Foundation Fieldbus Actuators

U26

C23

LK9

C24 C43

LK5

LK7

LK6

PARK

TERM

LK8

C42 L K4 LK2 LK3 LK1 C27 C44

U27

Publication number S114E Date of issue 03/00

SK 2

Foundation Fieldbus Systems

Foundation Fieldbus compatible electric and fluid power actuators from Rotork comply with the IEC 61158-2 international standards and ISASP50 recommendations for fieldbus devices. The Rotork IQ, IQM, AQ and Q range of electric actuator products and the Flowpak control unit for hydraulic and pneumatic actuators may be controlled over an IEC 61158-2, 2 wire highway using the Foundation Fieldbus system when they are fitted with the FF-01 option module.

Foundation fieldbus

International open fieldbus standard IEC 61158 IEC 61158-2, 2 wire communication H1 communication bus speed of 31.25 kbits/sec 32 devices per section, extendable to 152 per highway by using repeaters or active couplers. Addresses in the range 1 to 240 are accepted. Up to 4 repeaters or active couplers per highway 1900 metres per section, extendable to 9500 metres per highway by using repeaters or active couplers Independently Certified for inter-operability

Rotork FF-01 Module

Compatible with IQ, IQM, AQ and Q range electric actuators Compatible with Flowpak controlled hydraulic and pneumatic actuators Greater control system flexibility Link Master capability 14 Function Blocks

Understanding Foundation Fieldbus

Foundation Fieldbus is a digital, serial, two way communication system which interconnects field equipment such as Rotork valve actuators with other sensors or controllers. It differs from any other communication protocol because it is designed to resolve process control applications instead of simply to transfer data in a digital mode. The process control function may be distributed across the network and shared by the elements of the network instead of being performed by a host system, so with Foundation Fieldbus there is no need for a conventional DCS or PLC host system. The system complies with IEC 61158-2, the International Fieldbus standard for use in industrial control systems and follows the Open Systems Interconnect (OSI) 7 layer communication model using layers 1, 2 and 7 (Foundation is like most systems and does not use layers 3 to 6). It is also based on the ISA-SP50 recommendations for fieldbus networks and is designed to utilise standard instrumentation field cables. The field data highway or field network is known as the H1 bus, it operates at a fixed data rate of 31.25 kbits/sec and should be wired in a Type A cable. Type A cable is similar to the traditional single twisted pair with overall screen used for conventional field transmitters. The field network can be intrinsically safe with the field cabling and equipment protected by barriers. The drawback of using an IS system is that the number of devices permitted for connection in the hazardous area is reduced to 6. The H1 bus can also be used to power the devices in many cases, just as a traditional 4-20 mA transmitter may be powered by the loop standing current.

Control Room

Trunk

Junction Box

Spur

Total Cable length = Trunk length + all the spur lengths

Cable Lengths: Data Rate Type Topology Total Cable length Total Spur length

31.25 kbit/s Voltage Bus/Tree 1900 m (max) 120 m (max)

Type A Cable Type Shielding Size Resistance Nominal Capacitance

(e.g. Belden 3076F) 2 cores, twisted pair plus overall screen Minimum 90% copper shielding braid or foil 18 AWG (0.8 mm2) 24 ohm/km max 80 pF/m

The topology or system layout can use simple parallel connected devices directly on the bus highway, or a mixture of tree or spur type branching connections and bus connections. The distances covered by the network varies depending on the connection topology, the type of bus (IS or non-IS), the power drawn from the bus and the network cables parameters. Foundation Fieldbus equipped Rotork actuators are explosion-proof and do not require an Intrinsically Safe network. The explosion-proof cables should be contained within an armoured sheath or conduit to preserve the hazardous area protection. 3

Understanding Foundation Fieldbus

The Rotork FF-01 interface is bus powered and will operate when there is no power on the actuator. The fieldbus interface card draws its power from the bus power supply, consuming a nominal 18 mA. The minimum voltage at which the interface will work correctly is 9 V DC and this must be remembered when considering the layout of the network. Rotork FF-01 Interface Electrical Parameters Maximum voltage Nominal voltage Minimum voltage Current Drain (nominal) Current Drain (maximum) 35 V DC 32 V DC 9 V DC 17 mA 20 mA

IEC 61158-2 specifies that the bus should have a suitable DC power supply connected to it to bias the bus and power the individual Foundation devices. This power supply requires suitable conditioning components to be included or to be connected through a conditioner. Suitable power supplies and conditioners can be obtained from various vendors and are listed on the Foundation web site.
12 volts 33 Volts current
Power Supply JB

20 volts conditioner and termination 12 volts

The number of actuators on one segment will depend on their position relative to the power supply, since each will draw current, and the voltage drop along the cables has to be considered. If all the actuators were 1900 metres from the power supply the maximum number permitted would be 12, if they are spaced along the cable the maximum number will be 32. Provided the power supply can deliver the required current and voltage various combinations can be achieved. For example with a 33 V DC power supply capable of delivering 640 mA a network bus of 32 actuators could be made where the devices are spaced every 47 metres along a bus 1500 metres long. Termination conditioning networks must be added at both ends of the main bus. These are complex devices including inductors as well as resistors since they must impedance match the data line at the 31.25 kbits/sec frequency.

OSI Model

Foundation Fieldbus Actuator FMS

7 Application Layer FAS 2 Data Link Layer 1 Physical Layer DLL PHY Fieldbus

The communication between the actuators on the network has to obey the Foundation Fieldbus rules. The rules are based on the OSI model using layers 1, 2 and 7. The Physical layer (layer 1) is the electrical circuit for connection to the cable. The Data Link Layer (layer 2) controls the transmission of messages onto the fieldbus through a deterministic centralised bus scheduler called the Link Active Scheduler (LAS). The Fieldbus Access Sub-layer (which forms part of layer 7), and the Fieldbus Message Specification (the rest of layer 7) handles the connection to the actuator device itself, the access to the function blocks and the definition of the Virtual Field Device (VFD) together with the logical connections to the Data Link Layer (DLL).

Each Foundation device connected on the bus will either be a Basic Device or a Link Master. These two types are capable of different network functions in organising the data movement along the bus. Every bus must have at least one Link Master and all Rotork FF-01 modules have Link Master

LAS
Link Master Device
Active Link Master Device

Link Master Device

Link Master Device

Link Active Scheduler tasks PN Probe Node CD Compel Data TD Time Distribution PT Pass Token

capability. One of the actuators will become the Link Active Scheduler (LAS) which effectively maintains the control strategy and organises the routine data passing on the network once the system is configured and running. Any Rotork actuator can become the LAS for the network, if required, without need for intervention by the system operator. The LAS maintains a Live List which is a list of all the connected devices. The list automatically gets updated when actuators are connected to, or removed from, the bus. The LAS uses a Probe Node (PN) message to maintain the list and at least one PN message is sent out for every complete cycle of passing the token to all units in the live list. In addition the LAS controls the CD schedule which is a time based set of activities where the individual function blocks used in the control strategy are allocated a time slot to publish their data a Compel Data message from the LAS makes the publisher issue the data. All the actuators are publishers though they can use either the CD or the token to issue their information to the bus. The Time Distribution (TD) message issued by the LAS is used to make sure all the devices keep in step. All of the data transmission on the network is controlled by this time. Finally the LAS moves a token around the actuators one at a time with the PT message. It is only when an actuator has the token that it can provide data from its transducer block.

Subscribe

Publish

Subscribe Publish

Subscribe

Most messages are issued on a publisher/subscriber basis. This technique makes peer to peer communication very efficient and is also flexible enough for use on master/slave types of system. When the time is right each actuator in turn broadcasts, or publishes, information onto the bus, all other actuators and any host system receive the data and can either discard it or, if they are a subscriber, use it. If the system is a simple master/slave with a host and several actuators, then as each actuator publishes its data the host will subscribe to that data and use it in its display function. When the host has the token it can publish commands aimed at moving the actuators and those that subscribe to the various parts of the message will act on the commands to move. The system is deterministic and so a definitive response can be worked out for the time to collect or issue data provided the number of devices and the method of system configuration are known. The FF-01 has defined time requirements for its function blocks and transducer block. The Fieldbus Access Sublayer (FAS) sets up the communication links between the selected function blocks, data from the transducer block and resource block (defined in the Virtual Field Device) and the Data Link Layer for onward connection to the highway. The links are set up using Virtual Communication Relationships (VCRs) which are logical settings inside the FF-01 module, there are 3 types of VCR. Client/Server type VCRs are used when the actuator has the token, these are useful for queued, unscheduled or user initiated events and can only be used if the device is in possession

Understanding Foundation Fieldbus

Function Blocks

System Management VFD

User Application VFD

FMS FAS DLL

of the token. The client will request data from the server, for example the host might send a new setpoint to an actuator. When the token reaches the actuator it will respond to the message about the new setpoint. Report Distribution type VCRs, again used only when the actuator is in possession of the token, are for the transmission of trending data and alarms to the operator console. Since the actuator is seldom set up to trend data this form of VCR will not be common. Finally there are the Publisher/Subscriber VCRs used with the Compel Data commands. These are used for most of the communications and link the data from the function blocks and transducer block to the highway.

The Fieldbus Message Specification (FMS) layer defines the Virtual Field Devices. In the VFD the function blocks, transducer block and resource block are called Objects. The FF-01 has a defined set of objects in its Object Dictionary and these relate to Fieldbus the objects described in the DD file used by the system configurator. Information to and from the function blocks is carried out on the Publisher/Subscriber VCRs when a Compel Data request from the LAS is received.
PHY

Rotork FF-01 Function Blocks Digital Input DI 2 blocks for feedback data Digital Output DO 8 blocks for commands Analogue Input AI 2 blocks feedback data Analogue Output 1 block for command AO PID 1 block for 3 term controller Transducer block 1 block Resource block 1 block Every Foundation device includes function blocks, these are the building blocks used for the process control application, or the desired system response to changes on the inputs. These function blocks are logical devices that reside physically in the Rotork FF-01 or other Foundation Fieldbus compatible devices. The Rotork FF-01 interface includes five types of process function blocks plus the two blocks that always exist in every device, the transducer block and the resource block. The transducer block is used to logically connect the real hardware (the actuator itself in the Rotork case) to the network and process function blocks. The resource block contains information about the actuator itself, like the device name, the manufacturer and the serial number. The process function blocks in the FF-01 are DI (digital input), DO (digital output), AI (analogue input), AO (analogue output) and PID (three term controller). Inputs are feedback signals from the actuator to the network and may be valve position or local /remote selector status. Outputs are the commands to open and close the valve.

The network is logically assembled using the Object Dictionary, function blocks, virtual wiring using VCRs and data transmission methods depending on the command from the Link Active Scheduler (Pass Token, Compel Data etc.). Publisher/Subscriber messages are scheduled in the LAS and when the actuator receives a CD command from the LAS it will broadcast the specified data to the remainder of the network. The VCR is used to define the route used to connect the devices

FF-01 module 2x DI

together for these messages and it is used for data exchange between the various function blocks assembled to solve the process control requirement.
Fieldbus Message Specification

8 x DO Actuator

2 x AI 1 x AO PID Transducer

The setting up of a system requires the use of a suitable configuration tool. Actuator addresses are automatically set by the system. When a new device is detected by the PN message the device adopts a default address. The configuration tool is then used to give the device a tag and the system will then automatically allocate an address. All future references to the actuator or its function blocks will be via their tag names and never make use of an address. Since the actuator must be tagged it is essential to have a configuration tool during commissioning.

Fieldbus Access Sublayer

Data Link Layer

Function blocks in the FF-01 that are required to execute must be scheduled in the LAS. The configuration tool is used to perform this Resource scheduling and each block must be allowed sufficient time for complete execution as well as time to transmit its data onto the fieldbus if required. Note that the several blocks can execute at the same time, but only one block can have access to transmit at any time. The cycle time to execute all the blocks should allow sufficient spare capacity to ensure that all unscheduled events can also take place. In the diagram Absolute Link Schedule Start Time Actuator 2 DO Sequence repeats channel 1 is used to operate the Execution actuator, so it does Actuator 1 DI channel 1 not require any function block Transmission transmission Execution access time on the Actuator 2 DO channel 1 highway. Actuator 1 function block Unscheduled Communication Permitted needs to pass the state of its DI channel to Actuator 0 30 60 90 120 150 180 210 mS 2, so it does require transmission access time. Any execution time not used for highway access is free for routine PT (Pass Token) messages, Transducer block interrogation and general housekeeping on the network and Live List by the LAS. The network commissioning process involves using a configuration tool such as those available from National Instruments or SMAR, the FF-01 Device Description file and other FF-01 files, as well as other DDs and files needed for other devices on the network. A knowledge of the physical number devices and their distribution on the highway will also be needed. The configuration tool will allow the individual function blocks to be interconnected and the timing schedule to be set up. It is very important to ensure that the timing schedule has sufficient length to execute and transmit the chosen data over the highway. The time needed to do this will vary depending on the data to be moved and the number of devices on the network. 7

Data Highway

FF-01 Function Blocks

INPUT (AI) OUT Trends Alarms A_POS (AO) Cas IN OUT BKCal Out Trends Alarms

CONTROL (PID) IN Cas IN BKCal In TRK In D TRK Val FF Val OUT BKCal Out Trends Alarms

OUTPUT (AO) Cas IN OUT BKCal Out Trends Alarms

Rotork FF-01 Function Block Execution and Transmission Times Block Type Execution Time Transmission Time Digital Input DI 30 mSec 40 mSec Digital Output DO 35 mSec 40 mSec Transducer Not applicable 40 mSec Analogue Input AI 35 mSec 40 mSec Analogue Output AO 30 mSec 40 mSec PID 70 mSec 40 mSec Resource Not applicable

Digital Input Blocks

Data Highw ay 2x DI 8 x DO 2 x AI 1 x AO Transducer Actuator

Two function blocks for use in the process Block No. Function DI 1 1 of 00-38 in table control application handle Digital Inputs. DI 2 1 of 00-38 in table The feedback signals used in the blocks are selected from information in the transducer block table. For routine data input to a supervisory system the host reads data directly from the transducer block.

Digital Output Blocks

Data Highw ay 2x DI 8 x DO 2 x AI 1 x AO Transducer Actuator

There are eight Digital Output blocks, each of which has a pre-defined function in the control of the actuator. The Interlock command allows the actuator interlock function to be added to the process control strategy. On the IQ blocks DO5 to DO8 control the output relays of the actuator if these are not being used for indication. On Q, AQ and Flowpak DO5 to DO8 are not used.

Block No. DO 1 DO 2 DO 3 DO 4 DO 5 DO 6 DO 7 DO 8

Function Open Command Close Command ESD Command Interlock Command Relay 1 Command (IQ) Relay 2 Command (IQ) Relay 3 Command (IQ) Relay 4 Command (IQ)

Transducer Block
Data Highw ay 2x DI 8 x DO 2 x AI 1 x AO Transducer Actuator

The Transducer block defines the connections to and from the actuator itself and the function blocks, as well as to the Foundation highway. The DI/DO/AI/AO function blocks connect to the transducer block to access information or control the actuator. All the data in the Transducer Events table can be read by a host from the Transducer block directly. The data labels for the information are described to the host system by the Device Description file. The Transducer block also holds information on the settings for the control of the actuator by the FF-01 module. All the data in the transducer block is automatically transmitted to the highway each time the actuator gets the Pass Token.

Transducer Events Table

No 00 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 Identifier STOP OPEN CLOSE INHIBITED LOCAL OVERRIDE POSITION ACHIEVED TORQUE ACHIEVED MOVING POSITION & STOP POSITION & OPEN POSITION & CLOSE TORQUE & OPEN TORQUE & CLOSE MOVING & OPEN MOVING & CLOSE LOCAL OVERRIDE & STOP FAIL & MIDPOS @ Torque Reserved Reserved AUX INPUT 1 AUX INPUT 2 AUX INPUT 3 AUX INPUT 4 INTERRUPTED TIMER BLINKER INTERLOCK Reserved INTERLOCK & STOP INTERLOCK & CLOSE INTERLOCK & OPEN INTERLOCK & BOTH Reserved Reserved FAIL & ESD FAIL & CONTROL NOT AVAILABLE FAIL & LOW BATTERY FAIL & STALLED FAIL & HANDWHEEL FAIL & HOT Description Stop Command Issued Open Command issued Close Command Issued Motion Inhibit Timer Running Local Selected Stationary Mid Travel Torque Trip Actuator Moving Stopped Mid Travel at Desired Position Valve Open Limit Switch Valve Closed Limit Switch Valve Open Torque Switch Valve Closed Torque Switch Travelling in Open Direction Travelling in Close Direction Local Stop Selected Valve Obstructed Reserved Reserved Auxiliary Input 1 Active Auxiliary Input 2 Active Auxiliary Input 3 Active Auxiliary Input 4 Active Interrupter Timer Running Blinker On Interlock Active (electrical movement not permitted) Reserved Interlock Active and Stop Command Issued Interlock Active and Close Command Issued Interlock Active and Open Command Issued Interlock Active and both Open and Close Command Issued Reserved Reserved ESD Command Issued Monitor Relay (Local, Local Stop, or Thermostat tripped) Low Battery Valve Jammed Manual Movement Detected Thermostat Trip

FF-01 Function Blocks

Analogue Input Blocks
Data Highw ay 2x DI 8 x DO 2 x AI 1 x AO Transducer Actuator

Block No. Function Two function blocks handle analogue AI 1 Valve position inputs. The two Analogue Inputs are AI 2 Actuator torque (IQ) connected via the transducer block to the two analogue measurements on the IQ actuator giving position and torque feedback data. Note: On Q, AQ and Flowpak actuators there is no analogue torque signal and Q and AQ actuators require a potentiometer to be fitted for the valve position AI.

Analogue Output Block

Data Highw ay 2x DI 8 x DO 2 x AI 1 x AO Transducer Actuator

Block No. Function One function block is available for AO 1 Valve Desired position positioning the actuator using an analogue output . It connects to the transducer block to send the desired analogue position for the valve to adopt. If a digital signal is sent to the actuator the analogue positioning algorithm is disabled until a new analogue value is sent over the FF highway. Note: On Q, AQ actuators the actuator must be fitted with a potentiometer for valve desired position AO.

PID Control Block

Data Highw ay 2x DI 8 x DO 2 x AI 1 x AO PID

The PID block provides full 3 term control executed in 70 mSec. The Reset, Rate and Gain parameters are all set over the network and the function block meets the standards described in FF-891-1.4 The block does not connect internally to the Transducer block and can be used as a stand alone controller linking to AI and AO blocks elsewhere on the highway.

Resource Block
Data Highw ay 2x DI 8 x DO 2 x AI 1 x AO Resource

The Resource block includes characteristics of the FF-01 device and the serial number of the module. The device is identified as a Rotork FF-01 and the Configuration tool examines the Resource block to identify the correct DD file to use. The block also contains common data related to all the other function blocks.

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Technical Data
Device Description File
The Device Description file (DD file) provides an extended description of all the items in the FF-01 modules Virtual Field Device. That is the function blocks, resource and transducer blocks. The text label identifies each signal and data bit so that the configuration tool can easily be used to interconnect the function blocks to make up the control system required. The DD file is like a driver for the FF-01 and the rotork DD file is written using the Common File Format to FF-940-1.4.

Technical Details
Electrical Interface: Data Encoding: Data Rate: Processor isolation: Communications Interface: Communication protocol: Function Blocks: Power consumption: IEC 61158-2 electrical standard for 2 wire connection Manchester Biphase-L 31.25 kbits/sec Optical SMAR Foundation Fieldbus IEC-61158-2 2xAI; 1xAO; 2xDI; 8xDO; 1xPID; Transducer; Resource 18 mA nominal, (20 mA max) from the data highway

Interface Operating Voltage: 9V to 32V DC Data Files: Device Description (DD) file Capability file Symbol file All available on disk 0101.FFO 0101.CFF 0101.SYM

Enclosure: Environment:

Suitable for fitting to Rotork IQ, AQ and Q electric actuators and Flowpak controlled fluid power actuators As the actuator (-40 to +70 C)

The Rotork FF-01 Network Interface module has been approved by the Foundation for conformance with the IEC 61158-2 specifications and interoperability with other similar devices. The FF-01 is a Foundation registered device as defined by FF-542.

For more information on Foundation Fieldbus consult your regional User Group. The Foundation web site at http://www.foundation.org provides answers to many common questions. In addition Foundation system documentation is available from the resources section of the Foundation web site. Further information on all Rotork actuator products can be found on the Rotork web site at http://www.rotork.com

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Glossary
AI AO CD DCS DD DI DLL DO FAS FMS H1 HSE IEC Analogue Input Analogue Output Compel Data Distributed Control System Device Description (file) Digital Input Data Link Layer Digital Output Fieldbus Access Sublayer Fieldbus Message System Standard 31.25 kbit/s fieldbus High Speed Ethernet bus International Electrotechnical Committee IS ISA LAS OSI PHY PID PLC PN PT TD VCR VFD Intrinsically Safe Instrument Society of America Link Active Scheduler Open Systems Interconnect Physical Layer Proportional, Integral and Derivative Programmable Logic Controller Probe Node Pass Token Time Distribution Virtual Communication Relationship Virtual Field Device

http://www.rotork.com

UK head office Rotork Controls Ltd telephone Bath (01225) 733200 telefax (01225) 333467

USA head office Rotork Controls Inc telephone Rochester (716) 328 1550 telefax (716) 328 5848

As we are continually developing our products, their design is subject to change without notice. The name Rotork is a registered trade mark. Rotork recognises all registered trade marks.

telephone AUSTRALIA Ballarat CANADA Calgary CANADA Toronto CHINA Shanghai CHINA (North and Central) Beijing FRANCE Paris GERMANY Hilden HONG KONG & S. CHINA INDIA Chennai INDONESIA Jakarta ITALY Milan JAPAN Tokyo KOREA (SOUTH) Seoul MALAYSIA Kuala Lumpor NETHERLANDS Rotterdam RUSSIA Moscow SAUDI ARABIA Al Khobar Singapore South Africa Spain Thailand USA Houston Venezuela & N. Antilles Caracas (0353) 381566 (403) 569 9455 (905) 602 5665 (021) 62787680 (10) 64621617 (01) 43 11 15 50 (02103) 54098 2 520 2390 (044) 6254219 (21) 5806764 (02) 45703300 (03) 3294 8551 (02) 565 4803 (03) 5193093 (010) 414 6911 (095) 2292463 (03) 833 0702 4571233 (11) 453 9741 (94) 676 60 11 (02) 272 7165 (713) 782 5888 (02) 285 4208

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e-mail rotork@netconnect.com.au rcccalg@ibm.net mail@rotork.ca rotorksh@public6.sta.net.cn rotorkbj@public3.bta.net.cn mail@rotork.fr Info@rotork.de rotorkhk@netvigator.com rotork@vsnl.com rotork@indosat.net.id rotork.italia@rotork.it mail@rotork.co.jp rotork@unitel.co.kr rotork@rotork.com.my info@rotork.nl rotork.russia@mtu-net.ru hmrotork@batelco.com.bh post@rotork.com.sg lee.howard@rotork.co.za rotork@rotork.es rotork@loxinfo.co.th info@rotork.com rotorkvz@cantv.net

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