Iec 61158 Pdf Free Download

[Octavis Marquez]

Thisseries of standards set out the protocols for the interconnection of automation and process control system components by fieldbus network systems in manufacturing plants. The systems allow development of protocol hierarchies, linking Human Machine Interfaces (HMI) into Programmable Logic Controllers (PLC) through to sensors, actuators, electric motors and switches.

Commonly known as Fieldbus systems, the standard covers the BUS cables required to connect process control systems operating in environments with increased temperatures and humidity, and under mechanical stress from vibration. Cables manufactured according to IEC 61158 for data exchange and process control allow for one controller-level communication point to connect with multiple (ranging into the hundreds) of digital or analogue receiver points. IEC 61158 cables are shielded generally with an Aluminium Polyester Tape and with a tinned copper wire braid (TCWB) or steel wire armour (SWA) to offer protection from cross-talk and electromagnetic interference.

A fieldbus is a member of a family of industrial digital communication networks[1] used for real-time distributed control. Fieldbus profiles are standardized by the International Electrotechnical Commission (IEC) as IEC 61784/61158.

A complex automated industrial system is typically structured in hierarchical levels as a distributed control system (DCS). In this hierarchy the upper levels for production managements are linked to the direct control level of programmable logic controllers (PLC) via a non-time-critical communications system (e.g. Ethernet). The fieldbus[2] links the PLCs of the direct control level to the components in the plant of the field level such as sensors, actuators, electric motors, console lights, switches, valves and contactors and replaces the direct connections via current loops or digital I/O signals. The requirement for a fieldbus are therefore time-critical and cost sensitive. Since the new millennium a number of fieldbuses based on Real-time Ethernet have been established. These have the potential to replace traditional fieldbuses in the long term.

The most important motivation to use a fieldbus in a distributed control system is to reduce the cost for installation and maintenance of the installation without losing the high availability and reliability of the automation system. The goal is to use a two wire cable and simple configuration for field devices from different manufacturers. Depending on the application, the number of sensors and actuators vary from hundreds in one machine up to several thousands distributed over a large plant. The history of the fieldbus shows how to approach these goals.

Arguably the precursor field bus technology is HP-IB as described in IEEE 488[3] in 1975. "It became known as the General Purpose Interface Bus (GPIB), and became a de facto standard for automated and industrial instrument control".

The GPIB has its main application in automated measurements with instruments from different manufacturers. It is a parallel bus with a cable and connector with 24 wires, limited to a maximal cable length of 20 metres.

The oldest commonly used field bus technology is Bitbus. Bitbus was created by Intel Corporation to enhance use of Multibus systems in industrial systems by separating slow i/o functions from faster memory access. In 1983, Intel created the 8044 Bitbus microcontroller by adding field bus firmware to its existing 8051 microcontroller. Bitbus uses EIA-485 at the physical layer, with two twisted pairs - one for data and the other for clocking and signals. Use of SDLC at the data link layer permits 250 nodes on one segment with a total distance of 13.2 km. Bitbus has one master node and multiple slaves, with slaves only responding to requests from the master. Bitbus does not define routing at the network layer. The 8044 permits only a relatively small data packet (13 bytes), but embeds an efficient set of RAC (remote access and control) tasks and the ability to develop custom RAC tasks. In 1990, the IEEE adopted Bitbus as the Microcontroller System Serial Control Bus (IEEE-1118).[4][5]

Office networks are not really suited for automation applications, as they lack the upper bounded transmission delay. ARCNET, which was conceived as early as 1975 for office connectivity uses a token mechanism and therefore found later uses in industry,

The Manufacturing Automation Protocol (MAP) was an implementation of OSI-compliant protocols in automation technology initiated by General Motors in 1984. MAP became a LAN standardization proposal supported by many manufacturers and was mainly used in factory automation. MAP has used the 10 Mbit/s IEEE 802.4 token bus as transmission medium.

Due to its scope and complexity, MAP failed to make the big breakthrough. To reduce the complexity and reach faster processing with reduced resources the Enhanced Performance Architecture (EPA) MAP was developed in 1988. This MiniMap[7] contains only levels 1,2 and 7 of the Open Systems Interconnection (OSI) basic reference model. This shortcut was taken over by the later fieldbus definitions.

The Manufacturing Message Specification (MMS) is an international standard ISO 9506[8] dealing with an application protocol and services for transferring real time process data and supervisory control information between networked devices or computer applications published as a first version in 1986.

It has been a model for many further developments in other industrial communication standardizations such as FMS for Profibus or SDO for CANopen. It is still in use as a possible application layer e.g. for power utility automation in the IEC 61850 standards.

In the field of manufacturing automation the requirements for a fieldbus are to support short reaction times with only a few bits or bytes to be transmitted over not more than some hundreds of meters.

In 1979 Modicon (now Schneider Electric) defined a serial bus to connect their programmable logic controllers (PLCs) called Modbus. In its first version Modbus used a two wire cable with EIA 485 UART signals. The protocol itself is very simple with a master/slave protocol and the number of data types are limited to those understood by PLCs at the time. Nevertheless, Modbus is (with its Modbus-TCP version) still one of the most used industrial networks, mainly in the building automation field.

A research project with the financial support of the German government defined in 1987 the fieldbus PROFIBUS based on the Fieldbus Message Specification (FMS).[9] It showed in practical applications, that it was too complicated to handle in the field. In 1994 Siemens proposed a modified application layer with the name Decentralized Periphery (DP) which reached a good acceptance in the manufacturing industry. 2016 the Profibus is one of the most installed fieldbuses in the world[10] and reaches 60 millions of installed nodes in 2018.[11]

In 1987 Phoenix Contact developed a serial bus to connect spacially distributed inputs and outputs to a centralized controller.[12] The controller send one frame over a physical ring, which contains all input and output data. The cable has 5 wires: beside the ground signal two wires for the outgoing frame and two wires for the returning frame. With this cable is it possible to have the whole installation in a tree topology.[13]

The INTERBUS was very successful in the manufacturing industry with more than 22,9 million of devices installed in the field. The Interbus joined the Profinet technology for Ethernet-based fieldbus Profinet and the INTERBUS is now maintained by the Profibus Nutzerorganisation e.V.[14]

During the 1980s, to solve communication problems between different control systems in cars, the German company Robert Bosch GmbH first developed the Controller Area Network (CAN). The concept of CAN was that every device can be connected by a single set of wires, and every device that is connected can freely exchange data with any other device. CAN soon migrated into the factory automation marketplace (with many others).

DeviceNet was developed by the American company Allen-Bradley (now owned by Rockwell Automation) and the ODVA (Open DeviceNet Vendor Association) as an open fieldbus standard based on the CAN protocol. DeviceNet is standardised in the European standard EN 50325. Specification and maintenance of the DeviceNet standard is the responsibility of ODVA. Like ControlNet and EtherNet/IP, DeviceNet belongs to the family of CIP-based networks. CIP (Common Industrial Protocol) forms the common application layer of these three industrial networks. DeviceNet, ControlNet and Ethernet/IP are therefore well coordinated and provide the user with a graded communication system for the management level (EtherNet/IP), cell level (ControlNet) and field level (DeviceNet). DeviceNet is an object-oriented bus system and operates according to the producer/consumer method. DeviceNet devices can be client (master) or server (slave) or both. Clients and servers can be Producer, Consumer or both.

CANopen was developed by the CiA (CAN in Automation), the user and manufacturer association for CANopen, and has been standardized as European standard EN 50325-4 since the end of 2002. CANopen uses layers 1 and 2 of the CAN standard (ISO 11898-2) and extensions with regard to pin assignment, transmission rates and the application layer.

In process automation traditionally most of the field transmitters are connected over a current loop with 4-20 mA to the controlling device. This allows not only to transmit the measured value with the level of the current, but also provide the required electrical power to the field device with just one two-wire cable of a length of more than a thousand meters. These systems are also installed in hazardous areas. According to NAMUR a fieldbus in these applications has to fulfill these requirements.[15] A special standard for instrumentation IEC/EN 60079-27 is describing requirements for the Fieldbus Intrinsically Safe Concept (FISCO) for installations in zone 0, 1 or 2.

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