AC 800M

PROFIBUS DP
Installation
System Version 6.0

Power and productivity

TM
for a better world
AC 800M
PROFIBUS DP
Installation

System Version 6.0

NOTICE
This document contains information about one or more ABB products and may include a
description of or a reference to one or more standards that may be generally relevant to
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standard is not a representation that all of the ABB products referenced in this document
support all of the features of the described or referenced standard. In order to determine
the specific features supported by a particular ABB product, the reader should consult the
product specifications for the particular ABB product.

ABB may have one or more patents or pending patent applications protecting the intel-
lectual property in the ABB products described in this document.

The information in this document is subject to change without notice and should not be
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The software or hardware described in this document is furnished under a license and
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product meets the requirements specified in EMC Directive 2004/108/EC and in Low Volt-
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Copyright © 2004-2014 by ABB.

All rights reserved.

Release: August 2014

Document number: 3BDS009029-600
 Table of Contents

Table of Contents

About This User Manual

How to Use this User Manual..........................................................................................10
User Manual Conventions ...............................................................................................10
Warning, Caution, Information, and Tip Icons ....................................................10
Terminology.....................................................................................................................11
Released User Manuals and Release Notes.....................................................................14

Section 1 - Introduction
General Overview............................................................................................................15
The PROFIBUS Protocols....................................................................................16
PROFIBUS Technology Terms ............................................................................18
Transmission Technology Overview ...............................................................................20
FISCO (Fieldbus Intrinsically Safe Concept)..................................................................21

Section 2 - Transmission Technology

RS485 Transmission Technology ....................................................................................23
AC 800M and CI854/CI854A/CI854B ................................................................23
RS485 cable type and speed.................................................................................24
RS485 network limits...........................................................................................26
Adding field devices to the RS485 network.........................................................28
RS485 cycle time calculation...............................................................................29
RS485 installation recommendation ....................................................................30
RS485-IS Transmission technology ................................................................................30
MBP (IEC 61158-2) Transmission Technology ..............................................................31
MBP cable type and speed ...................................................................................31
MBP network limits .............................................................................................33
MBP power and line length calculation ...............................................................34
Adding field devices to the MBP network ...........................................................36

3BDS009029-600 5
Table of Contents

MBP cycle time calculation ................................................................................. 37

PROFIBUS DP/PA Linking Device LD 800P and SK3 ...................................... 38
PROFIBUS Power Hub SK3 ............................................................................... 40
Fibre Optic Transmission Technology ............................................................................ 40
Fibre optics cable type and speed ........................................................................ 41
Fibre optic network limits.................................................................................... 43
Monitoring of the communication quality ........................................................... 44
Basics of fibre optics topology technologies ....................................................... 45
Calculation of transmission delay time TTD ....................................................... 53

Section 3 - Fieldbus Topologies

Overview ......................................................................................................................... 55
Point-to-Point Topology....................................................................................... 57
Line Topology ...................................................................................................... 58
Line Topology with spurs ................................................................................... 58
Tree Topology ..................................................................................................... 60
Star Topology ...................................................................................................... 61
Ring Topology .................................................................................................... 62
Fieldbus Topology with RS485 (PROFIBUS DP) .......................................................... 63
Bus length and speed ........................................................................................... 63
Bus termination.................................................................................................... 64
Bus connector ...................................................................................................... 65
Shielding and data line connection ...................................................................... 67
Bus spur lines....................................................................................................... 67
RS485 limits and network design ........................................................................ 68
Fieldbus Topology with MBP (PROFIBUS PA) ............................................................. 70
Bus length and speed ........................................................................................... 71
MBP and intrinsically safe installation ................................................................ 73
Bus termination.................................................................................................... 74
PROFIBUS PA junctions and connectors ............................................................ 75
Shielding and data line connection ...................................................................... 77
Bus spur lines....................................................................................................... 81
Fieldbus Topologies with fibre optics ............................................................................. 82

6 3BDS009029-600
 Table of Contents

Bus length and speed............................................................................................82

Optical link modules and AC 800M in a star topology........................................83
Optical link modules and AC 800M in a ring topology .......................................85
Redundancy concepts ......................................................................................................87
RLM 01 - Redundancy Link Module...................................................................90

Section 4 - Commissioning of PROFIBUS equipment

Installation of data cables ................................................................................................91
Installation hints for electrical data cables ...........................................................91
Installation hints for optical fibre cables ..............................................................93
Special conditions regarding the installation of PROFIBUS DP ....................................94
Installation hints for CI854/CI854A/CI854B.......................................................96
Installing a Redundancy Link Module RLM 01 ..................................................97
Installing the PROFIBUS DP/PA Linking Device LD 800P ...............................98
Active network terminator and repeater .............................................................100
Grounding, Shields, Polarity ..............................................................................102
Testing the PROFIBUS bus cable and bus connectors.......................................103
Tips on the most frequently asked installation issues ........................................108

Index

3BDS009029-600 7
Table of Contents

8 3BDS009029-600
About This User Manual

About This User Manual

Any security measures described in this User Manual, for example, for user
access, password security, network security, firewalls, virus protection, etc.,
represent possible steps that a user of an 800xA System may want to consider
based on a risk assessment for a particular application and installation. This risk
assessment, as well as the proper implementation, configuration, installation,
operation, administration, and maintenance of all relevant security related
equipment, software, and procedures, are the responsibility of the user of the
800xA System.
This user manual provides application notes and advice for wiring and installation
of PROFIBUS networks. It is intended to be used by Instruments Engineers,
Instrument Technicians, Electricians and Installers for the wiring and associated
components for the PROFIBUS applications.
The main areas covered in this 3BDS009029-600 manual are:
• Fieldbus topology and the redundancy concepts
• Transmission technologies
• Cable media and PROFIBUS components
• Design of a plant and the cable laying regulations
• Commissioning and testing of PROFIBUS equipment
For a list of documentation related to ABB PROFIBUS products, please see the
Released User Manuals and Release Notes on page 14.

3BDS009029-600 9
How to Use this User Manual About This User Manual

How to Use this User Manual

Section 1 Introduction gives a brief overview of the PROFIBUS protocols,
technology terms, transmission technologies and the Fieldbus Intrinsically Safe
Concept (FISCO).
Section 2 Transmission Technology provides detailed information about the
PROFIBUS physics like RS485(-IS), MBP, fibre optics as well as basics of cable
types, transmission rates, network limits and bus line length. This chapter is
intended for users, they are not familiar with the basics of the PROFIBUS
technology.
Section 3 Fieldbus Topologies describes PROFIBUS topologies, usable with certain
transmission technology, described in section 2. This chapter is intended for readers,
they know PROFIBUS basics and need an introduction to install PROFIBUS
networks in connection with the AC 800M controller and the PROFIBUS master
interface CI854/CI854A/CI854B. Also the readers get recommendations and
important hints for installation work.
Section 4 Commissioning of PROFIBUS equipment describes additional hints on
the installation of PROFIBUS networks. Furthermore this chapter provides detailed
information to find errors and how to fix them.
For a list of documentation related to the products described in this user manual, see
Released User Manuals and Release Notes on page 14.

User Manual Conventions

Microsoft Windows conventions are normally used for the standard presentation of
material when entering text, key sequences, prompts, messages, menu items, screen
elements, etc.

Warning, Caution, Information, and Tip Icons

This User Manual includes Warning, Caution, and Information where appropriate to
point out safety related or other important information. It also includes Tip to point
out useful hints to the reader. The corresponding symbols should be interpreted as
follows:

10 3BDS009029-600
About This User Manual Terminology

Electrical warning icon indicates the presence of a hazard that could result in
electrical shock.

Warning icon indicates the presence of a hazard that could result in personal
injury.

Caution icon indicates important information or warning related to the concept

discussed in the text. It might indicate the presence of a hazard that could result
in corruption of software or damage to equipment/property.

Information icon alerts the reader to pertinent facts and conditions.

Tip icon indicates advice on, for example, how to design your project or how to
use a certain function
Although Warning hazards are related to personal injury, and Caution hazards are
associated with equipment or property damage, it should be understood that
operation of damaged equipment could, under certain operational conditions, result
in degraded process performance leading to personal injury or death. Therefore,
fully comply with all Warning and Caution notices.

Terminology
A complete and comprehensive list of Terms is included in the System 800xA,
Engineering Concepts instruction (3BDS100972*). The listing includes terms and
definitions that apply to the 800xA System where the usage is different from
commonly accepted industry standard definitions and definitions given in standard

3BDS009029-600 11
Terminology About This User Manual

dictionaries such as Webster’s Dictionary of Computer Terms. Terms that uniquely

apply to this User Manual are listed in the following table.

Term/Acronym Description
AC 800M ABB Controller 800M series, general purpose process
controller series by ABB.
AC 800M Controller Any controller constructed from the units and units
connected to the AC 800M hardware platform.
Connector A Connector is a coupling device used to connect the wire
medium to a fieldbus device or to another segment of
wire.
EMC EMC is defined as the ability of a product to operate within
its intended electromagnetic environment and to accept or
emit RF disturbances within defined limits.
FDE Fault Disconnection Electronic. The FDE in field devices
ensures that the communication of the bus segment does
not fail, even in case of a short circuit in a device.
Fieldbus A fieldbus is used to interconnect field devices, such as
I/O modules, smart sensors and actuators, variable speed
drives, PLCs, or small single loop devices, and to connect
these devices to the 800xA system.
GSD File Gerätestammdaten, device communication database file
for PROFIBUS devices.
Highway Addressable The HART protocol is a widely-used open protocol for
Remote Transducer communication with Smart devices.
(HART)
IEC International Electrotechnical Commission.
IS Intrinsic Safety.
Linking Device The linking device connects one or more ROFIBUS PA
segments to PROFIBUS DP.

12 3BDS009029-600
About This User Manual Terminology

Term/Acronym Description
MBP Transmission technology Manchester Coding and Bus
Powered. This term replaces the previously common
terms for intrinsically safe transmission “Physics in
accordance with IEC 61158-2, 1158-2, etc.
NRZ Non Return to Zero, a protocol behavior of the MBP
transmission technology.
PROFIBUS PROcess FIeldBUS. PROFIBUS is a manufacturer-
independent fieldbus standard for applications in
manufacturing, process and building automation. The
PROFIBUS family is composed of three types of protocol,
each of which is used for different tasks. The three types
of protocols are: PROFIBUS FMS, DP and PA.
PROFIBUS FMS Fieldbus Message Specification. Is designed for
communication at the cell level, where programmable
controllers, such as PLCs and PCs primarily communicate
with each other. It was the forerunner of PROFIBUS DP.
PROFIBUS DP PROFIBUS DP is the communication protocol for
Decentralized Peripherals. DP covers the versions DP-V0,
DP-V1 and DP-V2.
PROFIBUS PA PROFIBUS for Process Automation
PROFIBUS The international umbrella organization for PROFIBUS
International (PI) founded in 1995.
PROFIBUS User The PNO is the trade body of manufacturers and users for
Organization e.V. (PNO) PROFIBUS founded in 1989.
Redundancy The existence of more than one capability of an item
(system, equipment or component) to perform its intended
function.
Remote I/O Input/Output units connected to a controller via a fieldbus.
RLM 01 Redundancy Link Module for PROFIBUS DP. The RLM 01
connects a non redundant PROFIBUS slave to the line
redundant PROFIBUS.

3BDS009029-600 13
Released User Manuals and Release Notes About This User Manual

Term/Acronym Description
RS485 A communication interface standard from EIA (Electronics
Industries Association, USA), operating on voltages
between 0V and +5V. RS485 is more noise resistant than
RS232C, handles data transmission over longer
distances, and can drive more receivers
Segment A Segment is a section of a PROFIBUS DP fieldbus that is
terminated in its characteristic impedance. Segments can
be linked by Repeaters to form a longer PROFIBUS DP
fieldbus. Each Segment can include up to 32 devices.
tbit Time a bit needs to be transferred on PROFIBUS. This
time depends on the transmission rate.
tbit = 1/transmission rate.

Released User Manuals and Release Notes

A complete list of all User Manuals and Release Notes applicable to System 800xA
is provided in System 800xA Released User Manuals (3BUA000263*).
System 800xA Released User Manuals (3BUA000263*) is updated each time a
document is updated or a new document is released. It is in pdf format and is
provided in the following ways:
• Included on the documentation media provided with the system and published
to ABB SolutionsBank when released as part of a major or minor release,
Service Pack, Feature Pack, or System Revision.
• Published to ABB SolutionsBank when a User Manual or Release Note is
updated in between any of the release cycles listed in the first bullet.
A product bulletin is published each time System 800xA Released User Manuals
(3BUA000263*) is updated and published to ABB SolutionsBank.
For standards and commercially available PROFIBUS documentation please visit
the PROFIBUS Web Site (http://www.profibus.com).

14 3BDS009029-600
Section 1 Introduction General Overview

Section 1 Introduction

General Overview
Fieldbus systems are used as a means of communications for serial data exchange
between decentralized devices on the field level and the controller of the process
supervision level.
PROFIBUS means PROcess FIeldBUS, designed as a fieldbus for process
automation purposes for interconnecting Decentralized Peripheral devices
(PROFIBUS DP), and its extended version for Process Automation (PROFIBUS
PA). It is well known all over the world and the most popular fieldbus in Europe.
Due to its high data transmission rates over short distances and moderate ones over
long distances it is predominantly used for interconnecting I/O units like S800 /
S900 or smart devices to PLCs and controller like AC 800M.
This user manual provides a brief overview of the PROFIBUS technology, to help
you by planning, commissioning and testing. It does not release you from the
necessity to observe the relevant standards. The valid version of the EMC directive
and other PROFIBUS guidelines and the shield and grounding directives, particular
for PROFIBUS-PA must be observed.
Data in this document are based on experiences, but do not replace however the
relevant standards and regulations as there are for example:
British Standard BS EN 50170
Euro Standard EN 50170
International Electrotechnical Commission IEC 61158
PROFIBUS Specification 0.032, FMS, DP, PA Specification
PROFIBUS Guideline 2.112, PROFIBUS DP/FMS Installation Guideline
PROFIBUS Guideline 2.092, PROFIBUS PA User and Installation Guideline
PROFIBUS Guideline 2.021 (draft in german), Optical Transmission Technics

3BDS009029-600 15
The PROFIBUS Protocols Section 1 Introduction

The PROFIBUS Protocols

PROFIBUS is a manufacturer-independent fieldbus standard for applications in
manufacturing, process and building automation. PROFIBUS technology is
described in fixed terms in DIN 19245 as a German standard and in EN 50170 / IEC
61158 as an international standard. It specifies the technical and functional
properties of a serial bus system. The PROFIBUS standard is thus available to every
provider of automation product.
PROFIBUS distinguishes between master and slave. The masters determine the data
communication on the bus. A master can send messages without an external request
if it has access rights to the bus (token). The slaves are peripheral devices. Typical
slaves are I/O devices, valves, motors and transmitters. They have no bus access
rights. They can only confirm received messages or send a message on the request
of the master. Slaves are passive devices on the PROFIBUS.
PROFIBUS is composed of three types of protocol, each of which is used for
different tasks. Of course, devices with all three protocols can communicate with
each other in a complex system by means of a PROFIBUS network.
The three types of protocols are: PROFIBUS FMS, DP, PA.

16 3BDS009029-600
Section 1 Introduction The PROFIBUS Protocols

Only the two protocol types DP and PA today are important for process automation
and are supported within the 800xA System.

Figure 1. The PROFIBUS family embedded in Industrial IT

PROFOBUS DP: the bus for the Decentralized Periphery

The PROFIBUS DP (RS485) is responsible for communication between the
Controller level of a process automation system and the decentralized periphery in
the field, also intrinsic safety (RS485-IS) via DP-Ex barriers into hazardous area.
One feature of PROFIBUS DP is its scalable high speed of transmission up to
12 Mbit/s.

PROFIBUS PA: extension for Process Automation

This PROFIBUS variant was developed for the process industry. PROFIBUS PA
interacts with a fix transmission rate of 31,25 kbit/s and is designed for connection
of bus-powered 2-wire field devices such as transmitters and actuators.

3BDS009029-600 17
PROFIBUS Technology Terms Section 1 Introduction

It correspond to IEC Standard 61158-2 and can be also applied to intrinsically safe
installations (EEx i) in Zone 1 / Div.1.
Linking Devices are used to integrate PA bus lines into the PROFIBUS DP network.
This ensures that all information is available in a continuously connected network
through the complete PROFIBUS system (DP and PA).

PROFIBUS Technology Terms

ISO/OSI Reference Model

In accordance with the international ISO/OSI model, a fieldbus protocol can be
uniquely described by means of up to 7 transmission levels. Specific tasks are
assigned to each level in this system. PROFIBUS DP and PROFIBUS PA use only
the first two levels as well as the user interface, which resides in level 7 and where
application functions that can be utilized by the user are determined along with
system and device behavior. Level 1 defines the physical aspect of transmission
(physical layer). This includes, for example, the method of transmission, the
transmission medium, and lengths of lines, while level 2 specifies the bus access
protocol (data link layer).

Bus Access Control

The bus access control (MAC, Medium Access Control) is a specific procedure that
determines at which point in time a PROFIBUS device can send data. While active
devices (master) can start the exchange of information, passive devices (slaves) may
only begin communication when prompted by an active device. A distinction is
made between a controlled, deterministic access procedure with real-time
capabilities (master-slave with PROFIBUS) and a random, non-deterministic access
procedure (CSMA/CD with Ethernet)

Addressing
Each device, connected to a PROFIBUS network, needs an unique address for
selectively identify a field device. For this purpose, PROFIBUS device addresses are
assigned either by an address switch (hard addresses) or by parameter assignment
during commissioning (soft addresses).

18 3BDS009029-600
Section 1 Introduction PROFIBUS Technology Terms

A 7-bit device address serves to identify the bus participants in the network. The
addresses range from 0 to 127, and the following are reserved:
• Address 126: default for automatic address assignment via the master;
• Address 127: sending broadcast telegrams.
If the address 0 is used for the class-1 master, the addresses 1 to 125 are available for
addressing the field devices. Therefore up to 126 DP or PA field devices (master and
slaves) can be addressed. Each address can only be used once in a single
PROFIBUS network.

Communication Protocols
At the protocol level, PROFIBUS offers a broad spectrum of options, which enables
optimum communication between different applications. PROFIBUS DP is a fast
and deterministic process data exchange between a PROFIBUS master and the
assigned slave devices.
Presently the basic and extended functions supported with
AC 800M/CI854/CI854A/CI854B are:
• Basic function (V0):
– Cyclic data transfer
– Diagnostic
– Configuration via GSD files
• Extended function V1:
– Acyclic data transfer
– Alarm handling (planned, but not supported yet)
– FDT/DTM device management
– Function blocks acc. IEC 61131-3

3BDS009029-600 19
Transmission Technology Overview Section 1 Introduction

Transmission Technology Overview

Table 1. Transmission technologies at PROFIBUS

RS485 RS485-IS MBP Fibre Optic

Digital, differential Digital, differential Digital, bit- Optical, digital, NRZ

Data
signals according to signals according to synchronous,
transmission
RS485, NRZ RS485, NRZ Manchester coding

Transmission 9,6 to 12000 kbit/s 9,6 to 1500 kbit/s 31,25 kbit/s 9,6 to 12000 kbit/s
rate

HD=4, Parity bit, HD=4, Parity bit, Preamble, error- HD=4, Parity bit,
Data security start/end delimiter start/end delimiter protected, start/end start/end delimiter
delimiter

Shielded, twisted pair Shielded, twisted 4- Shielded, twisted pair - Multimode glass
copper, cable type A wirer, cable type A copper fibre,
- single mode glass
Cable
fibre
- PCF
- plastic

Available over Available over Optional available Available over hybrid

Remote feeding
additional wire additional wire over signal wire line

None Intrinsic safety Intrinsic safety None

Protection type
(EEx ib) (EEx ia/ib)

Line topology with Line topology with Line and tree Star and ring
termination termination topology with topology typical, line
Topology
termination; also in topology possible
combination

Number of Up to 32 stations per Up to 32 stations per Up to 32 stations per Up to 126 stations

stations segment without segment without segment, total sum of per network
repeater, up to 126 repeater, up to 126 max 126 per network
stations with repeater stations with repeater

Number of Max. 9 repeater with Max. 9 repeater with Max. 4 repeater Unlimited with signal
repeaters signal refreshing signal refreshing refreshing (time
delay of signal)

20 3BDS009029-600
Section 1 Introduction FISCO (Fieldbus Intrinsically Safe Concept)

FISCO (Fieldbus Intrinsically Safe Concept)

To render the proof of Intrinsic Safety as simple as possible, the so-called FISCO
model was developed. FISCO stands for Fieldbus Intrinsically Safe COncept. The
German Federal Physical Technical Institute (PTB) developed the FISCO model
and has published it in Report PTB-W-53 “Examination of intrinsic safety for
fieldbus systems“.
This model is based on the following prerequisites:
To transmit power and data, the bus system uses the physical configuration defined
by IEC 61158-2. This is the case for PROFIBUS PA.
• Only one active source is permitted on a bus segment (in this case the Linking
Device). All other components work as passive current sinks.
• The basic current consumption of a bus station is at least 10 mA.
• It must be ensured for each bus station that
– Ui> Uo of the Linking Device/Power Link
– Ii> Io of the Linking Device/Power Link
– Pi> Po of the Linking Device/Power Link.
• Each bus station must fulfill the following requirement:
– Ci < 5 nF
– Li < 10 µH
• Total length of the PA segment, incl. spurs, to be kept
– when using passive T-junctions in EEx ia IIC applications < 1000 m
– when using Multibarries or in non intrinsically safe areas < 1900 m
• The permissible spur line length for Ex applications is 30 m per spur line. The
definition of the spur line must be observed in this connection.
• The transmission line that is used must conform to the following cable
parameters:
– resistor coating: 15 Ohm/km < R’ < 150 Ohm/km
– inductance coating: 0.4 mH/km < L’ < 1 mH/km

3BDS009029-600 21
FISCO (Fieldbus Intrinsically Safe Concept) Section 1 Introduction

– capacitance coating: 80 nF/km < C’< 200 nF/km (including the shield)
• Taking the shield into consideration, the capacitance coating is calculated as
follows:
– C’ = C’conductor/conductor + 0.5 * C’conductor/shield if the bus line is
potential free
or
– C’ = C’conductor/conductor + C’conductor/shield if the shield is
connected with a pole of the Linking Device/Power Link.
• The bus segment must be terminated on both ends of the line with a fieldbus
terminator. According to the FISCO model the terminal bus resistance must
conform to the following limits:
– 90 Ohm < R < 100 Ohm
– 0 µF < C < 2,2 µF
On condition that the points are all satisfied, the proof of intrinsic safety has been
provided by means of the FISCO model. Devices that are certified in accordance
with FISCO are proven to be intrinsically safe and can be used in a plant’s
hazardous areas without the need for additional calculation effort. If FISCO-
approved devices are used, more devices can be operate on a single line and it is
allowed to replace devices during runtime by devices of other manufacturer or to
expand the bus line with additional devices.
The prerequisite for being allowed to bear the proof of intrinsic safety in
accordance with the FISCO Model is, that the Linking Device and all fieldbus
stations are certified according to FISCO.

22 3BDS009029-600
Section 2 Transmission Technology RS485 Transmission Technology

Section 2 Transmission Technology

PROFIBUS is an industrial communication system that uses a range of media such

as copper cable, fibre optics or wireless, with bit-serial transmission for coupling
smart field devices to a control system.
This chapter describes the transmission technologies mostly used in connection with
the AC 800M Controller. PROFIBUS provides different transmission technologies,
based on international standards such as IEC 61158 and IEC 61784, which
describes the digital data communications for measurement and control in fieldbus
networks.

RS485 Transmission Technology

RS485 is the most commonly used transmission technology for PROFIBUS DP. It
uses a shielded twisted pair copper cable and enables transmission rates up to 12
Mbit/s. Because of its simply installation it is cost-effective and requires no expert
knowledge.
The bus structure allows adding or removing of field devices as well as step by step
commissioning without influencing the system. Later extensions have no impact on
devices that are already working on the bus. RS485 is scalable in its transmission
rate from 9,6 kbit/s up to 12 Mbit/s, which is set in the PROFIBUS master.

AC 800M and CI854/CI854A/CI854B

In connection with the AC 800M Controller, the Communication Interface
CI854/CI854A/CI854B interacts as PROFIBUS master and builds up a PROFIBUS
network with RS485 technology. Up to 12 CI854/CI854A/CI854B modules can be
placed at one AC 800M Controller and each interface works as a single PROFIBUS
master, which can be configured with its own transmission rate. Supported
transmission rates are 9.6; 19.2; 93.75; 187.5; 500; 1500; 3000; 6000 and 12000
kbit/s. Not support are the transmission rates 31.25 and 45.45 kbit/s. The default
value is 1.5 Mbit/s. Higher values require careful consideration of correct cable
installation. The PROFIBUS configuration tool within the 800xA system is the

3BDS009029-600 23
RS485 cable type and speed Section 2 Transmission Technology

Control Builder M. This tool calculates the bus timing parameter and checks the
configuration values, inserted by the user. For example a compilation warning
occurs if a slave does not support the selected transmission rate. In this case the next
lower supported transmission rate will be selected automatically. Changing the
transmission rate may also require changing of other bus parameters to ensure
successful communication. The automatic calculation will determine the right
settings. The adjusted speed is valid for all connected devices on the bus, when
commissioning the system.
A detailed description of the AC 800M and CI854/CI854A/CI854B is available
in their specific product manuals.

RS485 cable type and speed

The maximum permissible bus length depends on the transmission rate and the bus
cable type. Different cable types (designation A to D) for different applications are
available for connecting PROFIBUS devices either each other or to network
elements (Linking Devices, Repeaters).
The electrical lines are shielded twisted two-wire cables with a circular cross-
section. The RS485 interface operates on voltage differences. It is therefore less
sensitive to interference than a voltage or current interface. Depending on the
transmission speed, segments can be implemented in lengths of from 100 meter to
over 1000 meter. The bus cable to be used for the bus modules is specified in DIN
19245/EN 50170 as cable type A and can be used according to the following table:

Table 2. Basic data for a PROFIBUS DP reference cable

Parameter DP, Cable type A

Cable design Twisted pair and shielded
Surge impedance 135 ... 165 Ohm at f=3 ... 20 MHz
Operating capacity =< 30 pF/m
Loop resistance =< 110 Ohm/km
Wire diameter > 0.64 mm
Wire cross-section > 0.34 mm2

24 3BDS009029-600
Section 2 Transmission Technology RS485 cable type and speed

Project-specific requirements and limitations such as underground wiring, UV

resistance, being free of halogen, etc. should be considered when selecting the
cable. Cables may be used with deviate mechanically or electrically from the type A
cable, but the surge impedance must be retained.
Note that cable for laying underground is not suitable for connecting to
PROFIBUS connectors because of the typically 10 mm diameter of the coating.
They can therefore only be connected to screw terminals of PROFIBUS devices.
Depending on the ambient EMC conditions, EN 50170 also allows for laying of
unshielded cable. However, the following reasons argue in favour of always using
shielded cable:
The only interference-free space is inside the switch cubicle, at best. As soon as a
relay is located within the switch cubicle, this is no longer the case.
Unshielded cable requires additional protective measures at the bus inputs to
protect against voltage overload.
From the line parameters specified above result the following bus segment lengths:

Table 3. Dependencies of bus length and transmission rate

Transmission rate in kbit/s 9.6 19.2 93.75 187.5 500 1500 12000

Range in m/segment 1200 1200 1200 1000 400 200 100

In a PROFIBUS DP installation, it must be chosen a data transfer rate which is

supported by all devices connected to the bus. The chosen data transfer rate then
determines the maximum segment lengths as shown above.
If other transmission rate shall be used which is not listed in the table above, an
approximation can determine the permissible length through linear interpolation of
two adjacent transmission rates from the table.

3BDS009029-600 25
RS485 network limits Section 2 Transmission Technology

Calculation of a bus length against of two transmission rates:

A transmission rate of 3 Mbit/s shall be used. The transmission rates in the table
close to this value are 1.5 Mbit/s with l1,5Mbit/s and 12 Mbit/s with l12Mbit/s. Thus,
you can calculate the line length l3Mbit/s:
l 1.5Mbit/s - l 12Mbit/s
l 3Mbit/s : = l 1.5Mbit/s + ( 3Mbit/s - 1.5Mbit/s ) × -------------------------------------------------
1.5Mbit/s - 12Mbit/s
l 3Mbit/s ≈ 185m

RS485 network limits

Up to 32 nodes (master and slaves) can be grouped in a single segment. When using
more than 32 nodes, several segments linked to each other through repeaters (power
amplifiers) are needed. Note that the repeater has to be considered as another bus
node, since the integrated bus drivers are an additional load on the bus. It is
recommended to use not more than three series-connected repeaters on a line.
However, the number of repeaters in a single PROFIBUS network is limited to 9.
The maximum admissible distance between two bus stations in each PROFIBUS
network can be calculated as follows:
(Number of repeater + 1) * Segment length
Number of repeater = The maximum number of repeaters connected in series.
Example: The repeater manufacturer’s specifications allow nine repeaters to be
connected in series.
The maximum distance between two bus stations at a data transfer rate of 1500
kbit/s is then as follows:
=> (9 + 1) * 200 m = 2000 m

26 3BDS009029-600
Section 2 Transmission Technology RS485 network limits

Figure 2. RS485 network limits

3BDS009029-600 27
Adding field devices to the RS485 network Section 2 Transmission Technology

Adding field devices to the RS485 network

A shielded twisted-pair copper cable is the hardware required for RS485
transmission. It connects all devices to the bus structure (line). The bus structure
allows for non-reactive coupling and decoupling of stations or step wise
commissioning of a system. Later extensions have no impact on stations that are
already working on the bus.
When connecting the field devices it must be ensured that the data lines are not
reversed. Always use a shielded data line to ensure high interference immunity of
the system against electromagnetic emissions. The shield should be grounded on
both sides and large-area shield clamps should be used for grounding to ensure good
conductivity. Furthermore the data lines should be laid separately and away from all
power cables. Never use spur lines for transmission rates > 1,5 Mbit/s (see also Line
Topology with spurs on page 58).
A 9-pin D-Sub connector is primarily used to connect PROFIBUS devices on the
bus, which complies with DIN 19245/ EN 50170. Normally connectors are used,
which supports direct connection of the incoming and outgoing data cable.

Figure 3. PROFIBUS connector

This eliminates the need for spur lines and the bus connector can be connected and
disconnected to the field device at any time without interrupting data
communication. The type of connector suitable for RS485 transmission technology
depends on the degree of protection.
To avoid signal reflections on the bus line, the line structure must be terminated by a
bus termination resistor network at either end. The bus is terminated at each end of a
segment with an active bus termination. Both bus terminators have a permanent

28 3BDS009029-600
Section 2 Transmission Technology RS485 cycle time calculation

power supply to ensure error-free operation. The bus terminator is usually switched
in the devices or in the connectors.

RS485 cycle time calculation

The bus cycle time should be shorter than the AC 800M program cycle time.
However, a faster data throughput alone is not enough for successful
implementation of a bus network. PROFIBUS DP only requires approx. 1 ms at 12
Mbit/s for the transmission of 512 bits of output data distributed over 32 stations.
The following figure shows different bus cycle times of a DP mono-master system
with 2 bytes in and output data per slave:

Figure 4. Bus cycle times of a DP mono-master system.

Boundary conditions: each slave has 2 bytes of input and output data

Each PROFIBUS master configuration tool (for example Control Builder M)

automatically calculates the bus cycle time. The detailed calculation rules are
described in the PROFIBUS specification.

3BDS009029-600 29
RS485 installation recommendation Section 2 Transmission Technology

RS485 installation recommendation

Problems with data transmission in PROFIBUS networks can be attributed to
incorrect wiring or installation. These problems can often be solved using bus test
equipment such as bus monitors, which are able to detect many typical wiring errors
even before commissioning.
The list below helps to build up a RS485 network quick and accurate:
• Only use shielded and twisted-pair wiring as a RS485 bus line.
• Use a PROFIBUS bus connector plug to connect the RS485 bus segment.
• If the module is at the beginning or end of a bus segment, this connector must
have an activated bus terminal resistor combination.
• Ensure that the bus segment connected to the RS485 interface is terminated at
both ends.
• All PROFIBUS bus connector plugs in a network must be securely screwed
onto the RS485 interfaces.
• Attaching or removing the bus connector plugs, inadequately attached bus
connector plugs or loose bus wires within the plug can lead to malfunctions in
the networks.
• Attach or remove the RS485 bus connector plug quickly and without twisting
them.

RS485-IS Transmission technology

The RS485-IS transmission technology is based on RS485 with its fast transmission
rate and simple usage, but additional for installation in intrinsically safe areas.
RS485-IS is specified as a 4-wire medium in protection type EEx-i for use in
potentially explosive areas. Therefore the specified level of power refer to the
safety-relevant maximum values must not be exceeded in either individual devices
or during interconnection in the system. An electrical circuit permits maximum
currents at the specified voltage level. With RS485-IS all stations represent active
sources, which is in contrast to the FISCO model, that only has one intrinsically safe
source. Also it is possible to connect up to 32 devices to the intrinsically safe bus
circuit.

30 3BDS009029-600
Section 2 Transmission Technology MBP (IEC 61158-2) Transmission Technology

More information about this technology is given in the guidelines and specification
from the PROFIBUS International organization (http://www.profibus.com).

MBP (IEC 61158-2) Transmission Technology

The MBP transmission technology (Manchester Coded, Bus Powered), which is the
new naming for the previous designation “IEC 61158-2 Physics”, is mostly used for
applications in the process automation with a requirement for bus powering and
intrinsic safety of devices. The reason for this name change is that, in its definitive
version, the IEC 61158-2 describes several different connection technologies,
including MBP technology, not being therefore unambiguous. Compared to the
previously used procedure RS485-IS, the Fieldbus Intrinsically Safe Concept
(FISCO), which was specially developed for interconnection of intrinsically safe
field devices, considerably simplifies planning and installation.

MBP cable type and speed

MBP is synchronous transmission with a fixed transmission rate of 31.25 Kbit/s and
Manchester coding. This allows installation of PROFIBUS networks also in
potentially explosive areas and be intrinsically safe. The intrinsically safe
transmission technology MBP is usually limited to a specific segment (field devices
in hazardous areas) of a plant, which is then to the RS485 bus line via PROFIBUS
DP/PA Linking Device.
Tree or line structures as well as any combination of the two are supported by
PROFIBUS with MBP transmission. The transmission medium for MBP is a
shielded two-wire cable, normally covered by an black color cable sheath for non
intrinsically safe areas and blue color for hazardous areas. The maximum
permissible spur line lengths must be taken into account when calculating the
overall PROFIBUS line length. In intrinsically safe applications a spur line has a
maximum permissible length of 30m.

3BDS009029-600 31
MBP cable type and speed Section 2 Transmission Technology

Table 4. Basic data for the PROFIBUS PA reference cable

Parameter PA, Cable type A

Cable design shielded twisted pair
Conductor cross section (nominal) 0,8 mm²
Loop resistor (direct current) 44 Ohm/km
Wave resistance at 31,25 kHz 100 Ohm +20%
Wave attenuation at 39 kHz 3 dB/km
Capacitive asymmetry 2 nF/km
Group runtime distortion (7,9 ... 39) kHz 1,7 µs
Covering level of the shield 90%

The bus trunk cable has a passive line terminator at each end.
The Power Link Modules of the PROFIBUS Linking Device LD 800P possess an
integrated bus terminator, which terminates the PROFIBUS PA line unilaterally
and therefore eliminates the need for a separate bus terminator on the Power Link
Modules. (see also PROFIBUS DP/PA Linking Device LD 800P and SK3 on
page 38

32 3BDS009029-600
Section 2 Transmission Technology MBP network limits

MBP network limits

The maximum of connected devices per single segment is limited to 32. This is a
theoretical value, because this number can be further determined by the protection
type selected and the bus power.
In intrinsically safe applications the power (maximum voltage and current) is
defined with strict limits. For example the current in hazardous area’s restricted to
100 mA and in non intrinsically safe networks to 400 mA. To determine the
maximum line length, is necessary to calculate the power consumption of the
connected devices and to specify a power supply and the line length for the selected
cable type (see also MBP power and line length calculation on page 34).
The required current is summarized from the power consumption of all connected
field devices plus a reserve of 9 mA per segment for the operating current of the
FDE (Fault Disconnection Electronics). The FDE prevents faulty devices
permanently blocking the bus.

Table 5. Limits of MBP networks

intrinsically safe non intrinsically safe

Measurement voltage 12,6 V ... 13,4 V 24 V ... 26 V
Measurement current 100 mA 400 mA
max. PROFIBUS PA slaves 10 32
max. line length 1000 m 1900 m

The maximum line length of the network comprises the total of the main line (trunk)
and all spur lines.
A PROFIBUS PA field device requires a minimum input voltage of 9 V. With an
unfavorable distribution of stations, for example if all PROFIBUS PA stations are
widely removed from the Linking Device, it can happen that the voltage drop along
the line is so great that the voltage level at the end is insufficient. This results in a
shortening of the transmission line or the necessity of using cable with a larger
cross-section.

3BDS009029-600 33
MBP power and line length calculation Section 2 Transmission Technology

MBP power and line length calculation

The distribution of stations on the PROFIBUS PA segment can have a negative
effects on the maximum possible line length in certain circumstances. The following
example is intended to clarify this point:

imax RL
Linking in
Device/ i1 i2
UL
Power Uout >9V
Link
Module

RL = Line resistance of line segment x

Ix = Current consumption of PA station x

Figure 5. Voltage calculation and line length

The case in question is an Ex application. The result of the current calculation is that
a maximum direct current including IFDE of 100 mA is flowing. Type A cable is
being used with a resistance coating of 44 Ohm/km.
A requirement for a PROFIBUS PA slave to be able to function properly is that the
input voltage on the bus line must be at least 9 V. The following therefore applies to
the maximum voltage drop over the lead:
ULmax = Uout - 9 V
Currently Uout for LD 800P with an Ex interface PL 890 is at least 12.8 V (12.8 V ...
13.4). For the worst case consideration, Uout should be set to 12.8 V. This results in:
ULmax = 12.8 V - 9 V = 3.8 V
Since all stations are connected at the end of the line, the maximum line resistance
must be
RL = UL/imax
RL = 3.8 V / 100 mA = 38 Ohm

34 3BDS009029-600
Section 2 Transmission Technology MBP power and line length calculation

The maximum line length of the PROFIBUS PA segment is calculated as follow:

Max. line length = 38 Ohm / 44 (Ohm/km) = 0.863 km
Max. line length = 863 m
Since in practice the stations are not all connected compactly at the end of the
transmission line, the resulting structure is as follows:

ln

l2

l1

RL1 RL2
Linking
Device i1 i2 in
Uout >9V

RLx = Line resistance of line segment x

Ix = Current consumption of PA station x

Figure 6. Voltage calculation and line length

Each station causes a voltage drop on the length segment through which its power
supply current flows. For the first station, this would be:
URL1 = i1*RL1 or URL1 = i1 * l1 * r; where r = the resistance coating of the line
For the second station, this appears as follows:
URL2 = i2* (RL1 + RL2) or URL2 = i2 * l2 * r
In general, the equation for Ex applications is then as follows:
– URL = r * Σ (ix * lx) < Uout - 9 V
If the condition described above is not fulfilled,
a) the line has be shortened or
b) a line with reduced resistance coating has to be used.

3BDS009029-600 35
Adding field devices to the MBP network Section 2 Transmission Technology

When selecting the type of line, make certain that for Ex applications the
requirements in terms of insulation voltage and single conductor insulation of EN
60079-14 and the characteristic values in accordance with the FISCO model are
maintained.

Adding field devices to the MBP network

PROFIBUS PA devices are mostly connected to the network by using multibarries
or T-junctions. The resulting spur has to be connected directly to the connector
block inside the device. Sometimes also M12 plugs are used to connect the device to
the network (see also Bus connector on page 65).
When using MBP technology, incorrect connection of a field device (for example
polarity reversal) has no effect on the functionality of the bus as these devices are
usually fitted with an automatic polarity detection function.
The Manchester signal used by fieldbus is an alternating voltage that changes
polarity once or twice per bit. In self-powered networks only this alternating voltage
exists.
In powered networks the alternating voltage is superimposed onto the DC voltage
being used to power the devices. In either case, the fieldbus receive circuits look at
only the alternating voltage. Positive voltage swings have one meaning, negative
swings have the opposite meaning. Therefore, the fieldbus signal is polarized. Field
devices must be connected so that they all see the signal in correct polarity. If a field
device is connected “backwards” it will see an inverted version of the alternating
voltage and won’t be able to communicate. However, there are non-polarized field
devices available. This field devices can be connected in either polarity across the
network. The non-polarized devices are invariably network-powered, which
provides a clue as to how they can work with either polarity.
If a fieldbus network is build up to accept all possible devices, the signal polarity
must be taken into account. All of the (+) terminals must be connected to each other.
Similarly, all of the (-) terminals must be connected to each other. Color-coded wire
makes this relatively easy. Polarized devices should always be marked or have
keyed connectors. Non-polarized devices might not be marked. It may be possible to
select devices with the intention of never having to consider polarity. But it may be
safer to build polarity into the network at the outset and accept as a bonus any
devices that can be blindly connected. This approach also lets to expand the network
with polarized devices if needed later on. Bus powered field devices may also be

36 3BDS009029-600
Section 2 Transmission Technology MBP cycle time calculation

polarized with respect to device power. These devices are designed so that signal
polarity and power polarity are the same. Connecting the +DC to the (+) terminal
automatically insures correct signal polarity. Non-polar bus powered field devices
accept both signal and power of either polarity.

MBP cycle time calculation

The PROFIBUS-PA data telegrams of the MBP transmission is very similar to
asynchronous RS485 transmission. While the bytes are transmitted asynchronously
in the form of UART characters over the RS485 line, the transmission on the MBP
segments is bit synchronous. Here, the telegram is additionally supplied with the
preamble and the start and end delimiter.

Figure 7. MBP data telegram

Fieldbus Data Link (FDL) defines the following telegrams:

• Telegrams without data field (6 control bytes)
• Telegrams with one data field of fixed length (8 data and 6 control bytes)

3BDS009029-600 37
PROFIBUS DP/PA Linking Device LD 800P and SK3 Section 2 Transmission Technology

• Telegrams with a variable data field (0 to 244 data bytes and 9 to 11 control
bytes)
• Brief acknowledgement (1 byte)
• Token telegram for bus access control (3 bytes)
With all data transmissions, the parity and block checking of the telegrams is used to
reach a Hamming distance of HD=4, so that up to three errors can be detected with
certainty.
A transmission rate of 31.25 kbit/s results in transmission times of 0.4 to 8.2 ms per
telegram so that per user data byte an average of 0.4 ms and 34 ms is required.
This data transmission rate is sufficient, for example, to serve 10 control loops -
including 10 sensors and 10 actuators respectively - within a control cycle time of
approx. 210 milliseconds.
During the evaluation, it was assumed that only one cyclic value (5 bytes user data)
must be transmitted per device. With each additional value, the minimum cycle time
increases by (5 x 8 bits)/(31.25 kbit/s) = 1.3 ms.
For a first estimate, the following formula can be used:
cycle time ≥ 10 ms * number of devices
+ 10 ms (for acyclic class-2 master services)
+ 1.3 ms (for each additional cyclic value)

PROFIBUS DP/PA Linking Device LD 800P and SK3

Linking Devices are needed to connect PROFIBUS DP to PROFIBUS PA and vice
versa. The PROFIBUS master module CI854/CI854A/CI854B is designed
exclusively for the connection of PROFIBUS DP nodes in RS485 technology. To
link a PROFIBUS DP line to a PROFIBUS PA line, it is recommended to use the
Linking Device LD 800P and SK3. The LD 800P and SK3 Linking Device converts
the physical bus characteristics of the RS485 interface for PROFIBUS DP into
PROFIBUS PA physical bus characteristics MBP according to IEC 61158-2,
enables connected PROFIBUS PA devices to be supplied with power via the bus,
and allows use in hazardous areas if so required.

38 3BDS009029-600
Section 2 Transmission Technology PROFIBUS DP/PA Linking Device LD 800P and SK3

Figure 8. PROFIBUS DP/PA Linking Device LD 800P

LD 800P performs the following tasks:

• Potential separation between the PROFIBUS DP and the PROFIBUS PA
• Conversion of the RS485 physical arrangement of the PROFIBUS DP to the
physical arrangement based on IEC 61158-2 of the PROFIBUS PA.
• Support of all standardized PROFIBUS transmission rates from 45.45 kbit/s up
to 12Mbit/s
• Automatic detection of transmission rate
• Fully transparent in the PROFIBUS line
– No configuration and commissioning
– Direct access from PROFIBUS DP master to PROFIBUS PA slaves
– Support of all cyclic and acyclic PROFIBUS protocol services (DP/V1)
– No restriction in PROFIBUS data volume with full 244 Byte read/write
access to each PA slave
• Optional PROFIBUS DP line redundancy
• Power Link Modules integrate bus termination, galvanic isolation and power
supply
• Powering of PROFIBUS PA segments without additional power supply
• Optional Power Link Module with intrinsically safe interface [EEx ia] IIC
For more details, please read the LD 800P product documentation.

3BDS009029-600 39
PROFIBUS Power Hub SK3 Section 2 Transmission Technology

PROFIBUS Power Hub SK3

The PROFIBUS Power Hub is a Pepperl + Fuchs’ new PROFIBUS DP/PA linking
device, successor of the SK2 resp. The PROFIBUS Power Hub SK3, compared to
SK2 and LD 800P, provides enhanced PROFIBUS functionalities. This can be
configured as a DP-slave and it supports slave redundancy.

Figure 9. PROFIBUS Power Hub SK3

For using PROFIBUS Power Hub SK3, refer Device AC 800M PROFIBUS DP
Configuration (3BDS009030*) and Device Management Power Hub,
(2PAA102122*) manual.

Fibre Optic Transmission Technology

Fibre-optic transmission is suitable for use in areas with high electromagnetic
interference or where greater network distances are required. The PROFIBUS
guideline (2.022) for fibre optic transmission specifies the technology available for
this purposes. When determining these specifications, great care was naturally taken
to allow problem-free integration of existing PROFIBUS devices in a fibre optic
network without the need to change the protocol behavior of PROFIBUS.
All familiar network structures such as point-to-point connections, line and star
structures as well as single-fiber ring or double-fiber ring can be set up with
PROFIBUS. Mixed structures combining electrical and optical networks are
possible. The transition between the two media is provided by an optical link
module, which convert the RS485 to fibre optic transmission technology. In the
communication between the stations on the bus, there is no difference between two-
wire and fiber-optic technology.

40 3BDS009029-600
Section 2 Transmission Technology Fibre optics cable type and speed

Optical link modules mostly supports all the transmission rates defined in the EN
50170 standard.

Fibre optics cable type and speed

Fibre optics is an additional transmission technology for PROFIBUS DP. It uses a
glass or plastic fibre cable and enables transmission rates in steps from 9.6 kbit/s to
12 Mbit/s, depending on the hardware. Fibre optic networks are mostly used in
connection with RS485 to increase network distances of PROFIBUS DP, to avoid
communication errors in areas with high electromagnetic interference or just to
ensure galvanic insulation between different hardware units (master, slaves)
connected to an RS485 networks. The fibre optic transmission technology is usually
limited to a specific segment of a plant, which is then connected to the RS485 bus
line via RS485/fibre optic converter.
Table 6 shows the different cable types, wave lengths and maximum distances,
reachable with the certain fibre media.

Table 6. Basic data for fibre optic cable

Fibre/Sheath
Media Wavelength Max. distance Path attenuation
diameter
Plastic fibre 660 nm 980/1000 μm 0 ... 80 m (increased) 0.25 dB/m
Multi mode glass fibre 860 nm 50/125 μm 0 ... 2 km 3 dB/km
62.5/125 μm 0 ... 2.8 km 3.5 dB/km
Single mode glass 1310 nm 62.5/125 μm 0 ... 10 km 1 dB/km
fibre 10/125 μm 0 ... 15 km 0.5 dB/km
PCF (HCS™) 1530 nm 200/230 μm 0 ... 30 m 5 dB/km

The path attenuation per km or meter is derived from the difference between the
total admissible path attenuation minus the system reserve divided by the distance
involved. The data in parentheses are (total path attenuation / system reserve).
In a ring structure (see Redundant Optical Ring on page 51), the maximum
bridgeable distance between two components is a function of the transmission
rate. A maximum of 15 km can be bridged at a transmission rate of 9.6 kBit/s; at
1.5 MBit/s, only 530 meters

3BDS009029-600 41
Fibre optics cable type and speed Section 2 Transmission Technology

For electrical media (half-duplex), an error in a single wire of the two-wire cable
blocks data transfer for both transmission directions. To get the same functional
behavior in case of a disturbed optical medium, the FO converter (full-duplex) must
be able to switch off the receiver port when detecting an error at the transmit port
and vice versa. Also hybrid cable, copper cables and fiber optic cables contained in
one cable, are available. This means that by using hybrid cables the data and the
power supply can be transferred together with one cable.

42 3BDS009029-600
Section 2 Transmission Technology Fibre optic network limits

Fibre optic network limits

Fibre Optic transmission technology is mainly used to expand the existing RS485
technology over its distance limits and to prevent communication errors in EMC
areas. However fibre optics are as well as RS485 limited in the distance and the
transmission speed, depending on the used hardware and the cable type.
Between the DP/fibre optic converter are no PROFIBUS slaves connected.
PROFIBUS DP slaves are always connected to the RS485 network. Fibre optic
transmission technology has to be converted in RS485 technology before, if DP
slaves shall be connected.
There are several RS485/fibre optic converter available from different
manufacturer. ABB recommends RS485/fibre optic converter from Hirschmann
(OZD Profi 12M) and OLM from Phoenix Contact (PSI-MOS-PROFIB/FO).
Optical link modules described in this document are based on the Hirschmann
RS485/fibre optic converter. However, the components from Phoenix Contact are
working in the same way as Hirschmann RS485/fibre optic converter.
Fibre cable types and its maximum distance are already described in Table 6 on
page 41.

3BDS009029-600 43
Monitoring of the communication quality Section 2 Transmission Technology

Monitoring of the communication quality

Optical link modules mostly provide segment monitoring at the RS485 and fibre
optic port.

Power supply

One RS485 port

Redundant fibre optic port

Figure 10. Optical link module with 1 RS485 port and redundant fibre optic ports

The following description of monitoring functionality can be build up with the

optical link modules from Hirschmann and Phoenix Contact. Optical link
modules from other manufacturer does not always support this functionality.
If the operating mode “Electric port with segment monitoring” is set at the RS485
port, each receiver monitors the RS485 bus segment connected to it for faulty
frames or continuously busy networks. If faulty frames are received by the receiver,
or if the network is busy for longer than the maximum permitted send time,
forwarding of the received signals is blocked until frames can be received again
correctly, or if no signal is received for one second.

Line monitoring with echoes

The optical link modules enable the connected optical paths to be actively
monitored for interruptions in the fiber line by means of the functions “Send echo”,
“Monitor echo” and “Suppress echo”.

44 3BDS009029-600
Section 2 Transmission Technology Basics of fibre optics topology technologies

• Send echo
A frame which is received by a module via any port is transmitted to all other
ports. If the receiving port is an optical port, the module sends the frame back
to the corresponding optical sender.
• Monitor echo
If a module sends a frame - no echo! – to an optical port, the module expects to
receive an echo. If the echo is not received after a predefined time, an echo
monitoring error is indicated.
• Suppress echo
The relevant receiver is separated from the other ports from the moment a
frame is sent until the echo has been received correctly.
Segmentation
If an echo monitoring error or a frame falsification arises at an optical port, the
module assumes that the line is faulty and blocks this port for user data. The
connected field bus partial network is then segmented (cut off). This segmentation
causes the module at the other end of the optical fiber to be segmented as well.
Both modules connected to the segmented field bus partial network send test frames
to the segmented ports. These test frames – which are to be received regularly – can
be used by both modules to check the status of the field bus partial network. The
segmentation is automatically lifted as soon as the test frames indicate to both
modules that the segmented field bus partial network is no longer disturbed. If all
active bus subscribers are deactivated in a previously active network, the modules
are segmented cyclically in order to check the fiber links to the neighboring
modules.
The next paragraph in this document describes the monitoring function within a
certain fibre optic topology.

Basics of fibre optics topology technologies

Fibre optics topology technologies is part of Fieldbus Topologies with fibre optics
on page 82. However, to understand the basics of the fibre optic transmission
technology, the next pages show main topologies supported by fibre optics.

3BDS009029-600 45
Basics of fibre optics topology technologies Section 2 Transmission Technology

Line Topology
In a line structure, the individual optical link modules are connected together by
dual-fiber optical fibers (transmit/receive fibres). Modules with one optical port are
sufficient at the beginning and end of a line, between then modules with two optical
ports are necessary. If single point-to-point connections are to be built up, this can
be achieved using two modules each with one optical port.

Figure 11. Network structure in an optical line topology

This operating mode should preferably be used if an interrupted fiber segment is to

be separated from the rest of the network.
The following monitoring mechanisms shall be set on the optical link modules:
• Send echo: yes
• Monitor echo: yes
• Suppress echo: yes
• Monitor: yes
• Segmentation: yes
In this operating mode the individual fiber links are monitored by the two connected
modules.

46 3BDS009029-600
Section 2 Transmission Technology Basics of fibre optics topology technologies

If a module fails, an optical fiber breaks or faults are determined on the optical
transfer link, the fiber link between the two optical link modules is interrupted. The
PROFIBUS network is divided into two partial networks, which remain functional
independently of one other. The segmentation is lifted automatically as soon as both
modules recognize that the field bus network is functioning correctly with the help
of test frames.
If single point-to-point connections are to be built up, this can be achieved using
two modules each with only one optical port.
The line topology can be realized with and without fiber link monitoring. If both
operating modes are used within an optical fiber line, the operating mode “Line
topology without fiber link monitoring” determines the availability of this fiber line.
It is recommended that fiber link monitoring be used in homogeneous fibre optic
networks.
If a module with two optical ports is used at the beginning or end of a line, the
optical port which is not assigned must be switched to the operating mode “Line
without fiber link monitoring”, so that it does not signal a break in the fiber line.
Please note that optical ports which are not connected must always be fitted with
protective caps to guard against extraneous light and dirt.

3BDS009029-600 47
Basics of fibre optics topology technologies Section 2 Transmission Technology

The following ambient conditions must be fulfilled to ensure that network

configuration functions correctly:
• The parameters MIN TSDR described in the PROFIBUS standard EN 50170
must be set to a value 11 on all terminals. This is usually the case, but the
setting should be checked if communication malfunctions continuously arise.
• When configuring your network, select low bus subscriber addresses wherever
possible. This ensures that master time-out times which may arise are kept as
short as possible in the event of a malfunction.
Low bus subscriber addresses are not necessary for the bus configuration with
AC 800M in connection with CI854/CI854A/CI854B.
Line topology without optical fiber link monitoring
Use this operating mode if you connect an optical link module with another optical
fiber network component, which does not send a frame echo and does not expect or
is not compatible with a frame echo in accordance with PROFIBUS guidelines
(optical/electrical converter).
Monitoring mechanisms, to be set on the optical link modules:
• Send echo: no
• Monitor echo: no
• Suppress echo: no
• Monitor: no
• Segmentation: no
Individual fiber links are not monitored in this operating.
Refer to the manufacturer’s manual of the optical link modules concerned for details
about how to alter the settings.

48 3BDS009029-600
Section 2 Transmission Technology Basics of fibre optics topology technologies

Star Topology
In a star structure several optical link modules are combined to form an active
PROFIBUS star coupler. Further optical link modules are connected to this by dual-
fiber optical fiber lines (transmit/receive fibres). The modules of the star coupler are
connected to one another via the electrical port (electrical star segment). Optical link
modules for different fiber types (plastic, PCF, glass) can be combined using the
electrical star segment.

Figure 12. Network structure in an optical star topology

3BDS009029-600 49
Basics of fibre optics topology technologies Section 2 Transmission Technology

Please take the following recommendations into account:

• Ensure that the electrical star segment is wired carefully. Keep it as small as
possible to avoid interference injection into the electrical star segment, and
from here into the entire network. This can be achieved by laying out the
optical link module in the electrical star segment directly next to each other on
a hat rail.
• Switch on the terminating resistors in the bus port connectors at both ends of
the electrical star segment.
• Do not connect a bus subscriber to the electrical star segment wherever
possible.
• Modules with one or two optical ports can be used to create an active
PROFIBUS star coupler. Modules with one optical port are sufficient for
connecting a terminal or an RS485 bus segment to the active star coupler.
• If the link monitoring on the optical ports is activated, the fiber optic links are
monitored by the respectively connected optical link module.
• Optical ports which are not assigned (for instance, because they are reserved
for a future system extension) indicate a fiber break if the link monitoring is
activated. To prevent this error from being issued by activating the operating
mode “Line without fiber link monitoring” at the non-assigned ports.
• Please note that optical ports which are not connected must always be fitted
with protective caps to guard against extraneous light and dirt.

50 3BDS009029-600
Section 2 Transmission Technology Basics of fibre optics topology technologies

Redundant Optical Ring

The redundant optical ring structure represents a special form of line topology. A
high degree of network operating safety is achieved by “closing” the optical line. A
redundant optical ring can only be realized with modules supporting two optical
ports of the same type.

Figure 13. Network structure in a redundant optical ring topology

Monitoring mechanisms, to be set on the optical link modules:

• Send echo: yes
• Monitor echo: yes
• Suppress echo: yes
• Segmentation: yes
An interruption of one or both optical fibers between two modules is detected by the
optical link module and the ring is transformed into an optical line.
If one module fails only those terminals connected to this module or the RS485
segment are uncoupled from the ring. The remainder of the network itself continues
to function as a line.

3BDS009029-600 51
Basics of fibre optics topology technologies Section 2 Transmission Technology

The segmentation is lifted automatically as soon as both modules recognize that the
segmented field bus network is functioning correctly with the help of test frames.
The line forms itself into a ring.
The ambient conditions described in the topic line technology and the following
conditions must be fulfilled to ensure that the network configuration functions
correctly:
• The operating mode “Redundant optical ring” must be set at both optical ports
of all the optical link modules (Hirschmann).
• All modules in a ring must be connected to one another by fiber lines. The ring
may not include an RS485 bus line.
• If a redundancy case occurs (for example a line break), there is a switching
time during that data cannot be correctly transmitted. In order to ensure a
smooth transition, it is recommended that the frame repeat setting (Retry) on
the PROFIBUS master shall be set to at least 3. After the error has been
corrected, no frames should be present in the network when the optical line is
transformed back into an optical ring to ensure that the process is completed
smoothly. This condition can arise when a master selects a device whose
address has been configured, but which does not physically exist.
The master tries to address this device cyclically and waits for a reply only until the
configured slot time has been exceeded (”GAP request“). Most optical link modules
recognizes this condition and closes the optical line to an optical ring in the middle
of this request sequence. This results in two configuration requirements for the
redundant optical ring:
• The value of the parameter HSA (Highest Station Address) must be set at least
one value greater than the highest address of a subscriber connected to the bus
segment
If this requirement is not fulfilled, the optical line will not be closed into a
redundant optical ring after segmentation.

The slot time must be set to approximately twice the value required in a non-
redundant network.

52 3BDS009029-600
Section 2 Transmission Technology Calculation of transmission delay time TTD

Calculation of transmission delay time TTD

In case of a large PROFIBUS network with numerous optical link modules and long
lines, allowance needs to be made when setting the monitoring times for the delay
caused by network components and lines (transmission delay). This involves
determining the transmission delay time (TTD): The transmission delay time is the
maximum time which elapses when transmitting a telegram on the transmission
medium from transmitter to receiver.
In connection with the AC 800M and CI854/CI854A/CI854B the TTD delay time
shall be added to the slot time (TSL) in the CI854/CI854A/CI854B settings tab.
If the planning software being used to configure the PROFIBUS network does not
support the PROFIBUS parameter TTD, then the two times min. TSDR and max.
TSDR are to be extended instead by 2 x TTD (reaction time of responder is extended
by the outward and return transmission delay time).
The first step is to determine the transmission link with the longest transfer time
between telegram transmitter and receiver. No allowance is made for PROFIBUS
users which do not communicate with one another (for example DP slave with DP
slave).
Indicators of long transfer times are:
• Long optical fiber or copper lines
• High cascading level of active components

3BDS009029-600 53
Calculation of transmission delay time TTD Section 2 Transmission Technology

Delay time of optical fiber lines

The delay time is approx. 5 µs for each km of line. Converted to bit periods this
gives:

Table 7. Delay times of optical fibre lines

Transmission rate in kbit/s Delay time in tbit per km

9.6 0.05
19.2 0.10
93.75 0.47
187.5 0.94
500.0 2.50
1500.0 7.50

For calculating the line delay time, the maximum line length in km is multiplied by
the delay time corresponding to the transmission rate (see table).

Delay time of Optical Link Modules

The processing time per module is 1.5 tbit. The overall processing delay results
from the number of modules passed between telegram transmitter and receiver
multiplied by 1.5 tbit.

Delay time of other active PROFIBUS network components

The delay time is to be taken from the respective product documentation.

Transmission delay time TTD

The overall delay time is the sum total of the values determined in
• Delay time of optical fiber and RS485 lines.
• Delay time of Optical Link Modules.
• Delay time of other active PROFIBUS network components.

54 3BDS009029-600
Section 3 Fieldbus Topologies Overview

Section 3 Fieldbus Topologies

Overview
Fieldbus systems are used as a means of communications for serial data exchange
between decentralized devices on the field level and the controller of the process
supervision level.
In addition to intelligent Transmitter and Actuators with a direct connection to the
fieldbus, intelligent Remote I/Os are also used as interface systems for conventional
4...20 mA or HART field devices to record process data on the field level. All
relevant signals such as input and output data, parameters, diagnostic information,
configuration settings and – for a wide range of applications – the power required
for operation can be carried over two wires (PROFIBUS PA).
There are several possible topologies for fieldbus networks. This section will
illustrate some of these possible topologies and discuss some of the characteristics

3BDS009029-600 55
Overview Section 3 Fieldbus Topologies

of each. Not every topology is applicable for each transmission technology like
RS485 or fibre optics.

Figure 14. Possible topologies for fieldbus networks

56 3BDS009029-600
Section 3 Fieldbus Topologies Point-to-Point Topology

Point-to-Point Topology

Figure 15. Point-to-Point Topology

Point-to-Point Topology means a connection and interaction of only two devices.

This topology is mostly used in sub-segments for example to connect HART devices
to Remote I/O. For the HART device the remote I/O operates as a master, however
the remote I/O is part of the PROFIBUS network. Point-to-Point connection in
PROFIBUS networks are not applicable, because it does not take advantage of the
multi-device-per-bus-segment capability.

3BDS009029-600 57
Line Topology Section 3 Fieldbus Topologies

Line Topology

Figure 16. Line Topology

With this topology, the fieldbus cable is routed from device to device on this
segment, and is interconnected at the terminals of each fieldbus device. Installations
using this topology should use connectors or wiring practices such that
disconnection of a single device is possible without disrupting the continuity of the
whole segment.

Line Topology with spurs

Figure 17. Line Topology with spurs

With this topology, the fieldbus devices are connected to the bus segment through a
length of cable called a spur. A spur can vary in length from 1 m to 120 m. A spur
that is less than 1 m in length is considered a splice.

58 3BDS009029-600
Section 3 Fieldbus Topologies Line Topology with spurs

PROFIBUS provides a wide range of possible transmission rates. The permissible

lengths of possible spur cables depend upon the transmission rate used. No spurs are
permitted for transmission rates over 1,5 Mbit/s. With transmission rates less than
1,5 Mbit/s the total length of all spur cables should be less than 6,6 m. When using
spurs with low transmission rates (93,75 kbit/s), the ratio between spur cable length
and next bus termination should be at least 1:20.
There is always a cable of several centimeters between a PROFIBUS connector
and the transceiver of a node. When connecting 32 nodes to the bus, an important
total spur cable length will result from this. If there should encounter
transmission problems in the installation although everything works reliably at a
low transmission rate, it is recommended to perform a dynamic bus analysis. This
analysis will reliably detect mismatches.

3BDS009029-600 59
Tree Topology Section 3 Fieldbus Topologies

Tree Topology

Figure 18. Tree Topology

With this topology, devices on a single fieldbus segment are connected via
individual twisted wire pairs to a common junction box, terminal, or I/O card. This
topology can be used at the end of a home run cable as well as in between. It is
practical if devices on the same segment are well separated, but in the general area
of the same junction box. When using this topology, the maximum spur length must
be taken into consideration. Maximum spur lengths are discussed in Line Topology
with spurs.
Combinations of the topologies above are possible. However, all rules for
maximum fieldbus segments length, including spurs, must be taken into account
for the calculation of the total bus length.

60 3BDS009029-600
Section 3 Fieldbus Topologies Star Topology

Star Topology

Figure 19. Star Topology

In a star structure several optical modules (for example optical link modules) are
combined to form an active PROFIBUS star coupler. The modules of the star
coupler are connected to one another via RS485 (PROFIBUS DP). In opposite to the
tree topology the star topology contains more main components to build a structure
like a tree.
This topology is also described in Basics of fibre optics topology technologies on
page 45.

3BDS009029-600 61
Ring Topology Section 3 Fieldbus Topologies

Ring Topology

Figure 20. Redundant ring topology

The ring structure represents a special form of the line topology. A high degree of
network operating safety is achieved by “closing” the line. A redundant ring can be
also realized to increase the high availability. This structure is commonly used in
connection with fibre optics and optical link modules.
This topology is also described in Basics of fibre optics topology technologies on
page 45.

62 3BDS009029-600
Section 3 Fieldbus Topologies Fieldbus Topology with RS485 (PROFIBUS DP)

Fieldbus Topology with RS485 (PROFIBUS DP)

Bus length and speed
When a PROFIBUS network is installed, boundary conditions of the RS485 transfer
technology must be observed. The electrical network uses a shielded, twisted pair
cable. All subscribers are connected in a line-shaped bus. The transmission rate can
be adjusted in steps from 9.6 kbit/s to 1.5 Mbit/s. For extremely time-critical
PROFIBUS-DP applications, additional transmission rates of 3, 6 and 12 Mbit/s are
possible.The maximum segment length depends on the transmission rate.

Figure 21. Bus length and speed

3BDS009029-600 63
Bus termination Section 3 Fieldbus Topologies

Bus termination
According to the PROFIBUS set-up instructions, the transmission line must be
terminated actively on both ends to minimize line reflections and to ensure
quiescent levels on the transmission lines. The RS485 interface operates on voltage
differences. This network must be provided with a ground-free voltage of 5 volts.
Depending on the device the required bus termination is already integrated into the
device so that it can be inserted into the circuit easily if the device is located at the
beginning or end of the line structure. According to the rules of certification, each
PROFIBUS DP device needs a minimum voltage of 5 V.

Figure 22. RS485 Bus termination

If it is not sure from the very beginning that, for a planned installation, the required
power supply for the active bus terminator will be ensured during plant operation,
suitable measures must be taken. A typical example of this application is, if the bus
participant supplying the terminating resistor with voltage, is switched idle
repeatedly for operational reasons or separated from the bus when the plant is
running. In that case, a bus terminator with external power supply or a repeater must
be used for the respective bus termination of the bus.
Details about Repeater are described in Active network terminator and repeater
on page 100.

64 3BDS009029-600
Section 3 Fieldbus Topologies Bus connector

Bus connector
A bus connector is used to connect the bus cable to the PROFIBUS device. Bus
connectors are available with a variety of protection classes and mechanical designs.
The choice of connector is mainly determined by the space available in the vicinity
of the PROFIBUS device.
The bus connector must have a low-impedance connection to the cable shield.
A 9-pin D-Sub connector is primarily used to connect PROFIBUS devices on the
bus, which complies with DIN 19245/ EN 50170.

Figure 23. Electrical port - assignment of Sub-D sockets

To allow correct bus termination, each station must connect the signals DGND
(Ground) and VP (5 V) to pins 5 and 6 of the connector, respectively. The 5 V
supply for the terminating resistors (VP) should have a minimum current rating of
10 mA (the current load can increase to 12 mA if a NULL signal is sent through the
bus).The current rating should be increased to approximately. 90 mA if you need to
be able to supply other types of devices on the bus such as bus terminator and
optical fiber cable drivers.
The RxD/TxD-P signal wire connected to pin 3 of the PROFIBUS module
connector must be connected to the relevant signal wires with the same designation
of all nodes. Proceed accordingly with the RxD/TxD-N signal lines on pin 8 of the
connector.
All fieldbus devices which use a standard 9-pin Sub-D connector should provide the
the VP and DGND signals on the bus connector in addition to the receive and

3BDS009029-600 65
Bus connector Section 3 Fieldbus Topologies

transmit signals. The Sub-D plug, connected to the Sub-D connector of the device,
needs only the receive and transmit signals for the communication transmission.
The connector shown below include a terminating resistor that can be turned on and
off.
This type of connector can be used equally well at the beginning, end or middle of a
PROFIBUS segment. The terminating resistor must be turned on in the connector
for the first / last device on the bus segment. It must be turned off for the devices in
the middle.

Figure 24. PROFIBUS connector

One connector with a PG socket should be used in the most accessible spot (at the
beginning or end) for each line on every segment. This connector makes it
possible to attach a diagnostic device for service access.
Be sure that the connector type used is suitable for the selected transmission rate.

66 3BDS009029-600
Section 3 Fieldbus Topologies Shielding and data line connection

Shielding and data line connection

To prevent EMC interference from entering the device, the cable shield should be
connected to the functional ground of the device (generally the electrically
conductive case). This is done by connecting the cable shield to the metal case of the
Sub-D connector and the functional ground over a large area. With correct system
installation, small external sources of interference are led to ground through the
cable shield without causing interference in the data lines. Interference of this type
can largely be avoided with appropriate EMC measures such as EMC-compliant
system installation, EMC-compliant cable laying and measures that avoid large
ground potential differences.
The cable shield must be connected to the functional ground at both ends of the
cable by making a large-area connection to a grounded conductive surface. When
laying the bus cables, particular care should be taken to ensure that the cable shield
is connected to the shield grounding clamp over a large area.
The two PROFIBUS data lines are designated A and B. There are no regulations on
which cable core color should be connected to which of the two data terminals on
each fieldbus device; the sole requirement is to ensure that the same core color is
connected to the same terminal (A or B) for all field devices throughout the entire
system (across all stations and bus segments).
If the data transfer cable has data wires with red and green insulation, then the
following assignment should be used:
• Green data cable - Connector pin A
• Red data cable - Connector pin B
This rule applies to both the incoming and the outgoing data lines.

Bus spur lines

The use of passive bus spur lines should be avoided.
Programming and diagnostic devices which are attached to the bus for example
during commissioning are generally connected using their own cable which acts as a
bus spur line. In such cases, you should use active bus tap-off devices (for example
bus terminals, repeaters, active cables etc.).

3BDS009029-600 67
RS485 limits and network design Section 3 Fieldbus Topologies

RS485 limits and network design

As described in the PROFIBUS RS485 specification, each bus segment can have a
maximum of 32 active devices. In order to be able to connect a larger number of
PROFIBUS DP devices, it is necessary to segment the bus. The segments are then
interconnected with repeaters which amplify and refresh the data signals. Repeaters
can also be used for galvanic isolation of bus segments or bus sections. Each
repeater allows the PROFIBUS system to be extended by an additional bus segment
with the maximum admissible cable length and the maximum number of fieldbus
devices. Repeaters increase the signal propagation times. This should be taken into
account during planning.

Table 8. General Data PROFIBUS DP

Maximum number of stations DP: 126 (addresses from 0 .. 125)

participating in the exchange
of user data
Maximum number of stations 32
per segment including
repeaters
Available data transfer rates 9.6 19.2 45.4 93.7 187. 500 1500 3000 6000 12000
in kbit/s 5 5 5
Max. RS485 segment length in 1200 1000 400 200 185 * 120 * 100
m*
Max. spur lines length Dependent on the data transmission rate. The use of passive bus
spur lines should be avoided.
Max. fibre optic cable length in 44 (plastic),1700 (glass) up to 15000 (PCF)
m
Max. number of segments 9
in series According to EN 50170, a maximum of 9 repeaters are allowed
between any two stations.

68 3BDS009029-600
Section 3 Fieldbus Topologies RS485 limits and network design

Figure 25. RS485 network design with bus termination and repeater

3BDS009029-600 69
Fieldbus Topology with MBP (PROFIBUS PA) Section 3 Fieldbus Topologies

Fieldbus Topology with MBP (PROFIBUS PA)

PROFIBUS PA with MBA transmission technology is realized in tree or line
structure, and any combination of the two. In the line structure, stations are
connected to the trunk cable using T-junctions.
The tree topology is comparable to the classic field installation method. The multi-
core cable is replaced by the two wire bus cable, the field distributor retains its
function of connecting the field devices. By tree topology the maximum permissible
spur line length must be taken into account when calculating the overall line length.

Figure 26. PROFIBUS PA embedded in 800xA

70 3BDS009029-600
Section 3 Fieldbus Topologies Bus length and speed

Bus length and speed

A twisted two-wire, shielded copper cable (type A) must be used as the transfer
medium. It is also possible to exchange and extend devices during operation. The
fixed, uniform transfer rate is 31.25 kBit/s. At this rate, cable lengths per segment of
up to 1900 m are possible in non Ex(Haz.) case, or 1000 m in Ex(Haz.) cases.
If power is supplied to field devices via the PA bus, partial voltage drops on the bus
lines must also be taken into consideration. This depends on the type of cable, the
length of the line and the power consumption.
For non-intrinsically safe applications, a typical 24 V DC power supply is used, and
there are only very minimal limitations on the total length of the line.
For intrinsically safe applications, the voltage of the power supply is approx. 12.8 V
DC (LD 800P). The resulting permissible line lengths must be observed so that the
necessary minimum operating voltage to the devices is not exceeded. The optimum
design of a fieldbus segment requires detailed calculation of the partial voltage
drops. By selecting a cable with a larger diameter it will be compensated to a certain
extent (see also MBP power and line length calculation on page 34)
The number of subscribers that can be connected to a segment is limited to 32. An
additional restriction in the Ex (Haz.) area results from the limited supply current
that is available, which is determined by the type of explosion protection selected. In
addition to the basic currents of the field devices, the modulation signal of 9 mA, the
maximum current in the case of error of the device with the greatest power
consumption and a reserve for dynamic power on procedures when the power is
restored to the DP/PA Linking Devices must all be taken into account for calculating
the required current. The assumption is also made here that the devices are equipped
with an electronics system for limiting the current (FDE = Failure Detection
Electronics).
Provided that maximum one FDE responds, the following condition must be
fulfilled:
Supply current ≥ sum of individual currents (per device ≥ 10 mA)
+ Manchester current signal (9 mA)
+ FDE fault current (0 to 9 mA)

3BDS009029-600 71
Bus length and speed Section 3 Fieldbus Topologies

The maximum length of the line is restricted by the type of explosion protection and
the drop in current over the bus line. The drop in current may result in a further
limitation to the number of subscribers.
The time required for a complete cycle of data exchange depends essentially on the
transmission rate, the number of subscribers and the size of the measurement
(Value) and status values to be transmitted cyclically. Delay times, which arise
through the Linking Devices and the field devices itself, must be taken into
consideration as well.
For detailed information about power consumption and delay times, please read
the specific user manuals of the field devices.

72 3BDS009029-600
Section 3 Fieldbus Topologies MBP and intrinsically safe installation

MBP and intrinsically safe installation

In the past, it was necessary to create time-consuming intrinsic safety audit trails in
order to obtain permission to operate plants in Ex (Haz.) areas. Now, thanks to the
use of the FISCO model (Fieldbus Intrinsically Safe Concept), you can easily design
and operate your PROFIBUS PA system in Ex (Haz.) areas in no time at all.
Requirements are:
• Devices certified acc. to FISCO (EC type attestation of conformity)
• U, I and P acc. to EN 50 020
• Cable parameters observed (R, L, C)
• Bus termination existing and correct
• Total length of the PA segment, incl. spurs, to be kept
– when using passive T-junction < 1000 m
– when using Multi Barrier < 1900 m
A system certification is no longer required for a PA segment in the Ex (Haz.) area!
When using passive T-junction in the Ex (Haz.) area acc. FISCO up to 8 PA devices
per segment are placeable, by using Multi Barrier up to 32 PA devices. The
PROFIBUS DP/PA Linking Devices LD 800P corresponds to the FISCO Model.

3BDS009029-600 73
Bus termination Section 3 Fieldbus Topologies

Bus termination
The bus segment must be terminated on both ends of the line. According to the
FISCO model the termination must conform to the following limits:
• 90 Ohm < R < 100 Ohm
• 0 µF < C < 2,2 µF

Figure 27. Bus termination according to FISCO

A fieldbus terminator is integrated into the Power Link Module PL 890 so that an
external bus termination is only required on the other end of the bus.

74 3BDS009029-600
Section 3 Fieldbus Topologies PROFIBUS PA junctions and connectors

PROFIBUS PA junctions and connectors

The PROFIBUS PA T-Connectors are available as Standard and Ex(Haz.) version.
They are used for coupling 1 up to 4 transmitters to the PA trunk via spurs. The
spurs can optionally be connected by an M 12 connection or directly via the EMC
cable gland.
The following points shall be taken into account when selecting a junction or
connector:
• Non-interrupted bus operation when exchanging or extending a PA transmitter
• External grounding cable
• Pressure-compensation element
• EMC cable gland
• Tension spring connection
• Non-Ex design (integrated bus termination, switchable)
• Ex(Haz.) design acc. to ATEX (external bus termination
Recommendation of mounting:
• Preparation of the PROFIBUS PA cable for M 12 connector:

Figure 28. Preparation of the PROFIBUS PA cable for M 12 connector

3BDS009029-600 75
PROFIBUS PA junctions and connectors Section 3 Fieldbus Topologies

• Usage of junction box (T-junction):

Figure 29. Junction box (T-junction)

The junction box retains its role as a central connection unit to build up a tree
topology, where all field devices are connected in parallel.
The line topology offers connection points along the field bus cable. The cable can
be looped through the individual field devices. The combination of tree and line
topology permits the optimization of the fieldbus length and the adaption to existing
system structures. It must be taken into account, that the limitation of the spur length
for intrinsically safe installations according to FISCO bases on pure tree- or line
topology. If a combination is used in a hazardous area, then the limit has to be
applied to each connection between a field device and the trunk cable (via junction
box). As an example, if the cable length between the trunk and the junction box is
20 m, then the cable length between the junction box any device connected to it
must not exceed 10m (see also next topic “Bus spur lines”).

76 3BDS009029-600
Section 3 Fieldbus Topologies Shielding and data line connection

Shielding and data line connection

Shielding and grounding rules for MBP transmission technology has the following
aspects to consider:
• Electromagnetic compatibility (EMC)
• Protection against explosion
• Protection of people
IEC 61158-2 specifies grounding as permanently connected to earth through a
sufficiently low impedance and with sufficient carrying capability to prevent voltage
build up which might result in undue hazard to connect equipment or people. Zero
volt lines should be connected to ground, where they are galvanically isolated from
the fieldbus trunk.
Field devices shall be able to function with the mid-point of one terminator or one
inductive coupler directly to ground. Neither of the two conductors of the twisted-
pair may be grounded at any point in the network. Signals shall be applied and
preserved differentially throughout the network.
In addition to the handling of signal conductors particular attention should be paid
to the cable shield and its connection to earth. Fieldbusses using signal frequencies
> 10 kHz should be protected against electromagnetic fields. Therefore the cable
shield and the metallic housing of the field devices and of any auxiliary equipment
(for example connectors) shall make up a common shielding system, avoiding
unnecessary gaps. Ideally the cable shields are connected to the field devices’
housings (or other protective coverings), which are frequently made of metal.

3BDS009029-600 77
Shielding and data line connection Section 3 Fieldbus Topologies

The connections between the cable shield and the metallic housings as well as the
connections between the shields of the different cable segments have to be low-
impedance (for high frequencies). As far as unshielded devices are connected to a
shield cable further methods may be applied to reduce the impact of noise (for
example galvanic isolation or filtering).

Figure 30. Ideal combination of shielding and grounding

78 3BDS009029-600
Section 3 Fieldbus Topologies Shielding and data line connection

If a sufficient potential equalization between the hazardous area and the safe area
cannot be guaranteed, the cable shield shall be directly connected to the
equipotential bonding earth only in the hazardous area. In the safe area the shield
shall be connected to earth through a capacitor. The impedance of the connection
should be minimized for high frequencies. However, the need for an electric
envelope as complete as possible cannot be entirely fulfilled.

Figure 31. Capacitive grounding

The connection between both groundings through a capacitor may also be placed at
an other position between power supply and the hazardous area (or between
different hazardous areas), but it has always to be in a safe area.

3BDS009029-600 79
Shielding and data line connection Section 3 Fieldbus Topologies

The capacitor shall have the following requirements:

• solid dielectricum (for example ceramic)
• C < 10 nF
• isolation voltage > 1,5 kV

For PROFIBUS PA only shielded wires should be used. The shield should be
hard-grounded at the Linking Device or the power link module and on all field
devices. For intrinsically safe applications a potential compensation between the
safe and hazardous areas is required.
If there is no potential compensation between the safe and hazardous areas, there
is a possibility of capacitive grounding on the LD 800P Linking Device/Power
Link Module.

connection
Screen

Bus
PROFIBUS PA
Shield

-+

- +

Field device

Power Link Module

PL 810 or PL 890

Shield/FE
- DC 24 V
RxD/TxD-N
RxD/TxD-P

Shield/FE

+ DC 24 V

PROFIBUS DP

80 3BDS009029-600
Section 3 Fieldbus Topologies Bus spur lines

Bus spur lines

PROFIBUS PA allows spur lines. The length of each spur line is determined by the
number of PROFIBUS PA bus elements and by the area of application. The table
below is specified for spur length using the MBP transmission technology with
31,25 kbit/s transmission rate:

Table 9. Recommended length of the spurs

Length of one spur cable

Length of one spur cable
Number of spur cables (non intrinsically safe)
(intrinsically safe)

1 to 12 30 m 120 m
13 to 14 30 m 90 m
15 to 18 30 m 60 m
19 to 24 30 m 30 m
25 to 32 - -

Please note that the permissible total line length (the total of the main line and all
spur lines) must not be exceeded.

3BDS009029-600 81
Fieldbus Topologies with fibre optics Section 3 Fieldbus Topologies

Fieldbus Topologies with fibre optics

Bus length and speed
An optical network can be implemented in a bus, star or ring topology using optical
link modules. The maximum distance between two optical link modules can be up
to 15 km with glass fiber-optic cables, 50 m with plastic fiber-optic cables and with
PCF (Polymer Cladded Fiber) up to 300 m.
The transmission rate can be adjusted in steps from 9.6 kbit/s to 12 Mbit/s,
depending on the hardware.
Mixed structures combining electrical and optical networks are possible. The
transition between the two media is provided by the optical link module. In the
communication between the stations on the bus, there is no difference between two-
wire and fiber-optic technology. Up to 126 stations may be connected to a
PROFIBUS network.
The optical transmission method offers the following advantages:
• Plastic, PCF or glass fiber-optic cables are insensitive to electromagnetic
radiation and make the EMC measures necessary in electrical networks
superfluous.
• In outdoor installations, there is no need for lightning protection measures.
• Fiber-optic cables make floating connections between the system components.
This means that there is no need for expensive equipotential bonding measures.
• Fiber-optic cables can cover long distances between stations.
• Galvanic isolation.
• Either plastic, PCF or glass fiber-optic conductors can be implemented
The optical link modules are suitable for connecting glass or plastic fibre optical
cables with BFOC/2.5 connectors. Depending on the topology, the fibre material,
the fibre diameter, the wavelength of the light and the path attenuation, distances of
up to 15 km and more can be bridged. For detailed information on the devices,
please refer to the manufacturer's product descriptions and operating instructions.

82 3BDS009029-600
Section 3 Fieldbus Topologies Optical link modules and AC 800M in a star topology

Optical link modules and AC 800M in a star topology

The following diagram shows PROFIBUS DP with a fiber optical link for bridging
long distances, for electrical isolation of parts of the system, or as a measure for
protecting against lightning.
A redundant line structure is shown, however it is possible to build this star topology
in a non redundant network.

3BDS009029-600 83
Optical link modules and AC 800M in a star topology Section 3 Fieldbus Topologies

Figure 32. Fiber optical link for bridging long distances

84 3BDS009029-600
Section 3 Fieldbus Topologies Optical link modules and AC 800M in a ring topology

Optical link modules and AC 800M in a ring topology

In comparison to the single-fiber ring, an optical double ring offers greater operating
safety. The failure of a fibre optical cable or an optical interface has no effect on the
availability of the network since the flow of data in both directions runs through the
ring.
Optical ring and line redundancy can be used together in a mixed configuration as
shown in Figure 33: Redundant optical ring. The line redundant interfaces of
CI854A/CI854B, RLM01, etc. can be connected to the ring by connecting each line
to a separate optical link module.
It is also possible to configure the master and slave redundancy as an option. The
figure shows both CI854A/CI854B and CI840 in a redundant configuration. If they
are used in a non redundant configuration it has to be taken into account, that the
disturbance of one optical link module can cause a failure of the connected module.
The optical ring in combination with the line redundancy can only be set up by
using the optical link module OZD Profi 12M from Hirschmann and PSI-
MOS-PROFIB/FO from Phoenix Contact. Other optical link modules will get
collisions of data frames that results in a complete disturbed communication on
the PROFIBUS.

3BDS009029-600 85
Optical link modules and AC 800M in a ring topology Section 3 Fieldbus Topologies

Figure 33. Redundant optical ring

86 3BDS009029-600
Section 3 Fieldbus Topologies Redundancy concepts

Redundancy concepts
Using a redundant PROFIBUS system makes it possible to considerably increase
the availability and thus the reliability in comparison with a single system. One
particular advantage is scalable redundancy that begins with a redundant
PROFIBUS transmission link, continues with a redundant master and ends with a
redundant PROFIBUS slave.

Figure 34. Redundancy concepts

3BDS009029-600 87
Redundancy concepts Section 3 Fieldbus Topologies

Figure 35. Master, Line and Slave Redundancy

88 3BDS009029-600
Section 3 Fieldbus Topologies Redundancy concepts

Master redundancy
The AC 800M controller is linked to the PROFIBUS master module
CI854A/CI854B. When a CI854A/CI854B module fails or bus communication is
interrupted, the redundancy partner is automatically activated. A CI854A/CI854B
pair balances the data cyclically via the CEX bus.

Line redundancy
Line redundancy requires a redundant transmission medium and a redundant bus
connection on the PROFIBUS master. The two transmission media are electrical
cables in the simplest case, or fibre optical cables for higher requirements. For
optimal usage of line redundancy, master/slaves/links with two bus terminals are
required.
The ABB PROFIBUS master module CI854A/CI854B has a build in line
redundancy. For slaves with only a single PROFIBUS DP interface, the
Redundancy link Module RLM 01 can be used to integrate the device in the
redundant line structure.
The master, slave or link detects the failure of a line and continues communication
over the intact redundant line. The requirements for line redundancy involve
immunity to open circuit, short circuit and error adaptation in respect of cables,
connectors, repeaters, media converters and links.
If the PROFIBUS slave has not been implemented a redundant PROFIBUS
interface, and if, however, an analysis of the system availability shows the necessity
of redundant PROFIBUS cabling, it is recommended to use a Redundancy Link
Module RLM 01.

Slave redundancy
Slave redundancy refers to a situation in which at least redundant links/gateways
and optionally redundant I/O modules are present. If a gateway module fails or a
disturbance in communication occurs, the second gateway module takes over the
task. The same principle applies to the I/O modules. The redundant module
continues to record and/or output measured values in the case of an error. The
connected sensors or actuators including the signal and command lines are generally
only set single.

3BDS009029-600 89
RLM 01 - Redundancy Link Module Section 3 Fieldbus Topologies

RLM 01 - Redundancy Link Module

The Redundancy Link Module RLM 01 converts two reciprocally redundant
PROFIBUS DP/FMS lines into simple, non-redundant A/B lines and vice versa. The
module works bidirectionally. It transmits and receives in parallel over both lines.
The first incoming plausible data are routed to the output.

Figure 36. RLM 01 - Redundancy Link Module

RLM01 features:
• Use on PROFIBUS-DP/FMS lines
• Conversion of a non-red. PROFIBUS line into two redundant lines and vice versa
• Automatic line selection
• Transmission rate 9.6 kbit/s – 12 Mbit/s
• Monitoring of the communication
• Repeater functionality
• Redundant power supply connection
• Status and error display via LED
• Alarm contact
The RLM 01 can also be set to support line redundancy for a master with non-
redundant PROFIBUS output.
RLM01 does not support master redundancy where one master only runs line A
and the other one only line B. The bus communication is asynchronous, even if
both masters are balanced with respect to each other on the program level.

90 3BDS009029-600
Section 4 Commissioning of PROFIBUS equipment Installation of data cables

Section 4 Commissioning of PROFIBUS

equipment

For commissioning tasks you should also be familiar with all other sections. There
are some additional hints about general limitations, cable lengths and laying
regulations, bus terminations and spur lines. This must be observed in the planning
phase and also during the commissioning phase.

Installation of data cables

Installation hints for electrical data cables
When connecting the devices, make sure that the data lines are not distorted or
confounded. Data cables can only take a certain amount of stress.

The following hints will help you to avoid damage when installing data cables:
• Protect data cables during storage and transportation (shrink cap)
• Observe minimum and maximum ambient conditions
• Install data cables separately (separate cable duct)
• Protect data cables against potential mechanical damage
• Install redundant data cables in separate cable routes
• Do not exceed the maximum tensile strength
• Fit strain relief devices where necessary
• Avoid exceed stress from pressure
• Avoid exceed torsional stress
• Do not undercut the minimum bending radius

Preparing a PROFIBUS cable (RS485 and MBP)

• Cut the PROFIBUS cable type A to the required lengths. Strip off the insulation
from the cable ends.
• Observe the manufacturer instructions for the PROFIBUS connector.

3BDS009029-600 91
Installation hints for electrical data cables Section 4 Commissioning of PROFIBUS equipment

• Make sure not to confound feed and return wires. The incoming and outgoing
signals must not be applied to the same pin.
• Connect the bare (non-insulated) wire ends to the appropriate pins. It is
recommended to note down the wire color to avoid that the data lines will be
confounded when the network will be extended at a later time.
For RS485 cable, the normal cases wire A / pin 8 has green color and wire B /
pin 3 has red color.
• Make sure that the braid shield and, if applicable, the tape shield underneath it,
is in good contact with the appropriate connector pin.
• Switch on the bus termination of the end connectors (no outgoing lines).
• Connect the cable shield to functional ground e.g. by using a grounding clamp.
• Put on the shield for every node of a line and make sure there is a good contact.
• To ensure RFI suppression in accordance with Class B to DIN/VDE install the
ferrite ring RFI suppressor from for example Würth-Elektronik. The
requirements of RFI suppression Class A are always met.
RFI suppression (Class B to DIN/VDE) is only ensured if the PROFIBUS cable is
provided with the ferrite-type RFI suppressor specified above. For installation
hints of RFI suppressor please read the specific manufacturer manual.

92 3BDS009029-600
Section 4 Commissioning of PROFIBUS equipment Installation hints for optical fibre cables

Installation hints for optical fibre cables

• Installation waste must be treated with care
• Do not look direct in open fibre ends
• Keep fibre optic cable plugs clean
• Do not stress fibre optic cables (stress increase the attenuation)
• Plan adequate attenuation reserves
An off-the-shelf interface converter is needed for the transition from RS485 bus
technology to a fiber-optic cable. An FO cable consists of two glass fiber leads, one
for transmit data and one for receive data.
Usually, the RTS signal on the PROFIBUS connector controls if data is transmitted
or received.
Note that this signal and the VP and GND signals additionally have to be applied
to an interface converter. Observe the instructions in the user manual delivered
with your interface converter.
Use fiber optic cables wherever it is possible to improve the operational reliability
and achieve optimal EMI shielding.
Always use fiber optic cables for links between buildings. Fiber optic cables provide
for protective voltage separation and ensure lightning protection without requiring
additional measures. Use multi-wire cable to reduce cable laying cost. As different
for indoor cable links, multi-wire cables enable additional data links in future.
Moreover, you can change over to an unused wire in case of wire-break.
Several outdoor cable types - e.g. gopher-protected or with a special steel or aramid
reinforcement - are available. Note that steel-reinforced cables should only be used
under special conditions for outdoor applications. In this case, the reinforcement are
available. Note that steel-reinforced cables should only be used under special
conditions for outdoor applications. In this case, the reinforcement must be
grounded at both ends when entering the buildings to provide lightning protection.
For details on PROFIBUS with fiber optic cables refer to:
PROFIBUS, Technical Guideline Optical Transmission Technology,
Catalog No. 2.022

3BDS009029-600 93
Special conditions regarding the installation of PROFIBUS DP Section 4 Commissioning of

Special conditions regarding the installation of

PROFIBUS DP
When using PROFIBUS - DP, also in intrinsically safe zones with remote I/O
modules, the following conditions regarding screening / earthing have to be
observed:
• Electrical grounding of the PROFIBUS cable screen on two points at the AC
800M control station:
– Connection at the 9-pole SUB-D plug on every device, for example
CI854/CI854A/CI854B, CI840, CI920, etc.
– Connection of the cable screen with a grounding clamp at the housing
entry.
• If the installation contains areas with high potential differences, a potential
equalization cable should be added to the data line when using an RS485
PROFIBUS cable. The potential equalization cable must have a minimum
cross-sectional area of 16 mm2 and must be linked with the shield of each
node. This avoids compensation currents through the cable shield or data lines.
A more flexible solution is provided by fiber-optic cables.
• Additionally, another screen grounding is required at each cubicle entry in non-
intrinsically safe and intrinsically safe zones by a low impedance connection
over a large surface via cable clips. The screen must continue between all DP
devices (Master/slaves) connected to the PROFIBUS.
Remark: The requirement for multiple screen grounding results from:
– Requirement according to the PROFIBUS installation Guideline (“The
cable shield should be connected to ground at both ends of the cable.”)
– The screen grounding of the bus cable on both sides is also possible in
hazardous locations if there are no compensating currents on the screen
which should be ensured in case of an optimum equipotential bonding
according to VDE 0165.
• Connection of all earthing points via continuous low impedance equipotential
bonding. In any case, it must be ensured that an adequate equipotential bonding
is existing during the whole life of the system. If an adequate equipotential
bonding cannot be ensured for the whole life of the system, an additional

94 3BDS009029-600
Section 4 Commissioning of PROFIBUS equipment Special conditions regarding the installation of

equipotential bonding line must be laid, if possible, in parallel to the data line
(e.g.: 16 mm²). Under no circumstances, the line shield must be used as
compensating line.
• Laying of the PROFIBUS cable in separate grid ducts to energy lines. If bus
cables and energy lines are laid in parallel, a minimum distance of 30 cm is
provided.
The lines provided for the energy line (e.g. for converter actuators) are screened
with a copper braiding. PROFIBUS International (PI) stipulates that the bus
cable has additionally to be laid in a steel tube or in a tight sheet metal channel
in case of extreme interference influencing. The tube or the channel must be
earthed regularly and protected against corrosion (see also PROFIBUS
installation Guideline).
• The grounding of field cable screens for wiring remote I/O housings with the
field devices must be carried out in conformity with the requirements of the
remote I/O suppliers.

3BDS009029-600 95
Installation hints for CI854/CI854A/CI854B Section 4 Commissioning of PROFIBUS equipment

Installation hints for CI854/CI854A/CI854B

Use the following procedure to install the CI854/CI854A/CI854B (for details see
related product documentation):
1. Install a connector on the shielded twisted pair PROFIBUS DP cable. A
connector with a switchable built-in bus termination is recommended.
Connect the cable screen to the metal case of the connector to ground the
screen via CI854/CI854A/CI854B. Connect the data cable wire A (green) to
the terminal
PIN8 (RxD/TxD-N) and the data cable wire B (red) to the terminal PIN3
(RxD/TxD-P).
2. Connect the cable shield for both lines to functional ground e.g. by using a
grounding clamp.
3. Connect the PROFIBUS DP cable to one of the connectors PROFIBUS A or
PROFIBUS B on the base plate. For support of Line Redundancy connect a
second PROFIBUS DP cable to the other contact.
4. If the CI854/CI854A/CI854B is at the end of the PROFIBUS DP cable, switch
the bus termination ON. Otherwise leave the bus termination switched OFF.
5. If the CI854A is installed in a redundant configuration connect the PROFIBUS
DP cable to primary and backup module. Do it like described in Figure 35:
Master, Line and Slave Redundancy. Switch the termination ON for the
interface on primary or backup module that is at the end of the line.

96 3BDS009029-600
Section 4 Commissioning of PROFIBUS equipment Installing a Redundancy Link Module RLM 01

Installing a Redundancy Link Module RLM 01

Use the following procedure to install the RLM 01(for details see related product
documentation):
1. Connect the redundant PROFIBUS lines are connected to ports A and B. Port
M is to be used for the not redundant PROFIBUS line to the master or one of
the slaves. All three PROFIBUS ports, for example A, B and M, have the same
9-pin Sub-D connectors (sockets). The pin assignment is in accordance with
the PROFIBUS standard.
2. If the A/B ports of an RLM 01 module are located at the start or end of a bus
segment, two connector plugs with integrated bus terminating resistors must be
provided. If the M port resides at the start or end of a PROFIBUS, one
connector plug with integrated bus terminating resistors must be provided. It is
preferable to use PROFIBUS terminals with an integrated resistor combination
that can be turned on and off. A short-circuit-proof power supply to supply the
resistors located in the connector is available on pins 5 (VP+) and 6 (DGND).
3. Use only shielded PROFIBUS connectors of suitable design. The connectors
should preferably have a cable connection that is angled down at 35° and is no
wider than 18 mm. The power supply and alarm lines are connected directly to
the terminals labelled 1 to 8.
4. Set the transmission rate with the rotary switch on the front panel before
turning on the power supply. You can select transmission rates of from 9.6
kbit/s to 12 Mbit/s. If the transmission rate is changed during ongoing
operation, you should push the reset button once briefly to reset the control
logic and the counters etc. to a defined initial state.
5. RLM 01 also tests whether the supply voltage is present at inputs L1+ and L2+.
A single power supply with L1+ alone always requires a cable jumper from
L1+ to L2+. This prevents an unwanted error message.

3BDS009029-600 97
Installing the PROFIBUS DP/PA Linking Device LD 800P Section 4 Commissioning of PROFIBUS

Installing the PROFIBUS DP/PA Linking Device LD 800P

The PROFIBUS module CI854/CI854A/CI854B is designed exclusively for the
connection of PROFIBUS DP nodes.
The Linking Device LD 800P is the interface between the PROFIBUS DP and the
PROFIBUS PA. If an intrinsically safe PROFIBUS PA segment is used, the Power
Link Module PL 890 with an intrinsically safe interface has to be used.
LD 800P supports both cyclic as well as acyclic PROFIBUS communication. The
way in which LD 800P works is essentially transparent. This means that
PROFIBUS DP masters have direct access to PROFIBUS PA slaves.
Use the following procedure to install the LD 800P (for details see related product
documentation):
1. Snap the Head Station and the Power Link Modules of the channel 1 as well as
the power supply unit onto the corresponding DIN Rail segment. Please note
that the distance between the PROFIBUS DP socket of the head station and an
intrinsically safe PROFIBUS PA connection of the Power Link Module PL 890
must be at least 50 mm measured straight.
2. If a 2- or 4-channel Head Station (HS 820 or HS 840) is being used snap the
Power Link Modules of the channels 2 to 4 as well as the power supply units
onto the corresponding DIN rail segments.
3. Connect the power supply to the LD 800P modules.
4. Connect the PROFIBUS DP transfer line to the Head Station.
5. If it is being used, connect the redundant PROFIBUS DP transfer line to the
Head Station (HS 840).
6. Add the external bus termination if the head station is the last station on the
PROFIBUS DP segment.
7. Connect the PROFIBUS PA transfer lines with the Power Link Modules
provided for this purpose. The terminal resistances for the PROFIBUS PA
segments are integrated into the Power Link Modules.
8. Connect the outputs for channels 2 through 4 of the head station with the
terminals “Connection to the Head Station” of one Power Link Module of the
corresponding channel. Connect the PROFIBUS PA terminals of all power link
modules of one channel.

98 3BDS009029-600
Section 4 Commissioning of PROFIBUS equipment Installing the PROFIBUS DP/PA Linking Device

9. Connect the power pack.

The watch dog time TWD is set within the LD 800P to a default value of 5 sec.
This setting leads to a 5 sec. watchdog time of all underlying PA slave devices
independent of the TWD settings within the PROFIBUS DP master. If a watchdog
time adjustment of is not possible for the individual PA slave device there is a
possibility to use a service tool and a serial connection to adjust the watchdog
time for all PA slave devices within LD 800P.
10. Each PROFIBUS PA segment must be terminated at the end of the line. The
terminating resistance required for the Linking Device LD 800P is already
integrated into the power link modules PL 810 and PL 890.
11. The PROFIBUS PA cable shield must be grounded for reasons of EMC
protection. This is possible in 2 ways:
– Hard grounding at both ends of the PROFIBUS PA transmission line. This
requires laying a potential compensation line.
– Hard grounding on all field devices, potential compensation in the field,
capacitive grounding on the Linking Device.
12. If the LD 800P is used, independently of whether or not it is a manufacturer
specific or profile GSD, always use the DP-GSD. Some PROFIBUS PA field
device manufacturers do not offer any PROFIBUS DP-GSDs. In this case, the
existing PROFIBUS PA-GSD must be converted by using the LD 800P convert
tool. The task of this conversion software is exclusively to enter the missing
transfer rate and set specific bus parameters to values that allow for problem-
free operation of the PROFIBUS DP.

3BDS009029-600 99
Active network terminator and repeater Section 4 Commissioning of PROFIBUS equipment

Active network terminator and repeater

The active network components described below can be used to construct simple or
complex PROFIBUS networks, and either electrical cables or optical fibre cables
can be used as the transmission medium. Since most active components have IP20
protection, it will usually need a cabinet, a wall mounted cubicle or a comparable
packing to protect the components. A DIN mounting rail is adequate for attachment.
Network devices cause a N x bit time delay of data telegrams. The delay times are
device specific and depend upon the selected transmission rate. They must be
taken into consideration in the bus configuration manually.
It may implement an external active bus terminator by means of a special bus
terminator or a repeater. The external bus terminator relieves the bus subscriber
from supplying the resistor network. Now the redundant master or the last
subscriber on this transmission line can be switched idle without loss of
communication.
Depending on the type, the module can be fed with 24 VDC or 230 VAC. The
resistor network (terminator) is not placed in the module itself, but in the
PROFIBUS connector.

Figure 37. Active PROFIBUS Terminator from Kuhnke and Siemens

RS485 Repeater
There are component under the type description “Repeater RS485” available, that
can be used to connect two electrical PROFIBUS segments with a maximum of 32
stations each. Nine repeaters can be included in a line. This makes it possible to

100 3BDS009029-600
Section 4 Commissioning of PROFIBUS equipment Active network terminator and repeater

increase the distance covered by a PROFIBUS network to 10 km (two-wire cable

and 93.75 kBit/s) and the number of stations to 127 (with a maximum of 32 bus
connections per segment).
Please find detailed information in the manufacturer's product description and
operating instructions.

Figure 38. Repeater

Also the Redundancy Link Module RLM 01 has repeater functionality.

3BDS009029-600 101
Grounding, Shields, Polarity Section 4 Commissioning of PROFIBUS equipment

Grounding, Shields, Polarity

Always observe the following points when installing bus line grounding:
• Secure the shield braid using metal cable clamps.
• The clamps must fully enclose the shield and make good contact.
• Only connect the lines via the copper braid shield, and not via the aluminum
foil shield. One side of the foil shield is attached to a plastic film to increase its
tearing strength, and is therefore non-conductive!
• The shields of all cables which are routed into a cabinet from the outside must
be clamped at the point of entry inside the cabinet and connected to the cabinet
ground with a large contact surface area.
• When removing the cable jackets, it is important to ensure that the braid shield
of the cables is not damaged. Tin-plated or galvanically stabilized surfaces are
ideal for optimum contacting between grounding elements. With zinc-plated
surfaces, suitable threaded connections must be provided for the required
contacts. Painted surfaces at the contact points are unsuitable.
• Shield clamps/contact points should not be used as strain relief devices.
Contact with the shield bus could otherwise deteriorate or break completely.

Figure 39. Securing shielded lines using cable clamps and tube clips
(schematic diagram)

102 3BDS009029-600
Section 4 Commissioning of PROFIBUS equipment Testing the PROFIBUS bus cable and bus

Testing the PROFIBUS bus cable and bus connectors

The measurements described below allow you to test an installed network and
eliminate the most common errors, such as reversal of the cable polarity, open or
short circuits of data cables or shield and incorrectly connected terminating
resistors. The measurements should be carried out for each bus segment after
installing the PROFIBUS cables and attaching the bus connectors.

Figure 40. PROFIBUS DP Connector

Table 10. PROFIBUS DP Connector

PIN Designation Description

1 Shield Shield/protective ground
2 – Not Used
3 RxD/TxD-P Receive/Transmit Data P-line (B-line, red)
4 CNTR-P repeater control signal,
indicates direction to repeater (TTL)
5 DGND Digital Ground

3BDS009029-600 103
Testing the PROFIBUS bus cable and bus connectors Section 4 Commissioning of PROFIBUS

Table 10. PROFIBUS DP Connector

PIN Designation Description

6 VP +5 V, supply voltage for terminating resistors
7 – Not Used
8 RxD/TxD-N Receive/Transmit Data N-line (A-line, green)
9 DGND Digital Ground

Use an ohmmeter to check the static characteristics of the ready made cable:
• Passage on pin 3 between all PROFIBUS connectors.
• Passage on pin 8 between all PROFIBUS connectors.
• Insulation between pin 3 and pin 8 with bus termination switched off.
• one bus termination switched on é around 390 ohms between pin 3 and 6
• both bus terminations switched on é around 195 ohms between pin 3 and 6
• one bus termination switched on é around 220 ohms between pin 3 and 8.
• both bus terminations switched on é around 110 ohms between pin 3 and 8
• one bus termination switched on é around 390 ohms between pin 8 and 5
• both bus terminations switched on é around 195 ohms between pin 8 and 5
In the values above we have unattended the loop resistance of typical 110 Ohm/km

Figure 41. Schematic diagram of testing the PROFIBUS cable

104 3BDS009029-600
Section 4 Commissioning of PROFIBUS equipment Testing the PROFIBUS bus cable and bus

The following pictures shows the correct installation as well as the common
installation errors. Use an oscilloscope to check the voltage signals on the bus
segment:
1. A correct PROFIBUS installation:

The measured voltage between the both transmission lines shall be 1,1 V

Figure 42. Correct terminated PROFIBUS line

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Testing the PROFIBUS bus cable and bus connectors Section 4 Commissioning of PROFIBUS

2. One bus termination is not powered (5 V) (or two 390 Ohm resistors are
missing):

The measured voltage between the both transmission lines is 0,62 V

Figure 43. Incorrect terminated PROFIBUS line (termination only on one side)

106 3BDS009029-600
Section 4 Commissioning of PROFIBUS equipment Testing the PROFIBUS bus cable and bus

3. One bus termination is not powered (5 V) (or two 390 Ohm resistors are
missing) and one additional bus termination (220 Ohm) placed between the
transmission lines:

– The measured voltage between the both transmission lines is 0,43 V

4. One additional bus termination (220 Ohm) is placed between the transmission
lines:

– The measured voltage between the both transmission lines is 0,79 V

3BDS009029-600 107
Tips on the most frequently asked installation issues Section 4 Commissioning of PROFIBUS

Tips on the most frequently asked installation issues

Are multiple devices with the default address 126, or with the same address
connected to the bus?
• Make certain that there are no instances of multiple devices on the bus
simultaneously with the same address. In case of doubt, attach one device after
the other to the bus and assign the address you desire to each device, with the
Web server of CI854/CI854A/CI854B. It is best to note the address on the
device. If you proceed according to this method in assigning the address, make
certain you can assign the installation location to the address.
Have you made note of the polarity for PROFIBUS DP?
• In contrast to PROFIBUS PA, you must ensure the correct polarity for
PROFIBUS DP. When using a 9-pin D-SUB connector, the connector
assignment is Pin No. 3 RxD/TxD-P (Receive/Transmit data-Plus) and Pin No.
8 RxD/TxD-N (Receive/Transmit data-N). If the question comes up, simply try
switching polarity.
Are the bus connections present and active?
• Make certain that the bus segments are present on both sides in each segment.
How can I get more specific information on how to start - relative to my
particular plant, application, and installed hardware?
• Contact PROFIBUS International (www.profibus.com) or your suppliers of
choice. Training courses, additional reference materials, and consulting
services are available to provide more detailed information on specific products
from the appropriate supplier.
Where do I get the specs?
• The specifications (and additional documents) are available from PROFIBUS
International. Standards documents are available from the IEC.

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Section 4 Commissioning of PROFIBUS equipment Tips on the most frequently asked installation

Where can I buy the correct wire, terminals, terminations, and other items
required to install a fieldbus?
• ABB offers a complete portfolio of PROFIBUS network components. Please
get in contact with your regional sales manager. PROFIBUS International
offers additional references to the most comprehensive list of suppliers,
devices, services, and other fieldbus related items.
How can I determine if the installed wire will work? Is there a test? Is there any
test equipment I can rent, buy,...?
• A number of suppliers are developing products for simulating and testing
fieldbus signals and devices. In addition, suppliers of hand-held
communications network test equipment are currently offering fieldbus
communications test devices that can be used to verify the quality of potential
or operating fieldbus segments. A list of supplier is available on the
PROFIBUS International web page (www.profibus.com).
Can I add new wire, and mix it with installed wire in the same fieldbus
segment?
• YES! The suppliers of fieldbus cable will be able to provide assistance in the
form of data sheets, training, and services.
How many devices can I put on one segment?
• It depends on several factors. The PROFIBUS segment is specified to handle a
maximum number is 32 devices per segment. The controller capacity, power
requirements and etc. may lower this amount. Refer to the specific
documentation for operational capacity and consult the device manufacturer for
individual field device’s power requirements.
I need a 3.2 kilometer long PROFIBUS PA network. How do I handle this
requirement?
• The Physical Layer specification recommends a maximum length of 1900 m
for cable type A wire. If this is not sufficient, up to 4 repeaters can be used to
extend the total length to five times 1900 m, for a total of 9.5 kilometers.

3BDS009029-600 109
Tips on the most frequently asked installation issues Section 4 Commissioning of PROFIBUS

What happens if the bus gets grounded on one side (or at one end)?
• A temporary short to ground may temporarily disrupt the bus, but any errors
will be detected and handled by the fieldbus protocol. A permanent short to
ground could disrupt the bus until the ground is removed (just as with present
analog or digital communications).
I don’t understand “termination”. What is it, why do I need it, and is
placement critical?
• Termination is the addition of the appropriate fieldbus “terminator” at (or near)
the end of each fieldbus segment. The “terminator” has the same characteristic
impedance as the bus, and is required to preserve the integrity of the signal. It is
especially important on long segments, and placement is critical— one should
be connected to the bus as close as possible to each end of the segment. Some
devices (especially I/O and/or fieldbus test/simulation PC cards) include the
option of using an internal terminator. It is important to know in this case
whether it is connected.
• My PROFIBUS is not running properly.
– Check the bus terminations
– Check the connectors
– Check the cabling (polarity, grounding, short-cuts, etc.)
– Check the correct settings for all slave addresses (for example with the
Web server of CI854)
– Check the PROFIBUS master settings
For more details about the Web server of CI854/CI854A/CI854B and the
PROFIBUS master settings please read the specific product documentation.

110 3BDS009029-600
 Index
A Energy lines 95
AC 800M 23, 89
Active network components 100 F
Actuators 55 FDE 33, 71
Alternating voltage 36 Fibre Optic 40
Fibre optics 82
B FISCO 21, 31
BFOC 82 Full-duplex 42
Bus connector 65, 66
Bus Powered 31 G
Bus termination 64, 74 Glass 82
Ground-free 64
C Grounding 102
Cable 20
CI854(A) 23, 38, 89 H
Half-duplex 42
D HCS 41
Data security 20
Data transmission 20 I
Delay times 72 IEC 61158-2 31
DGND 65 Installation 91
DP V0 19 Intrinsically safe 31, 71
DP V1 19 ISO 18
DP, Cable type A 24
D-Sub 65 J
Dual-fiber optical 46 Junction box 76

E L
EMC 67 LD 800P 38, 98

3BDS009029-600 111
Index

Line redundancy 89 R
Line Topology 43, 58 Redundancy 89
Line Topology with spurs 58 Redundancy Link Module 92
Linking Device 38 Remote feeding 22
Repeater 102
M RLM 01 92, 99
M12 75 RS485 25
MAC 18 RS485-IS 32
Manchester Coded 31 RxD 67
MBP 31
Multi Barrier 73 S
N Shielded twisted pair 30
Number of repeaters 20 Shields 104
Number of stations 20 Signal reflections 30
SK3 40, 42
O Slot time 54
Optical Ring 51 Splice 60
OSI 18 Star coupler 40, 51, 63
Star Topology 51
P
PA, Cable type A 34 T
PCF 84 T-Connectors 77
PG socket 68 Topology 22
Plastic 84 Total length 23
Point-to-Point 59 Transmission delay 55
Polarity 38, 104 Transmission rate 22
PROFIBUS 17 Transmitter 57
DP 19 Tree Topology 62
DP/PA Linking Device 40 TxD 67
PA 19
Protocols 18
V
Protection type 22
VP 67
PTB 23

112 3BDS009029-600
Contact us

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