RECOMMENDATION FOR THE INSTALLATIONOF 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 aPROFIBUS or WorldFIP fieldbus network at CERN. It defines the installation rulesand the various elements to be used.

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

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SUMMARY

• CABLES RECOMMENDED AT CERN : Page 3

• WORLDFIP installation guide : Page 7

• PROFIBUS installation guide : Page 23

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CABLESRECOMMENDED

AT CERNJacky BRAHY & Raymond BRUN

LHC-IAS

4

HALOGEN FREE CABLE COMMON TOPROFIBUS and WORLDFIP NETWORKS

The cables used must correspond to the characteristics defined in the standards in useand to the Safety Requirements at CERN.The colours are not imposed by the standards, but in order to better distinguish thenetworks 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 willprobably be the WorldFIP instrumentation bus.The transmission speed is 31.25 kbit/s.

• Black for the (H1) instrumentation network without intrinsicprotection.

Note : For information, the colour orange is already reserved for the opticalcables 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 : 150 ΩCapacity : < 30 pf/mLine Impedance: ≤ 110 Ω/kmWire Gauge : 0.64 mmSection : > 0.34 mm2

Colour :• Outer covering : Purple for PROFIBUS

Green for WorldFIP• Conductors : 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 150Ω cable and it shouldbe multistranded for the realisation of more flexible and "nonbreakable" Derivations.

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4) Cable for intrinsic protection (or not) for PROFIBUS PA and WorldFIP (FF) at 31.25kbit/s

Characteristic impedance: 100 ΩLine impedance : ≤ 44 Ω/kmWire gauge : 0.64 mmSection : > 0.8 mm2

Colour : Blue for EX(Explosive Environment)applicationsBlack for not EX applications

References :• Belden : Cable PROFIBUS PA 3076F LSNH• Kerpen : Cable PROFIBUS PA FB-02YS(St+C)H

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

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5) Tool for "Fast Connect" fast stripping of wiring

The tool "Fast Connect" makes it possible to quickly prepare the end of the cable tobe 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.

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WorldFIP

installation Guide

Raymond BRUNLHC-IAS

8

RECOMMENDATIONS FOR THE INSTALLATIONOF A WORLDFIP FIELDBUS

Figure 1 shows the various elements of a standard WorldFIP fieldbus at CERN.

Figure : 1

Terminaison 150 OHM

BUS WorldFIP 1 MHz et 2.5 MHz

PLCPremium

(Acc7)

11a

3

1

2

(Acc4) (Acc4)

(Acc2) (Acc2)7

EtancheMétallique

+ 1 SUB_D9

Boîtier deDérivation

L1 L2

L3

SUB_D9Femelle

ConnecteurMétallique

Cable 1 paire torsadéeblindée 150 Ohm

Ln-1 Ln

Cable 2 paires torsadées blindées

150 Ohm

Distance maxi : 5 Km théorique mais 1 Km conseillée

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

RR

Boîtier deDérivation

(Tronc)

(Dérivation)

EtancheMétallique

+ 1 SUB_D9

ConnecteurMétallique

(Acc4) (Acc4)

ConnecteurMétallique

(Acc2)

(Acc2)

(TSXFPCG10)

PCMCIA Module(TSXFPP10)

R

Terminaison 150 OHM

(Acc7)

11

11b

Terminaison 150 OHM

9

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

Code : TSX FP ACC 4.

CONNECTORReference mark 7 : SUB-D9 female connector and metal cap allowing connection inchain or derivation.

Code. : TSX FP ACC 2

LINE TERMINATORReference mark 11 : Its role is to adapt the end of the fieldbus to the characteristicimpedance (150Ω) in order to avoid any reflections. It can be established on theconnector itself (Reference mark 11a) or in a distribution box (Reference mark 11b).

Code : TSX FP ACC 7

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"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 bythe creation of additional segments with a 1000 metres maximum length. It is possibleto 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.

Figure : 2

R

+/- 24V*

8

R R

+/- 24V*

8

R

R

150 Ohm

R

150 Ohm

* Alimentation DC redressée mais non filtrée (+19 V à + 36 V )

( 256 Stations Maxi)

Repeteur Repeteur

150 Ohm150 Ohm150 Ohm150 Ohm

1000 m max

32 Stations

1000 m max

32 Stations

1000 m max

32 Stations

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

1111

11

Reference mark 12 : ditto for the Alstom repeater represented in figure 3.

Code : RP131 / IR 155-1CIt must be supplied with 24V and designed for a speed of 2.5Mbit/s.

Code : RP131 / IR 155-2CIt 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

Figure : 3

R

150 Ohm

( 256 Stations Maxi)700 m max

32 Stations

700 m max

32 Stations

700 m max

32 Stations

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

R

150 Ohm

R

R

150 Ohm

R

150 Ohm

150 Ohm

12 IR155-2C 12 IR155-2C

R

150 Ohm

Répéteur RP131 / IR155-2C (48V) / IR155-1C (24V)12

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

Segment No 1

Segment No 2

Segment No 311 11

1111

11 11

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OPTICAL BUS REPEATER

Reference mark 9 : The optical repeater represented in figure 4, makes it possible tointerconnect 2 copper segments via an optical fibre which ensures good behaviour ofthe 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 of1Mbit/s.

Figure : 4

* Alimentation DC redressée mais non filtrée (+19 V à + 36 V )

R

R

R

R

TerminaisonACC 7

TerminaisonACC 7

+/- 24V*+/- 24V*

Coupleur Cuivre / Optique

150 Ohm150 Ohm

Liaison Optique

99Distance

jusqu'à 30km

9

11

11 11

11

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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, onefrom Schneider [1], and the other from Alstom [2].

SPEED AND DISTANCE

According to the condition of use (environment, quality of the cable), the operationalmaximum 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 thefollowing:

• 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 theWorldFIP 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)

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

femelle femelle femelle

ConnexionCâble WorldFIP

+ -

Module microFIP CC131

PC FIPDesigner

SUB DB 9 Femelle

MBX 1000

MaleMale Male

Au moins un point direct à la terreLes autres (le maximum) à traversun condensateur "haute tension"

normalement implanté sur chaque moduel WorldFIP

(pont de connexion -a- ou -b-)

76

pont de connexion

du blindagea b

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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.

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2- Connection of connectors TSX FP ACC2

One distinguishes two kinds of connections for WORLDFIP/FIPIO equipment : in achain and as a derivation. The WorldFIP standard which defines the physical layerdoes not allow a "Pure electric derivation", so all WORLDFIP/FIPIO equipment iselectrically 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).

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3- Wiring of the connectors

The connection of the various cables is carried out by a screw connector box. Theimplementation is the following :

1 - open the connector,2 - prepare the cables as described previously, then tighten each conductor in thescrew connector box, by respecting the pairing and the polarity of theconductors :Red (+) / Green (-) and Orange (+) / Black (-). The wiring drawings hereafterillustrate 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 theconductors,4 - remove the cover(s) located on the lid in order to release the passage of thecables,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 theWORLDFIP/FIPIO segment, only cable 1 is connected to the case. In this case, cable2 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 toface. They must arrive either on the same side (left or right) or shifted with respect tothe other.

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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 connectionis the same one as for a chain. In this type of configuration, the cable can arriveindifferently 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, aconnector 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 cablemust take account of its fixing in the case (on the right or on the left of thecable),4 – tighten each conductor in the screw connector block by respecting thepairing 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 theconnection :- of a terminal provided with a card : TSX FPC 10 or FCP FPC 10 and of its wire ofconnection 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 beconnected as indicated here.The user will be able to also connect aprogramming terminal on the Sub-Dconnector after having removed the stopper aquarter of a turn.

Connection of a TSX FP ACC7 terminator

If the derivation box is at the beginning orthe end of the segment, only the cable T1 isconnected and a non polarised TSX FPACC7 terminator is connected in place ofthe second section of the cable.

The connection is carried out, according towhether the derivation box is on standby orthat a derivation is already cabled, asindicated below. The user will be able toalso connect a programming terminal onthe Sub D connector after having removedthe stopper a quarter of a turn.

Standby box, "cabled chaining" box

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1 Main TSX FP CA/CRxxx,5 TSX FP ACC7 terminator,(+) Corresponds to the red or orange wire,(-) Corresponds to the green or black wire. TSX FP ACC7 terminator, ACC4

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Cabled derivation box

1 Main cable TSX FP CA/CRxxx,2 Branch cable TSX FP CCxxx,5 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 theSchneider PLCs tested in the radiation zone in TCC2.

18 V AC220 V AC 26 V-DC

Transfo Torique : 220V/ 2x 10-12-15V 2,5A

Diode SI. REDR. GBPC

Condensateur Alu.ELC. Fix.CE :

40V : 10000 MF

Alimentation testée et résistant aux Radiations

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Appendix 3 :

Shielding and grounding of the WorldFIP Fieldbus (ALSTOM Recommendation)

LinTerminat

LinTerminat

Drop Drop

Trunk Trunk Trunk

PinPin

PinPin

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PROFIBUSInstallation Guide

J. Brahy LHC-IAS

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See also:

Guides of PROFIBUS national organisation

PROFIBUS Technical Guideline-Installation Guideline for PROFIBUS DP N° 2.112PROFIBUS 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) 9.6 19.2 19.2 45.45 93.75 187.5 500 1500 3000 6000 12000

Lengthsegment (m)

1200 1200 1200 1200 1200 1000 400 200 100 100 100

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 inthe event of intervention on the last station. To avoid that, it is recommended to usean active termination at the end of the line.

Siemens reference :Active element of termination for PROFIBUS 6ES7 972-0DA01-0AA0

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Bus connector:The bus connector is placed directly on the decentralised system or the master. It canreceive two cables for wiring in « daisy chain » .There is a version without end of line terminating resistor and the version withterminating resistor of end of line. The latter although not necessary for theintermediate stations is nevertheless recommended because the use of the terminationcauses the insulation of the more distant stations, this insulation of the part which isdownstream from the finished connector facilitates the progressive commissioning ofthe 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 ofprogramming 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 972-0BA50-0XA0With extra socket: Siemens 6ES7 972-0BB50-0XA0

Convention of wiring :Connector limit A Green conductorConnector 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.

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Bus terminal 12M:

One can use this means of connection when it is difficult to bring the bus cabledirectly on the off-set equipment.

Like for the bus connector, the use of the terminating resistor isolates the rest of thenetwork.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 busterminal 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.

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Equipment list supporting the bus terminal 12M

Repeater :

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

Siemens reference :RS 485 Repeater for PROFIBUS 6ES7 972-0AA01-0XA0

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PROFIBUS PA

Transmission speed: 31.25kbits/sMaximum 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 branchcable

Coupler DP/PA Coupler DP/PA Ex1 to 12 Maximum 120 m Maximum 30m13 to 14 Maximum 90 m Maximum 30m15 to 18 Maximum 60 m Maximum30m19 to 24 Maximum 30 m Maximum 30m

One uses the same cable for the trunk and derivations.

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

Components for PROFIBUS PA

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32

Networks with optical fibre.

Under certain conditions- noisy environment- long distances- ground problemsit 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. Thetransmission speed is automatically detected

Linear topology example with OLM

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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.

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35

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

36

The OLM exist in versions with one or two optical interfaces for various types ofFO cable :

- Plastic FO cables (980/1000 µm) can be used to a length of section of 80m. Theycan be equipped with BFOC connectors on site.

- PCF FO cables (200/300 µm) can be used to a length of section of 400m. Theycan be equipped with 4 BFOC connectors and a polling loop.

- The cables with multimode glass optical fibres (62,5/125 µm) are usable to coverdistances up to 3000m. . They can be equipped with 4 BFOC connectors

- The cables with monomodes glass optical fibre (10/125 µm) are usable for verylong distances up to 15 km.

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OLM modules available at Siemens.

Number of ports and distances usable for the different OLM.

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Acknowledgments

R. RAUSCH for his constructive advice and his rich person experiment on thefieldbuses components

A. BLAND for his assistance in the correction of the English document