test 5

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885

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Oct/Nov 2008 | industrial automation asia 37

into automation systems without extra effort and expense. Devices that currently have ‘intelligence on board’ are ideal for applications with IO-Link.

With this approach, the devices can be configured, parameterised and operated via a three-way cable. Each device has an extensive parameter set and can be configured and parameterised in a time-savings manner. Simple proximity switches are not as well suited for use with this new standard.

T h e I O - L i n k u s e s e x i s t i n g communications systems (fieldbuses or Ethernet based systems); the last few meters to the actuators and sensors are connected in a point-to-point connection using commercial, unshielded standard cables. The IO-Link thus helps reduce the number of interfaces and the multitude of variants.

Typical intelligent actuators and sensors include valve clusters, motor

starters, optical sensors, light grids, analogue signals, RFID or positioners. T h e s e d e v i c e s m a y p o s s e s s application-specific parameters and data (for example, diagnosis data) that are transferred via a serial communication process.

To achieve this, flexible message lengths are possible in order to be able to transfer comprehensive data sets, such as those for pressure sensors or light grids.

No Special CablingThe IO-Link enables both binary process data as well as analogue signals to be transferred. With a continual IO-Link communication, there exists the possibility of operating analogue and binary sensors on a joint interface module.

If the binary connection was previously laid out only to transfer pure switching information, now, thanks to the IO-Link, typically 2 bytes in 2 ms cycles can each be transferred

by means of a combined process and data channel.

This opens up the ‘last meter’ to the sensors and actuators for continuous communication. The IO-Link therefore requires no special cabling. The proven, inexpensive and unshielded industrial cables can continue to be used for connecting the sensors and actuators.

IO-Link facilitates centralised error diagnosis and location right down to the sensor and actuator level. Exact error location or maintenance requirement reduces machine downtimes, and a centralised parameter address makes it considerably easier to replace devices.

This means that the standard creates an optimal, cost-effective solution for the entire chain, from actuator or sensor to integration into the automation system.

Investment GuaranteedWhen it comes to developing the

38 industrial automation asia | Oct/Nov 2008

sOftware & NetwOrks

interface, investment protection is also important for the manufacturer and user. That’s why conventional sensors and actuators can be operated on an IO-Link module and, conversely, IO-Link sensors and actuators can be connected to standard switching mode on conventional digital input/output modules.

That’s how all currently available sensors can be used; mixed operation with enhanced intelligent products is possible. Therefore, converting an existing system to the IO-Link is not a problem. Its biggest advantage is its backwards compatibility to conventional technology, which makes it possible for users to convert their machines or plants gradually at any time.

Another important point is the integration of the IO-Link system in the fieldbus world. How can the process or the parameter data be transferred and managed? Here, the user has various options available: for customers who only want to transfer pure process data, simple GSD files are available on an input/output data basis, regardless of device. In this case, it isn’t possible

to parameterise. In case users intend to configure

and parameterise individual devices, there are specific GSD files available that can be implemented depending on the device design or type. Data is managed in the control system.

The use of device-specific DTMS is also a good solution. Users can change the configuration using an integrated FDT during operation. Operation is menu-based. This solution works regardless of fieldbus and manufacturer.

Lower Time ExpenditureWith the IO-Link, devices that are basically on site and have to be easily accessible are installed on the system close to the application, reducing

installation time considerably. In this case, the centralised control system simply handles parameterising and configuration. Due to the transfer of parameter data from the higher-level control system, the start-up times are also considerably reduced.

T h a n k s t o c o n t i n u o u s communication and using the IO-Link, the user can flexibly respond to new requirements even during the machine’s run-time. So, for example, during a product change, the configuration settings can be changed centrally and in real time via IO-Link, reducing costly downtimes. The same applies to replacing an IO-Link sensor during a service call: The parameter and configuration data are transferred to the new device via the centralised control system.

The chances are good that this standard will spread worldwide. The original collaborators may be German companies, but they clearly have something to say to the world. Furthermore, because the IO-Link is fieldbus-neutral, it is not just a purely European solution. The process is currently underway to obtain approval for IEC standardisation. These factors will help the IO-Link gain recognition outside of Europe as well.

The IO-Link integrates conventional and intelligent actuators and sensors into automation systems without extra effort and expense.

ENQUIRY NO. 7303The IO-Link helps reduce the number of interfaces and the multitude of variants.

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Co-sponsored by




Co-sponsored by



sOftware & NetwOrks

ENQUIRY NO. 7304

he fieldbus is the enabling technology of a new generation of process plants. It allows the

integration of all plant instrumentation, control loops and I/O devices. Due to new solutions like Advanced Diagnostics, it also offers total control of the physical fieldbus layer in combination with remote access to every detail of each instrument connected.

With up to 31 field instruments attached to one and the same cable, modern fieldbus technology significantly reduces the amount of wiring needed for power supply and signal transmission.

Remote DiagnosisThe Advanced Diagnostics Module (ADM) for monitoring the physical layer is a test instrument which is fully integrated into the fieldbus power supply and connected directly to the trunk of the network. After a first run immediately following the commission of a new or modified system, the operating condition is stored as a baseline along with respective alarm limits.

From then on it works fully automatic and is able to determine and document

the compliance of the complete system with the design rules of the fieldbus standard IEC 61158-2. Audible and visual alarms will make the system operator or maintenance staff aware of any deviations from the baseline.

Complex wiring diagrams can be replaced with a simple spreadsheet documenting all components the physical layer is comprised of. In this way, numbers and locations of the wiring blocks and field devices connected to each trunk can be easily found.

The service technician only needs to run a software package right at the maintenance station. Clear text messages point to possible problems and suggest remedies for the fault. It is then up to the maintenance staff to decide what kind of action needs to be taken and plan their activities accordingly. After maintenance work, alterations or extensions of the fieldbus infrastructure, a quick check with the Diagnostic Manager is all that is needed to verify the quality of the physical layer.

Advanced Diagnostics is able to sort out 90 percent of all alarms

caused by problems with the fieldbus physical layer before causing harm. Since the complete fieldbus structure is under constant supervision, plant performance and system availability will be improved drastically.

The Hard CasesA single deficiency in the fieldbus infrastructure normally does not really affect plant operation. Real problem cases usually are often intermittent and therefore difficult to detect. Or they are caused by multiple faults on one segment.

In such cases it is helpful that the Advanced Diagnostic Manager also allows remote access via the Internet. Maintenance technicians can therefore call on offsite fieldbus experts who are able to immediately access all information and give supportive instructions over the phone.

Alternatively, it is also possible to write all status data into a file and mail it to the expert. In either case, help is available within a short time frame and at reduced cost, since time and expenses for traveling are eliminated.

Inherent SafetyThe fieldbus also allows the integration of safety-related equipment up to SIL 3. In this way, standard and safety equipment can share the very same physical layer for communication, while the fieldbus infrastructure is left out of the evaluation of safety related equipment.

Additional availability of the fieldbus infrastructure is ensured through redundant electronic components such as the power supplies and the use of Advanced Diagnostics for the fieldbus physical layer.

With all these advantages, installing an Advanced Diagnostics system for an existing fieldbus infrastructure is a cost benefit almost right from the start. The capital investment required to service one hundred fieldbus segments supporting 1,200 field devices, approximately equals the cost of one skilled instrument and electrical engineer for only three months.

Installing an Advanced Diagnostics system for an existing fieldbus infrastructure presents a cost benefit to a process plant. By Arasu Thanigai (L), business development manager for fieldbus devices, AP and Andreas Hennecke (R), product marketing manager for fieldbus technology, Pepperl+Fuchs

ControlInsight

Total

Total

ENQUIRY NO. 681

ESS0001082 Industrial Automation Asia Oct-Nov 2007Size:275H x 205Wmm 150# Epson+CD(PDF)

M YC K

While every effort has been taken to carry out instruction to customers satisfaction NO RESPONSIBILITY liablilty will be accepted for errors CUSTOMERS ARE THEREFORE URGED TO CHECK THOROUGHLY BEFORE AUTHORISING PRINT RUNS DALIM

11 2 3 4 5 6 7 8 9 10 OK LLLMcCann CN MOD: CN1911CN230102 MAC8 Osx 12.09.2007 150#

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imple smart pressure and temperature measurement transmitters could be configured without need for graphics. However, more sophisticated (complex)

devices such as valve positioners, variable speed drives, machinery health monitors, and radar level transmitters now common in process industry plants require advanced graphical setup and diagnostics.

By upgrading software to the new enhancements of the international standard IEC 61804, plant personnel can make their devices, both old and new, simple and advanced, easier to use than ever before.

Similarly, predictive diagnostics can be better integrated into daily work practices by displaying them to the

right persons. This is achieved without making system management more difficult with respect to staying current with new devices and Windows versions.

This article recommends a best practice for device integration outlined in the NAMUR NE 105 recommendation by upgrading to a single standard: IEC 61804-3.

Meet The RequirementsBack in 1992, the original Device Description (DD) technology made it possible for the first time to configure many types of smart transmitters from different manufacturers using the same universal communicator rather than one proprietary communicator from each


instrumentation & measurement

EDDL with enhancements enables a single tool for simple and sophisticated devices including advanced setup and diagnostics. By Jonas Berge, director, PlantWeb consulting, Emerson Process Management

marchingmainstreamEDDL:

manufacturer. This led to a significant improvement in productivity.

Challenged with greater user expectations, engineers were faced with the task of providing graphics for DD while not sacrificing the ease of system management, robustness, and investment protection to which plant personnel have become accustomed.

The solution: HTML-like graphical extensions in an enhanced technology renamed enhanced Electronic Device Description Language (EDDL). This technology makes all HART, Foundation fieldbus, and Profibus devices easier to use.

NAMUR NE 105NAMUR is an associat ion of process industr y automation technology users, whose members work together to define requirements for new technologies, systems, and devices. NE 105 is their recommendation for integrating fieldbus devices in engineering tools. It is the best collection of user requirements for device integration.

End-user requirements for device integration defined in NAMUR NE 105 include:• Investmentprotection• Nosoftwareversionconflicts&non-interfering• Easydeviceupdate

• Intuitive• Consistentlookandfeel• Singleuniversalsolution• Nolicensekeys• NoWindowsversionconflict• Supportforfulldevicefunctionality• Interoperabilitytesting

NE 105 deals partly with the displays technicians see. They must be able to show all functionality in the device, and the look and feel must be consistent from one device to the next. However, for the most part NE 105 has a focus on system management and investment protection.

Using a single device integration technology meeting all the requirements of NE 105 is considered ‘best practice’ for process industry plants.

Enhanced EDDLEDDL is a compressed text file that exists in the computer, not in the device, and tells the software what commands to send to the device to exchange information, how to decode the information, and how to display this information to the user. EDDL is an integral part of HART, Foundation fieldbus, Profibus, and WirelessHART communications.

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Graphical elements in EDDL with enhancements.

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Device integration technology time-line.

The original DD technology, dating from 1992, lacked the ability to display and store graphics and thus did not meet the requirement for support of full device functionality. Other solutions had the graphics but did not meet the other NE 105 requirements. New EDDL with enhancements supports graphics while preserving all the advantages of original DD.

The enhancements to EDDL were jointly developed by engineers from the Fieldbus Foundation, HART Communication Foundation, Profibus Nutzerorganisation eV (PNO), and OPC Foundation to meet the requirements of NE 105.

Full Device FunctionalityMost plants today have sophisticated (complex) devices like control valve positioners, machinery health transmitters, variable speed drives, and radar level transmitters that must be managed from the same software as simple pressure and temperature transmitters.

Since the original DD did not have graphics or persistent data storage, other solutions had to be developed to support the more sophisticated devices. Systems mixing multiple technologies were harder to manage and had added limitations.

EDDL solved this with enhancements providing rich graphics, a menu system, persistent data storage, and ability to handle data dependencies. Wizards and calculations are available to make complex procedures such as setup and calibration easy, reducing mistakes, and at the same time make sure all technicians perform these tasks the same way with greater consistency.

Charts and graphs with multiple simultaneous values as well as table grids allow advanced setup and advanced diagnostics of sophisticated (complex) devices. The enhanced menu system makes navigating large sets of parameters much easier.

Manufacturers impart their device and application know-how to users in the form of text, images, and context sensitive help to make their devices easy to use. It is the device manufacturer that decides on the content and structure of the information displayed to make their devices user friendly while all information is presented.

EDDL with enhancements enables a single tool for simple and sophisticated devices including advanced setup


iNstrumeNtatiON & measuremeNt

and diagnostics. Thus EDDL is suitable for all phases of the life-cycle including maintenance and operation. Users see the full, rich, and familiar Windows graphical presentations on their computers.

EDDL makes devices fully interoperable, and since they are displayed as intended by their manufacturers, nothing hidden. Devices that fully support EDDL with enhancements need no additional software.

Consistent Look & FeelDevice manufacturers must be allowed to determine how information and features in their devices are organised in displays: content and structure. Previously however, device manufacturers used different icons, different button locations, and different color schemes etc for their displays.

The variations resulted in inconsistencies between devices, which made life difficult for technicians who had to manage a mix of devices from different manufacturers using different protocols.

This dilemma is solved using EDDL, which allows manufacturers to define the display content and structure of a device, but not look and feel details. Therefore, colour coding for parameterisation status such as ‘writable’, ‘read-only’, ‘changed but not downloaded’, and ‘compare mismatch’ is defined by the device software and thus identical for all devices regardless of protocol, manufacturer, or type.

Moreover, the look and feel are the same as for the entire control system and asset management package. EDDL displays devices graphically but without undue creativity.

The look and feel of buttons to accept parameter changes, access help, and print are the same for all devices. Consistent use of option lists, check boxes, and multiple status indication are also standardised by EDDL.

Tools to pan and zoom for trend charts and waveform graphs work the same way for all devices. Gauges, bar-graphs, and histograms are the same for all devices regardless of protocol, manufacturer, or type.

Device displays make use of a standard multilingual EDDL dictionary of common phrases displayed in user interaction such as prompts and help text. Furthermore, IEC/TR 61804-4 includes a standard root menu for navigation.

As a result, EDDL-based tools are easy to learn. Working with a mix of devices soon becomes intuitive thanks to the consistent look and feel, nomenclature, and messaging.

The consistent look and feel of EDDL are intrinsic properties of the technology not matched by earlier attempts to style guides.

Investment ProtectionA control system needs to operate for 15 years without having to be replaced. Therefore:• ItshouldnotbenecessarytoupgradeWindowsversion

when a new device type or version is integrated to the system.


Consistent look and feel across all manufacturers, device types, and protocols.

• Systemsupport foranexistingdeviceshouldnotbe lost when Windows is upgraded or when service packs or hot fixes are installed.

• Support for an existing device should not be lost when device management software is upgraded.

• It should not be necessary to upgrade devicemanagement software when a new device type or version is integrated.

Device integration solutions using Windows software interfaces are coupled to fast-paced changes of the IT revolution.

As an independent standard IEC 61804-3, decoupled from Windows, EDDL is intrinsically unaffected by rapid obsolescence in the IT world. EDDL files for new devices are independent from, and therefore compatible with, old Windows versions, patches, .NET framework, and service packs.

New Windows versions, patches, .NET framework, and service packs are equally compatible with EDDL files for old devices. New versions of device management software are compatible with EDDL files for old devices. DD files without graphical enhancements are supplied together with enhanced EDDL files to support older device management software.

EDDL staves off obsolescence because an EDDL file is a document, not software. There is:• NoneedtoupgradeWindowsversionorinstallpatches,

.NET framework, or service packs to support new device versions.

• Noneed towait fornewEDDLfilesbeforeWindowsupgrade, patches, service packs, .NET framework or upgrade.

• No need towait for new EDDL files before devicemanagement software upgrade.

• Abilityforfuturedevicestobeintegratedintoexistingdevice management software.

There should be few surprises associated with a Windows language version/edition. Plant personnel can quickly adopt any new Windows version and benefit sooner. Files created for devices in 1992 still work on systems shipped today, showing that EDDL protects the control system investment.

No Software Version ConflictsPlants cannot afford the risk of new versions of software interfering with control systems or even device management software. This is why third-party software is never allowed to be installed on a DCS. Nor are device integration solutions that rely on device drivers allowed on a DCS, since each driver is actually third-party software.

For this reason, device diagnostics had to be done from a console that is not integrated with the DCS operator station, so checking diagnostics was not a natural part of daily operations.

EDDL solved this because the file is compressed text, and no software is installed to support a device. Thus it does not interfere with the DCS. Thus, EDDL-based diagnostics can be totally integrated with the DCS. Moreover, because each version of every device type has its own unique file, integrating a new type or version of device does not interfere with existing devices.

In an integrated system, EDDL enables work to be done from a single ‘dashboard’. That is, there is no need to change seats to diagnose a device failure. Device diagnostics can be done from the operator workstation. Operators can differentiate device problems from process problems and take appropriate action such as putting a loop into manual control before the process is affected. Then, the operator can call on a technician in the field with the details so that the problem can be fixed.

Easy Device UpdateNew types and versions of devices come into plants as part of improvements and replacements all the time, so it must be easy for technicians to integrate them into the system.

Some earlier solutions required installation of driver software to support a new device type or version. The technician who commissioned a new device also had to be a bit of an IT expert to handle installation prompts such as license agreement, disk space, replacing existing files, etc. He also needed an 'administrator' level password, but installation was still time-consuming.

EDDL solves this as well because the file is not a programme or driver so there is no need for the technician who commissions a new device to install software. New EDDL files are downloaded from the device manufacturer, then simply copied and pasted onto the system, like a document. Because EDDL files are very small, they can even be emailed as an attachment if need be. Moreover, EDDL files for existing devices are never removed, thus ensuring robustness.

Beyond mere detection, EDDL supports automatic association of a device to its EDDL file without manual

Device diagnostics integrated with plant operations.


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Documents

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binary sensors

special cablingthe iolink

t h e i o

optical sensors

pressure sensors

binary process data