Professional Documents
Culture Documents
Stonel
Stonel
c o n n e c t i n g t h e p r o c e s s
c o n n e c t i n g t h e p r o c e s s
c o n n e c t i n g t h e p r o c e s s
c o n n e c t i n g t h e p r o c e s s
Topics Covered
environments.
c o n n e c t i n g t h e p r o c e s s
Process Environments
• Corrosion & Impact Resistance:
- Aluminum; Marine Grade, Anodized, Urethane Coated
- Plastics; Polycarbonate (May Fusion Coat) or Nylon
- External Fasteners Typically Stainless Steel
Bund wall
c o n n e c t i n g t h e p r o c e s s
Hazardous areas
c o n n e c t i n g t h e p r o c e s s
NEC 500
CENLEC NEC 505
c o n n e c t i n g t h e p r o c e s s
ATEX Directives
Mandatory in Europe, 1 July 03
• Zone 0 = Category 1
• Zone 1 = Category 2
• Zone 2 = Category 3
c o n n e c t i n g t h e p r o c e s s
Hazardous Area
Power Barrier
Supply
Protection Compliance
• Manufacturers May Use Ratings on Labels Even Though Non Third
Party Approved
• Third Party Approval Agencies; Equipment must be Tested by Third
Party to NEC Standard to have Logo on Label:
- FM (Factory Mutual, US Market)
- UL (Underwriters Labs, US Market)
- ULc (UL for Canada & US Markets)
- CSA (Canadian Standards Association)
EEC Directives and EN Standards
-CENELEC (European Committee for Electrotechnical Standardization)
c o n n e c t i n g t h e p r o c e s s
c o n n e c t i n g t h e p r o c e s s
Topics Covered
Wireless
Time
c o n n e c t i n g t h e p r o c e s s
Switching
Solenoid
Power Output Valve
Source
c o n n e c t i n g t h e p r o c e s s
Computer Input
Switch
Power
Source
120VAC or 24VDC
• Estimate over 95% provide feedback into Solid State (Computer) Inputs
Computer Input
Switch
Power
Source IS Barrier
24 VDC or less
• Current and Voltage are typically less than 20VDC & 10mA at switch
c o n n e c t i n g t h e p r o c e s s
Analog Input
Position
24 VDC Transmitter
• 4 to 20mA Circuit
•Voltage remains constant with changing current
c o n n e c t i n g t h e p r o c e s s
Basic 4 to 20 mA Circuits
Analog Input
Load
4 to 20 ma +
24 VDC
Load
-
Position
Transmitter
c o n n e c t i n g t h e p r o c e s s
Basic Electricity
Resistance A switch or
sensor by
itself is not a
Voltage Supply Load!
c o n n e c t i n g t h e p r o c e s s
Basic Electricity
Load-A component that provides significant
resistance or inductance in an electrical circuit.
Loads:
1. Solenoids
2. Lights
3. Relays Coils
4. Computer Inputs
Is an LED a Load?
c o n n e c t i n g t h e p r o c e s s
Basic Electricity
Basic Electricity
Computer Input:
Power
StoneL
Supply
Monitor
c o n n e c t i n g t h e p r o c e s s
Switch/Sensor Types
• Mechanical
Mechanical Switches
• Single Pole Double Throw (SPDT) Silver Contacts
Applications: - Use for 120VAC Only
- Operating Life of 400,000 Cycles Normally Closed
Common Normally Open
• Single Pole Double Throw (SPDT) Gold Contacts
Applications: - Use for 120VAC & 24VDC Computer Inputs
- Operating Life of 100,000 Cycles
Mechanical Switches
• Advantages:
- High Power (Up to 10 Amps @ 250VAC )
• Disadvantages:
- Wear Out & Corrode Out
- Oxidize and fail in 24VDC Computer Inputs
- Require Seal-Off in hazardous areas
• Competitor Differentiation
- None; Competitor Switches are Similar
c o n n e c t i n g t h e p r o c e s s
MAGNET
c o n n e c t i n g t h e p r o c e s s
• Disadvantages
- MayLose Hermetic Seal Over Time
- Must be used for specialized applications
- Require Magnets to Trigger
• Magneto Strictive
Operation: Metal object interrupts “transformer like” field
Analysis: Reliable operation but costly; may be used for analog
• Hall Effect
Operation: Magnetic field changes properties Sensing Switching
Analysis: Magnetic field may change at temperature extremes and Circuits Circuits
tends to be power hungry
Target
• Inductive
Operation: Triggers off conductive metal object
Analysis: Reliable, proven, minimal power, low cost and very
Sensing
stable with temperature extremes Head
StoneL continues to use Inductive technology because it
continues to offer the greatest reliability at the least cost.
c o n n e c t i n g t h e p r o c e s s
I = 0.5mA to 5mA
Computer Input
Namur Sensor
Power 6 to 29VDC
Source Repeater Barrier
24 VDC
Barrier Off State (Target Off): Current in Namur Sensor Circuit >3mA
• Disadvantages:
- Not usable in standard monitoring circuits
- Most customers not familiar with sensors
- Need Specialized application training
• Competitor Differentiation
- Must Outsource from other manufacturers; Standard
with StoneL
- Part of Dual Module System with StoneL
- Less Costly
c o n n e c t i n g t h e p r o c e s s
24VDC
24VDC
Sinking Sensor
Sourcing Sensor
• Used to eliminate leakage current and voltage drop problems with solid
state switches
• Very common in factory automation applications
c o n n e c t i n g t h e p r o c e s s
• Disadvantages:
- Confusing to Apply
- Often miss-wired causing problems
• Competitor Differentiation
- StoneL only uses on special applications
- Used by Turck and ETC but confusing & expensive
c o n n e c t i n g t h e p r o c e s s
Computer Input
Switch
Power
Source
120VAC or 24VDC
• Used as a more reliable direct replacement for mechanical and reed switches
• Voltage Drop is amount of voltage reduced in circuit for sensor operation in the “On State”
- Computer Inputs typically require up to 90VAC in 120VAC
up to 14 VDC in 24 VDC
(StoneL voltage drop < 7V)
Voltage at Computer Input = PS Voltage – Switch Drop – Barrier Drop (IS)
c o n n e c t i n g t h e p r o c e s s
• Competitor Differentiation
- StoneL makes all proximity sensors; low cost, high reliability
- StoneL integrates solid state proximity sensors directly into
Eclipse and Hawkeye platforms. Most others use reed
switches or mechanical proximity switches
c o n n e c t i n g t h e p r o c e s s
Cost/Reliability Comparison
• Configuration
- 2 discrete sensor inputs
- 2 discrete auxiliary inputs (3mA @ 28VDC)
- 2 discrete power outputs(4 watts combined power)
• Special Features
- Short circuit protected outputs
- Predetermined output fail state
c o n n e c t i n g t h e p r o c e s s
AS-Interface Protocol
Main Characteristics:
• Two wire Signal and Power (Up to 8 Amps)
• Free wiring topology up to 100 meters in length(300 meters with repeaters)
• Up to 31 Field Devices per Network
• Simple, fast protocol
Appplications:
• On/Off Operation; May have analog with 2.1 Master
• Lowest cost discrete bus implementation
• Interfaces to most existing DCS systems via Modbus or other higher level protocols
DeviceNet Protocol
Main Characteristics:
• Two wire Signal and two wire Power (Up to 8 Amps) on bundled Cable
• Trunk Cable Structure with Length Speed Dependent (500 meters at
slowest speed)
• Up to 62 Field Devices per Network
Applications:
• Both Modulating and On/Off Operation (Mainly On/Off)
• Requires Specialized Knowledge to Install and Support
• Interfaces to most Allen Bradley PLCs (Tends to be Driven by Rockwell
Automation Suppliers)
• Used extensively in factory automation
c o n n e c t i n g t h e p r o c e s s
• Configuration
- 2 Discrete Inputs (Solid State Sensing)
- 2 Discrete Outputs (4 watts each or combined) powered externally
- 1 Analog Input with 4 to 20 mA powered externally (10 bit resolution)
• Special Features
- Predetermined output fail state (watchdog)
- Voltage regulated output (maintains output at 24VDC with voltage input
from 10 to 24VDC)
c o n n e c t i n g t h e p r o c e s s
Modbus Protocol
Main Characteristics:
• Two Wire Communication with no Power (May Include Separate Power Cable)
• Up to 4,000 Foot Length with up to 32 Devices per Network
• Trunk Topology
Appplications:
• Analog and Discrete Operation
• Simple to Apply without Specialized Knowledge
• Interfaces to most Existing DCS & PLC Systems
• Popular among Electric Actuator Manufacturers
c o n n e c t i n g t h e p r o c e s s
Foundation Fieldbus Dual Module
(VCT)
• Configuration
- 2 Discrete Inputs (Solid State Sensing)
- 2 Discrete Outputs with 4 Watt Maximum (Externally Powered “94”) OR
2 Discrete Outputs for Piezo Valving (Bus Powered “93”)
- Current Consumption under 16mA
• Special Features
- Stores Number of Actuations
- Stores Date of Last Service
- Temperature Sensing of Module & Sensors
- Device Description file from FF or StoneL describing device characteristics
- Watchdog Function (Predetermined Output Communication Fail State)
c o n n e c t i n g t h e p r o c e s s
0.5 Cv 1.3 Cv
c o n n e c t i n g t h e p r o c e s s
• Westlock
- Recently introduced module to follow StoneL
- Separate units for auxiliary outputs
- Module is 50% to 70% larger than dual module
• Topworx
- Use Reed Switches for sensing elements
- “Cube” is 50% larger than dual module
- Have mechanical switch to take unit off line
(StoneL has found mechanical switches to be
subject to corrosion and failure)
• Monituer
- Similar to Westlock in size and functiionality
c o n n e c t i n g t h e p r o c e s s
c o n n e c t i n g t h e p r o c e s s
Legacy
PRODUCT PLATFORM
FEATURES
c o n n e c t i n g t h e p r o c e s s
c o n n e c t i n g t h e p r o c e s s
The Quartz
c o n n e c t i n g t h e p r o c e s s
StoneL Quartz
QUARTZ Features
• Up to 3 Conduit Entries
QUARTZ Sensors
• Mechanical Switches
- Silver Contacts for 120 VAC
- Gold Contacts for 24 VDC
- Up to 6 Switches Allowed
• Maxx-Guard Reed Switches
- SPDT for 120 VAC
- SPST for 120 VAC or 24 VDC
- Available with or without LEDs
c o n n e c t i n g t h e p r o c e s s
QUARTZ Sensors
QUARTZ Options
Position Transmitters
• Used on Modulating Valves to tell Control
System Exact position of Valve
• Can be Used for Both Quarter Turn and
Linear Valves
• 4 to 20 mAmp Output
• Standard Transmitter
- Minimum Cycle Life: 2 Million Rotations
The Quartz
c o n n e c t i n g t h e p r o c e s s
StoneL Onyx
• Fusion Coating
c o n n e c t i n g t h e p r o c e s s
StoneL
CYCLONE II
c o n n e c t i n g t h e p r o c e s s
Cyclone II Options
• Internal Manual Override standard
• External Manual Override standard
• Valve options:
- Single Coil 4-way
- Dual Coil - Shuttle Piston
- Dual Coil - Blocked Center
• Material Options:
- Brass
- Stainless Steel
c o n n e c t i n g t h e p r o c e s s
Cyclone II Features
• 0.75 Cv
Cyclone II in VCT
• Standard 24 VDC Coil may be directly bus powered
with AS-Interface and DeviceNet VCTs.
• 0.2 Cv
StoneL Onyx
The SolaR
c o n n e c t i n g t h e p r o c e s s
StoneL SolaR
• StoneL’s “Low Cost” product
consideration
SolaR Sensors
• Mechanical Switches Normally Used
- Silver Contacts for 120 VAC
- Gold Contacts for 24 VDC
• Maxx-Guard Reed Switches are Available
- SPST for 120 VAC or 24 VDC
- Available with or without LEDs
• Solid State Switches are Available
- Dual Modules for 120 VAC or 24 VDC
c o n n e c t i n g t h e p r o c e s s
The SolaR
c o n n e c t i n g t h e p r o c e s s
Available Today
StoneL Eclipse
c o n n e c t i n g t h e p r o c e s s
StoneL Eclipse
• Very Compact Design
• Solid State Sensors with LEDs
• Class 1, Div 2; EEx ia IIC T6
• Mounts Directly to Actuator
with Namur (VDI/VDE 3845)
Mounting Holes
• Low Cost for 2 Solid State
Switches; $225 list (ECN) &
$185 list (ECG) Gen. Purpose
c o n n e c t i n g t h e p r o c e s s
Eclipse Features
Very Sophisticated Technology in a
Simple, Low Cost Package
• Equipped with (2) SST Solid State Sensors, Good for
120 VAC or 24VDC
• Lowest Leakage Current Available
• StoneL’s Lowest Cost Solid State package
• Combination of NAMUR Module, LED’s, & Internal
Terminal Block is Patented!
c o n n e c t i n g t h e p r o c e s s
• ECG3313DS----General Purpose
• Lowest cost
1) Flow Line
Eclipse Sensors
• Solid State Switches
- 2 SST Sensors for 120 VAC or 24 VDC
- 2 Namur Sensors for I.S. (DIN 19234)
• Bus Network Sensors
- AS-i VCT
- DeviceNet VCT
-Modbus
-Foundation Fieldbus
- Others in Development
c o n n e c t i n g t h e p r o c e s s
Sensors
Inductive Solid State Switches
• Namur
• AS-i
• DeviceNet
• Foundation Fieldbus
• Modbus
c o n n e c t i n g t h e p r o c e s s
Eclipse with
AS-i
Eclipse is Available with AS-i Communications
for Bus Network Connection
• Low Cost
up to 70 feet
distance up to 30 feet
c o n n e c t i n g t h e p r o c e s s
StoneL Eclipse
c o n n e c t i n g t h e p r o c e s s
The Hawkeye
c o n n e c t i n g t h e p r o c e s s
Hawkeye Features
• LED indication
• Slide Gates
• Knife Gates
• Globe valves
• Diaphragm valves
• Rotary Valves
• Rotary Actuators
• Dampers
c o n n e c t i n g t h e p r o c e s s
Sensors
Inductive Solid State Sensors
NC)
• AS-i
• DeviceNet
• Foundation Fieldbus
• Modbus
c o n n e c t i n g t h e p r o c e s s
The Hawkeye
c o n n e c t i n g t h e p r o c e s s
StoneL VCTs
Communications Integrated
Directly Into Unit
Dual Module
Dual Module
Dual Module
Mechanical
Electrical
Environmental
Consider in reverse order
c o n n e c t i n g t h e p r o c e s s
c o n n e c t i n g t h e p r o c e s s
Environmental
• Class 1, Div 1 x
• Class 1, Div 2 x x x x
• Nema 4/4X/6 x x x x x
• FM approvals x x x x
• CSA approvals x x x x x
• Class 1, Div 1 x x x x
Intrinsically Safe
c o n n e c t i n g t h e p r o c e s s
Features Quartz Onyx Eclipse Solar Hawkeye
Electrical
• Mechanical x x x
Switches
• Proximity Reed x x x
Switches
• Proximity Solid x x x x x
State Sensors
• AS-Interface x x x x I/O module
• DeviceNet x x x x I/O module
• Integrated x
Solenoid Valve
• 4 to 20 mA x x
Position Transmitter
• 3 Position Control x x
c o n n e c t i n g t h e p r o c e s s
• ISO NAMUR x x x x
• Quarter Turn x x x x
• Linear x x x x
• Manual x x x x
Explosion Proof
Legacy Products
VS
• QZE series
Intrinsically Safe Sensors (StoneL & P&F DIN 19234, SPST Reed)
European Legacy
Quartz (CENELEC certified EEx d IIC T6)
Cover Lock
c o n n e c t i n g t h e p r o c e s s
c o n n e c t i n g t h e p r o c e s s
c o n n e c t i n g t h e p r o c e s s
Monomer A
Monomer B
Catalyst
Steam
Gateway
Market Change
Dramatic Increasing
Technology Compelling
Need for Change Productivity
Improvements Pressure
c o n n e c t i n g t h e p r o c e s s
To Computer To Computer
Monomer A Monomer B
To Computer To Computer
Catalyst
Steam
To Computer
To Computer To Computer
Network Hierarchy
c o n n e c t i n g t h e p r o c e s s
Device Bus
• Some Complexity to Protocol
• Device Complexity Dependent on Application
• Cost Application Dependent
c o n n e c t i n g t h e p r o c e s s
Sensor/Actuator Bus
•Positioners -
•Flow Sensors - Device Bus
•Complex
Diagnostics -
•Position Sensors-
•Temperature
Sensors- Sensor Bus
•Basic
Diagnostics-
Modulating
•Limit Switch-
On/Off
c o n n e c t i n g t h e p r o c e s s
• Continuous Operation
AS-i System
AS-i Configuration
c o n n e c t i n g t h e p r o c e s s
AS-i Configuration
Gateway
Power Supply
To Valve
Configuration Software
Communication
Modules
c o n n e c t i n g t h e p r o c e s s
AS-i Valve Modules
Trigger System
Closed
Open
Sensor Systems
ASI Switching
Circuits Circuits
Solenoid Output
ASI Connection
c o n n e c t i n g t h e p r o c e s s
AS-Interface
VCT Dual Module & Eclipse
Cut Valve
Installation Costs with
Bus Networks
c o n n e c t i n g t h e p r o c e s s
StoneL’s Mission
StoneL will be the valve communication
and process networking market leader
by enabling process customers
to adopt communication technologies.
c o n n e c t i n g t h e p r o c e s s
Control NEC
Architecture Classifications Process
Interfacing and Instrumentation
Compliance
Process
Network FieldLink Operation
Protocols Products
Process Networking & FieldLink
Introduction
c o n n e c t i n g t h e p r o c e s s
c o n n e c t i n g t h e p r o c e s s
Bus Communications
Bus Protocol
• Fully Defines the Hardware and Software
Characteristics and Procedures Used on a Particular
Bus Network
OSI Model
User Layer (Objects Used on Operating System)
Presentation Layer 6
Session Layer 5
Transport Layer 4
Network Layer 3
Physical Layer
Serial Communications
Define the Only the Physical Layer (1) of the Communication Protocol
Number of Bits 11 11 16 8 2 4
Start of Frame
Control Field
Identifier
Data Field
CRC
Acknowledge
End of Frame
c o n n e c t i n g t h e p r o c e s s
Application Layer
• Where the system meets the user.
• Application Layer takes requests and gives output to the user in their
required form
c o n n e c t i n g t h e p r o c e s s
User Layer
AI PID
Level Control AO
Control Valve
c o n n e c t i n g t h e p r o c e s s
Network Hierarchy
c o n n e c t i n g t h e p r o c e s s
Optimized Network
HSE
H1
c o n n e c t i n g t h e p r o c e s s
EthernetIP
H1
c o n n e c t i n g t h e p r o c e s s
Proprietary
Ethernet
H1
c o n n e c t i n g t h e p r o c e s s
Network Composition
Power Supplies
Master/Gateway/Hosts
Cabling
Drop Connectors
I/O Modules
Networking “Tools”
Handhelds
Commissioning Kits
Field Training
On-Site Support
c o n n e c t i n g t h e p r o c e s s
Networking Components
Masters/ Power Input/Output Drop Repeaters & Commissioning
Protocol Gateways Supplies Modules Connectors Cabling Power Cond Handhelds Kits
FF H1 - - 88-90 91-95 96 - - -
NEC 500
CENLEC NEC 505
c o n n e c t i n g t h e p r o c e s s
instrument
instrument
• Advantages
- Well Understood in North America
- Unlimited Network Power Delivery
- May use most Bus Protocols
• Disadvantages
- Protection degrades with Corrosion
- Difficult to Maintain
- Expensive, Bulky & Inflexible
c o n n e c t i n g t h e p r o c e s s
• Advantages
- Low cost enclosures
- More wiring flexibility without Seals
- Unlimited Power Delivery
- May use most Process Protocols
• Disadvantages
- Division 2 Areas Only
- Relatively expensive and Somewhat
Inflexible
c o n n e c t i n g t h e p r o c e s s
Conditions
• Disadvantages
- Very Limited Power Delivery
- Barriers Reduce Voltage Limiting
Length
- Limited to FF H1 & Profi PA Protocols
- Not Well Understood in North America
c o n n e c t i n g t h e p r o c e s s
Unsupported Drops
Division 2)
c o n n e c t i n g t h e p r o c e s s
• Advantages
- Low cost enclosures
- Low cost wiring
- Significant Power (2.8A @ 30VDC)
- May use most Process Protocol
• Disadvantages
- Division 2 Areas Only
- Limited Understanding of Concept
- Limited Component Availability
c o n n e c t i n g t h e p r o c e s s
Example:
22V (Supply)
- .082 x 126 10.3V(Barrier)
- .082 x 15 1.2V (Trunk Cable)
- 1V (Protected Drop Connector)
- .022 x 3 0.1V (Drop)
= 9.4V at Device D1
Acceptable Voltage Range 9 to 32V
Voltage = Current x Resistance
D1 D4
D2
D3
V=IxR
c o n n e c t i n g t h e p r o c e s s
Example:
30V (Supply)
- .1.6 x 1 1.6V (Trunk Cable)
- 1V (Protected Drop Connector)
- .94 x 0.3 0.3V (Drop)
= 28.1V at Device VCT8
Acceptable Voltage Range 26.5 to 31.6V
c o n n e c t i n g t h e p r o c e s s
END
c o n n e c t i n g t h e p r o c e s s