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PROFIBUS

4.1 Introduction

PROFIBUS (Process Fieldbus) is an open fieldbus standard to EN 50 170 (European standard) initiated in 1989
by Siemens to cater to the needs of both process automation and factory manufacturing automation. It is
suitable for both fast, time-critical applications and complex communication tasks. Profibus can connect a
maximum of 126 devices on a single network segment. The initial release of PROFIBUS specified a complex
protocol version called PROFIBUS-FMS (Field bus Message Specification) that was replaced by the following
two alternatives:

• PROFIBUS-DP (Decentralized Peripherals).

• PROFIBUS-PA (Process Automation)

A PROFIBUS network can have both DP and PA segments interfaced using a DP/PA segment coupler to
facilitate communication between different wiring standards as shown in Figure 4.1. DP/PA segment couplers are
used as repeaters. They do not have their own bus address and are transparent to the DP master station controlling
the PA network. When DP/PA segment couplers are used, every PA device will have its own station address,
which must be unique within the overall PROFIBUS network.

Figure 4.1: Profibus PA/DP– showing the link device (or coupler)

PROFIBUS supports two types of devices: master devices and slave devices. The former is called an “active
station”, while the latter is called a “passive station”. A master device has the right to control the bus when it
has bus access. Then it can transmit messages without any remote request. Transmitters, sensors, and actuators
are examples of slave devices. A slave device acknowledges any received message upon receiving a request from
a master and they can send messages to that master.

4.2 PROFIBUS-DP (decentralised periphery)

Profibus-DP (variant DPV1) is an extension of the original PROFIBUS standard. An extension contains a subset
of the functionality of the original standard and is targeted at a specific area of application.

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PROFIBUS-DP handles fast communication processes such as drives, and remote inputs/outputs (I/O)
normally encountered in factory automation. In the original version, PROFIBUS-DP allowed only one master
that communicated via the master-slave method. Multi-masters are also used in which case a slave is assigned to
one master only. It means that multiple masters can read inputs from a specific device but only one master can
write outputs to that device. The extended version of DPV1 allows up to 127 participants including up to 32
masters. A slave, however, may be allocated to only one "Class 1" master. Slaves are configured by a Class 2
master using acyclic services. The Technical data of Profibus-DP can be summarised as follows in Table 4.1:

Standard EN 50 170
Physical layer RS-485 and/or Fibre optic
Maximum length 1200 m
Number of devices 32/segment, max 4 repeaters=126 devices
Transmission rate 9.6kbps to 12Mbps
Table 4.1 Summary of Profibus-DP Features

4.2.1 PROFIBUS-DP Topology

PROFIBUS-DP is based on a linear topology (bus structure). For lower data transmission rates, a tree structure
is also possible. Up to 32 stations (masters or slaves) can be connected in a single segment. The beginning and
end of each segment are fitted with an active bus terminator (see Figure 4.2). Both bus terminators have a
permanent power supply to ensure error-free operation. The bus terminator is usually switched in the devices
or the connectors. If more than 32 stations are implemented or there is a need to expand the network area,
repeaters must be used to link the individual bus segments.

Figure 4.2 Terminator

Different cable types (type designation A - D) for different applications are available on the market for connecting
devices either to each other or to network elements (segment couplers, links, and repeaters). When using RS485
transmission technology, PI (PROFIBUS & PROFINET International) recommends the use of cable type A. A
summary of the specifications for type A cable is given in Table 4.2.

Impedance 135 to 165Ω

Capacitance ≤30 pf/m
Loop resistance ≤110Ω/Km
Wire diameter > 0.64 mm
Core cross-section > 0.34 mm2
Table 4.2 Specifications for the Type A cable

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PROFIBUS cables are offered by a wide range of manufacturers; PI particularly recommends the fast connect
system which, when used with a suitable cable and special stripping tool allows fast, reliable, and extremely
simple wiring. When connecting the stations, always ensure that the data lines are not reversed. Always use a
shielded data line (type A is shielded) to ensure high interference immunity of the system against electromagnetic
emissions. The shield should be grounded on both sides where possible and large-area shield clamps should be
used for grounding to ensure good conductivity. Furthermore, always ensure that the data line is laid separately
and where possible, away from all power cables. Spur lines should not be used for transmission rates ≥ 1.5
Mbit/s. Commercially available connectors support direct connection of the incoming and outgoing data cable in
the connector. This eliminates the need for spur lines and the bus connector can be connected and disconnected
from the bus at any time without interrupting data communications. The type of connector suitable for RS485
transmission technology depends on the degree of protection. A 9-pin D-Sub connector is primarily used for
protection rating IP 20. Problems with data transmission in PROFIBUS networks can usually be attributed to
incorrect wiring or installation. These problems can often be solved using bus test devices, which can detect
many typical wiring errors even before commissioning.

A summary of the features of cable types A – D is given in table 4.3 below.

Type A Type B Type C Type D

Cable design Twisted wire pair, Individual or several Several twisted Several not
shielded twisted wire pairs, totally wire pairs, not twisted lines,
Shielded shielded Not shielded
Wire diameter 0.8 mm2 0.32 mm2 0.13 mm2 1.25 mm2
(AWG 18) (AWG 22) (AWG 26) (AWG 16)
Cable length 1900 m 1200 m 400 m 200 m
Table 4.3 Cable Types A – D Specifications

4.2.2 RS485-IS

There has been great demand among users to support the use of RS485 with its fast transmission rates in
intrinsically safe areas. The PNO (in German name: PROFIBUS Nutzer organisation) (same meaning as PI) has
addressed this task and worked out a guideline for the configuration of intrinsically safe RS485 solutions with
simple device interchangeability. The specification of the interface details the levels of current and voltage
that must be adhered to by all stations in order to ensure safe functioning during operation. An electric circuit
permits maximum currents at a specified voltage level. When connecting active sources, the sum of the
currents of all stations must not exceed the maximum permissible current.

An innovation of the RS485-IS concept is that, in contrast to the Fieldbus Intrinsically Safe Concept (FISCO)
model that only has one intrinsically safe source, all stations now represent active sources. The continuing
investigations of the testing agency led us to expect that it will be possible to connect up to 32 stations to the
intrinsically safe bus circuit.

4.3 PROFIBUS-PA (process automation)

Developed specifically for the process automation to replace 4-20mA transmission, at the field level of the
industrial network hierarchy. It uses the same two-wire analogue loop copper connection carrying both power

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and data. Generally designed for external use for connecting field devices. It is slower than PROFIBUS DP and
runs at a fixed speed of 31.2Kbps using the Manchester-coded bus-powered (MBP) transmission technology.

It has two specialities: firstly, participants can draw intrinsically safe power from the bus and secondly, the
data transfer is handled according to the international standard IEC 61158-2. A maximum of 32 participants
can be connected to a PROFIBUS-PA segment.

Bus access is governed by the master/slave method. Unlike the automated applications in manufacturing
engineering which require short cycle times of a few milliseconds, other factors are of importance in process
automation, such as the following:

• intrinsically safe transmission techniques,

• field devices are powered over the bus cable,
• reliable data transmission, and
• Interoperability (standardization of device functions).

With PROFIBUS-PA, as with DP three device types can be differentiated as follows:

• The class-1 master (DPM1) is the central control unit of a system, e.g. a PLC, which exchanges data
with the field devices within a specified message cycle. Class 1 masters have the following
characteristics: tokens are passed between the masters; can write data into the slaves assigned to it and
can read data from a slave in the network; sets the data rate; and the connected slaves detect the same
data automatically. When compared with conventional techniques, the cyclic communication of the
class-1 master assumes tasks of the analogue 4 to 20 mA standardized signals and additionally enables
the bidirectional exchange of data.

Note: The DPV1 services also enable the class-1 master to have cyclic access to field device data. However,
masters available on the market as well as the current GSD specifications do not yet support this function.

• Class-2 masters (DPM2) are used for operation and monitoring purposes as well as during start-up. It
acts as supervisory masters, used for diagnostic purposes and slave commissioning, control slaves at
any given point of time, and can only read slaves but do not have written access. For example, a PC
can be used as a class 2 master. Therefore, class-2 masters require acyclic communication services
exclusively.
• A slave is a peripheral or field device which communicates only when requested by a master.
Actuators receive input information from the master and actively influence the process. Sensors
collect state and process data and provide the master with this information.

4.3.1 Manchester coding Bus Powered Transmission (MBP)

The term MBP stands for transmission technology.

It is available for applications in process automation with a demand for bus powering and the intrinsic safety of
devices. Compared to the previously used procedure, the "Fieldbus Intrinsically Safe Concept “(FISCO) which
was specially developed for the interconnection of intrinsically safe fieldbus devices, considerably simplifies
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planning and installation. MBP is the synchronous transmission with a defined transmission rate of 31.25 Kbit/s
and Manchester coding. This transmission technology used in process automation satisfies the key demands of
the chemical and petrochemical industries for intrinsic safety and bus power using two wire-technology. The
characteristics of the different transmission technology are summarized in Table 4.4. This means that PROFIBUS
can also be used in potentially explosive areas and be intrinsically safe.

MBP RS485 RS485-IS Fibre Optic

Data Digital, bit Digital, differential Digital, Optical, digital,
transmission synchronous signals according differential NRZ
Manchester encoding to RS485, NRZ signals according
to RS485, NRZ
Transmission 31.25 KBit/s 9.6 to 12,000 KBit/s 9.6 to 1,500 9.6 to 12,000
rate KBit/s KBit/s
Data security Preamble, error HD=4, Parity bit, HD=4, Parity bit, HD=4, Parity bit,
protected, start/end delimiter start/end delimiter start/end delimiter
start/end delimiter
Cable Shielded, twisted pair Shielded, twisted Shielded, twisted Multimode glass
copper pair copper, cable 4-wire, cable type fibre, single mode
type A A glass fibre, PCF,
plastic
Remote feeding Optional available Available over Available over Available over
over signal wire additional wire additional wire hybrid line
Protecting type Intrinsic safety None Intrinsic safety None
(EEx ia/ib) (EEx ib)
Topology Line and tree Line topology with Line topology with Star and ring
topology with termination Termination topology typical;
termination; also in line topology
combination possible
Number of Up to 32 stations per Up to 32 stations per Up to 32 stations Up to 126 stations
stations Segment; total sum segment without per per
of max. 126 per repeater; up to 126 segment; up to 126 network
network stations with stations with
repeater repeater
Number of Max 4 reapeters Max. 9 repeater with Max. 9 repeater
Unlimited with
repeaters signal refreshing with signal refreshing
signal refreshing
(time delay of
signal)
Table 4.4 Summary of Profibus Transmission Technologies – Physical Layer

4.3.1.1 Connection technology using MBP

The intrinsically safe transmission technology MBP is usually limited to a specific segment (field devices in
hazardous areas) of a plant, which is then linked to the RS485 segment (control system and engineering devices
in the control room) via a segment coupler or links (Figure 4.3).

Segment couplers are signal converters that modulate the RS485 signals to the MBP signal level and vice versa.
They are transparent from the bus protocol standpoint. In contrast, links have their own intrinsic intelligence. They
map all the field devices connected to the MBP segment as a single slave in the RS485 segment. There is no limit
to the transmission rate in the RS485 segment when using links so fast networks can also be implemented using
field devices with MBP connection.

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Figure 4.3 Profibus Network with IS MBP

4.3.3.2 Network Topologies with MBP

Tree or line structures (and any combination of the two) are network topologies supported by PROFIBUS with
MBP transmission. In a line structure, stations are connected to the trunk cable using tee adapters. The multi-
core master cable is replaced by the two-wire bus master cable. The field distributor retains its function of
connecting the field devices and detecting the bus terminator impedance. When using a tree topology, all field
devices connected to the fieldbus segment are wired in parallel in the field distributor. In all cases, the maximum
permissible spur line lengths must be taken into account when calculating the overall line length. In
intrinsically safe applications, a spur line has a maximum permissible length of 30m.

4.3.4 Transmission Medium

A shielded two-wire cable is used as the transmission medium. The bus trunk cable has a passive line terminator
at each end, which comprises an RC element connected in series with R = 100Ω and C = 2μF. The bus terminator
is already integrated into the segment coupler or link. When using MBP technology, an incorrect connection of
a field device (i.e. polarity reversal) has no effect on the functionality of the bus as these devices are usually fitted
with an automatic polarity detection function.

4.3.4.1 Number of Stations and Line Length

The number of stations that can be connected to a segment is limited to 32. However, this number may be
further determined by the protection type selected and bus power (if any). In intrinsically safe networks, both
the maximum feed voltage and the maximum feed current are defined within strict limits. However, the output
of the supply unit is limited even for non-intrinsically safe networks.

As a rule of thumb for determining the maximum line length, it suits to calculate the power requirements of
the connected field devices and to specify a supply unit and the line length for the selected cable type. The
required current (=Σ power requirements) is derived from the sum of the basic currents of the field devices
connected in the respective segment plus, where applicable, a reserve of 9 mA per segment for the operating
current of the FDE (Fault Disconnection Electronics).

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The FDE prevents faulty devices from permanently blocking the bus. Joint operation of bus-powered and
externally fed devices is permissible. Note that externally fed devices also consume a basic current over the bus
terminator, which must be taken into account accordingly when calculating the maximum available feed
current.

4.3.4.2 Fibre Optic Transmission Technology

Some fieldbus application conditions place restrictions on wire-bound transmission technology, such as those in
environments with very high electromagnetic interference or when particularly large distances need to be
covered. Fibre optic transmission over fibre optic conductors is suitable in such cases. The PROFIBUS guideline
(2.022) for fibre optic transmission specifies the technology available for this purpose. 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 behaviour of PROFIBUS (layer 1).
This ensures backward compatibility with existing PROFIBUS installations. The supported fibre optic types are
shown in Table 4.5. The transmission characteristics support not only star and ring topology structures but also
line structures. In the simplest case, a fibre optic network is implemented using electrical/optical transformers
that are connected to the device and the fibre optics over an RS485 interface. This allows switching between
RS485 and fibre optic transmission within a plant, depending on the circumstances.

Fibre type Core diameter [µm] Range

Multimode glass fibre 62.5/125 2-3 km
Single-mode glass fibre 9/125 > 15 km
Plastic fibre 980/1000 < 80 m
HCS fibre 200/230 approx. 500 m
Table 4.5 Fibre Optics Type

Some of the advantages and disadvantages of using fibre optic cables instead of copper are: Fibre optic cables
are lighter and smaller and are immune to electromagnetic interference. It is immune to differences in ground
plane potentials. It can support more complex network topologies and can be used over longer distances than
copper. The main disadvantages are that it is more expensive and difficult to handle (installation, connection,
etc). With very complex networks it may also be necessary to adjust the bus timing parameters.

Cables with differing optical characteristics are available. The method of construction, materials used, and
dimensions of the cable influence the characteristics. The cable can be single or multi-mode fibre. The cable is
further categorised by the core diameter, cladding diameter and jacket diameter. The construction of a fibre optic
cable is illustrated in Figure 4.4 with the most commonly used diameters for jacket, cladding and core indicated.

Figure 4.4 Fibre Optic Cable Construction

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A cable might thus be designated 10/125/250 single mode fibre or 50/125/250 multimode fibre. For multimode
fibre, the core size will be 50 or 62.5 µm and for the single mode, the core size will be 10 µm. The maximum
distances for the different fibre optic cables are indicated in Table 4.5 above. The maximum distances can be
extended using fibre optic repeaters. Fibre optic repeaters serve the same purpose for fibre optic transmission
as RS-485 repeaters serve for copper communication. Two types of connectors are generally used. They are
Bayonet Fibre Optic Connectors (BFOC) and Field-Installable Sub-miniature Assembly (F-SMA).

RS-485 is normally used in a straight-line configuration. Repeaters can be used to obtain branching. With
fibre optic cable transmission several different topologies are possible. Redundancy can also be achieved. In
Figure 4.5(A) a straight-line topology is followed. This can be used in a noisy environment where fibre optics
are used, and only short runs of copper are used for the devices. In Figure 4.5(B) a star topology is used. It should
be noted that for any break in the fibre optic when using redundancy topology, there will still be an alternate path
to any of the repeaters and thus to any copper segment.

4.4 Planning a Profibus-PA Installation

When planning installation certain aspects need to be considered and some variables need to be calculated.
Aspects that must be considered are the following:

• Select a suitable segment coupler.

• Consider the cable type and lengths of the bus and spurs.
• Calculate the current consumption taking all devices into consideration.
• Ensure that the voltage at the last device in the segment is sufficient.
• Consider the cycle times of the network.

4.4.1 Selecting the Segment Coupler

When selecting a segment coupler, the type of atmosphere (environmental conditions – hazardous atmosphere
or normal) should be taken into consideration. If it is a hazardous atmosphere the zone/explosion group and
type of protection required should be known and the appropriate devices selected. Devices that are classified
as non-ex may not be operated in an explosion-hazardous area. Segment couplers are available from various
manufacturers for ex and standard conditions.

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4.4.2 Cable Length and Type of Cable

The maximum length of the segment depends on the protection required for the segment and the specification
of the cable. For the basic requirements for transmission on the IEC 61158-2 physical layer to be fulfilled and the
inductance and capacitance of the cable can be neglected, the bus length and loop resistance are limited. The
Profibus-PA specifications are listed in Table 4.6 below.

Standardised power supplies are assumed with maximum loop resistance and bus length for various applications
(standard and explosion-proof). The bus length is the length of the trunk and all spurs. The length can be
doubled by using a repeater. When using spurs, the following should be kept in mind:

• The maximum length of a spur in an explosive atmosphere is 30m.

• For non-hazardous installations the maximum spur length is determined by the number of devices
used. More detail on this is indicated in Table 4.7.
• Spurs shorter than one meter are considered junction boxes and are not included in the calculation
of the total length provided that the total length of these spurs does not exceed 8 m for a 400 m bus or
2% of the total length of a longer bus.

Table 4.6 Profibus-Pa Segment properties with Standard Power Supplies

Power supply Type A Type B Type C

Application EEx [ia/ib] IIC EEx [ib] IIB standard
Supply voltage* 13.5 V 13.5 V 24 V
Max power* 1.8 W 4.2 W 9.1 W
Max. current ≤ 110 mA ≤ 280 mA ≤400 mA
consumption*
Max loop resistance ≤ 40 Ω ≤ 16 Ω ≤39 Ω
Max bus segment length 1000 m (EEx ia) 1900 m (EEx ia) 1900 m (EEx ia)
Max spur length 30 m 30 m See Table 4.7

Table 4.7 Maximum Spur Length for Non-Hazardous Applications

No. of filed devices 25-32 19-24 15-18 13-14 1-12
Spur length ±1 m 30 m 60 m 90 m 120 m

4.4.2.1 Permissible Cable Length

Keeping the limits in Table 4.7 above in mind, the maximum cable length for a particular cable type can be
calculated as follows:

𝑀𝑎𝑥 𝑙𝑜𝑜𝑝 𝑟𝑒𝑠𝑖𝑠𝑡𝑎𝑛𝑐𝑒 𝑜𝑓 𝑠𝑒𝑔𝑚𝑒𝑛𝑡 𝑐𝑜𝑢𝑝𝑙𝑒𝑟

𝑀𝑎𝑥𝑖𝑚𝑢𝑚 𝑐𝑎𝑏𝑙𝑒 𝑙𝑒𝑛𝑔𝑡ℎ (𝐾𝑚) =
Ω
𝑠𝑝𝑒𝑐𝑖𝑓𝑖𝑐 𝑟𝑒𝑠𝑖𝑠𝑡𝑖𝑣𝑖𝑡𝑦 𝑜𝑓 𝑐𝑎𝑏𝑙𝑒 ( )
𝑘𝑚

For maximum loop resistance of segment coupler, see Table 4.6 If it is not given the loop resistance is:

Ω
(𝐿𝑜𝑜𝑝 𝑟𝑒𝑠𝑖𝑠𝑡𝑎𝑛𝑐𝑒) 𝐾𝑚 = 2 ∗ 1000 ∗ ρ/A.

Where ρ= specific resistivity in Ω/mm2 and A= area of conductor in mm2

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The loop resistance of the various cables is available from the manufacturer of the cable. In general, a value of ≤
44 Ω/km is normal for the cable resistance. Table 4.8 list examples of cable available from different
manufacturers.

Table 4.8 Examples of Profibus-PA Cable available

Manufacturer Application Specific resistance
Siemens Standard ≤ 44 Ω/Km
Siemens EEix ia/ib IIC ≤ 44 Ω/Km
Kerpen Standard
Kerpen EEix ia/ib IIC
Belden Standard 45.4 Ω/Km

4.4.3 Calculating the Current Consumption of a Segment

The number of devices in a segment is primarily determined by the current that can be supplied by the power
supply. When designing a system, the current consumption has to be calculated for each segment.

The following rules should be considered when designing a system:

• In non-hazardous areas 32 devices per segment are permissible. A repeater can be included to
increase the number of devices in the segment.
• In the hazardous areas category (ia), 10 devices are allowed. To do the calculation the following is
required to be known:
➢ The current supplied by the segment coupler Is
➢ The basic current of each device IB and
➢ The fault current of each device IFDE.

A segment is permissible when Is ≥ ISEG and ISEG = ⅀ IB + IFDE

The basic current, fault current and other specifications can be obtained from the manufacturers of the devices.

4.4.4 Voltage at the Last Device

Due to the length and resistance of the cable, a volt drop on the segment will occur. The volt drop is the largest
at the last device in the segment furthest from the segment coupler. An operating voltage of at least 9 V (for Zone
0, and 9,6 V in Zone 1) is required for a Profibus-PA device to operate.

Using Ohm’s law:

UB = US – (ISEG x RSEG)

Where:

UB = Voltage at the last device

US = Output voltage of the segment coupler (according to manufacturer)

ISEG = Current consumed on the segment (as calculated in 4.4.2)

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RSEG = Cable resistance = bus length x specific resistivity

Example 1: Calculation of a Bus Design (Standard Conditions)

The following example is for a bus in a safe area. The layout of the bus is shown in Figure 4.6 below and a
standard Siemens Segment coupler is used. The specifications for the segment coupler are as follows:

Is = 400 mA and Us = 19 V. The cable is Siemens and has a cable resistance of 44 Ω/km.

Maximum loop resistance for a standard segment coupler (Table 4.6 – standard cable) =39Ω. The specific
resistance of the cable = 44 Ω/km

T Trunk Cable: Length = 60 m

Coupler

20m 20 m 15m 5m 7m 7m 20m 20 m 15m 5m 7m

Level

Control Level
Valve
Temp
Transmitter
Temp Control
Transmitter Valve
Flow Flow
Transmitter Transmitter
Flow Flow
Transmitter Transmitter
Control Control
Valve Valve

Figure 4.6 Calculations of the Bus Parameters

1000∗39
Maximum allowable length (in m) = (1000 x loop resistance)/specific resistance = = 𝟖𝟖𝟔. 𝟑𝟔 𝒎
44

Length of trunk cable (given) = 60 m

Total length of spurs = 20+20+15+5+7+7+20+20+15+5+7=141 m

Total length of cable (trunk + spurs) = Lseg = 141 + 60 = 201 m

Therefore, Maximum allowable length (886,36m) > Total length of cable (201m)

Current consumption of the segment:

The following table shows the devices used and the current consumption of each device.

Table 4.9 Current Consumption of Various Devices

Device Quantity Basic current/ device Fault current/ device
Flow transmitter 4 12 mA 0 mA
Temperature Transmitter 2 13 mA 0 mA
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Level transmitter 2 11 mA 0 mA
Valve positioner 4 13 mA 4 mA
Current consumption: ISEG= ⅀IB + maximum IFDE = 148 + 16 = 164 mA

Output Current of the Segment Coupler (Is) = 400 mA

Is ≥ ⅀ IB + Max IFDE

Therefore, the Segment current is within specifications.

The voltage at the Last Device

Given information:

The output voltage of the segment coupler (Us according to manufacturer) = 19 V

The specific resistance of the cable RK = 44 Ω/km

Length of the segment LSEG = 201 m

Resistance of the cable RSEG = LSEG * RK = 201* 44/km = 8,844Ω

Current consumption of the segment =164 mA

Voltage drops across segment UA = ISEG x RSEG = 164 x 8,844 = 1,45 V

Voltage at the last device UB = US – UA = 19 – 1,45 = 17,55V

Thus, Voltage at the last device = 17,55 V which is more than the required 9 V

Conclusion

The Cable Length, Voltage at the last device and Current are within the specified limits. The installation is
therefore in order.

Example 2 (Explosion Conditions)

The PROFIBUS-PA segment is to operate in an explosion-hazardous EEx ia area. In accordance with the FISCO
model, the devices are on two separate segments with the type of protection EEx ia for Zone 0 and EEx ib for
Zone 1. Calculations are made for both segments. The Temperature and Level devices are in an EEx ia, Zone 0
environment while the rest of the devices are in an EEx ib, Zone 1 environment. The layout of the equipment is
shown in Figure 4.7.

Calculation of the Segment in Zone 0 Environment

For Zone 0 (Segment coupler (EEx ia):

IS = 100mA, US = 13V, Cable: Resistance/km = 44Ω, Max bus length = 1000m

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 PROCESS CONTROL & INSTRUMENTATION EIDCS2A – DIGITAL CONTROL SYSTEMS 2
PROFIBUS LEARNING UNIT 4

Figure 4.7 Segments in a Zone 0 & Zone1 Environment

Calculation of the Cable Length

Max. loop resistance, EEx ia (see Table 3.6) = 40Ω

Specific resistance of cable = 44 Ω/km

Max. length (m)= 1000 x loop resistance/specific resistance = 1000 x (40 Ω/44 Ω) = 909 m

Length of trunk cable = 50 m

Total length of spurs = 40 m

Total length of cable (= trunk cable + spurs) LSEG = 90 m

The total length of the cable 90 m < Max. length 909 m

The cable length of the segment is within specified limits.

Device Quantity Basic current/device Fault current/device

Temperature transmitter 2 13 mA 0 mA
Level transmitter 2 11 mA 0 mA

Current consumption ISEG =⅀ IB + Max IFDE = (13 + 13 + 11 + 11) + 0 = 48 mA

The output current of the segment coupler IS = 100 mA

IS ≥ ΣIB + max. IFDE

Voltage at the last Device

The output voltage of segment coupler US (according to manufacturer's data) =13.00 V

The specific resistance of cable RK = 44 Ω/km

The total length of cable LSEG is 90 m.

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Digital Control Systems 2

Ref # Vaal University of Technology/Electrical Engineering
 PROCESS CONTROL & INSTRUMENTATION EIDCS2A – DIGITAL CONTROL SYSTEMS 2
PROFIBUS LEARNING UNIT 4

Resistance of cable RSEG = LSEG x RK = 3.96 Ω

Current consumption of segment ISEG = 48 mA

Voltage drop UA = ISEG x RSEG = 0.19 V

Voltage at last device UB = US - UA = 12.81 V

To comply with specifications UB ≥ 9 V (Therefore, Installation complies)

Calculation of the Segment in Zone 1 Environment [EEx ib]

The segment in the hazardous area Zone 1 is shown in Figure 4.7. A Segment coupler [EEx ia/ib] IIC with the
following specifications is used: Is = 100 mA, Us = 13 V. The cable is Siemens with a specific resistance = 44
Ω/km

Calculation of the Cable Length

Max. loop resistance for EEx ib according to table 3.6 = 16 Ω

The specific resistance of cable (given) = 44 Ω/km

Max. length (m) = 1000 x loop resistance/specific resistance = 1000 x (16 Ω/44Ω) = 363 m

Length of trunk cable 60 m

Total length of spurs 101 m

Total length of cable =(trunk cable + spurs) with, LSEG = 161 m

Total length of cable 161 m

Max. Length (allowed) = 363 m.

Therefore, Total cable length < Maximum Length allowed.

Calculating the Current Consumption

The segment consists of 4 valve positioners and 4 flow meters. The flow meters are identical and each has a basic
current of 12 mA. The fault current for the flow meters is 0 mA. The positioners have a basic current of 13 mA
each and 3 of the positioners have a fault current of 4 mA. One of the positioners has a maximum fault current of
6 mA. This is the highest fault current and is to be used in the calculation. The current consumption will thus
be:

⅀ISEG + IFDE = (4 flows meter x 12 mA) + (4 positioner x 13 mA) + (4x6 mA) = (48+52) + 24 mA = 124 mA

The output current of the segment coupler Is (EEx ia IIB) = 100 mA

The segment coupler is therefore not suitable. An alternative segment coupler can be used, or the segment
can be divided as will be shown below in Figure 4.8. An alternative segment coupler with a maximum current
of 280 mA is available.
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Digital Control Systems 2

Ref # Vaal University of Technology/Electrical Engineering
 PROCESS CONTROL & INSTRUMENTATION EIDCS2A – DIGITAL CONTROL SYSTEMS 2
PROFIBUS LEARNING UNIT 4

Voltage at the Last Device

The output voltage of segment coupler US according to manufacturer's data = 13 V Specific resistance of cable
RK (given information) = 44 Ω/km

The total length of cable LSEG = 161 m (already calculated)

Resistance of cable RSEG = LSEG x RK = 161 x 44/1000 = 7.084 Ω

Current consumption of segment ISEG = 124 mA (already known)

Voltage drop UA = ISEG x RSEG = 124 x 10-3 x 7,084 = 0,878 V

Voltage at last device UB = US - UA = 13 – 0,878 = 12.122 V

Therefore, Voltage at the last device > 9 V

In the above case, the current consumption is too high. An alternative is: that two segments with type of protection
EEx ib are routed to one trunk each to measure the level and temperature. In this case, the current consumption
is reduced to 56 mA. A segment coupler with the type of protection EEx ia IIC is adequate for this requirement.
This arrangement is shown in Figure 4.8 below.

Figure 4.8 Alternative Arrangement to Reduce Current per Segment

4.4.7 Data Quantity to be communicated.

If the participants communicate directly with the PROFIBUS-DP master through a segment coupler, then the
amount of data exchanged sets no limits to the design of the PROFIBUS-DP segment. If a link is used as an
interface to the PROFIBUS-DP system, however, the amount of data that can be stored in the I/O buffer is limited.
The maximum telegram length that can be handled by the PLC must also be taken into consideration. The
length of data and the maximum length of the data telegram vary and should be checked with the
manufacturer of the equipment.

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Digital Control Systems 2

Ref # Vaal University of Technology/Electrical Engineering
 PROCESS CONTROL & INSTRUMENTATION EIDCS2A – DIGITAL CONTROL SYSTEMS 2
PROFIBUS LEARNING UNIT 4

Example 1: Determine if the devices in Figure 4.6 can be connected to a Profibus –DP segment using a link
module. The following information is given: The temperature and the level transmitters require 5 bytes each. The
flow transmitters require 6 – 51 bytes each. The 4 positioners require 0 – 15 bytes each.

Calculation:

4 x level and Temperature transmitters = 4 x 5 = 20 bytes

4 x Flow transmitters (6 – 51) = 4 x 6 to 51 = 24 to 204 bytes

4 x Positioners (0 – 15) = 4 x 0 to 15 = 0 to 60 bytes

Total number of bytes = (20 + 24) to (20 + 24 + 204 + 60) bytes

= 44 – 284 bytes

Depending upon the device configuration, from 44 bytes to 284 bytes is periodically exchanged with the PLC. In
the case of a link, the data are transmitted to the PLC in a telegram. The telegram length is limited by:

a) The buffer size of the link, e.g. 244 bytes,

b) The maximum telegram length of the PLC (assume this to be 122 bytes).
c) The PROFIBUS-PA specification (244 bytes).

As can be seen, the use of a link is determined by the configuration of the field devices and the system
components used. Should the maximum configuration be required, a link could not be used due to the length
of the communications.

4.4.8 Cycle Times

In addition to the amount of data, the cycle times must also be considered when the PROFIBUS-PA segment is
planned. Data exchange between a PLC (a Class 1 master) and the field devices occurs automatically in a
fixed, repetitive order. The cycle times determine how much time is required until the data of all the devices
in the network are updated. The more complex a device is, the greater the amount of data to be exchanged
and the longer the response time for the exchange between PLC and the device. The amount of data and the
response times for the various devices from different manufacturers can be obtained from the manufacturers.

The total cycle time for the updating of network data is calculated as follows:

Total cycle time = Sum of the cycle times of the field devices + internal PLC cycle time + PROFIBUS-DP
transmission time.

The total cycle time of a system can be reduced considerably using links. The Link’s limitation placed on the
transmission rate of the PROFIBUS-DP side by a segment coupler is eliminated.

4.4.9 Addressing

Every device in the bus system is assigned a unique address. Valid addresses lie in the range of 0...126. If the
address is not set correctly, the device cannot communicate.

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Digital Control Systems 2

Ref # Vaal University of Technology/Electrical Engineering
 PROCESS CONTROL & INSTRUMENTATION EIDCS2A – DIGITAL CONTROL SYSTEMS 2
PROFIBUS LEARNING UNIT 4

Addressing with segment coupler

The PLC can assign up to 126 addresses to individual devices. A device address may appear only once within
a particular PROFIBUS-DP system. If a segment coupler is used, then the addresses assigned to the
PROFIBUS-PA devices count as PROFIBUS-DP addresses. For a typical bus configuration with PLC and
PC, the addresses are assigned as follows:

• The PLC is assigned an address (Class 1 master)

• The PC or operating tool is assigned an address (Class 2 master)
• The other addresses are assigned to the field devices.

Addressing with a link

If one or more links are in use, these are considered to be on the PROFIBUS-DP network. However, the field
devices connected to the link form a separate PROFIBUS PA system. In this case, the PROFIBUS-DP
addresses are assigned as follows:

• The PLC is assigned an address (Class 1 master)

• The PC or operating tool is assigned an address (Class 2 master)
• Every link is assigned an address:

The field devices connected to the link are assigned a unique address for the PROFIBUS-PA segment of
which they are part. They are not counted as part of the PROFIBUS-DP system.

• the rest of the addresses are assigned to the other field devices that are connected to transparent
segment couples or directly to the PROFIBUS-DP system.

On the PROFIBUS-PA side, every device is assigned an address between 3 and 126, (the addresses 0 and 1 are
reserved). Address 2 is reserved for the link.

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Digital Control Systems 2

Ref # Vaal University of Technology/Electrical Engineering