RECOMMENDATION FOR THE INSTALLATION OF PROFIBUS AND WORLDFIP NETWORKS

8 May 2001

Jacky BRAHY and Raymond BRUN

SUMMARY The purpose of this note is to define how to correctly and professionally install a PROFIBUS or WorldFIP fieldbus network at CERN. It defines the installation rules and the various elements to be used.

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Jacky BRAHY, Division LHC/IAS, CERN, 1211 GENEVE 23 (CH) Tel : 00 41 22 767 86 48, Fax : 00 41 22 767 95 80 E-Mail : Jacky.Brahy@cern.ch Raymond BRUN, Division LHC/IAS, CERN, 1211 GENEVE 23 (CH) Tel : 00 41 22 767 69 46, Fax : 00 41 22 767 95 80 E-Mail : Raymond.Brun@cern.ch

SUMMARY

CABLES RECOMMENDED AT CERN :

Page 3

WORLDFIP installation guide :

Page 7

PROFIBUS installation guide :

Page 23

CABLES RECOMMENDED AT CERN

Jacky BRAHY & Raymond BRUN LHC-IAS

HALOGEN FREE CABLE COMMON TO PROFIBUS and WORLDFIP NETWORKS

The cables used must correspond to the characteristics defined in the standards in use and to the Safety Requirements at CERN. The colours are not imposed by the standards, but in order to better distinguish the networks installed at CERN it is preferable to respect the recommended colours. 1) Colour of the cable : a colour by type of network Purple for PROFIBUS Green for WorldFIP Blue for the (H1) instrumentation network with intrinsic protection for PROFIBUS PA and FIELDBUS-FOUNDATION (FF) which will probably be the WorldFIP instrumentation bus. The transmission speed is 31.25 kbit/s. Black for the (H1) instrumentation network without intrinsic protection. Note : For information, the colour orange is already reserved for the optical cables and brown for ETHERNET. 2) Main cable "Trunk" PROFIBUS DP (9,6 kHz to 12 Mhz) WorldFIP (1Mbit/s and 2.5Kbit/s) Impedance characteristic : Capacity : Line Impedance: Wire Gauge : Section : Colour : Outer covering : Conductors : 150 < 30 pf/m 110 /km 0.64 mm > 0.34 mm2

Purple for PROFIBUS Green for WorldFIP Red and Green

WorldFIP & PROFIBUS are available permanently at the CERN store under the SCEM : 04.21.60.020.4 for PROFIBUS under the SCEM : 04.21.60.120.1 for WorldFIP 3) Derivation cable for WorldFIP One has to use 2 twisted pairs of armoured 150 cable and it should be multistranded for the realisation of more flexible and "non breakable" Derivations.

4) Cable for intrinsic protection (or not) for PROFIBUS PA and WorldFIP (FF) at 31.25kbit/s Characteristic impedance: Line impedance : Wire gauge : Section : Colour : 100 44 /km 0.64 mm > 0.8 mm2 Blue for EX(Explosive Environment) applications Black for not EX applications Cable PROFIBUS PA 3076F LSNH Cable PROFIBUS PA FB-02YS(St+C)H

References : Belden : Kerpen :

Note : These cables follow the IEC-1158-2 Standard. The Derivation cable is not selected for the moment.

5) Tool for "Fast Connect" fast stripping of wiring The tool "Fast Connect" makes it possible to quickly prepare the end of the cable to be connected to the connector. This tool requires the use of a specific cable. References : Tool : SCEM 34.94.36.320.2 Cable : Standard at CERN under the references previously quoted.

WorldFIP installation Guide

Raymond BRUN LHC-IAS

RECOMMENDATIONS FOR THE INSTALLATION OF A WORLDFIP FIELDBUS Figure 1 shows the various elements of a standard WorldFIP fieldbus at CERN.

PLC Premium PCMCIA Module (TSXFPP10)

1

Terminaison 150 OHM (Acc7)

11
R

(TSXFPCG10) L3

Botier de Drivation

Botier de Drivation

Cable 1 paire torsade blinde 150 Ohm (Tronc)

11b
R

(Acc4)

(Acc4)

(Acc4)

(Acc4)
2

Terminaison 150 OHM Cable 2 paires torsades blindes 150 Ohm (Drivation)

Etanche Mtallique + 1 SUB_D9 L1 L2

Etanche Mtallique + 1 SUB_D9 Ln-1

11a

Ln

SUB_D9 Femelle
7

Terminaison 150 OHM Connecteur Mtallique (Acc2) (Acc2) Connecteur Mtallique (Acc2) Connecteur Mtallique
R

(Acc2)

(Acc7)

Distance maxi : 5 Km thorique mais 1 Km conseille

Nota : La distance maxi est gale la somme des distances L1 Ln

BUS WorldFIP 1 MHz et 2.5 MHz

Figure : 1

JUNCTION BOX "TAP" [Ref. 1] Reference mark 3 : Metal IP 65 derivation box. It has in addition one female 9 pin SUB-D9 for the connection of all the equipment being connected to the bus via a PCMCIA (TSXFPP10) card established in a Schneider PLC. Code : TSX FP ACC 4.

CONNECTOR Reference mark 7 : SUB-D9 female connector and metal cap allowing connection in chain or derivation. Code. : TSX FP ACC 2

LINE TERMINATOR Reference mark 11 : Its role is to adapt the end of the fieldbus to the characteristic impedance (150) in order to avoid any reflections. It can be established on the connector itself (Reference mark 11a) or in a distribution box (Reference mark 11b). Code : TSX FP ACC 7

"COPPER" BUS REPEATER Reference mark 8 : The Schneider bus repeater is represented in figure 2. It makes it possible to increase the number of stations or the length of the fieldbus by the creation of additional segments with a 1000 metres maximum length. It is possible to cascade a maximum of 4 repeaters allowing a fieldbus length of 5000m. Code : TSX FP ACC 6. Note : The repeater must be supplied with power and designed for a speed of 1Mbit/s.

1000 m max 32 Stations

1000 m max 32 Stations

1000 m max ( 256 Stations Maxi) 32 Stations

150 Ohm 150 Ohm

R R

150 Ohm
R

150 Ohm
R

11
R

11
R

150 Ohm

150 Ohm

+/- 24V* Repeteur

+/- 24V* Repeteur

* Alimentation DC redresse mais non filtre (+19 V + 36 V )

REPETEUR ELECTRIQUE 1 MHz SCHNEIDER ( 32 Stations ou 1 Km )

Figure : 2

10

Reference mark 12 : ditto for the Alstom repeater represented in figure 3. Code : RP131 / IR 155-1C It must be supplied with 24V and designed for a speed of 2.5Mbit/s. Code : RP131 / IR 155-2C It must be supplied with 24V and designed for a speed of 2.5Mbit/s. Note : Repeater RP131 can also function at 1Mbit/s and 31.25kbit/s

700 m max 32 Stations

700 m max 32 Stations

700 m max ( 256 Stations Maxi) 32 Stations

11
R

Segment No 1

150 Ohm
R

150 Ohm
R

Segment No 3

11
R

150 Ohm
12

11

11 12

150 Ohm IR155-2C

IR155-2C

11

11

150 Ohm Segment No 2

12

150 Ohm

Rpteur RP131 / IR155-2C (48V) / IR155-1C (24V)

REPETEUR ELECTRIQUE 2,5 MHz ALSTOM ( 32 Stations ou 700 m )

R. BRUN et D. GLENAT le : 4-4-2000

Figure : 3

11

OPTICAL BUS REPEATER Reference mark 9 : The optical repeater represented in figure 4, makes it possible to interconnect 2 copper segments via an optical fibre which ensures good behaviour of the fieldbus over long distances or for the connection of optical equipment. Code : TSX FP ACC 8M. Note : It must be powered like the copper repeater and designed for a speed of 1Mbit/s.

Terminaison ACC 7
R

Terminaison ACC 7
11
R

11

11
R R

11

150 Ohm

Distance jusqu' 30km

150 Ohm

+/- 24V*

+/- 24V*

Coupleur Cuivre / Optique

* Alimentation DC redresse mais non filtre (+19 V + 36 V )

Liaison Optique

Figure : 4

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CONNECTION RULES The rules for connection of the active conductors and shielding are: Connection of the conductors : See Appendix 1 and 2 Shielding and grounding of the fieldbus : See Appendix 2 and 3. Minimum radius of curvature of the cable equal to ten times its diameter, that is 80 to 100mm. Note : Other recommendations relating to this chapter are detailed in two notes, one from Schneider [1], and the other from Alstom [2].

SPEED AND DISTANCE According to the condition of use (environment, quality of the cable), the operational maximum distances will be the following ones: With a copper fieldbus 31,25 kbit/s : from 5 to 20km 1 Mbit/s : from 1 to 4km 2.5 Mbit/s : from 500m to 1,5km In practice, to prevent any problems, the maximum distances selected are the following: 31,25 kbit/s : 10km 1 Mbit/s : 1km 2.5 Mbit/s : 700m With an optical fieldbus 31,25 kbit/s, 1 Mbit/s and 2,5 Mbit/s : 40km

CONCLUSION During all the LHC construction, the cables and distribution boxes relating to the WorldFIP fieldbus will be held in stock in the CERN store.

REFERENCES [1] Schneider Electric : Platform of Automatism Premium / Catalogue August 99 [2] Alstom-Cegelec / WorldFIP : Design and installation Manual / ALS 50414 b-en / edition 03-98

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Appendix 1 : Network of the WorldFIP laboratory (Example of connection and grounding)

MBX 1000
Module microFIP CC131

PC FIP Designer

Male femelle

Male

Male

femelle

femelle

pont de connexion du blindage

SUB DB 9 Femelle

Au moins un point direct la terre Les autres (le maximum) travers un condensateur "haute tension" normalement implant sur chaque moduel WorldFIP (pont de connexion -a- ou -b-)

Connexion Cble WorldFIP

See also CERN WorldFIP site : http://wwwlhc.cern.ch/IAS/Frames/WS_Frames.html

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Appendix 2 : Connection of fieldbus cable

(Extracted from the " FIPIO Reference Handbook ") 1- Preparation of the cables. draw the cable over a length of approximately 5 cm, Cut the braid at the level of the ground connection, Set up the ground connection collar (the position of the collar on the cable must take account of its fixing in the connector, on the right or on the left of the cable), divide the strip iron and the colourless snap rings to release the conductors, strip each conductor over a length of approximately 5 mm and equip them with the ends provided.

15

2- Connection of connectors TSX FP ACC2 One distinguishes two kinds of connections for WORLDFIP/FIPIO equipment : in a chain and as a derivation. The WorldFIP standard which defines the physical layer does not allow a "Pure electric derivation", so all WORLDFIP/FIPIO equipment is electrically connected to the nearest the twisted pair.

In the case of an installation requiring a derivation, this one will be obtained by a "return " cable (2 pairs of wires).

16

3- Wiring of the connectors The connection of the various cables is carried out by a screw connector box. The implementation is the following : 1 - open the connector, 2 - prepare the cables as described previously, then tighten each conductor in the screw connector box, by respecting the pairing and the polarity of the conductors : Red (+) / Green (-) and Orange (+) / Black (-). The wiring drawings hereafter illustrate the various types of possible connections (daisy-chain or derivation), 3 - fix the grounding collar(s) in the connector by taking care not to grip the conductors, 4 - remove the cover(s) located on the lid in order to release the passage of the cables, 5 Put back the lid and fix it.

Connection by chaining If the connector of the equipment is positioned at the beginning or the end of the WORLDFIP/FIPIO segment, only cable 1 is connected to the case. In this case, cable 2 is obligatorily replaced by a non polarised TSX FP ACC7 terminator. The fixing of the grounding collars prohibits having the arrival of the cables face to face. They must arrive either on the same side (left or right) or shifted with respect to the other.

17

Derivation Connection In this drawing the cable 1 is a drop cable of type TSX FP CCxxx. If the derivation is carried out by 2 cables of type TSX FP CA/CR xxx, the connection is the same one as for a chain. In this type of configuration, the cable can arrive indifferently by the left or the right-hand side, the bottom or the top.

4 Connection of the derivation box TSX FP ACC4 The connection of the various cables is carried out by screw connector boxes, a connector box per twisted pair. The implementation is the following : 1 open the derivation box, 2 prepare the cables as previously indicated then make them pass in the seal, 3 set up on each cable a ground collar. The position of the collar on the cable must take account of its fixing in the case (on the right or on the left of the cable), 4 tighten each conductor in the screw connector block by respecting the pairing and the polarity of the conductors : Red (D+) / Green (D-) or Orange (D+) / Black (D-), 5 fix the ground collars then tighten the seal passed by a cable or a terminator, 6 put back the lid and fix it. The TSX FP ACC4 derivation box also has a 9 pin female connector which allows the connection : - of a terminal provided with a card : TSX FPC 10 or FCP FPC 10 and of its wire of connection wire TSX FP CE 030, - of an equipment provided with a PCMCIA type 3 card : TSX FPP 10, TSX FPP 20, or FCP FPC 10 and of its connection wire TSX CG 010 / 030.

The diagrams hereafter show the various types of possible connections :

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chaining carried out with trunk cable, connection of a TSX FP ACC7 terminator, standby box, derivations carried out with drop cable.

Chaining carried out with the trunk TSX FP CA/CRxxx cable In this case, the derivations must be connected as indicated here. The user will be able to also connect a programming terminal on the Sub-D connector after having removed the stopper a quarter of a turn.

Connection of a TSX FP ACC7 terminator If the derivation box is at the beginning or the end of the segment, only the cable T1 is connected and a non polarised TSX FP ACC7 terminator is connected in place of the second section of the cable.

The connection is carried out, according to whether the derivation box is on standby or that a derivation is already cabled, as indicated below. The user will be able to also connect a programming terminal on the Sub D connector after having removed the stopper a quarter of a turn.

Standby box, "cabled chaining" box

19

1 5 (+) (-)

Main TSX FP CA/CRxxx, TSX FP ACC7 terminator, Corresponds to the red or orange wire, Corresponds to the green or black wire. TSX FP ACC7 terminator, ACC4

20

Cabled derivation box 1 2 5 (+) (-) Main cable TSX FP CA/CRxxx, Branch cable TSX FP CCxxx, TSX FP ACC 7 terminator. Corresponds to the red or the orange wire, Corresponds to the green or the black wire.

Power Supply which resists Radiation The figure below represents simple powering which resists radiation. It is used on the Schneider PLCs tested in the radiation zone in TCC2.

Diode SI. REDR. GBPC

220 V AC

18 V AC Condensateur Alu. ELC. Fix.CE : 40V : 10000 MF Transfo Torique : 220V/ 2x 10-12-15V 2,5A

26 V-DC

Alimentation teste et rsistant aux Radiations

21

Appendix 3 : Shielding and grounding of the WorldFIP Fieldbus (ALSTOM Recommendation) Trunk Lin Terminat Trunk Trunk

Lin Terminat

Drop

Drop

Pin Pin Pin

Pin

22

PROFIBUS Installation Guide

J. Brahy LHC-IAS

23

See also:

Guides of PROFIBUS national organisation PROFIBUS Technical Guideline-Installation Guideline for PROFIBUS DP N 2.112 PROFIBUS Guideline PROFIBUS Interconnection Technology N 2.142

The Siemens handbook SIMATIC NET PROFIBUS Network Ref. 6GK1970-5CA20-0AA0

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PROFIBUS DP Authorised distances according to the transmission speed.

Flows (kbits/s) Length segment (m) 9.6 1200 19.2 1200 19.2 1200 45.45 1200 93.75 1200 187.5 1000 500 400 1500 200 3000 100 6000 100 12000 100

Maximum number of stations by segment : 32 Network example:

The elements which are the subject of a recommendation in a network DP are - the active termination - The connectors (bus connector or bus terminal) - The cable (see chapter recommended cables at CERN ) - The repeaters Active termination : The bus is supplied by the stations placed at each end, which can cause problems in the event of intervention on the last station. To avoid that, it is recommended to use an active termination at the end of the line. Siemens reference : Active element of termination for PROFIBUS

6ES7 972-0DA01-0AA0

25

Bus connector: The bus connector is placed directly on the decentralised system or the master. It can receive two cables for wiring in daisy chain . There is a version without end of line terminating resistor and the version with terminating resistor of end of line. The latter although not necessary for the intermediate stations is nevertheless recommended because the use of the termination causes the insulation of the more distant stations, this insulation of the part which is downstream from the finished connector facilitates the progressive commissioning of the installation and the search for problems on the bus. There is also a version with extra socket ; it makes it possible to connect a console of programming for tests or breakdown service without having to stop the bus. To use when this need is expressed. The recommended connectors are of type Fast Connect : Without extra socket: Siemens 6ES7 972-0BA50-0XA0 With extra socket: Siemens 6ES7 972-0BB50-0XA0

Convention of wiring : Connector limit A Green conductor Connector limit B Red conductor Preparation of the cable for connector Fast Connect

Foot note : It is not necessary to strip the end of the wires.

26

Bus terminal 12M: One can use this means of connection when it is difficult to bring the bus cable directly on the off-set equipment. Like for the bus connector, the use of the terminating resistor isolates the rest of the network. The length of the connection cable to the final equipment is 1.5m. The final equipment must deliver 90mA under 5V for the power supply of the bus terminal 12M. It is possible to connect 32 BT12M to the maximum on a bus segment.

Siemens reference : Bus terminal 12M for PROFIBUS

6GK1 500-0AA10

Cable preparation for bus terminal and repeater connection.

27

Equipment list supporting the bus terminal 12M

Repeater : If the distances are higher than those which are authorised for a segment, one must use repeaters. The maximum number is 9 or 10 segments.

Siemens reference : RS 485 Repeater for PROFIBUS

6ES7 972-0AA01-0XA0 28

PROFIBUS PA Transmission speed: 31.25kbits/s Maximum length of a segment : 1900m

Particularity of PROFIBUS PA The bus cable transports the power supply and the communication. Maximum current of power supply circulating in the cable: Ex Zone 100mA Non Ex zone 400mA

Length of the branch cables Number of branch cables Maximum length of a branch cable Coupler DP/PA 1 to 12 Maximum 120 m 13 to 14 Maximum 90 m 15 to 18 Maximum 60 m 19 to 24 Maximum 30 m

Coupler DP/PA Ex Maximum 30m Maximum 30m Maximum30m Maximum 30m

One uses the same cable for the trunk and derivations.

29

The elements which are the subject of a recommendation in a standard PA network type are - connections - terminators - the cable (see chapter Cables recommended at CERN)

Components for PROFIBUS PA

30

31

Networks with optical fibre.

Under certain conditions - noisy environment - long distances - ground problems it is possible to use an optical network. One then uses OLM (Optical Link Module) OLM : The OLM have an electric channel with floating contact (as on a repeater) and, according to the model one or two optical channels. The OLM are conceived transmission speeds of 9,6kbit/s to 12Mbits/s. The transmission speed is automatically detected

Linear topology example with OLM

32

Redundant optical rings with OLM The redundant optical rings are a particular form of linear topology. The looping of the optical line in a ring endows on the network with a great reliability.

Components for optical network : Cables with optical plastic fibre Properties of cables with optical plastic fibre.

33

34

Glass Fibre-Optic cables Properties of glass fibre-optic cables

35

The OLM exist in versions with one or two optical interfaces for various types of FO cable : Plastic FO cables (980/1000 m) can be used to a length of section of 80m. They can be equipped with BFOC connectors on site. PCF FO cables (200/300 m) can be used to a length of section of 400m. They can be equipped with 4 BFOC connectors and a polling loop. The cables with multimode glass optical fibres (62,5/125 m) are usable to cover distances up to 3000m. . They can be equipped with 4 BFOC connectors The cables with monomodes glass optical fibre (10/125 m) are usable for very long distances up to 15 km.

36

OLM modules available at Siemens.

Number of ports and distances usable for the different OLM.

37

Acknowledgments
R. RAUSCH for his constructive advice and his rich person experiment on the fieldbuses components A. BLAND for his assistance in the correction of the English document

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