Introduction to Profibus

Michael Bryant
Executive Director
Profibus Trade Organization
CPAC Workshop - Seattle
May 6, 2004

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Industrial Communication

OS OS

Internet
Internet

PROFINET

Manufacturing Process
IPC
PLC

RS-485/FO IEC 61158-2

PROFIBUS-DP PROFIBUS-PA

AS-Interface

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 Cost Comparison

Reduced installation costs

100%
100%
22%
Savings > 40%

27% 57%
50% 12% Engineering

22% Assembly
51%
23% Hardware
0% PROFIBUS
4...20mA, discrete wired

Source: Namur (Bayer)

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 Profibus in comparison with 4..20

4 . . 20 ma System PROFIBUS-PA

PLC PLC
n

1 I/O modules (1-n)

Terminal block (PLC)

I/O module

Terminal block
PROFIBUS DP

x x
Transmitter
power supply i i
Segment Segment
Terminal block coupler n
coupler 1

Distribution
PROFIBUS PA 1
Panel

Junction box PROFIBUS PA n

sensor 1 ... n

sensor 1 ... n
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 Cost Savings with Profibus

The following numbers are based on an installation at

in Cologne, Germany

Magnetic Valve with two

Temperature transmitter Pressure transmitter position control signals
(binary)

4...20 mA PROFIBUS-PA 4...20 mA PROFIBUS-PA 4...20 mA PROFIBUS-PA

Share Price Share Price Share Price Share Price Share Price Share Price
[%] [DM] [%] [DM] [%] [DM] [%] [DM] [%] [DM] [%] [DM]

Mounting 21 2380 26 1700 18 2380 20 1700 40 6035 35 2720

Equipment 48 5610 52 3400 56 7650 64 5440 29 4590 30 2380

Planning 26 3060 16 1020 27 3060 12 1020 26 4080 20 2040

Starting up 5 510 5 340 4 510 4 340 5 850 5 510

Total 100 11560 100 6460 100 13600 100 8500 100 15980 100 7650

Savings 45 % DM5100 37 % DM5100 52 % DM8330

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 Installed Base

The installed base was greater than 10 Million devices at the

end of 2003, with 2 Million sold in 2003 and already .5 Million
sold this year. Of the 10 Million, 1.5 Million are in the Process
Industries with >300,000 PA devices installed.

Detailed case studies are listed in

the PROFIBUS Online Product
Guide at www.PROFIBUS.com

1989 2004
*Status: Q1/2004
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 Product Range

More than 2,500 PROFIBUS products from nearly 300 vendors

are available today*

The latest PROFIBUS Products are

detailed in the Online Product Guide
at www.PROFIBUS.com

1989 2004

*Status: Q1/2004
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 Membership

With more than 1200 members, PROFIBUS International is the

leading vendor/user organization for industrial communications
world-wide*
The latest membership list may be obtained
online from www.PROFIBUS.com

1989 2004
WWW.PROFIBUS.COM *Status: Q1/2004
 World-wide Support
France Italy Korea Poland
RPA RPA RPA
Australia/ PTL RPA
New Zealand Germany Netherlands PCC
RPA Ireland
RPA RPA Russia
RPA
PCC PCC RPA
Belgium PTL
RPA
Japan Norway
PCC Great Britain South-East-Asia
RPA RPA
RPA RPA
Brazil
RPA
Southern Africa
RPA
China
RPA
Sweden
RPA
Czech Republic PCC
RPA
Switzerland
RPA
Denmark PCC
RPA
USA
RPA
Finland
PTL
RPA
PCC

RPA = Regional PROFIBUS Association

PCC = PROFIBUS Competence Center
PTL = PROFIBUS Test Laboratory
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 Certification

Vendor Independent Quality Control

 PROFIBUS International has Each Device

established a qualified certification

system which includes conformance
and interoperability testing Test at
test
laboratory
 Several hundred products have
been certified
No
OK ?

 Test laboratories in Europe, USA and

Yes
China
Certification by
 Certified products are listed with their PROFIBUS
International
certificate number in the Electronic
PROFIBUS Product Guide
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 Profibus Test Labs

itm – TU Munich ComDec PROFIBUS Interface Center

Matthias Roemer Werner Goetz Ron Mitchell
Boltzmannstrasse 15 Würzburger Strasse 121 One Internet Plaza
D-85748 Garching D-90766 Fürth Johnson City, TN 37605-1255
Germany Germany USA
Phone: 49-89-289-164 00 Phone: 49-911-750-2074 Phone: 423-262-2687
Fax: 49-89-289-164 10 Fax: 49-911-750-2100 Fax: 423-262-2174
Email: roemer@itm.mw. Email: werner.goetz@siemens.com Email: ronald.mitchell@siemens.com
tu-muenchen.de

ifak e. V. PROFIBUS Center Nederland Chinese PROFIBUS Test Laboratory

Arne Neumann Dennis van Booma
Steinfeldstrasse (IGZ) Joseph Ledelstraat 56
D-39179 Barleben 2518 KM Den Haag
Germany Netherlands
Phone: 49-39203-8100 Phone: 31-70-3020-412
Fax: 49-39203-81100 Fax: 31-70-3464-275
Email: ane@ifak.fhg.de Email: dbooma@profibuscenter.nl
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Jiyang Tang
No.1 Jiaochangkou Deshengmenwai
100011 Beijing
China
Phone: 86-10-820-78264
Fax: 86-10-820-78264
Email: tangiy@riamb.ac.cn
 Media Access

PROFIBUS differentiates between master and slave devices

Active Devices (Masters)

PC
PLC PLC

PROFIBUS

Passive Devices (Slaves)

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 DP Monomaster System

Master (Class 1) Master (Class 2)

Central Controller Engineering tool is used
PLC exchanges data with the for setup/configuration
distributed peripherial of the slaves
devices

PROFIBUS

Slaves
Analog or digital peripherial devices such as I/O, drives,
transmitters, valves or operator terminals

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 DP Multi-master System

Several DP-Masters may access a DP DP Multi-Master systems consist of:

Slave with read functions but only one - multiple Masters (class 1 or 2)
Master may write to a slave - 1 to max. 124 DP-Slaves
DP-Master - max. 126 devices on the same bus
(class 2) PC

CNC PLC
DP-Master
(class 1) DP-Master
(class 1)

PROFIBUS

Distributed inputs and outputs

Distributed inputs and outputs
DP - Slaves
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 System Configuration

Standardized electronic data sheets are used to permit open,

vendor- independent configuration PROFIBUS
Configuration tool

 GSD-Files contain the

communication parameters
 EDD-files contain the
application parameters
PLC

PROFIBUS

A library with GSD files of PROFIBUS devices is available online at www.PROFIBUS.com

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 Application in Process Automation

Control system
Engineering

x
Tool

RS-485 or Fiber Optic

PROFIBUS-DP

I IEC 61158-2 (MBP_IS)

+ x
PROFIBUS-PA
transmitter
Segment-
coupler/Link

24V power

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 PROFISafe Profile

The PROFISafe Profile permits the use of PROFIBUS in

“fail-safe” applications

“fail-safe” “fail-safe”
application application
Standard Standard
application application

PROFISafe- PROFISafe-
Layer Layer

PROFIBUS
PROFIBUS

Standard PROFIBUS
RS 485 / IEC 61158-2
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 Motion Control

New functions for motion control

New functionality has been added to the
PROFIBUS protocol (V2):

 Slave-to-Slave communication
 Clock synchronous transmission
 Time synchronization

With these new functions, PROFIBUS opens

up new applications in motion control

With these new functions, Profibus can synchronize 12 axes

with a cycle time of less than 2 ms

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PROFINET CONCEPT

Engineering, HMI

Ethernet

Intelligent
field device Programmable
Proxy controller

PROFIBUS

Engineering, Field Device Drive

HMI

PROFIBUS and PROFINET are two

complementary parts of PROFIBUS
International automation technology
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 PROFINET

Between
Management and Production

Internet
Engineering
HMI

TCP/IP- Ethernet

Integration
Tech. Module Tech. Module Tech. Module
of PROFIBUS

Within Production
Tech. Module Tech. Module

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 Applications

Nearly 1,000,000 applications are operational

• Manufacturing Automation
Car manufacturing
Bottling systems
Waste Water Purification
Car manufacturing, at General Storage systems
Motors, BMW, Ford, FIAT....
• Building Automation
Breweries
Heating, air-conditioning
• Process Automation
Purification plants Polymer
Storage
Chemical and petrochemical plants
Pipelines
Paper and textile industries Glue
Production
• Power industry and power distribution
Power plants
Switchgear Food Production

Bottling Plants Building Automation

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 North American Users

3M, CT Alcan, Canada Applied Extrusion Tech, VA

3M, MN Alliant Techsystems, VA
A. Schulman, OH Allied Signal, OH
ABB Flexible Automation, MI Alpine Engineered Products, TX
ABB Seatech, TX American Baler, OH
Abbott Laboratories, TX American Kuhne, CT
Accu-Fab Systems, OR American National Can, OH
Accusort, PA American National Can, TX
Acklin Stamping, OH American Standard, OH
Acme Brick, TX Amoco Fabrics, GA
Advanced Energy, CO Amplex Electric, OH
Advanced System Integration, TX Amycel, TX
Advantage Industrial Auto., GA Anarundel Cty Water Auth., VA
AgriNW, WA Anchor Brewing, CA
Air Liquide, TX Andritz Runther, TX
AIS, IN Anheuser Busch, MO
Alabama Power, AL Applied Digital Engineering, TX
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Aqua Glass, Canada
ARCO Alaska, AK
Artech, NC
ASI, TX
ATG, WA
ATJ Industrial Auto., Canada
Atronix Engineering, OH
Autoliv, UT
Automation Control, CO
Automation Systems, MI
Autotec, OH
AVCA Corporation, OH
Ballard Power, Canada
Barnes and Noble, MA
Barrilla Pasta, IA
Best American Foods, ID
 North American Users
Basler Electric, IL
Baxter Healthcare, AR
Bayer, Mexico
Bell & Howell, IL
Best Press, NC
Bethlehem Steel, OH
Biersdorf, CT
Blue Bell Creameries, TX
Blue Circle Cement, GA
Blue Diamond Nut Company, CA
Blue Ridge Growers, VA
BMH Americas Inc., TX
BOC, TX
Bodine Test Assembly, CT
Boise Cascade, OR
Brightstar Synfuels, TX
British Aerospace, TN
Burlington Industries, VA Chemrex, MN
Burton Snowboards, Canada Chicago Dryer, IL
BWX Technologies, VA Chiles Drilling, TX
C. Kirk Ryan Cincinnati Machines, OH
CA Lawton Co., WI Cincinnati Test, OH
CAE Newnes Ltd., Canada Circon ACMI, OH
CAE, Canada City of Houston Public Works, TX
Cal Polymer, ID City of Jacksonville Public Works, FL
Calgon, SC City of Los Angeles Public Works, CA
Cameron Controls, TX City of Phoenix Public Works, AZ
Canrig, TX Coe Manufacturing, OR
Capsugel, SC Cold Springs – Texas Granite, TX
Carpenter Company, TX Cole Electric, WI
Carpenter Technology, VA Colgate, NJ
Cast Masters, OH Columbia Electric, WA
Caterpillar, IL Columbia Pacific Aluminum, CA
CCL Container, VA Compressor Controls, IA
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 North American Users

Connexant, CA Davis Standard, CT Ebner Furnace, OH

Conserve II, FL DECO Tools, OH
Control Concept Corp., WI Defasco Steel, PA
Control General, TX Dell Computers, TX
Control Panels & Systems, MD Delta Brands, TX
Controlled Power & Automation, TN Dexter Nonwovens, CT
Cooper Tire & Rubber, OH Dmytryka Jacobs Eng, OH
Copes Vulcan Dorner Manufacturing, WI
CP Films, VA Dow Chemical, TX
Crane Kemlite, IL Dow Corning, MI
Crown, Cork & Seal, TX DSM Engineered Plastics, PA
CSD, MA DSM, VA
CTR, SC Duke Power, TX
Cummins Engine, MI Dunlop Tires, AL
Curt Joa, WI Eastman Chemicals, TN
Cytec Industries, OH Eastman Kodak, NY
Dan River Mills, VA Ebarra Technologies, CA
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Edler Industries, CA
EDS, MI
Electronic Power Design, TX
Elgin-Butler Brick, TX
Eli Lilly, IN
EMD, TX
Encore Wire, TX
Enerpro, CA
Engineered Systems, OH
Englewood Electric, FL
Englewood Electric, IL
ENSCO Kodiak II
Environmental Waste H2O, ID
EOS Engineering, TX
EPCO, OH
EPD, TX
 North American Users
Evanite Fiber Corp, OR
Exion, WI
Exonic Systems, MI
Exxon Baytown, TX
Fairmont Tamper, MN
Falmouth Scientific, MA
Fiber Visions, GA
Findley, OH
Fisher Controls, TX
Flight Safety Int’l, TX
Fogg Filler, MI
Forest Products Machinery, GA
Formosa Power
Fort James Corp, OR
Foxjet, TX
Framatome Cogema Fuels, VA
Frank W. Murphy, TX
Friskies, MO Global Marine Drilling, TX
Frostbite Brands, OH Globitech, TX
GAF Materials, MN Glomar Celtic Sea
Galvacor, Canada Glomar Explorer
Gaston County Dyeing, NC GM PowerTrain, MI
GE Fanuc, UT Golden Cheese, CA
GE Plastics, NY GPM Gas, TX
GE Team Controls, TX Grobe Electric, AL
General Atomic, CA H.B. Fuller, CA
General Mills, MI Haarman & Reimer, SC
General Shale Brick, TN Harmon Motive, IN
Georgia Gulf, TX Harnisfeger, WI
Georgia Pacific, MI Harvard Industries, VA
Georgia Pacific, WA Harza Engineering Co., IL
Giddings & Lewis, WI Hauni, VA
Gillette, MA Hazentech, AR
Glassline, OH
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Heidelberg Finishing, OH
 North American Users

Heidelberg Web Presses, NH I²S, CT ITW/MiniGrip, TX

Heidtman Steel, OH IBM, VT J.R. Simplot, OR
Helm Instrument, OH ICD, NJ Jacobs Engineering, OR
Henkel, OH Imperial Holly, TX Jagenberg, CT
Henry Filters, OH Incom, WI Kendall Electric, MD
Hess Electrical, MI Indianapolis Casting, IN Kendall Electric, WI
Hitec, Canada Industrial Automation Eng., MN Kiefel, NH
Hitec, TX Innovative Controls, OH Kirk Lumber, VA
Holt Electric, WI Innovative Electronics, TX Kister, OH
Hoosier Magnetics, OH Intec Permaglas, OR Kraft Foods, IL
Houston Chronicle, TX Intech, TX Kvaerner Metals, PA
HPM Hemscheidt Corp. Integrated Chemical Solutions, TX L&H Supply, TN
Huels Intelicon, OH LaFarge Alum., VA
Huffman, SC Intellution, MA Lamb Weston, OR
Huntair, OR Interface Flooring, GA Lemforder, ME
Husky, Canada Intevac, CA Linklater, CA
Hydralift, TX ITT WWW.PROFIBUS.COM
Automotive, NC Lockwood Green, TX
 North American Users
M&M Mars, IL
Mallinkrodt, MO
Mantissa Corporation, NC
Maple Leaf Bakery, VA
Martin Feed Mills, Canada
McNaughton-McCay, IL
MD/Totco, TX
Medical Lake Waste Water, WA
MG Generon, TX
Micron Technology, ID
Middlesex Industries, MA
Milliken, SC
Minaric, NC
MM Controls, OR
Mobil Chemical, CT
Mobile Oil Pipeline, TX
Mobile Oil, TX
Molins Richmond, VA
Monterrey Mushroom, TX
Montgomery Watson, TX
MPM Engineering, Canada
Nanoose Systems, Canada
NASA Cape Kennedy, FL
NASA Langley, VA
National Envelopes, KS
National Instruments, TX
National Oilwell, TX
NEC, CA
Nestle R&D Center, OH
Newport News Shipbuilding, VA
Noell Crane and Service, TX
Northland Electric, MN
NorthSails, NV
Northwest Cybernetics, OR
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Norton, TX
Novartis Pharmaceuticals, NJ
NPC, TX
NSC Technologies, IL
O’Sullivan Industries, VA
Ocean Spray, NJ
Ocean Spray, WI
OEM, TX
OMC Services, TX
On Trak Systems, CA
Pacific Flow Controls, CA
Packard-Hughes, CA
Pan Pacific Co., OK
Pasadena Paper, TX
Pearson Packaging, WA
Pemco, WI
Perdue Farms, MD
 North American Users

Petrotech, TX Qtera, FL Sandvick Sorting, KY

Pfizer, NE Quad Graphics, WV Sanibel Island Water, FL
Pharmacia Upjohn, MI Quad+, IL Sasib Bakery, TX
Philip Morris, VA R&B Falcon Drilling, TX Sauder Woodworking, OH
Philips Lighting, KS RA Hanson, WA Savanah Foods, TX
Phoenix Environmental, IL RapidPak, WI Schlumberger, TX
PLENCO, WI Rayonier, GA Scholle, CA
PML, Canada Raytheon, TX Seacor Gerand Jordan, TX
Polybond, VA Reading and Bates, TX Seacor Vanguard, TX
Port of Houston, TX Redhook Brewery, WA Sematech, TX
Potlatch, ID Reliant Energy, LA Seneca Foods, ID
PPG Industries, PA Retrotech, NY Shaffer, TX
Praxair, TX Roberts Filters, PA Shiner Brewery, TX
PRI Automation, MA Rockwell Automation, OH Siebe APV
Procter & Gamble, OH RR Donnelly & Sons, TN Siemens Automotive, VA
Promotional Printing, TX Rubbermaid, KS Siemens Electrocom, TX
Protec Coating, OH Rumsey Electric, PA Siemens Telecommunications, TX
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 North American Users
Sierra Nevada Brewing Co., CA
Signode – IPS, IL
Simpro, TX
Simpson Sawmill, WA
Sinclair Marine Electric
Skagit Smatco, TX
SOR
Southeastern Containers, VA
Standard Gypsum, TX
Sterling Berkefeld, Canada
Sterns Airport Equipment, TX
Stupp, TX
Sumitomo, VA
Sunkist Growers, CA
Surface Combustion, OH
Sverdrup, TN
Systel, TX
TA Engineering, CA
Tamko Roofing, MO
Taylor Clay, NC
Tech Conveyor, NJ
Tech Logic, MN
Tech Power, TX
Technisys, UT
TEI Engineering, IN
Teledyne Advanced Metals, TN
Tennessee Eastern Chemicals, TN
Tennessee Valley Authority, TN
Texaco, TX
Texas Eastern, TX
Texas Farm Products, TX
Texas Instruments, MA
Texas Instruments, TX
Thermal Engineering, SC
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Thermoguard Equipment, WA
Titan Industries, TX
Toledo Transducers, OH
Transdyne Controls, GA
Transocean (Marianis), TX
Tree Top, WA
Trident Tooling, OH
Trinity Industries, TX
Trunkline, TX
Trus Joist MacMillan, ID
Tru-Si Technologies, CA
TRW, AZ
Tuchenhagen-Zajac, MD
Turtle & Hughes, NJ
Tyler Controls, NY
UAS, Canada
UCB Films, KS
 North American Users

UCB, IL USS Ronald Reagan WilsonArt, TX

Ulvac, MA Valley Record, CA Wirtz Manufacturing, MI
Unilever Varco, TX WL Gore, NC
Unilever, NJ Vetrotex, TX Woodgrain Millwork, ID
Uniloy-Milacron Manchester, MI Wabash Plastics, IN Woodward Governor, CO
Uniroyal, Canada WABCO, SC WPS Industries, LA
United Copper, TX Walbridge Coatings, OH WR Grace, MI
United Distillers and Vintners, Canada Walla Walla Waste Water, WA Wright Industries, TN
Update Systems, MO Wallace Printing, IL
US Army Corps of Engineers, KY Warren Electric, LA
US Filters, AZ Warren Electric, TX
US Gypsum, CA WC Woods, OH
US Postal Service Western Container, TX
USS (?) New Carrier (CVN 77) Wetmore, TX
USS Carl Vinson White Oak Semiconductor, VA
USS Chester A. Nimitz Williams Pipeline, KS
USS Harry S. Truman Williamson Printing Corp., TX
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The End

Questions?

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