system, whose
device-specific parameters and data formats must also be made known (integrated) to
ensure error-free data exchange with the field devices. PROFIBUS has developed a
number of methods and tools ("integration technologies", GSD, EDD and DTM) which
enable standardization of device management. The performance range of these tools is
optimized to specific tasks (simplest handling, device-tuning at runtime, ...), which has
given rise to the term scaleable device integration. GSD and EDD are both a sort of
"Electronic device data sheets", developed with different languages, whilst a DTM
(Device Type Manager) is a software component containing specific field device
functions for parameterization, configuration, diagnostics and maintenance, generated by
mapping and to be used together with the universal software interface FDT (Field Device
Tool), which is able to implement software components.
GSD
GSD is a readable ASCII text file and contains both general and device-specific
specifications for communication (Communication Feature List) and network
configuration. Each of the entries describes a feature that is supported by a device. By
means of keywords, a config-uration tool reads the device identification (ID number), the
adjustable parameters, the corresponding data type and the permitted limit values for the
configuration of the device from the GSD. Some of the keywords are mandatory, for
example Vendor_Name. Others are optional, for example Sync_Mode_ supported. A
GSD replaces the previously conventional manuals and supports automatic checks for
input errors and data consistency, even during the configuration phase. Distiction is made
between a device GSD (for an individual device only) and profile GSD, which may be
used for devices that comply exactly with a profile such as PROFIdrive or PA Devices.
GSD for compact devices, whose block configuration is already known on delivery, can
be created completely by the device manufacturer. GSD for modular devices, whose
block configuration is not yet conclusively specified on delivery, must be configured by
the user in accordance with the actual module configuration using the configuration tool.
The device manufacturers are responsible for the scope and quality of the GSD of their
devices. Submission of a profile GSD (contains the information from the profile of a
device family) or an individual device GSD (device-specific) is essential for certification
of a device.
EDD (Electronic Device Description) Top
EDD is, like a GSD, an electronic device data sheet, but developed by using a more
powerful and universal language, the Electronic Device Desciption Language (EDDL). A
EDD typically describes the application-related parameters and functions of a field
device such as configuration parameters, ranges of values, units of measurement, default
values, etc. A EDD is a versatile source of information for engineering, commissioning,
runtime, asset management, and documentation. It also contains support mechanisms to
integrate existing profile descriptions in the device description, allow references to
existing objects, to access standard dictionaries and to allow assignment of the device
description to a device. An EDD is independent of operating systems and supports the
user by its uniform user and operation interface (only one tool, reliable operation,
reduced training and documentation costs) and also the device manufacturer (no specific
knowledge required, existing EDDs and libraries can be used). The EDD concept is
suitable for tasks of low to middle complexity.
DTM (Device Type Manager) Top
DTM is a software which is generated by mapping the specific functions and dialog of a
field device for parameterization, configuration, diagnostics and maintenance, complete
with user interface, in a software component. This component is called DTM and is
integrated in the engineering tool or control system over the FDT interface. A DTM uses
the routing function of an engineering system for communicating across the hierarchical
levels. It works in field devices as a 'driver', similar to a printer driver, which the printer
supplier includes in delivery and must be installed on the PC by the user. The DTM is
generated by the device manufacturer and is included in delivery of the device.
DTM generation Top
DTM generation may be performed using one of the following options: Specific
programming in a higher programming language, Reuse of existing component or tools
through their encapsulation as DTM, Generation from an existing device description
using a compiler or interpreter, or Use of the DTM toolkit of MS VisualBasic. With
DTMs it is possible to obtain direct access to all field devices for planning, diagnostics
and maintenance purposes from a central workstation. A DTM is not a stand-alone tool,
but an ActiveX component with defined interfaces. The FDT/DTM concept is protocol-
independent and, with its mapping of device functions in software components, opens up
interesting new user options. The DTM/FDT concept is very suitable for tasks of middle
to high comlexity.
Quality Assurance Top
In order for PROFIBUS devices of different types and manufacturers to correctly fulfill
tasks in the automation process, it is essential to ensure the error-free exchange of
information over the bus. The requirement for this is a standard-compliant
implementation of the communications protocol and application profiles by device
manufacturers.To ensure that this requirement is fulfilled, the PNO has established a
quality assurance procedure whereby, on the basis of test reports, certificates are issued to
devices that successfully complete the test . Basis for the certification procedure is the
standard EN 45000. The PROFIBUS User Organization has approved manufacturer-
independent test laboratories in accordance with the specifications of this standard. Only
these test laboratories are authorized to carry out device tests, which form the basis for
certification. The test procedure, which is the same for all test laboratories, is made up of
several parts: The GSD/EDD Check ensures that the device description files comply with
the specification. The Hardware Test tests the electric characteristics of the PROFIBUS
interface of the device for compliance with the specifications. This includes terminating
resistors, suitability of the implemented drivers and other modules and the quality of line
level. The Function Test examines the bus access and transmission protocol and the
functionality of the test device. The Conformity Test forms the main part of the test. The
object is to test conformity of the protocol implementation with the standard. The
Interoperability test checks the test device for interoperability with the PROFIBUS
devices of other manufacturers in a multivendor plant. This checks that the functionality
of the plant is maintained when the test device is added. Operation is also tested with
different masters. Once a device has successfully passed all the tests, the manufacturer
can apply for a certificate from the PROFIBUS User Organization. Each certified device
contains a certification number as a reference. The certificate is valid for 3 years but can
be extended after undergoing a further test.
Implementation Top