Field Communications

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FIELD COMMUNICATIONS

Think with the wise but

talk with the vulgar
- Greek Proverb

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Field Communications

Synopsis
A definition of "signal" leads into an analysis and comparison of pneumatic, analog
electrical and digital protocols.
In analog electrical signals, the importance of power supply and the relative merits of
a current/voltage standard are considered.
Digital communications' standards are viewed from the perspective of pure and hybrid
(smart) systems. Comparisons are made between competing network topologies for a
future Field Standard.

Signal
Information in the form of a pneumatic pressure, an electric current, or mechanical position that
carries from one control loop component to another.

Pneumatic Signals
The basic pneumatic mechanism converts a small motion or force into an equivalent (proportional)
pneumatic signal. Most systems use 3-15 psig/20-100 kPa span which corresponds to 0-100% of
scale.
Using the traditional flapper nozzle control element, it may be seen that the scale movement is not
linear (see Fig. 3.1). Electronics can correct for this non-linearity.

Fig. 3.1

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Pneumatic Signalling
Disadvantages

Advantages
1.

Sufficient power levels for positive valve

actuation.

1.

The longer the run of tubing the more

significant the errors due to lag and
temperature.

2.

Safe in Hazardous areas.

2.

Dirty air can clog orifices in those sensors

using traditional technologies.

In common practice, a 0-100% input signal to a current to pressure transducer can be calibrated to
a 1-17 psig (7-115 kPa) output to ensure firm closing and complete opening of valves.
Greater non-standard pressures (500 kPa say) are used to reduce Actuator sizing and save money.

Electrical Signals - Analog

In the past, competition for the Analog field standard was between 0-20 mA, 10-50 mA and 4-20
mA.
The latter emerged as the preferred option. In practice it is better to have a 'live zero' input to a
device. Otherwise a zero milliamps input could be ambiguously related to either zero output or a
complete loss of signal due to power supply failure. In the standard, 4 mA corresponds to zero
input and 0 mA to complete loss.
Using the Analog standard gives rise to considerations best appreciated in the case of 2 wire
transmitters in series with a power supply and various control room indicators.

Fig. 3.2 Wiring Connection

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Field Communications

The transmitter acts as a variable load. To enable the meter to register the full 4-20 mA deflection,
the combined effects of the transmitter and control room instrumentation's load can't exceed a value
determined from the table below.

Fig. 3.3 Load Limitations

In the example shown, the combined load cannot exceed about 800 ohm for a 30 VDC supply.
In reverse, a given load demands a minimum driving voltage. If the power supply should fall below
this minimum, the effects on output are shown below.

Fig. 3.4

It can be seen to be in someways preferable to have a VOLTAGE field standard. In this way indicators
would be in parallel with the instrument. However, current based standards are less noise susceptible
and are not subject to voltage drop on long cable runs.

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Electrical Signals - Digital

The latest move in increased communications effectiveness is to employ digital communications in
pure or hybrid systems.
In general, no universally accepted standards exist and many groups are in existence to complicate
deliberations.
MAP -

Manufacturing Automation Protocol. A specification being developed by General

Motors for standardizing communications on the factory floor.

MPII -

MAP Process Industry Initiate. Coordinates process industry activities and

requirements within the MAP specification.

TOP -

Technical and Office Protocol. A specification being developed by Boeing Computer

Services for standardizing communications between information systems.

Mini-MAP - A specification that is a subset of the full MAP specification for standardizing realtime
communication networks.
ISO -

International Standards Organization. Responsible for developing the model that

the communication specifications are based upon as well as standards for each layer
of the MAP and TOP communication specification.

IEEE -

Institute of Electrical and Electronics Engineers. Formed the IEEE 802 Project for
defining standards for network media and access methods.

SP72 -

Instrument Society of America, Standards & Practice committee Number 72.

Developing EIA1393 companion standards for process control messaging.

SP50 -

Instrument Society of America, Standards & Practice Committee Number 50.

Developing standards for digital communication between field devices (i.e.
transmitters and control equipment).

MAP/TOP Users Group An independent Organization made up of users and vendors of MAP based equipment
that are recommending changes to the MAP and TOP specifications to make the
more acceptable industry wide.
F.I.P -

Factory Information Protocol. Approved French National Standard.

Profibus -

Process Fieldbus. Approved German National Standard.

Fieldbus
consortium of manufacturers and end users developing an international digital
Foundation - communication system.
*World FIP - A U.S./French conglomerate of instrument manufacturers.
*ISP -

Interoperable Systems Project. a multinational group of some 80 manufacturers

spanning U.S./Europe and Japan.
(* now merged to form the Fieldbus Foundation.)

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Field Communications

Pure Digital Systems

The OSI (Open Systems Interconnections) Model is used to delineate the various parts of the digital
standard.
LAYERS
7

Application

Provides Services to User Applications

Presentation

Restructures data to/from standard format

Session

Synchronizes & Manages data

Transport

Provides reliable data transfer

Network

Performs routing functions between nodes

Data Link

Manages access control

Physical

Physically transfers bits

This model modularises the components of the networking hardware and software based on
functionality. Each module takes the form of a layer in the model and is responsible for providing
services to the layer above. A service is an abstract capability provided at the boundary between
any two layers of the model. Services are provided by either hardware, software, or through the
services available from the layer below.

Fieldbus
With the merger of World FIP and ISP into Fieldbus Foundation, progress towards an international
agreed standard of digital communication took a leap forward and Beta testing of software is now
complete. Full plant trials are now under analysis.

Hybrid System
In these systems, 2-wire transmitters are employed. The Analogue signal is so modulated that it
carries digital control communication simultaneously with analog process measurement.
Such a system is called "SMART".
A 'SMART' instrument employs simultaneous analogue and digital communications

The standard of SMART instrument is the HART (Highway Addressable Remote Transducer)
Protocol, and is supported by more than 75 manufacturers.

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Features:

1.

The Analogue signal can drive local devices, such as remote indicators, whilst re-ranging
(say) is accomplished from the Control Room.

Fig. 3.5 Two basic signalling

mechanisms.
2.

These devices may accommodate 'multiple masters' for example a control system, hand-held
communicator, process computer, or in some cases, a combination of the three.

Fig. 3.6 Smart transmitter linked to control.

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3.

Field Communications

Multi-dropping" is possible with digital communications

Analog or digital process value

automatic reranging based on
analog output.
Commicate transmitter status
Remote diagnostics.

Fig 3.7a Typical point-to-point link.

However no common standard yet exists for a
purely digital system. The more instruments
on the loop, the slower it is and the single
communications link leaves the system
vulnerable to disruption if it is severed.
4.

No reranging required
Communicate transmitter status
Remote diagnostics
(Digital communications only)

Fig 3.7b Multi-drop or bus network.

A vast amount of information can flow between the device and the Control System eg.
Process Variable, Transmitter Status, Configuration Data, Device physical layout, maintenance,
construction information, temperature compensation data, alarm units, diagnostics and loop
checks.

Communication can be managed remotely.

Fig 3.8a Leased telephone

communications.

Fig. 3.8b Radio

communications.
No RTU required
No reranging required
Communicate transmitter status
Remote diagnostics
Tranmitters powered locally

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Topologies
There are several versions of topologies that may be considered for a fieldbus network.
1.

The Bus Topology shown lends itself to a wide separation of devices because each drop on
the network is independent of the rest. Devices are not required to complete communications
to other devices.

Design atrributes: Efficient wiring for wide separation of devices. Potential

for simpler protocols. Single device failure cannot
cause a catastrophic network failure.
Design liabilities:

Greater installed cost due to the number of taps.

Spacing and length of drop are critical. Maintenance
complexity. Up-front engineering to plan for device
connection.

Fig. 3.9 Bus topology

2.

The ring topology shown provides two potential communication paths, increasing the reliability
of the network. Each device acts as a repeater, so a fiber optic implementation is easily
accomplished. This version is some what more expensive because of the more complex
nature of the electronics involved.

Design attributes: Potential for simple point-to-point connections. Lends itself to

fiber optics. Enhanced reliability.
Design liabilities:

Increased planningfor wiring. Increased hardware for complexity.

Each device is active and/or a repeater of information.

Fig. 3.10 Ring topology

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Field Communications

The tree topology shown is an alternate version of the bus configuration. The junction box can be
either active or passive and is consistent with current wiring practices. It also allows field wiring to
be done independently of the "home-run" cabling from the junction box back to the controller.

Design attributes:

Uses current wiring practices. Power is easily applied

from the network. A single failure cannot cause a
catastrophic network failure.

Design liabilities:

Communications are sensitive to the number of drops.

Loss of trunk cable causes loss of network.

Fig. 3.11 Tree topology

Integrated Systems
With the advent of more powerful computers (PCs) and software systems (Windows NT),
manufacturers are starting to combine process control with maintenance, engineering and
management systems to give an integrated approach to instrumentation.
Such a system enables an operator or maintenance engineer to plug a portable notebook computer
anywhere in the system loop and obtain information on the whole plant system, both current
information and plant history; check maintenance programs and obtain a variety of reports.
Such a system is very flexible and easily expandable and when working under Windows environment,
easy for all to understand and communicate with.

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Case Study

LCD
Function Keys

Action Keys

Alphanumeric
Keys

Shift Keys

Fig. 3.12 The HART communicator

Introduction
The HART (Highway Addressable Remote Transducer) Communicator is the hand-held interface
that provides a common communication link to all HART-compatible, microprocessor-based instruments. This case study discusses the HART Communicator display, keypad, connections, battery pack, and maintenance.
The HART Communicator interfaces with any HART instrument from any wiring termination
point in a 4-20 mA loop provided a minimum load resistance of 250 ohms is present between the
communicator and power supply. The HART Communicator uses the Bell 202 frequency shift
keying (FSK) technique. This technique uses high frequency digital communication signals superimposed on the standard 4-20 mA transmitter current loop. Because the net energy added to the
loop is zero, communication does not disturb the 4-20 mA signal.

Liquid Crystal Display

The LCD is an eight-line by twenty-one-character display that provides communication between
you and the connected device. When connected to a HART-compatible device, the top line of each
on-line menu displays the model name of the device and its tag. In addition, the bottom line of each
menu is reserved for a dynamic label for each software-defined Function key, F1-F4 (found directly below the display).

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Field Communications

The dynamic labels reflect available functions. For example, the label HELP appears above the Fl
key when access to on-line help is available.

The Action Keys

As shown in Figure 3.12, the Action keys are the six keys located above the Alphanumeric keys.
The function of each key is described as follows:

On/Off Key
Use this key to turn the HART Communicator on and off. When the communicator is turned
on, it searches for a HART-compatible device on the 4-20 mA loop. If a device is not found,
then the communicator displays the message, No Device Found. Press OK. Press OK
(F4) to display the Main menu.
If a HART-compatible device is found, the communicator displays the Online menu. See your
device manual for more information on the options available in this menu

Disabled Off Key

When performing certain operations, the message OFF KEY DISABLED indicates that the HART
Communicator is unable to be powered off. This feature helps to avoid situations where the HART
Communicator could be unintentionally powered off while a devices output is fixed or when configuration data has not been sent to a device.

Up Arrow Key
Use this key to move the cursor up through a menu and to scroll through lists of available characters
and options when editing a field.

Down Arrow Key

Use this key to move the cursor down through a menu and to scroll through lists of available
characters and options when editing a field.

Left Arrow and Previous Menu Key

Use this dual-function key to move the cursor to the left or to back out of a menu.

Right Arrow and Select Key

Use this dual-function key to move the cursor to the right or to select menu options.

Hot Key
Use this key to quickly access important, user-defined options when connected to a HART-compatible device. Pressing the Hot Key turns the HART Communicator on and displays the Hot key
menu.
F1

F2

F3

F4

Software-defined Function Keys

Use the four software-defined Function keys, marked Fl through F4, located below the LCD to
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perform software functions as indicated by the dynamic labels. On any given menu, the label
appearing above a Function key indicates that keys function for the current menu. As you move
between menus, different function key labels appear over the four keys. For example, in menus
providing access to on-line help, the HELP label may appear above the Fl key. In menus providing
access to the Home menu, the HOME label may appear above the F3 key. Table 1 describes the
labels that appear above each function key throughout the menus.

Table 3.1 Function Key Labels.

Alphanumeric and Shift Key

The Alphanumeric keys perform two functions: the fast selection of menu options and data entry.

Selecting Options Using the Fast Select Feature

From within any menu, you can select available options in two ways: You can use the Up
and Down Arrow keys and the Select key to
select available options, or use the Fast Select
feature. Just press the corresponding number
on the alphanumeric keypad to select the desired option. Figure 2, shows how to quickly
access the Utility menu from within the Main
menu by pressing the indicated key.
Fig. 3.13 Quickly Accessing Menus.

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Field Communications

Data Entry
Some menus require data entry. Use the Alphanumeric and Shift keys to enter all alphanumeric
information into the HART Communicator. If you press an Alphanumeric key alone from within
an edit menu, the bold character in the center of the key appears. These large characters include the
numbers zero through nine, the decimal point (.) and the dash symbol (-).
Example: To enter one of the letters or other symbols appearing above a large bold character on an
Alphanumeric key, first press and release the corresponding Shift key then press the alphanumeric
key. Do not press these keys simultaneously, but one after the other. For example, to enter the letter
R press the following key sequence:

Pressing the right shift key activates shift and causes the right shift arrow icon to appear in the
upper right corner of the display. Pressing the Shift key again deactivates shift. With shift activated, pressing the 6 key causes an R to appear in the editable field.

Hart Communicator Connections

Explosions can result in death or serious injury. Do not make connections
to the serial port or NiCad recharger jack in an explosive atmosphere.
The HART Communicator can interface with a transmitter from the control room, the instrument
site, or any wiring termination point in the loop via the rear connection panel as shown in Fig. 3.14.
To communicate, connect the HART Communicator in parallel with the instrument or load resistor.
The connections are non-polarized.
Leadset Jacks

Serial Port

Battery Charger Jack

(R) option only)

Fig. 3.14 HART Communicator rear

connection panel with optional battery

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Fig. 3.15 illustrates the wiring connections for the communicator and any HART compatible instrument. Fig. 3.16 illustrates the same connection as Fig. 3.15 using the optional 250 ohm load
resistor.

Explosions can result in death or serious injury. Before connecting the

HART Communicator in an explosive atmosphere, make sure the instruments in the loop are installed in accordance with intrinsically safe or
nonincendive field wiring practices.

Fig. 3.15 Connecting the HART

Communicator to a Transmitter Loop.
NOTE
For the HART Communicator to function properly, a minimum of 250 ohms resistance must be
present in the loop. The HART Communicator does not measure loop current directly.

Fig. 3.16 Connecting the HART Communicator

with the Optional Load Resistor.

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Field Communications

Servicing the HART Communicator

As shown in Fig. 3.17, the modular construction of the HART Communicator allows easy disassembly of the battery pack and the memory module. This section discusses how to change alkaline
batteries, recharge the NiCad battery pack, and upgrade the communicator software.

Figure 3.17 HART Communicator Exploded View.

Battery Pack
The HART Communicator is available with a battery pack that holds five AA alkaline cells, or with
a rechargeable nickel-cadmium power pack. The alkaline cells last approximately 150 hours, and
the NiCad cells last approximately 60 hours with normal usage. When approximately one hour of
battery life remains a low-battery icon appears in the upper right corner of the display.

Changing Alkaline Batteries

Explosions can result in death or serious injury. Do not remove or replace
battery pack in an explosive atmosphere
Refer to Fig. 3.18 and use the following steps to change alkaline batteries:

Fig. 3.18 Battery Pack Removal.

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1.

Completely loosen the three captive screws holding the communicaton battery pack.

2.

Grasp the battery pack and pull it away from the communicator. Make sure not to bend the
pins connecting the battery pack to the communicator.

3.

Remove and properly dispose of batteries.

4.

Referring to the battery orientation diagram on the inside of the battery pack, insert five
AA alkaline batteries.

5.

Carefully align the pins with the communicator base and replace the battery pack.

6.

Tighten the three screws.

7.

Turn on the communicator to ensure that the batteries are installed properly.

Replacing the Memory Module

Explosions can result in death or serious injury. Do not remove or replace
battery pack in an explosive atmosphere.

Fig. 3.19 Memory Module Removal.

Refer to Fig. 3.19 and use the following steps to replace the Memory Module:
1.

Completely loosen the three captive screws holding the communicator battery pack,

2.

Grasp the battery pack and pull it away from the communicator. Make sure not to bend the
pins connecting the battery pack to the communicator.

3.

Loosen the two captive screws holding the Memory Module.

4.

Grasp the Memory Module and pull it away from the communicator.

5.

Align the new Memory Module with the communicator and tighten the two screws.

6.

Replace the battery pack.

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Field Communications

Functional Specifications
MEMORY
Nonvolatile memory retains contents when the HART Communicator is not Powered.
Program (and Device Descriptions):
1.25 MB.
Transmitter data:
2 KB.
POWER SUPPLY
Five AA 1.5 V batteries (rechargeable Nickel-Cadmium battery pack optional).
BATTERY CHARGER OPTIONS
110/120 V ac, 60 Hz, US plug.
220/230 V ac, 50 Hz, European plug.
220/230 V ac, 50 Hz, UK plug.
MICROPROCESSORS
32-bit Motorola type 68331.
8-bit Motorola type 68HC05.
CONNECTIONS
Leadset:
Battery charger:
Serial port:
Memory Module:

Two 4 mm banana plugs.

2.5 mm jack.
PC connection through optional adapter.
26 pin, 0 1 -in. Berg connector.

Performance Specifications
TEMPERATURE LIMITS
Operating Limits
32 to 1220F (0 to 500C).
Storage Limits
-4 to 1580F (-20 to 70 0C)
Humidity Limits
Operates in 0-95% relative humidity under noncondensing conditions below 104 0F (400C) without
error.
HAZARDOUS LOCATIONS CERTIFICATIONS
Baseefa/Cenelec
Factory Mutual
Canadian Standards Association

Physical Specifications
DISPLAY
8-line liquid crystal display with 21-character line width (128 by 64 pixels).
KEYPAD
25 large keys including six Action keys, a complete alphanumeric keypad, four software defined
function keys, ON/OFF, and cursor control keys; membrane design with tactile feedback.

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WEIGHT
Approximately 3 lb (1.4 kg) including batteries.

Ordering Information
Table 3.2 lists possible options as either standard or optional selections. The
selections that make up the model number 275D9E.

symbol indicates

STANDARD SELECTIONS

Table 3.2 Ordering Information.

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Field Communications

Spare Parts
Refer to Table 3.3 and Fig. 20 to choose spare parts for the HART Communicator.

Table 3.3 Spare Parts.

Fig. 3.20 HART Communicator Spare Parts.

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Discussion
What are the pros and cons of moving to plant-wide Smart instrumentation?
What practical implications arise in the maintenance of a Plant-wide, purely digital network?

Test
Q. 1 What is the pneumatic signal field standard?
Ans. ___________________________________________________________________
Q. 2 What is the analog electrical signal field standard?
Ans. ___________________________________________________________________
Q. 3 Explain "live zero"
Ans. ___________________________________________________________________
_______________________________________________________________________
_______________________________________________________________________
Q. 4 Explain "Fieldbus"
Ans. ___________________________________________________________________
_______________________________________________________________________
_______________________________________________________________________
Q. 5 Define a "Smart" Instrument
Ans. ___________________________________________________________________
_______________________________________________________________________
Q. 6 Explain "OSI Seven Layer" Model
Ans. ___________________________________________________________________
_______________________________________________________________________
_______________________________________________________________________
Q. 7 Describe a "Bus" Network
Ans. ___________________________________________________________________
_______________________________________________________________________
_______________________________________________________________________

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Field Communications

Q. 8 Describe a "Ring" Network

Ans. ___________________________________________________________________
_______________________________________________________________________
_______________________________________________________________________
Q. 9 Describe "HART""
Ans. ___________________________________________________________________
_______________________________________________________________________
_______________________________________________________________________

Third Printing: October 1996

Second printing: July 1993
First printed: October 1991

Principles of Instrumentation and Control

Course 9050 - October 1996