PROCESS AUTOMATION

SIMPLIFY PROCESSES

FIELDCONNEX® – INFRASTRUCTURE FOR PROFIBUS PA

SIMPLIFY PROCESSES

The fi eldbus is a perfect example of simplici-ty at its best. It offers straight forward com-munication from the control room all the wayto each individual fi eld device. One common cable is suffi cient to supply power to the fi elddevices and transport all communications.

It is this versatility that has turned the fi eld-bus into the enabling technology for modern-day process plants. It not only supports pro-cess control, but also allows a totally newlevel of device management. Via the fi eldbus,the process control system is given total con-trol over each individual instrument. Field de-vices can be confi gured and checked from the control room. Status information and pro-cess values are available anytime. Preventive maintenance has fi nally become reality.

When compared to conventional 4…20 mA technology, the fi eldbus provides a much higher level of reliability and accuracy. There is no longer a need for scaling and device drift is a matter of the past.

Besides actual process control, the fi eldbus offers cost-effi cient benefi ts all along the sys-

tem lifecycle. System planning requires lesseffort. Installation and commissioning are easier and less time consuming. Fewer shut-downs dramatically increase plant perform-ance and availability.

Being an internationally accepted industry standard, the fi eldbus is supported by nu-merous manufacturers. New technologies arebased on the same standards, thus protect-ing the investment in installations, training and technology.

Being a well established technology, the fi eld-bus offers a solid communications infrastruc-ture which combines innovation with proven reliability. There are countless plants all over the world successfully using the fi eldbus for more than ten years.

This brochure will give you an overview over FieldConnex, the innovative and comprehen-sive product line from Pepperl+Fuchs for fi eld-bus communications.

The best solutions are usually very simple

SIMPLIFY PROCESSES

The fi eldbus is a perfect example of simplici-ty at its best. It offers straight forward com-munication from the control room all the wayto each individual fi eld device. One common cable is suffi cient to supply power to the fi elddevices and transport all communications.

It is this versatility that has turned the fi eld-bus into the enabling technology for modern-day process plants. It not only supports pro-cess control, but also allows a totally newlevel of device management. Via the fi eldbus,the process control system is given total con-trol over each individual instrument. Field de-vices can be confi gured and checked from the control room. Status information and pro-cess values are available anytime. Preventive maintenance has fi nally become reality.

When compared to conventional 4…20 mA technology, the fi eldbus provides a much higher level of reliability and accuracy. There is no longer a need for scaling and device drift is a matter of the past.

Besides actual process control, the fi eldbus offers cost-effi cient benefi ts all along the sys-

tem lifecycle. System planning requires lesseffort. Installation and commissioning are easier and less time consuming. Fewer shut-downs dramatically increase plant perform-ance and availability.

Being an internationally accepted industry standard, the fi eldbus is supported by nu-merous manufacturers. New technologies arebased on the same standards, thus protect-ing the investment in installations, training and technology.

Being a well established technology, the fi eld-bus offers a solid communications infrastruc-ture which combines innovation with proven reliability. There are countless plants all over the world successfully using the fi eldbus for more than ten years.

This brochure will give you an overview over FieldConnex, the innovative and comprehen-sive product line from Pepperl+Fuchs for fi eld-bus communications.

The best solutions are usually very simple

SYSTEM OVERVIEW PROFIBUS PA

SEGMENT COUPLER/POWER SUPPLY

HIGH-POWER TRUNK CONCEPTFIELDBUS INFRASTRUCTURE FOR PROCESS AUTOMATION

PLC/DP-MASTER

TERMINATOR INTEGRATED

SEGMENT PROTECTORSHORT-CIRCUIT PROTECTION

FIELD DEVICES

General Purpose Area

HIGH-POWER TRUNK

Hazardous Area Zone 2/Class I, Div. 2

SEGMENT PROTECTORUP TO 12 SPURS PER SEGMENT PROTECTOR

Ex nL

FIELD DEVICES

FIEL

DB

US

DIS

TRIB

UTI

ON

PR

OCE

SS

INTE

RFA

CES

SEG

MEN

T CO

UP

LER

FIELDBARRIERWITH GALVANIC ISOLATION

Ex nA Ex e

HIGH-POWER TRUNK

Ex i

FIELD DEVICES CONVENTIONAL FIELD I /O

FIELD DEVICES

Ex i Ex e

Ex d

FIELD DEVICES

FIELDBARRIERWITH GALVANIC ISOLATION SEGMENT PROTECTOR

R-SP-E12

TERMINATORINTEGRATED

SURGE PROTECTION

Hazardous Area Zone 0/Class I, Div. 1

Hazardous Area Zone 1/Class I, Div. 2

FIELDCONNEX THE LEADING FIELDBUS INFRASTRUCTURE

The fi eldbus is the leading technology with afuture. FieldConnex is the keyword for fi eld-bus technology at its highest level. With FieldConnex, Pepperl+Fuchs offers a com-prehensive product portfolio for effi cient pro-cess control.

Setting the pace with over 60 years of experi-ence in process control, Pepperl+Fuchs hasrepeatedly surprised the market with innova-tive solutions. Technologies such as the High-Power Trunk concept were originally develop-ed by Pepperl+Fuchs and have gained indus-try-wide acceptance. FieldConnex represents the sum of our experience and is comprised of highly reliable products that realize tangible competitive benefi ts for our customers.

All products from Pepperl+Fuchs were de-signed with utmost quality and reliability in mind. We not only develop and distribute a

comprehensive range of fi eldbus interface products, but also build them in our own manufacturing facilities. Insisting on a manu-facturing depth of 90% gives us total control over the overall quality. This guarantees fast delivery and puts us into the position to tailor our products to the individual needs of our customers.

Pepperl+Fuchs is technology partner of all major players in the process industry. Being present on all major markets around the world, we are able to offer comprehensive support and support our customers with our comprehensive know-how in fi eldbus and ex-plosion protection.

If you like to get into a dialog with Pepperl+Fuchs, please feel free to contact us at www.pepperl-fuchs.com

Benefi t from the know-how of the inventors

CONTENTS

Fieldbus – Defi nition and Design 8

Explosion Protection with the High-Power Trunk Concept 10

The Physical Layer and Signals 12

System Components 14

Advanced Diagnostics for the Physical Layer 16

PROFIBUS Segment Coupler and Power Supply 18

Fieldbus Distribution in the hazardous area 20

Enclosure Solutions for Fieldbus Distribution 22

Process Interfaces 24

Termination, Wiring and Surge Protection 26

Fieldbus Training 27

LB/FB PROFIBUS Remote I/O 28

Ethernet Isolator 29

Driving the Development 30

INTRODUCTION – FIELDBUS TECHNOLOGY

PRACTICE AND PRODUCT DESCRIPTIONS

COMPLEMENTARY PRODUCTS

MADE BY PEPPERL+FUCHS

FIELDBUS TECHNOLOGY

8

WORK STATION

INTERNET/INTRANETETHERNET/TCP/IP FACTORY LEVELBus Cycle time

< 1000 ms

Bus Cycle time

< 10 ms

PROFIBUS PA PROFIBUS DP FIELD-LEVEL

MANAGEMENT PC/VME

CELL-LEVELBus Cycle time

< 100 ms

ETHERNET/TCP/IP

PLC/DP-MASTER

PROCESS CONTROL SYSTEM MAINTENANCE

a spur depends upon several aspects, such as cable type and total

number of devices on the segment. It is recommended to connect

only one device per spur.

Although the IEC standard allows any kind of topology, the trunk-

and-spur topology has become the most common topology for pro-

cess plants. Due to its clearly structured design it is both easy to

understand and maintain.

DESIGN CONSIDERATIONS

Designing a fi eldbus infrastructure starts with typical control and

monitoring loops. At this stage, it is vital to carefully consider the

number of devices, cable resistance, and distances in order to meet

all design criteria of the fi eldbus standard.

Segment Checker is a widely accepted segment planning tool that will

speed up the design process considerably. It has become the stand-

ard software package for planning and documenting fi eldbus net-

works and offers valuable functions to verify the design based on the

selected explosion protection:

Calculation of voltage drop on the cable

Validation of cable length and number of devices

Segment Checker as well as standard libraries for fi eld instrumenta-

tion are available for download at www.segmentchecker.com

The software also allows the creation and storage of custom libraries

with specifi c devices.

When it comes to fi eldbus technology in process automation,

Pepperl+Fuchs has established itself as a worldwide market leader

with a wealth of experience and expertise. We offer our customers

comprehensive support and know-how transfer anytime and anywhere.

Digital process control is based upon a three-tier hierarchy. At admi-

nistrational and factory level Ethernet has established itself as the

communications backbone, allowing direct data exchange between

the PCS system and the ERP system.

At the fi eld level, the process industry has adopted FOUNDATION

Fieldbus H1 and PROFIBUS PA as the dominant fi eldbus systems.

They comply with the international standard IEC 61158 (Fieldbus for

use in Industrial Control Systems). IEC 61158-2, defi nes the physical

layer of the H1 fi eldbus.

Requirements for PROFIBUS PA:

Transmission of both data and fi eld device power over the same two-wire cable

Various topology structures Interoperability of all fi eld devices Explosion protection for hazardous environments Division of one infrastructure into multiple segments Connection of up to 31 devices to each segment

FIELDBUS INFRASTRUCTURE

Segment A fi eldbus network is divided into multiple segments,

which are usually electrically independent and can have an overall

cable length of up to 1900 m. Depending on factors, such as current

consumption, cable type, explosion protection and the required re-

sponse or bus cycle time, up to 31 devices may be connected to one

segment.

Trunk The trunk – also called home run cable – is the main cable

within a fi eldbus structure that carries power and communication

into the fi eld. Fieldbus termination and power supplies are con -

nected to the trunk.

Spur A spur is the cable that connects the fi eld instrument to the

trunk. It may have a length of up to 120 m. The maximum length of

PROFIBUS PA – DEFINITION AND DESIGN

9

SPURS WITH ENERGYLIMITATION AND SHORT-

CIRCUIT PROTECTION

FIELDBARRIER/SEGMENT PROTECTOR

SEGMENT COUPLER/POWER SUPPLY

HIGH-POWER TRUNK

PLC/DP-MASTER

THE HIGH-POWER TRUNK CONCEPT

10

PROFIBUS DP PROFIBUS PA

PLC/DP-MASTER

The High-Power Trunk Concept is a widely accepted approach for

hazardous areas and general-purpose fi eldbus applications. Part of

the concept is the protected installation of the trunk (US: Div 2 wiring

method) in accordance with IEC 60079-14 (US: NEC 505). It also

needs to be equipped with short-circuit protection and is run without

energy limitation.

To provide energy limitation for explosion protection, all devices are

connected to the trunk via smart wiring blocks, such as Segment Pro-

tectors or FieldBarriers. Using such a topology allows hot working on

the spur and the fi eld device without requiring access to the trunk. It

also allows maximum cable lengths and a high number of devices; while

the trunk itself is protected from short-circuit conditions at the spur.

FISCO AND ENTITY VALIDATION

FISCO and Entity are well-established concepts for the validation of

explosion protection. Both standards are described in IEC-standards

IEC 60079-27 and IEC 60079-11 and defi ne attributes for the fi eldbus

infrastructure that simplify validation.

Basically, system planers need to observe only two requirements:

(1) only one power source is allowed per segment, and (2) all compo-

nents including the cables need to conform to any of these stand-

ards. Observing product-specifi c restrictions, such as energy con-

sumption, electronic design, stray capacitance and inductance is the

manufacturer’s responsibility. Practically all hardware available today

conforms to FISCO, Entity or both.

EXPLOSION PROTECTION WITH THE HIGH-POWER TRUNK CONCEPT

Independent validation of explosion protection

for each spur and device

The High-Power Trunk concept greatly simplifi es validation of explo-

sion protection, because each spur is validated separately with the

wiring block as the only power source and the fi eld device as the only

power drain. Validation of explosion protection only requires to ob-

serve the rating of each device and to verify FISCO or Entity confor-

mance of the entire fi eldbus infrastructure.

This concept allows the mixed use of FISCO or Entity devices. It is

therefore not surprising that three times more devices are connected

using the High-Power Trunk concept compared to FISCO power sup-

plies limiting the energy on the trunk.

High-Power Trunk Concept simplifi es application of fi eldbus

The High-Power Trunk concept offers a number of practical benefi ts

to both system installers and users:

Live work and maintenance is permitted on fi eld instrumentation without gas clearance

Longest cable runs and maximum number of devices enabled in any hazardous area

Use of cost-effective standard power supplies

Easy plant modifi cation and expansion

Mixed use of FISCO or Entity devices

11

PHYSICAL LAYER

12

Supply voltage

0 1 1 0 0 1 1

NOISE SIGNAL LEVEL

Bit error

JITTER

Tolerance

Ideal OKTYPICAL PHYSICAL LAYER MEASUREMENTS

Value DescriptionSignal level The voltage level of the data signal. Measured per device

Noise Unwanted disturbance. Measured per device or per segment

Unbalance Difference in isolation levels between each of the two leads and the shield. Ground fault

Jitter Deviation of the actual from the optimal zero crossing. Measured per device

and per segment

CRC Error Cyclic Redundancy Check Error: A telegram where the checksum is invalid, i.e.: one or

more bits were detected as invalid

Framing Error A fault or an inconsistency in the telegram structure, i. e. caused by an interruption in the

middle of a transmission. Part of the telegram is lost

THE PHYSICAL LAYER AND SIGNALS

According to the fi eldbus protocol only one device may transmit data

at any given time. Information is transmitted in data packets called

telegrams which include address information and checksums to

ensure accuracy of the transmission. If a telegram is detected as bad,

invalid, or incomplete it is rejected and will be transmitted again.

Field devices act as loads drawing at least 10 mA of current. The signal

is transmitted through a change in the load current of ± 9 mA, a rec-

tangular wave indicating the ‘1’ and ‘0’ state of digital communication.

The fi eldbus terminators at each end of the trunk cable translate the

current change into a signal voltage detectable on the cable.

Additionally, the terminators suppress signal refl ections, which can

have a negative effect on signal quality.

Highly accurate data transmission and fast cycle times are typical of

a well-designed and maintained fi eldbus infrastructure. Any increase

in lost or rejected telegrams is a clear indication of problems at the

fi eldbus physical layer. Without the use of online diagnostics, slowly

deteriorating signal quality usually remains undetected until it

severely affects plant performance.

Monitoring the quality of the fi eldbus signals is vital in order to main-

tain the physical health of the fi eldbus infrastructure. There are three

different indicators pointing to problems at segment and device level:

Signal Level The signal level describes the actual signal voltage

transmitted by a device. It can be measured at the power supply as

the voltage drop on the cable. A change in signal level may indicate

unintended load changes on the segment.

Noise Low or high frequency noise describes any unwanted voltage

on the cable. It can be caused by any active component on the seg-

ment or result from EMI generated by power cables and frequency

inverters.

Jitter Jitter describes the timing of each individual bit. The width of

the digital signal is a key performance indicator of the overall physical

health of the network. Since all components within the network

interact to some extent, changes of the electric values of any circuit

also infl uence fi eldbus timing. The resulting effect on signal quality

is measured as jitter.

Advanced continuous monitoring of the physical layer is a cost-effec-

tive step towards increased productivity and plant output. It has a

positive effect on all stages of the network lifecycle – from commis-

sioning to online-monitoring and troubleshooting and is a vital con-

tribution to increased plant availability.

13

Advanced Diagnostic ModuleFor supervision of the fi eld-bus physical layer, for retro-fi t of existing Power Hubs.

Segment Coupler 1Compact single modules forsafe and intrinsically safe seg-ments. Mountable on DIN Rail.

Aluminum housing forSegment Protector orFieldBarrier for mounting in the fi eld. With a selec-tion of cable glands

Modular Surge ProtectorComplete unit for installa-tion in the cabinet

Fieldbus Terminatorfor installation in the fi eldwith robust “screw-in typehousing”

Power Hub for 4 SegmentsComplete with redundancy,fl exible confi guration. Foruse with various Exprotec-tion concepts.

Compact Power HubMost compact design fortwo segments. For manystandard applications.

Valve Couplerfor four intrinsically safe low power valves

Sensor InterfaceFor 12 binary inputs.Version for DIN Railinstallation.

SYSTEM COMPONENTS

14

FieldBarrier in stainless

steel housing. Instrinsicallysafe connection of devices to the High-Power Trunk. Galvanic isolation

Segment Protector R2Simple connection of fi eldinstruments. Short circuitprotection for the Segment.Energy limitatation Ex nL

Preconfi gured housing

solutions. Installation ready.With FieldConnex® compo-nents and accessories. Ex-certifi cation included

RELIABILITY AS A CORE VALUE

Innovative solutions are of limited value if they do

not live up to the challenges of real-life process

plant operation. Pepperl+Fuchs has established a

name for proven technologies that are based upon

established standards and are designed up to the

detail with utmost reliability in mind. As a result,

every component of the FieldConnex system stands

out for its long product lifecycle even under deman-

ding process conditions.

It is therefore not surprising that Pepperl+Fuchs has

developed into a preferred supplier of major system

planners and gained a clearly positive approval by

the experts in the renowned FuRIOS study.

Availability and reliability are the key requirements in the process industry. This is particularly important for the fi eldbus infrastructure as the backbone for reliable communication in the fi eld. Pepperl+Fuchs has supported the worldwideprocess industry for over 60 years. We not only provide innovative products for even more effi cient process control. We also offer comprehensive support and know-how transfer on a global basis.

Pepperl+Fuchs is dedicated to the needs of the glo-

bal process industry. Our products are characterized

by a simple and robust design, leading to superior

quality and long-time reliability. Knowing the prac-

tical needs in the fi eld, we even give attention to

seemingly small details that improve operation

and simplify installation.

The following pages will provide you with an over-

view of FieldConnex system components.

You will fi nd product descriptions and basic selec-

tion criteria to aid you in choosing exactly the right

products for your fi eldbus application.

15

APPLICATION DATA

Installation practices have a tremendous infl uence on the long-term signal quality of a fi eldbus infrastruc-

ture. Maintenance work, moisture, loose wire strands, corrosion and other factors can degrade communi-

cations in course of time and eventually lead to network instabilities.

Conventional handheld diagnostic tools provide only basic analysis of the physical layer. Only real-time

monitoring will detect the slow process of degrading fi eldbus signal quality. This approach maximizes

system availability by providing advance notifi cation before changes can affect system integrity.

Tools for monitoring the fi eldbus physical layer also offer support in every stage of the fi eldbus project from

installation to operation and troubleshooting. In this way, installation and maintenance personnel do not

need to have in-depth knowledge of the physical aspect of the fi eldbus infrastructure.

Fieldbus diagnostic tools with online monitoring capabilities are typically integrated into the fi eldbus power

supply. Here, the module can monitor everything from load conditions to noise, ground faults, or earth leak-

age and measure the device signal level. Status information is easily communicated to the DCS.

Advanced DiagnosticModule HD2-DM-Aintegrated into theFieldConnex Power Hub

Mobile Advanced Diagnostic ModuleDM-AM-KITavailable for single segment monitoring

Stand-alone Diagnostic Module KT-MB-DMAfor upgrade of existing fi eldbus systems

Selection of Physical Layer Diagnostics

Bulk power health

Segment voltage and current

Ground leakage or fault

Segment noise

Device signal level

Signal polarity

Signal jitter

Selection of communication statistics

Segment live list

CRC error counter (Cyclic Redundancy Check)

Frame error counter

Number of received frames

Modules Application and Features

HD2-DM-A Plug-in module for FieldConnex Power Hub system supporting four segment with remote access

DM-AM-KIT Mobile module for single segment check-out and troubleshooting

KT-MB-DMA Stand-alone Module and motherboard for upgrade of any fi eldbus system.Up to four segments

DTM-FC.AD* Diagnostic Manager – Professional Edition for the FieldConnexAdvanced Diagnostic Module - Wizard for commissioning including automated documentation- Detailed measurements and monitoring per device and segment- Integrated oscilloscope for detailed view and troubleshooting- Remote diagnostics included

ADVANCED DIAGNOSTICS FOR THE PHYSICAL LAYER

16

PEPPERL+FUCHS

IN GENERAL

The FieldConnex Advanced Diagnostic Module (ADM) for the FieldConnex Power Hub system provides real-

time monitoring and local data storage of physical layer values for up to four fi eldbus segments. It automat-

ically triggers alarm messages and allows easy node commissioning and remote access for troubleshooting.

Alarm History with time stamps. Clear text points out potential issues and guides the user to quick identifi cation and resolution.

Segment Monitoring with color in-dication for easy identifi cation clarifi es and brings transparency to the fi eldbus physical layer.

Integrated oscilloscope allows users to track down intermittent communication problems.

DIAGNOSTIC MANAGER – PROFESSIONAL EDITION

The Diagnostic Manager Professional is an intelligent

software platform with wizard support, designed for

fast commissioning and effective monitoring of the

physical layer. The built-in segment monitor displays

communication data per segment and device. Each

item is clearly classifi ed as excellent, good, or out

of spec. Reports, alarm lists and historic data can be

exported for detailed analysis.

SIMPLIFIED COMISSIONING

The Commissioning Wizard is part of the Diagnostic

Manager and is used to measure device signal level,

proper termination, and cable continuity. It provides

a baseline report, comprehensive system documen-

tation and points to potential installation problems.

Verifying cables and nodes only requires a few

mouse clicks, thereby reducing the time for system

checkout by more than 80%.

During commissioning, the wizard automatically eval -

uates and recommends warning and alarm levels

for each segment and component. These levels can

be modifi ed to adapt them to the operating philoso-

phy of the plant. They form a baseline, which is

stored in a non-volatile memory inside the ADM.

TARGETED ACTION THROUGH REAL-TIME MONITORING AND TRENDING

The baseline is continuously compared against ac-

tual values. Alarms can be communicated as sum-

mary alarms to the DCS or via solid state contact.

An alarm list shows the history of alarms with time

stamps and indicates possible causes and remedies

guiding the user with actionable information in

plain text.

The ADM captures scheduled snapshots of all

values. It is able to store two years of historic data

Offering various analysis functions and data export

to the maintenance system, the Diagnostic Man-

ager supports proactive maintenance strategies to

increase overall system availability at reduced

maintenance cost.

REMOTE ACCESS FOR EXPEDITED, IN-DEPTH TROUBLESHOOTING

The Diagnostic Manager provides online access to

the Advanced Diagnostic Module. This allows live

monitoring of the fi eldbus physical layer directly

from the control room or remote analysis by an off-

site fi eldbus expert.

Besides measurement and display of vital network

characteristics such as crosstalk/noise, signal jitter,

and resonance, the ADM also includes a powerful

fi eldbus oscilloscope for in-depth analysis of net-

work communication. Fieldbus-specifi c triggers

even allow tracing of complex or intermittent errors

that would otherwise be hard to fi nd. In other

words: the ADM signifi cantly enhances trouble-

shooting and provides the basis for quick diagnosis

and repair.

www.fi eldconnex.info

THE ADVANCED DIAGNOSTIC MODULE

Use the link below for further de-tailed information and to see the data sheets.

17

PEPPERL+FUCHS

PROFIBUS PA is always operated as a sub network to PROFIBUS DP. The segment coupler connects the two

networks for data transmission and supplies power to the PROFIBUS PA segment. Data is transmitted from

the DP-Master via the segment coupler to the PA fi eld device.

The segment coupler provides a transparent connection so that all PA slaves appear to be connected to the

PROFIBUS DP segment. This is true for all aspects of communication: cyclic data exchange, fi eld device con-

fi guration and status information. Field instruments are confi gured and operated based on their native GSD-

fi les. Transparent behavior removes complexity in segment design, engineering, operation and maintenance

– and the segment coupler remains confi guration free.

The segment coupler provides up to 31 V at 500 mA to power up to 31 devices connected to a fi eldbus seg-

ment. Typically, the segment coupler is installed in a cabinet near the control room, where the trunk with a

length of up to 1900 m terminates. For increased availability, many process plants demand redundancy.

The Segment Coupler needs to be designed for longtime operation at low MTBF and low power dissipation.

A modular design is preferred where plug-in modules can be exchanged without disrupting plant operation.

For explosion hazardous areas, FieldConnex segment couplers will power segments designed according to

the High-Power Trunk concept.

PROFIBUS SEGMENT COUPLER AND POWER SUPPLY

18

Compact Segment Coupler SK3 – the two segment solutionCompact and cost-effective for smaller applications demanding full speed on the DP network

Segment Coupler SK3 –the PROFIBUS Power Hubfor four segments with optional redundancy. The optional grounding bar solidly connects the fi eld-bus cable and its shield to the Power Hub

Basic Segment Coupler SK1For single safe-area and in-trinsically-safe FISCO segments

IN GENERAL

PEPPERL+FUCHS

FieldConnex PROFIBUS Power Hubs feature high output power, greater signal quality, and advanced circuitry.

Their modular design allows easy, tool-free installation. All terminals are removable. All power and communi-

cation connections feature retaining screws.

The versatility of the Power Hub together with a variety of power modules allows easy and transparent con-

nection of PA devices to any DCS system via PROFIBUS DP. CREST (Crosstalk and Resonance Suppression

Technology) guarantees perfect communication even under extreme operating conditions. Unique features

include:

Redundancy – the motherboard can hold two power modules per segment.

Diagnostic Functions – Self monitoring system with alarm reports power supply status, fi eldbus short circuit or overload condition, as well as insuffi cient voltage from the bulk power supply.

Advanced Diagnostic Module – available as an option

FieldConnex Basic Segment Couplers are designed to supply PROFIBUS PA devices with ample voltage and

current or with intrinsically-safe energy limitation.

FieldConnex PROFIBUS Segment Couplers always feature transparent connection between PROFIBUS DP and

PROFIBUS PA. They establish an industry standard for fi eldbus networks by providing superior service life,

optimized electrical symmetry, and maximum use of passive components. Impedance generation and galvanic

isolation ensure minimum distortion of the fi eldbus signal, thereby contributing to high system availability.

FieldConnex power supplies are available in two versions:

Power Supply Modules feature galvanic isolation and a choice of controlled output voltages.

Power Conditioner Modules are equipped with current limitation without galvanic isolation. Their output voltage depends on the bulk power supply.

PROFIBUS POWER HUBS

BASIC SEGMENT COUPLERSUse the link below for further de-tailed information and to see the data sheets.

www.fi eldconnex.info

19

APPLICATION DATA

Seg

men

t C

oup

ler

Mo

ther

bo

ard

Gat

eway

Red

und

ancy

PR

OFI

BU

S D

P

tran

smis

sio

n ra

te

No

. of

Seg

men

ts

15…

17 V

/500

mA

21…

23 V

/500

mA

24…

26 V

/400

mA

25…

28 V

/360

mA

28…

30 V

/500

mA

Po

wer

Mo

dul

e R

edun

dan

cy

Gal

vani

c Is

ola

tio

n

Hig

h-P

ow

er T

runk

Intr

insi

cally

-saf

e Tr

unk

CR

ES

T N

ois

e re

duc

-ti

on

AD

M O

pti

on

Att

rib

utes

Segment Coupler SK3

Op-tion

45.45 kbps …12 Mbps

4Op-tion

Plug-in

Highest output power and advanced circuitry

Compact SK3 Segment Coupler

45.45 kbps …12 Mbps

2Stand-alone

For small installations and laboratories

Basic Segment Coupler SK1

93.75 kbps 1Stand-alone

For single segments

PEPPERL+FUCHS

With FOUNDATION Fieldbus, typically 8 through 16 devices are connected to one segment. A Trunk-and-spur

topology is used as de facto standard. It is recommended to connect only one device per spur. The number of

instruments per segment determines bus cycle time as well as the available cable length at the spur. Typi-

cally installations connect between 8 and 16 devices to one trunk.

EXPLOSION PROTECTION WITH THE HIGH-POWER TRUNK CONCEPT

At the core of the High-Power Trunk concept are Segment Protectors or FieldBarriers. These smart wiring inter-

faces are mounted near the fi eld devices to provide short-circuit protection as well as energy limitation for ex-

plosion protection. They also guarantee that the segment remains in operation even during a fault condition

at a spur.

FISCO or Entity are typical concepts for easy validation of explosion protection. The High-Power Trunk concept

expands established FISCO and Entity validation methods by considering each spur connection separately.

This not only simplifi es validation, but also allows the mixed use of Entity and FISCO certifi ed devices.

Segment Protector R-SP-E12For increased safety installations in Zone 1

The FieldBarrierThe High-Power Trunk con-cept applied: Four outputsfor intrinsicallysafe fi eldbus devices

FIELDBUS DISTRIBUTION IN THE HAZARDOUS AREA

20

T-Connector: R2-Segment Protector with innovative connection to the trunk – and a well-defi ned place for the terminator

Test points at trunk andspur enable hasslefree connection of measure-ment devices

Modular Segment Protector snaps on the DIN-Rail with internal connection between modules

IN GENERAL

PEPPERL+FUCHS

FieldConnex Segment Protectors and FieldBarriers are backed by extensive experience. They offer best-in-

class segment reliability even with a large number of fi eld devices. All wiring interfaces are easily mounted on

DIN-Rails with built-in or connectable terminators included. LED trunk and spur status indication further sim-

plify fi eldbus operation and repair.

APPLICATION DATA

Use the link below for further de-tailed information and to see the data sheets.

www.fi eldconnex.info

Number of masters & devices Spur length

1-12 120 m/400 ft

13-14 90 m/300 ft

15-18 60 m/200 ft

19-24 30 m/100 ft

25-32 1 m/3.28 ft

Wiring Device Spur No. of Spurs Installed in Field Devices installed in

FieldBarrier Ex i 4 Zone 1/Div. 2 Zone 0/Div. 1

Segment Protector R-SP-E12 Ex e 12 Zone 1/Div. 2 Zone 1/Div. 2

R2 Segment Protector Ex nL 4…12 Zone 2/Div. 2 Zone 2/Div. 2

Modular Segment Protector Ex nL 2…28 Zone 2/Div. 2 Zone 2/Div. 2

21

FIELDBARRIER

The FieldConnex FieldBarrier is an innovation by Pepperl+Fuchs, which revolutionized the fi eldbus industry

through the introduction of the High-Power Trunk concept. The majority of devices installed in the hazard -

ous area Zone 1/Class I, Div. 0 is connected to the fi eldbus via FieldConnex FieldBarriers with many plants

and many hours of operation. An important safety feature is the IP 30 cover for the trunk connectors, which

prevents unintended opening of the trunk circuits.

Combined short-circuit protection and intrinsic safety at each output

Galvanic isolation between trunk and spurs

The new R2 series Segment Protectors feature innovative design for superior availability:

Easy connection of multiple Segment Protectors Incorrect termination is prevented by design, since the terminator can be placed only on the T-Connector

of the last Segment Protector Durable installation due to connectors with retaining screws Test points allow the connection of diagnostic tools such as the Mobile Advanced Diagnostic Module

without disturbing the wiring

All fi eld devices within a segment, as well as the R2 Segment Protector can be maintained, exchanged or up-

graded without disturbing plant operation.

SEGMENT PROTECTOR

PEPPERL+FUCHS

In many process plants throughout the world, Segment Protectors, Field-

Barriers and associated accessories need to be installed in applications in-

volving hazardous and corrosive environments. This involves ready-to-in-

stall solutions on the basis of certifi ed components as well as the assembly

of enclosures in accordance with the specifi c rules and regulations for

hazardous areas.

Modern enclosures come with the hazardous area certifi cation, saving con-

siderable time and costs for planning, engineering, and installation while

providing worry-free fi eldbus implementation.

Stainless Steel Enclosurewith 2 Segment Protec-tors, 12 spurs each

Stainless Steel Enclosurewith 3 FieldBarriers, 4 outputs each

Stainless Steel Enclosurewith FieldBarrier and a choice of plastic or metallic cable glands

Polyester Enclosure with Segment Protector

Polyester Enclosures Choice of isolated groun-ding bar for the shield and surge protection shown

FieldBarrier in aluminumhousing with metallicglands. Most compactdesign for installationin the fi eld near theinstrumentation

ENCLOSURE SOLUTIONS FOR FIELDBUS DISTRIBUTION

22

IN GENERAL

PEPPERL+FUCHS

FIELD JUNCTION BOX

WE PUT THINGS TOGETHER...

Pepperl+Fuchs fi eldbus products are found in pro-

cess plants throughout the world. From the initial

concept to start-up and commissioning, we provide

professional service and unmatched performance.

As market leaders especially with solutions for haz-

ardous environments, we are able to offer world-

class products in a variety of panels and enclosures.

Due to our own engineering capacity, we are also

able to design and build solutions according to cus-

tomer specifi cations. One example is our wide range

of custom-engineered fi eld junction boxes, which

are manufactured in house in order to guarantee

superior consistency and quality.

...AND DELIVER SOLUTIONS.

Each process plant is different and comes with its

own set of unique requirements. This also applies

to the confi guration of the Field Junction Boxes.

The answer of Pepperl+Fuchs to specifi c process

requirements and individual plant circumstances is

the modular FieldConnex Field Junction Box system.

It represents a modular solution based upon a set

of standardized components and is designed to

match a variety of interface standards. It is even

available as a certifi ed solution matching the spe-

cial requirements of hazardous areas.

Due to this modular design concept, system plan-

ners are able to customize each Field Junction Box

to match any given application and requirement,

by simply selecting specifi c characteristics, such as

dimensions, cable glands, electronic components

and surge protection. This unique solution not only

STAINLESS STEEL

HOUSING

POLYESTER(GRP)

HOUSING

ELECTRONICS

CABLE GLANDS

TERMINALS

OVERVOLTAGEPROTECTION

ACCESSORIES

Simple steps leading to ready-to-install Field Junction Boxes

reduces engineering efforts. It also provides fast in-

stallation on site and contributes to a reduced cost

structure during all phases of the system life cycle:

Ex-approved fi eldbus installation solutions for zones 1/2/2 /22 and Div. /Div. 2

Customer-oriented availability Customer- and industry-specifi c solutions for

fi eldbus distribution. Non-Ex solutions also available

STAINLESS STEEL ENCLOSURES

Our stainless steel enclosures are ideal for use

in applications requiring frequent washing of the

equipment. They offer fully watertight seals and

are the perfect choice for highly corrosive areas

where standard enclosures would not hold up.

Pepperl+Fuchs stainless steel enclosures are

available with ingress protection ratings IP68

and Type 6.

POLYESTER (GRP) ENCLOSURES

Pepperl+Fuchs GRP Field Junction Boxes are the per-

fect choice, where low weight and cost are the issue.

They represent an ideal solution for most installa-

tions requiring ingress protection rating IP66 and

Type 4X.

ALUMINIUM ENCLOSURES

For non-corrosive environments aluminium fi eld

junction boxes are an even more economical

choice. They are the best match for most

installations requiring ingress protection ratings

IP67 and Type 4X.

23

PEPPERL+FUCHS

Effi cient data exchange with fi eld devices is an important requirement for any fi eldbus infrastructure. Proxim-

ity switches, on/off valves, digital inputs, low-power valves and other devices are connected to the fi eldbus

via Process Interfaces. Multiple devices may share a single Process Interface and fi eldbus address. Integration

into the DCS is achieved via standard EDDL or FDT/DTM technology.

The ability of the fi eldbus to transport power and communication makes Process Interfaces an economic so-

lution especially for explosion hazardous areas. They can be installed close to the sensors in Zone 1/Class I,

Div. 2, while the sensors themselves can be located in Zone 0/Class I, Div. 1.

Valve Coupler

FD0-VC-EX4.FFfor four instrinsically safe low-power valves

Sensor Interface

FD0-BI-Ex12.PATwelve inputs connect conventional digital, in-trinsically-safe control circuits such as NAMUR sensors and mechanical contacts

APPLICATION DATA

Pneumatic Interface for twelve pneumaticcontrol valves

Process Interface Protection No. of Outputs Installed in Devices installed in Signals and Sensors

Valve Coupler Ex i 4 DO/8 DI Zone 1/Div. 1 Zone 0/Div. 1 Low power valves, Digital I/O

Fieldbus Pneumatic Interface Ex i Confi gurable Zone 1/Div. 1 Zone 1/Div. 1 High power valves

Sensor Interface Ex i 12 DI Zone 1/Div. 1 Zone 0/Div. 1 NAMUR Sensors

PROCESS INTERFACES

24

IN GENERAL

PEPPERL+FUCHS

SENSOR INTERFACE

FIELDBUS PNEUMATIC INTERFACE

FieldConnex Valve Couplers connect low-power so-

lenoid valves to a fi eldbus segment. They serve to

translate control commands into discrete output sig-

nals to actuate the valve. Two end position sensors

per valve may share one cable.

Valve Couplers are able to conduct partial stroke

tests in either valve position and generate alarm

messages for preset limit values, lead breakage or

short circuits on the cables. Galvanic insulation be-

tween the fi eldbus segment and each valve further

enhances simplicity and plant availability.

Power and control via fi eldbus and pressured air only

Pre-fabricated connection points for heavyduty valves on the sturdy Field Junction Box

Choice of 3/2-way and 5/2-way solenoid valves PROFIBUS DP Remote I/O solutions provide add-

itional power for driving sensors and actuators

An extensive and up to date list of valves and sensors compatiblewith the valve coupler can be foundon www.fi eldconnex.info

The Sensor Interface provides galvanic isolation and connects digital inputs to the fi eldbus using one PROFI-

BUS address. Each output is certifi ed intrinsically safe. The sensor interface will monitor lead breakage and

short-circuit conditions at each input.

VALVE COUPLER

HIGHLIGHTS:

Power and control via the fi eldbus cable Up to four valves via one fi eldbus address Galvanic isolation between fi eldbus and valves Integrated end position monitoring with two

sensors Partial stroke test and other software functions

integrated Lead breakage and short-circuit monitoring for

each conventional signal cable

The Fieldbus Pneumatic Interface is a typical ex-

ample of Pepperl+Fuchs packaging solutions. One

housing with electronic components is designed for

safe and easy connection of up to 32 high-power

valves and can be used in hazardous areas.

25

PEPPERL+FUCHS

PROPER TERMINATION FOR OPTIMAL FIELDBUS QUALITY

Proper termination of fi eldbus segments is extremely important. Attaching one terminator at the end of each

trunk provides the impedance to suppress signal refl ections and improve signal quality. This terminating

impedance also translates data signals transmitted as current change into a detectable voltage change.

The load created by the terminator determines the signal voltage on the cable. Consequently, over-termina-

tion can result in signal levels which cannot be recognized at the other end of the line. Incorrect termination

also increases the signal jitter which can lead to communication errors. Advanced Diagnostics is able to

detect both incorrect termination and impedance changes caused by aging.

SURGE PROTECTION

Due to their design and exposed situation, process plants are often affected by direct or indirect lightning

strikes. Other surge risks include static discharges from plastic materials, crosstalk from cables installed in

close proximity to the fi eldbus cable and surges from power lines. Such conditions can damage the fi eldbus

electronics and even lead to plant shut down.

Surge protection adds to the availability of a plant by eliminating or at least reducing power surges to ground

potential.

For best possible protection, surge protection devices need to be installed between power supply and wiring

interface, between wiring interfaces, and at the ends of each spur. To reduce surge protection cost, risk analy-

sis is used to identify those parts of the plant with a high risk for power surges.

Modular Surge ProtectorComplete unit for installa-tion in the cabinet

Fieldbus Terminatorfor installation in the fi eldwith robust “screw-in typehousing”

TERMINATION, WIRING AND SURGE PROTECTION

26

IN GENERAL

PEPPERL+FUCHS

FieldConnex terminators according to IEC 61158-2 ensure reliable fi eldbus communication. Based upon a

high-availability design, they create the needed impedance by means of a resistor and multiple capacitors.

To further increase system availability, changes in the physical layer including termination errors can be

detected through online monitoring with the Advanced Diagnostic Module.

FieldConnex Surge Protectors are based on a modular design, consisting of a base unit and protection

modules and match the EMC-orientated Lightning Protection Zones Concept in accordance with IEC 61312-1.

They offer system planners the option to determine whether the signal is interrupted or continued while the

protection module is removed from the socket.

FieldConnex includes devices in sturdy IP67 housings designed for installation of terminators or surge pro-

tectors in hazardous areas. These units come with a choice of threads and offer explosion protection.

PRACTICE: FIELDBUS TRAINING

Building or updating a process plant with fi eldbus-based process control has a strong impact on planning, installation and commission-

ing procedures. Pepperl+Fuchs provides extensive know-how transfer to share their knowledge, experience and expertise on fi eldbus

technology. With training services ranging from basic knowledge to detailed product handling, we assist our customers in all aspects

of fi eldbus infrastructure – from initial planning all the way to production start.

Proper training is the key to success. Public courses are often offered through public engineering and management organizations. Cus-

tom trainings tailored to the needs of the team on site will incorporate practical details which might be vital for the success of a project.

FIELDBUS TERMINATORS

SURGE PROTECTION

www.fi eldconnex.info

Use the link below for further de-tailed information and to see the data sheets.STURDY HOUSINGS

27

PEPPERL+FUCHS

There are still many fi eld devices without direct fi eldbus connection.

LB/FB Remote I/O offers a cost-effi cient way to integrate such de-

vices into a fi eldbus infrastructure. It adapts all types of analog and

digital signals, such as on/off status information and classic 4…20

mA/HART signals to PROFIBUS DP.

A wide spectrum of single-channel and multi-channel I/O modules

offer intrinsically-safe and non-intrinsically safe fi eld connections.

Engineering becomes easy and adaptable to the needs of your plant

concept.

LB REMOTE I/O FOR INSTALLATION IN ZONE 2

Matching Ex-Zone 2/Div. 2 requirements

Outputs rated for Zone 1, Zone 0 and Div. 1

SIL 2 for digital and analog outputs

24 V DC power supply

FB REMOTE I/O FOR INSTALLATION IN ZONE 1

Matching Ex-Zone 1 /Div. 2 requirements

Protection methods Ex-i and Ex-e

Exchange of modules while energized in the hazardous area

Integration of FieldBarrier and Modular I/O into one fi eld enclosure

Fully encapsulated for demanding environments

24 V DC or 120/230 V AC power supply

LB/FB PROFIBUS REMOTE I/O

PROFIBUS LB Remote I/O PROFIBUS FB Remote I/O

COMPLEMENTARY PRODUCTS

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ETHERNET ISOLATOR

The FieldConnex Ethernet Isolator is designed especially for tempo-

rary installations, mobile applications and equipment that needs to be

connected and disconnected frequently. It provides galvanic isola-

tion and intrinsically-safe energy limitation and allows plug and play

connections at 100 Mbit/sec even within hazardous areas.

Built-in galvanic isolation eliminates the need for equipotential

bonding and solid grounding between the safe area and the connec-

tion point inside the hazardous area. Advanced electronic circuits

combine durability with high performance. A highly energy-effi cient

design with extremely low heat dissipation makes the Ethernet Isola-

tor an ideal match for switching cabinets with limited space.

The Ethernet Isolator is a cost-effi cient alternative to costly and

infl exible installations.

TECHNICAL SPECIFICATIONS

Approval for intrinsically-safe Ethernet in Zone 0

Installation in Zone 2 or in flame-proof housing (Ex d) in Zone 1

Two Ethernet Isolators per connection

Connecting cable type CAT5e, 100 m max. length

Transfer rate 10/100 MBit/s, 10-BASE-T/100 BASE-TX

Connector type 2 x RJ45

Half/Full Duplex and Auto-Negotiation

LEDs for Power, Communication and Transfer rate recognition

Ambient Temperature range –40 °C … 60 °C

Ethernet IsolatorEI-0D2-10Y-10BIntrinsic safety now available for 100 MBit fast Ethernet

29

DRIVING THE DEVELOPMENT

MADE BY Pepperl+FuchsAll the way from its beginnings, Pepperl+Fuchs was characterized by a spirit of invention. We are a driving force in all symposiums and committees setting standards for fi eldbus technology. We have provided the market with numer-ous innovations that have turned the fi eldbus into a safe environment for process control and plant asset management.

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INNOVATIONS AND INVENTIONS

One typical example of the innovative power of Pepperl+Fuchs is the invention of the High-Power Trunk concept. It refl ects our comprehensive experiencewith solutions for explosion hazardous areas and has become a widely accepted fi eldbus technology which many other suppliers have adopted. The High-Power Trunk is a major step towards simplifi ed installation and operation of fi eld devices within classifi ed Ex zones and conforms to all relevant safety standards.

GLOBAL EXPERT SUPPORT

Being present on all major markets, Pepperl+Fuchsis the ideal partner for the global process industry. We are able to supply any product to just about any location of the world. We also back it by the compre-hensive support of experienced experts. Simply ask us and we will not hesitate to support you from the problem to the solution.

CONTROLLED QUALITY FOR MORERELIABILITY

Pepperl+Fuchs has a long history as manufacturer of products for process automation. We not only insist on our own research and product development. We also maintain own manufacturing facilities with a manufacturing depth of 90%. This guarantees the development of market-driven products with tangiblebenefi ts and puts us into a position to fully control the quality and reliability of our products.

SOLID PARTNER WITH A FUTURE

For many decades, Pepperl+Fuchs is well known in the global process industry. We are world market leaders with intrinsically safe components for ex-plosion hazardous areas. We are also technology partner of major players and play a vital role in in-ternational associations. This makes Pepperl+Fuchs a depend- able partner that will continue its history of innovation and drive the further development of fi eldbus technologies.

Teaming up with all leading suppliers of systems for process automation, Pepperl+Fuchs has gathered a wealth of experience from countless projects of theglobal process industry. We not only provide a complete range of products and solutions for fi eldbus installations of any dimension. We are also able to develop custom solutions tailored to the specifi c requirements of any given application.

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Subject to modifications • Copyright PEPPERL+FUCHS • Printed in Germany • Part. No. 122322 01/08 03

For over a half century, Pepperl+Fuchs has been continually providing new concepts for the world of process automation. Our company sets standards in quality and innovative technology. We develop, produce and distribute electronic interfacemodules, Human-Machine Interfaces and hazardous location protection equipment on a global scale, meeting the most demanding needs of industry. Resulting from our world-wide presence and our high flexibility in production and customer service, we are able to individually offer complete solutions – wherever and whenever you need us. We are the recognized experts in our tech-nologies – Pepperl+Fuchs has earned a strong reputation by supplying the world’s largest process industry companies with the broadest line of proven components for a diverse range of applications.

www.pepperl-fuchs.com

PROCESS AUTOMATION – PROTECTING YOUR PROCESS

Southern/Eastern Europe HeadquartersPepperl+Fuchs Elcon srl Sulbiate · ItalyTel. +39 039 62921E-Mail: pa-info@it.pepperl-fuchs.com

Northern Europe HeadquartersPepperl+Fuchs GB Ltd. Oldham · EnglandTel. +44 161 6336431E-Mail: pa-info@gb.pepperl-fuchs.com

Southern America HeadquartersPepperl+Fuchs Ltda.São Bernardo do Campo · SP · Brazil Tel. +55 11 4341 8448E-Mail: pa-info@br.pepperl-fuchs.com

Worldwide/German HeadquartersPepperl+Fuchs GmbH Mannheim · GermanyTel. +49 621 776 2222E-Mail: pa-info@de.pepperl-fuchs.com

North/Central America HeadquartersPepperl+Fuchs Inc. Twinsburg · Ohio · USATel. +1 330 486 0002E-Mail: pa-info@us.pepperl-fuchs.com

Western Europe & Africa HeadquartersPepperl+Fuchs N.V. Schoten/Antwerp · BelgiumTel. +32 3 6442500E-Mail: pa-info@be.pepperl-fuchs.com

Asia Pacific HeadquartersPepperl+Fuchs PTE Ltd. SingaporeCompany Registration No. 199003130ETel. +65 6779 9091E-Mail: pa-info@sg.pepperl-fuchs.com

Middle East/India HeadquartersPepperl+Fuchs M.E (FZE)Dubai · UAETel. +971 4 883 8378E-mail: pa-info@ae.pepperl-fuchs.com

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