Data Communications and Networking Prepared by: CMMFesarit

DCS Architecture – I/O

The major components that make up a process control system:

 Equipment that the operator uses to monitor process conditions and to manipulate the set
points of the process operation is located in a central control room or distributed on the plant
floor close to the equipment.
 From these locations, the operator can:
(1) view information transmitted from the processing area and displayed on operator
displays and
(2)change control conditions from an input device.
 Changing control conditions usually requires security privileges.
 The controlling portions of the system, which are distributed at various locations throughout
the process area, perform two functions at each location: the measurement of analog
variable and discrete inputs and the generation of output signals to actuators that can
change process conditions.
 Input and output signals can be both analog and discrete. By means of electrical transmission,
information is communicated between the central location and the remotely located controller
locations.
 The communication path is either a cable from each remote location to the central station, or
a single cable data highway interfacing all the remote stations—the cable in some cases can be
a wireless connection via radio, microwave, or satellite.
 DCS are made of workstations, controllers, IO Cards, IO buses, control networks, control
technology, and a variety of applications.
 Controllers are connected to field devices via analog, digital, or combined analog/digital
buses.
 The field devices, for example, valves, valve positioners, switches, and transmitters (e.g.,
temperature, pressure, level, and flow rate sensors), are located within the process
environment and perform process functions such as opening or closing valves, measuring
process parameters, etc.
 Smart field devices, such as the field devices conforming to the IO bus protocols, may also
perform control calculations, alarming functions, and other control functions.
 The controllers hold control strategies, which often encompass control strategies distributed
across field devices.
 Control strategies in controllers send signals over the communication lines to the field devices
to control the operation of the process.

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The core functional components of process control system:

Analog I/O

Analog Input
 Converts continuous analog signals into input values for the controller (A/D)
 Inside every analog input module is an ADC, or Analog-to-Digital Converter, circuit designed to
convert an analog electrical signal into a multi-bit binary word
 Temperature, flow, level, pressure & analytical transmitters
 Current: 0 to 20 mA, 4 to 20 mA signals
 Voltage: 0 to 10 volts, 0 to 5 volts
 Thermocouple, RTD, strain gauge, etc.

Analog Output
 Interpret controller output to analog signals for the field device (D/A)
 Every analog output module contains a DAC, or Digital-to-Analog Converter, circuit to convert
the PLC’s digital command words into analog electrical quantities
 Actuators, electric motor drives, etc.
 Current: 0 to 20 mA, 4 to 20 mA signals
 Voltage: 0 to 10 volts, 0 to 5 volts

Discrete I/O

Discrete Input
 Sense input from on/off or opened/closed device signal. These signals can either be AC or DC.
 Process switches, pushbutton switches, limit switches, and proximity switches
 Thumbwheels, circuit breakers, photoelectric eyes, motor starter contacts, relay contacts, etc.
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Discrete Output
 Provide output signals to on/off or opened/closed devices. These signals can be either AC or
DC.
 Alarms, control relays, fans, lights, and horns
 Valves, motor starter, solenoid, indicator lamps, etc.

Intelligent Modules
 Used for specific applications such as position control, PID, and external device communication
 Ability to communicate vast amounts of data over a limited number of data channels
 One pair of wires can communicate a nearly limitless number of variables, the only limit being
the speed of that data communication
 HART
 Modbus
 FOUNDATION Fieldbus
 Profibus PA
 Profibus DP
 Profibus FMS
 AS-i
 CANbus
 ControlNET
 DeviceNet
 BACnet
HART
 Highway Addressable Remote Transmitter
 The purpose of the HART standard was to create a way for instruments to digitally
communicate with one another over the same two wires used to convey a 4-20 mA analog
instrument signal.
 Is a master-slave communication protocol, which means that during normal operation, each
slave (field device) communication is initiated by a master communication device.

ModBus
 Is a protocol designed specifically for exchanging process data between industrial control
devices.
 Modbus defines a set of commands for reading (receiving) and writing (transmitting) data
between a master device and one or more slave devices connected to the network. Each of
these commands is referenced by a numerical code, with addresses of the master and slave
devices’ internal registers (data sources and data destinations) specified along with the
function code in the Modbus message frame.
 There are two modes available for transmitting serial data over a Modbus network RTU and
ASCII. The Remote Terminal Unit RTU mode is faster and more robust than ASCII and it is for
these reasons that it is widely used in Modbus interfaces.

FOUNDATION Fieldbus
 Is a standard for digital field instrumentation enabling field instruments to not only
communicate with each other digitally, but also to execute all continuous control algorithms
(such as PID, ratio control, cascade control, feedforward control, etc.) traditionally
implemented in dedicated control devices.
 increased capabilities due to full digital communications
 reduced wiring and wire terminations due to multiple devices on one wire
 increased selection of suppliers due to interoperability
 reduced loading on control room equipment due to distribution of control and input/output
functions to field devices
 connection to the HSE backbone for larger systems

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Profibus
 is an open, digital communication system with a wide range of applications, particularly in the
fields of factory and process automation. PROFIBUS is suitable for both fast, time-critical
applications and complex communication tasks.
 PROFIBUS DP (Decentralized Peripherals) is used to operate sensors and actuators via a
centralized controller in production (factory) automation applications. The many standard
diagnostic options, in particular, are focused on here.
 PROFIBUS PA (Process Automation) is used to monitor measuring equipment via a process
control system in process automation applications.
 PROFIBUS FMS (Fieldbus Message Specification), was designed to communicate between PLCs
and PCs, sending complex information between them.

AS-i
 Actuator-Sensor interface
 Is a low-cost electromechanical connection system
designed to operate over a two-wire cable carrying
data and power over a distance of up to 100m.
 It is most often used for proximity sensors, limit switches,
valves and indicators in applications like packaging
machines and material handling systems.

DeviceNet
 is a low-cost communications link to connect industrial
devices (such as limit switches, photoelectric sensors,
valve manifolds, motor starters, process sensors, bar code
readers, variable frequency drives, panel displays and
operator interfaces) to a network and eliminate
expensive hardwiring.

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Factors Affecting the Selection of I/O Modules

Selection Factors Selection Criteria

Application-specific Voltage range and type

Level of diagnostic monitoring required
Speed required for passing I/O data between I/O circuit and controller
Backplane current
Output current
Number of I/O points
Isolation requirements
Sinking or sourcing of inputs/outputs (dc)
Solid-state or relay outputs (dc)

Environmental Temperature
Space restrictions
Humidity
Proximity to wash-down area
Vibration
Shock restrictions
Noise restrictions
Distance restrictions
Atmospheric conditions (gases, corrosives)

Communication Networking requirements

Desired transmission communication rate
Termination Method of connection to sensors/actuators
connection to (dc) sinking or sourcing sensor/actuator
Expansion Room for additional modules
Capacity of power supply to accommodate additional modules
Capacity of programmable controller memory and features to
accommodate additional modules
Power Total current draw for all I/O modules in chassis
Total current draw for programmable controller in chassis
Total current draw for future I/O modules
Power supply internal or external to the chassis and input-line voltage

Power Supplies
 System Power Supply:
 System Power Supply (AC/DC) – Input 110VAC or 220VAC
 System Power Supply (DC/DC) – Input 24VDC or 12VDC
 Bulk Power Supply:
 Bulk AC to 24 VDC Power Supply
 Bulk AC to 12 VDC Power Supply
 Bulk 24 VDC to 12 VDC Power Supply
 An Intrinsically Safe Power Supply is available for the Intrinsically Safe I/O
 Intrinsically safe (DC/DC) - Input 24VDC

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DCS Architecture

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Hubs and Switches

Hubs and switches provide a means to connect multiple nodes. Available Hub options include:

 8-port 10BaseT
 12-port 10BaseT
 12-port 10BaseT, Fiber Optic Interface
 12-port Dual-Speed
 12-port Dual-Speed, w/Fiber Optic Link
 12-port Dual-Speed, w/2 Fiber Optic Links
 24-port Dual-Speed
 24-port Dual-Speed, w/Fiber Optic Link
 24-port Dual-Speed, 2 Fiber Optic Links
 6-port 10MB Fiber Optic
 6-port 10MB Fiber Optic, w/Twisted Pair Copper Interface Module
 12-port 10BaseT/100Base TX Copper
 12-port 10BaseT/100Base TX Copper, with Fiber Optic Link
 12-port 10BaseT/100Base TX Copper, with Dual Fiber Optic Link
 24-port 10BaseT/100Base TX Copper
 24-port 10BaseT/100Base TX Copper, with Fiber Optic Link
 24-port 10BaseT/100Base TX Copper, with Dual Fiber Optic Link
 8-port 100MB Fiber Optic
 8-port 100MB Fiber Optic, with Fiber Optic Link
 8-port 100MB Fiber Optic, with Dual Fiber Optic Link

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Wiring for I/Os – Traditional vs. Fieldbus

Wiring for I/Os – Traditional vs. AS-i

DO DI DO AS-i Card

Traditional Discrete I/O AS-i Network

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Examples

DeltaV M-Series Controller and I/O Modules

Siemens Simatic PCS7 Hardware

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Honeywell Experion Controller and I/O Modules

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