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AUMA – 50 YEARS OF ELECTIC ACTUATONMotor controls and remote communication
Werner Laengin, AUMA Germany
ONCE UPON A TIME….
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THE HISTORY OF COMMUNICATION
4 – 20 mA 1950
1980
1989
1994
Industrial Ethernet
All these communication protocols are now standardised in IEC 61158 and IEC 61784
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Wireless Mesh
2000
2007
Modbus TCP/IP
1986
Various aspects fieldbus systems
DIGITAL COMMUNICATION
Topology
Application interfaces
Service / Commissioning support
Cable length
Standardisation
Repeaters
Redundancy options
Field device integration
Communication services
Control in the field
Cycle timeCapex / Opex
No of participants
Baudrate
Reaction time
DCS integrations
Certification / Registration
ReferencesGuidelines
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Network characteristics of Profibus DP / Modbus RTU Line topology
Supports also star topology (with repeaters)
DIGITAL COMMUNICATION
R
Repeaters(if necessary)
RS-485Max. 1200 m / segmentMax. 32 devices / segmentTotal max 125 (Profibus DP) resp. 247 (Modbus RTU) devicesTypical: 40 – 60 devices / networkCycle time (Profibus) ≈ 250 ms (@ 50 actuators & @ 93,75 kBit/s) Cycle time (Modbus) ≈ 1 s (@ 50 actuators & @ 115,2 kBit/s)
R
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Profibus DP Most favoured fieldbus system with AUMA actuators Widespread
Worldwide knowledge available supported by Profibus & Profinet International (www.profibus.com)
Fast and deterministic ≈ 5 ms / Actuator (@ 93,75 kBit/s)
Relieable further redundancy options including an integral fibre optic interface
Ideal for Water/ waster water applications Power plants Tank farms
Dedicated services DP-V0 Optional: DP-V1 (add-on for diagnosis and asset management) Optional: DP-V2 (add-on for specified redundancy and timestamped alarms)
DIGITAL COMMUNICATION
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Communication services of Profibus DP Cyclic communication (DP-V0)
by PLC/DCS Acyclic communication (DP-V1)
User initiated
DIGITAL COMMUNICATION
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Req.: Motor operating time?Res.: 1 h and 12 minReq.: Stepping mode = ONRes.: O.k.
RS-485 Signal
DIGITAL COMMUNICATION
Communication services of Profibus DP Cyclic communication (DP-V0)
by PLC/DCS Acyclic communication (DP-V1)
User initiated Host system integration required
– EDD– DTM
Communication services of Profibus DP Cyclic communication (DP-V0)
by PLC/DCS Acyclic communication (DP-V1)
User initiated Further services (DP-V2)
Specified redundancy Time Stamping of alarms
DIGITAL COMMUNICATION
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Modbus RTU Universal communication protocol
„Basically you can do anything with Modbus RTU“
Simple and reliable Various additional redundancy options
Quick communication ≈ 20 ms / Actuator (@ 115,2 kBit/s)
Typical applications Any
DIGITAL COMMUNICATION
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DIGITAL COMMUNICATION
Modbus RTU Provides the communication
foundation for our redundant Loop communication with our SIMA Master Station
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Modbus TCP/IP
SIMA
Fast commissioning with Modbus loop
DIGITAL COMMUNICATIONSIMA
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Ex works settings of AC.2:
• address = 247, • baud rate = Auto
Automatic configuration of the Modbus loop
Consecutive and automatic configuration of
• slave address• baud rate
further actuators can be added later
• no change of existing slave addresses• no change of existing data memory mapping to DCS
Benefit:
Simple and fast commissioning
247
247
247
247
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2 3
4
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SIMA Master Station applications Complete systems Cabinets Network design Network equipment
DIGITAL COMMUNICATION
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SIMA
Foundation Fieldbus Different philosophy Power suppy and data over
the same wires
DIGITAL COMMUNICATION
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DCSFF H1
400 VAC
Foundation Fieldbus Different philosophy Power suppy and data over
the same wires Process values are
represented by Functionblocks
DIGITAL COMMUNICATION
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DCS
AI
IN AO
OUT
PIDINOUT
FF H1400 VAC
Foundation Fieldbus Different philosophy Power suppy and data over
the same wires Process values are
represented by Functionblocks
„Control in the field“
DIGITAL COMMUNICATION
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DCS
IN AO
OUT
PIDIN
LAS
Link Master
BasicDevice
Link Master LAS
FF H1400 VAC
AIOUT
?!
DIGITAL COMMUNICATION
Hybrid technology• AUMA actuators support hybrid interface types (fieldbus combined with conventional
interface)
DCS with conventional interfaces andfieldbus interface
fieldbus conventional
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DIGITAL COMMUNICATION
Hybrid technology• AUMA actuators support hybrid interface types (fieldbus combined with
conventional ESD input)
ESD PLC
DIGITAL COMMUNICATION
Safety PLC
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Hybrid technology• AUMA actuators support hybrid interface types (fieldbus combined with SIL
capability)
DIGITAL COMMUNICATION
Control BoxControl Box
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Hybrid technology• AUMA actuators support hybrid interface types (fieldbus combined with
conventional control box in the field, installed e.g. 15 m away from MOV)
DIGITAL COMMUNICATION
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Line redundancy• AUMA actuators support redundant fieldbus communication directly to the MOVs
DIGITAL COMMUNICATION
HART (Highway Addressable Remote Transducer protocol)
Basically a plain 4 – 20 mA signal
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with additional digital Command and Response telegramms
DIGITAL COMMUNICATION
HART provides two channels
A plain 4 – 20 mA Signal and
additional Command and Response telegrams
Device category “Actuator”:4-20 mA Signal = Setpoint
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4-20 mA
4-20 mA
22 wire cable
DIGITAL COMMUNICATION
HART provides two channels
A plain 4 – 20 mA Signal and
additional Command and Response telegrams
Device category “Current output”:4-20 mA Signal = Position feedback
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4-20 mA
2
4-20 mA
2 wire cable
DIGITAL COMMUNICATION
Wireless systems License free data transmission using the ISM (Industrial, Scientific and Medical) Band
ISM (433 MHz, [868 MHz], 2,4 GHz, 5 GHz, ….) Point – to – Point systems
– Bluetooth, WLAN, RFID, car keys, smoke detectors,…) Mesh systems
– WirelessHART, ISA100.11a, WIA(PA), (ZigBee)
Data transmission based on licenses Radio frequencies Wireless systems for aviation control, sea control, ships / offshore applications, GPS, BOS (national authorities) systems Satellite applications Mobile network systems
– GSM, EDGE, GPRS, UMTS,..
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AUMA ACTUATORS WITH WIRELESS INTERFACE
AUMA wireless system is based on WirelessHART
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IEEE 802.15.4Distances:Outdoor: max 200- 250 mIndoor: max. 50 – 70 m
PROJECT EXAMPLE
Project scope Operation of jetties to load / unload oil products
to / from ships Main (primary) operation philosophy:
Control and feedback over I/O wiring (point – to – point)
Commands OPEN / CLOSE Setpoint
Feedback Endposition OPEN / CLOSE Position feedback Failure
Alternative (backup) operation method: Used once primary operation path fails Same commands and feedback Dedicated Host / DCS system Dedicated physical layer => Wireless
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PROJECT EXAMPLE
The challenges
350 m
14 WirelessHART actuators
220 m
14 WirelessHART actuators 28
Control room
PROJECT EXAMPLE
The solution
350 m (IEEE 802.11)
1 Access point
220 m (IEEE 802.11)
1 Gateway
WirelessHART(802.15.4)
14 WirelessHART actuators 1 Gateway
WirelessHART (802.15.4)
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14 WirelessHART actuators
PROJECT EXAMPLE
System overview
IEEE 802.3Ethernet (HART IP)
DCS220 m
(IEEE 802.11)
WirelessHART(802.15.4)
WirelessHART (802.15.4)
350 m (IEEE 802.11)
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PROJECT EXAMPLE
System overview of a typical WirelessHART application
220 m (IEEE 802.11)
350 m (IEEE 802.11)
WirelessHART(IEEE 802.15.4)
WirelessHART(IEEE 802.15.4)
DCS
Access Point
HART IP (IEEE 802.3)
Gateway
Gateway WLAN
Controller
Switch
Jetty 1
Jetty 3
Control room
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AUMA ACTUATORS WITH WIRELESS COMMUNICATION
Typical system design Actuators with WirelessHART WirelessHART gateway
Detailed configuration depends on the project Further system devices might be required
Access points, FO couplers, repeaters, remote mounted controls / antennas
Site survey!
WirelessHART(IEEE 802.15.4)
DCS
HART IP over IEEE 802.3Modbus TCP/IP over IEEE 802.3Modbus RTU over RS-485
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INDUSTRIAL ETHERNET
Can you provide actuators with Ethernet??
There are various industrial ethernet protocols used in process automation Profinet (Profibus over industrial ethernet) Modbus TCP/IP (Modbus over industrial ethernet) HSE (FF over industrial ethernet) HART IP (HART over industrial ethernet) Ethernet/IP (CIP protocol [e.g. DeviceNet] over industrial ethernet) …. … ..
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INDUSTRIAL ETHERNET PROTOCOLS
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INDUSTRIAL ETHERNET PROTOCOLS
Available now: Modbus TCP/IP interface for AUMA actuators
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Modbus TCP/IP
AUMA ACTUATORS WITH MODBUS TCP/IP
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Connectionfield mountable RJ-45 plug(Cat. 6A)
Modbus TCP/IP
AUMA ACTUATORS WITH MODBUS TCP/IP
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Commissioning
Webserver forcommissioning
Adress Type Static IP
Static IP Address 192.168.255.1
Subnet Mask 255.255.0.0
Default Gateway 192.168.0.1
Ex works settings:
Login password: admin
Ex works settings:• Baudrate: Auto (115,2 Kbit/s)• Parity: Even• Slaveaddress: 247
Display / CDT forcommissioning
Modbus TCP/IP
AUMA ACTUATORS WITH MODBUS TCP/IP
Project example: Tunnel ventilation
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FO cable withModbus TCP/IP
(Backbone, used fortunnel automation)
Industrial switch
Modbus TCP/IPEthernet cable
802.3
Modbus TCP/IP
AUMA ACTUATORS WITH MODBUS TCP/IP
Project example: Remote stations of e.g. pumping stations
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Internet Mobile networkSmall PLC(e.g. WAGO 750)
VPN HSPA Router(e.g. INSYS EBW-H100)
Remote area
Plant area
Modbus TCP/IP
AUMA ACTUATORS WITH MODBUS TCP/IP
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Network – topologyIEEE 802.3 (copper cables): max. 100 m
EngineeringPlant Asset
ManagementIndustrial Ethernet
Modbus TCP/IP
Switch Switch
IEEE 802.3, max. 100 m Plant Access
PointController
Switch
Modbus TCP/IP
AUMA ACTUATORS WITH MODBUS TCP/IP
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Network – topologyFO for bigger distances
Modbus TCP/IP
Switch Switch Switch
IEEE 802.3, max. 100 m Plant Access
PointController
FO,> 10 km
EngineeringPlant Asset
ManagementIndustrial Ethernet
Modbus TCP/IP
AUMA ACTUATORS WITH MODBUS TCP/IP
Applications:Actuators with network capability
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Ethernet network
Modbus TCP/IP
AUMA ACTUATORS WITH MODBUS TCP/IP
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≈ 1100 km
Modbus TCP/IP
INDUSTRIAL ETHERNET PROTOCOLS
Also available now: PROFINET interface for AUMA actuators
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AUMA ACTUATORS WITH PROFINET
PROFINET interface for AUMA actuators
Connectionfield mountable RJ-45 plug (Cat. 6A)
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New:Integrated 2 port switchfor utmost network design flexibility
AUMA ACTUATORS WITH PROFINET
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Network option 1a/3Star topologyIEEE 802.3 (copper cables): max. 100 m
Engineering Plant Asset Management
Industrial Ethernet
Switch Switch
Plant Access PointController
Switch
IEEE 802.3, max. 100 m
AUMA ACTUATORS WITH PROFINET
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Network option 1b/3Star topologyFO for bigger distances combinedwith IEEE 802.3
Engineering Plant Asset Management
Industrial Ethernet
Switch Switch
IEEE 802.3, max. 100 m
Plant Access PointController
Switch
FO,> 10 km
AUMA ACTUATORS WITH PROFINET
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Network option 2/3Line topologyIEEE 802.3 (copper cables): max. 100 mIntegral switches
Engineering Plant Asset Management
Industrial Ethernet
IEEE 802.3, max. 100 m
Plant Access PointController
Integral switchfunction
AUMA ACTUATORS WITH PROFINET
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Network option 3/3Ring topologyIEEE 802.3 (copper cables): max. 100 mIntegral switchesMRP (Media RedundancyProtocol)
Engineering Plant Asset Management
Industrial Ethernet
IEEE 802.3, max. 100 m
Plant Access PointController
Integral switchfunction
FURTHER “COMMUNCATION” OPTIONS
Connectivity to the AUMA freeware “CDT” Bluetooth communication path for data exchange Available as standard Focus of CDT
Commisioning & Configuration
FURTHER “COMMUNCATION” OPTIONS
Connectivity to the AUMA freeware “CDT” Bluetooth communication path for data exchange Available as standard Focus of CDT
Commisioning & Configuration Diagnosis & Asset Mangement
FURTHER “COMMUNCATION” OPTIONS
Connectivity to the AUMA freeware “CDT” Bluetooth communication path for data exchange Available as standard Focus of CDT
Commisioning & Configuration Diagnosis & Asset Mangement Testing & Simulation
FURTHER “COMMUNCATION” OPTIONS
FURTHER “COMMUNCATION” OPTIONS - OFFLINE
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AUMA App (available via App Store or Play Store)
Provides device specific information and documents by scanning the bar code of the physical type plate
Product identification: order number and serial number
Documents– Operation Instructions– Wiring diagram– Technical data sheet– Inspection Certificate– 3D solid model
FURTHER “COMMUNCATION” OPTIONS - OFFLINE
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AUMA App
Further features
List of devices Documentation Service calls
FURTHER “COMMUNCATION” OPTIONS - OFFLINE
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AUMA App
Available for iOS and Android
Various languages
ONCE UPON A TIME….
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DIGITAL COMMUNICATION
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Modbus TCP/IP
AUMA AUTOMATES VALVES
AUMA – 50 YEARS OF ELECTRIC ACTUATION
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