Automation Network Selection: A Reference Manual Third Edition

By Dick Caro

Notice The information presented in this publication is for the general education of the reader. Because neither the author nor the publisher has any control over the use of the information by the reader, both the author and the publisher disclaim any and all liability of any kind arising out of such use. The reader is expected to exercise sound professional judgment in using any of the information presented in a particular application. Additionally, neither the author nor the publisher has investigated or considered the effect of any patents on the ability of the reader to use any of the information in a particular application. The reader is responsible for reviewing any possible patents that may affect any particular use of the information presented. Any references to commercial products in the work are cited as examples only. Neither the author nor the publisher endorses any referenced commercial product. Any trademarks or tradenames referenced belong to the respective owner of the mark or name. Neither the author nor the publisher makes any representation regarding the availability of any referenced commercial product at any time. The manufacturer’s instructions on the use of any commercial product must be followed at all times, even if in conflict with the information in this publication.

Copyright © 2016 International Society of Automation (ISA) All rights reserved. Printed in the United States of America. 10 9 8 7 6 5 4 3 2 ISBN: 978-1-941546-80-2 No part of this work may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording or otherwise, without the prior written permission of the publisher. ISA 67 T. W. Alexander Drive P.O. Box 12277 Research Triangle Park, NC 27709 Library of Congress Cataloging-in-Publication Data in process

Contents

Acknowledgments and Dedication . . . . . . . . . . . . . . . . . . . . . . . . . v Unit 1: Prologue . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Unit 2: How to Use this Book . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 2.1 Application Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 2.2 Technology Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Unit 3: Introduction to Industrial Networks . . . . . . . . . . . . . . . . . . 9 3.1 Sensor Networks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 3.1.1 Wireless Sensor Networks (WSN) . . . . . . . . . . 16 3.2 Fieldbus Networks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 3.3 Control Networks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 3.4 Safety Buses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 3.5 User Layer Protocols . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 3.5.1 Real-Time Data Acquisition and Control . . . . 25 3.5.2 OPC and Information Access . . . . . . . . . . . . . . 27 3.5.3 Microsoft .NET Architecture and Java. . . . . . . 29 3.5.4 Field Device Tool (FDT) . . . . . . . . . . . . . . . . . . . 30 3.6 Convergence and Downward Migration . . . . . . . . . . . 32 3.6.1 Wireless on the Shop Floor . . . . . . . . . . . . . . . . 33

vii

viii

Automation Network Selection: A Reference Manual, Third Edition

Unit 4: Network Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 4.1 Sensor Network Applications. . . . . . . . . . . . . . . . . . . . . 42 4.1.1 Factory Automation Sensor Network Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 4.1.2 Process Control Sensor Network Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 4.1.3 Picking the Sensor Network. . . . . . . . . . . . . . . . 53 4.2 Fieldbus Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 4.2.1 Factory Automation Fieldbus Applications . . 64 4.2.2 Process Control Fieldbus Applications . . . . . . 73 4.2.3 Building Automation Fieldbus Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 4.3 Control Level Network Applications . . . . . . . . . . . . . . 87 4.3.1 Object Technology . . . . . . . . . . . . . . . . . . . . . . . . 90 4.3.2 Factory Automation Applications. . . . . . . . . . . 92 4.3.3 Process Control Applications. . . . . . . . . . . . . . . 98 4.3.4 Building Automation Applications. . . . . . . . . 105 Unit 5: Network Technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 5.1. Introduction to Industrial Network Technology . . . . 108 5.2 AS-Interface (AS-i) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111 5.2.1 Technical Overview. . . . . . . . . . . . . . . . . . . . . . 112 5.2.2 AS-i Applications. . . . . . . . . . . . . . . . . . . . . . . . 116 5.2.3 AS-i Consortium . . . . . . . . . . . . . . . . . . . . . . . . 116 5.3 CAN and CiA (CAN in Automation) . . . . . . . . . . . . . 116 5.3.1 Technical Overview. . . . . . . . . . . . . . . . . . . . . . 117 5.3.2 Application Layers . . . . . . . . . . . . . . . . . . . . . . 118 5.3.3 CAN Kingdom . . . . . . . . . . . . . . . . . . . . . . . . . . 119 5.3.4 CANopen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 5.4 ControlNet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 5.4.1 Technical Overview. . . . . . . . . . . . . . . . . . . . . . 122 5.4.2 Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123 5.4.3 ControlNet International . . . . . . . . . . . . . . . . . 123 5.5 DeviceNet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124 5.5.1 Technical Overview. . . . . . . . . . . . . . . . . . . . . . 125 5.5.2 Open DeviceNet Vendors Association (ODVA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126 5.6 Ethernet and TCP/IP . . . . . . . . . . . . . . . . . . . . . . . . . . . 126 5.6.1 Technology Overview. . . . . . . . . . . . . . . . . . . . 128 5.7 EtherNet/IP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

Contents

5.8

5.9 5.10 5.11 5.12 5.13 5.14 5.15 5.16 5.17 5.18 5.19 5.20 5.21 5.22 5.23 5.24

ix

5.7.1 Common Industrial Protocol (CIP) . . . . . . . . 132 FOUNDATION Fieldbus . . . . . . . . . . . . . . . . . . . . . . . . . . 133 5.8.1 Wiring and Signaling . . . . . . . . . . . . . . . . . . . . 134 5.8.2 Intrinsic Safety (IS) . . . . . . . . . . . . . . . . . . . . . . 135 5.8.3 Fault Tolerance and Single-Loop Integrity . . 138 5.8.4 Protocol. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140 5.8.5 Function Blocks . . . . . . . . . . . . . . . . . . . . . . . . . 141 FOUNDATION Fieldbus HSE . . . . . . . . . . . . . . . . . . . . . 144 5.9.1 Technology Overview . . . . . . . . . . . . . . . . . . . 146 HART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147 5.10.1 Technology Overview . . . . . . . . . . . . . . . . . . . 149 Interbus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151 5.11.1 Interbus Technical Overview . . . . . . . . . . . . . 152 LonWorks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154 5.12.1 LonTalk Technical Overview . . . . . . . . . . . . . 155 Modbus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156 5.13.1 Modbus Protocol Overview . . . . . . . . . . . . . . 161 PROFIBUS-FMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164 PROFIBUS-DP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164 5.15.1 PROFIBUS-DP Technical Overview. . . . . . . . 165 PROFIBUS-PA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166 PROFINET. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167 5.17.1 PROFINET Technology Overview . . . . . . . . . 169 CC-Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172 5.18.1 CC-Link Technology Overview . . . . . . . . . . . 173 Ethernet-PowerLink. . . . . . . . . . . . . . . . . . . . . . . . . . . . 174 EtherCAT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175 SERCOS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176 5.21.1 SERCOS III Technology Overview. . . . . . . . . 177 Seriplex . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179 5.22.1 Seriplex Technical Overview. . . . . . . . . . . . . . 179 SDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180 WorldFIP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180 5.24.1 WorldFIP Protocol Overview . . . . . . . . . . . . . 182

Unit 6: Answers for Review Questions . . . . . . . . . . . . . . . . . . . 185 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195 About the Author . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203