PROFIBUS

Installation Guidelines
Revision 7.1
December 2008

PROFIBUS Competency Centre

Automation Systems Centre
Manchester Metropolitan University
 Table of Contents
1. INTRODUCTION ...................................................................................................1
1.1. PICKUP IN FIELDBUS CABLES ...............................................................................1
Electrostatic pickup ......................................................................................................1
Electromagnetic pickup ................................................................................................1
Pickup Reduction ..........................................................................................................2
1.2. PROFIBUS CONNECTION TECHNOLOGY.............................................................2
1.3. RS 485 TRANSMISSION ........................................................................................3
Balanced Transmission and screening .........................................................................3
1.4. SEGMENTATION ...................................................................................................5
1.5. FIBRE-OPTIC TRANSMISSION ...............................................................................6
1.6. MBP TRANSMISSION ...........................................................................................6
2. DEVICE ADDRESSING ........................................................................................6
2.1. SETTING ADDRESSES ...........................................................................................6
Physical address switch on the device..........................................................................7
Software setting of device address over PROFIBUS....................................................7
Special software and communication link ....................................................................7
2.2. SETTING AN ADDRESS ON A BINARY SWITCH ........................................................7
2.3. RESERVED ADDRESSES .........................................................................................8
3. PROFIBUS RS485 WIRING..................................................................................8
3.1. REFLECTIONS AND TERMINATION ........................................................................9
3.2. SPUR LINES ........................................................................................................11
3.3. PROFIBUS RS485 CONNECTORS AND WIRING TOOLS.......................................11
3.4. PIGGY-BACK SOCKETS .......................................................................................13
3.5. COMMON RS 485 WIRING ERRORS .....................................................................14
3.6. HAND-HELD CABLE TEST TOOLS ........................................................................14
3.7. WIRING TESTING USING THE BT200 ..................................................................15
Basic cable testing ......................................................................................................15
Use of the BT200 keypad and display.........................................................................16
Wiring Testing using the HMS NetTest II...................................................................17
3.8. M12 CONNECTOR SYSTEMS ...............................................................................17
4. LAYOUT OF DP SEGMENTS ............................................................................19
4.1. IDEAL SEGMENT LAYOUT ...................................................................................19
4.2. NETWORK LAYOUT WITH REPEATERS AND OLMS ............................................21
4.3. RS485 CABLE LENGTH CONSIDERATIONS .........................................................21
When are stub-lines allowed?.....................................................................................22
4.4. SPECIAL REQUIREMENTS FOR BAUD RATES >1.5 MBIT/S ....................................23
5. LAYOUT OF PA SEGMENTS ............................................................................23
5.1. COUPLER AND LINK TECHNOLOGY .....................................................................24
Simple DP/PA couplers ..............................................................................................24
Siemens DP/PA Link Module......................................................................................24
Pepperl+Fuchs Modular Coupler ..............................................................................25
5.2. MBP SPUR LINES...............................................................................................25
5.3. MBP TERMINATION ...........................................................................................26
5.4. INTRINSIC SAFETY CONSIDERATIONS.................................................................27
6. CABLES FOR PROFIBUS...................................................................................28
6.1. CABLES FOR PROFIBUS RS485 SEGMENTS ......................................................28
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 6.2. CABLE FOR PROFIBUS PA...............................................................................29
7. INSTALLING PROFIBUS CABLES..................................................................29
7.1. GENERAL GUIDELINES .......................................................................................29
7.2. CABLE SEGREGATION ........................................................................................30
7.3. USE OF CABLE TRAYS AND CHANNELS ...............................................................31
7.4. CABLING WITHIN WIRING CABINETS.................................................................31
7.5. POTENTIAL EQUALISATION ................................................................................32
8. REPEATERS .........................................................................................................34

9. FIBRE OPTIC COMPONENTS..........................................................................34

9.1. OPTICAL LINK MODULES ...................................................................................34
10. BIBLIOGRAPHY..................................................................................................35
Documents available from PROFIBUS International ([Link]) ..............35
Other documents and publications .............................................................................35
INDEX ..............................................................................................................................36

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1. Introduction
This document provides information on the design, lay-out, installation and testing of
PROFIBUS networks. The information contained originates from a number of sources (see
bibliography).

Important Notice
Although considerable care has been taken to ensure that the information
contained in this document is accurate and complete, no responsibility can be
taken for errors in the document or installation faults arising from its use.

PROFIBUS is an extremely flexible and reliable communication technology, however, like

all high-speed digital communications systems, problems can be caused by a number of
simple errors. Poor wiring and layout can cause pickup or interference in cables giving
corrupted telegrams. Incorrect termination and many other errors can cause reflections to
occur in fieldbus cables, resulting in distorted and corrupted telegrams. In order to
understand how to avoid some of these problems we must first understand how they occur.

1.1. Pickup in Fieldbus Cables

Pickup occurs when outside influences such as cables or equipment carrying high voltages
and/or high currents induce unwanted signals in our fieldbus cables. There are two main
mechanisms for pickup of interference from other electrical cables or equipment:

Electrostatic pickup
Here, electrostatic or capacitive coupling between the interference source and the fieldbus
cable induces electrical voltages in the cable. The closer the cables the greater the coupling
between the cables and hence the worse the pickup will be. Cables carrying high voltages,
high frequencies or rapidly changing voltages are particularly prone to inducing
electrostatic pickup.
High Voltage
Interference source
e.g. Power cable
Capacitive coupling between cables
Signal cable
e.g. Instrumentation Pickup

Electromagnetic pickup
Here, magnetic or inductive coupling between the interference source and the fieldbus
cable induces electrical currents in the cable. Again, the closer the cables the greater the
coupling and the worse the pickup will be. Cables carrying high current or rapidly
changing current are particularly prone to inducing electromagnetic pickup.
High Current
Interference source
e.g. Power cable
Inductive coupling between cables
Signal cable
e.g. Instrumentation Pickup

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Pickup Reduction
Shielding or screening the signal cable can reduce electrostatic pickup. However, shielding
is only effective when the shield is properly connected to earth (ground). Unearthed
screening has no effect whatsoever; in fact it can make the pickup worse!
High Voltage
Interference source
e.g. Power cable
Pickup passes to ground
Signal cable
e.g. Instrumentation Pickup

Twisted pair cable significantly reduces electromagnetic pickup. This is because the
induced currents that flow in each loop of the twisted pair cable are flowing in different
directions along the wire and hence on average tend to cancel out.

Pickup

Induced currents in adjacent loops tends to cancel

Installation of the fieldbus cable in earthed, magnetically impervious ducting (i.e. steel tray
or conduit) can further reduce both electrostatic and electromagnetic pickup. This is
because the steel provides magnetic shielding for the magnetic fields that induce
electromagnetic pickup and the earthed enclosure provides additional shielding against
electrostatic pickup.

Interference

Steel enclosure
provides electromagnetic screening

Earth connection
provides electrostatic screening

1.2. PROFIBUS Connection Technology

PROFIBUS has an extremely wide range of application and therefore utilises several
different transmission technologies. PROFIBUS DP and FMS both use RS 485 (also called
H2) transmission. In addition fibre optic (FO) transmission can be used. PROFIBUS PA
uses Manchester Bus Powered (MBP) transmission as specified in IEC 61158-2 (also
called H1).

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 FMS DP PA
Layer
FMS device DP device PA device
User Profiles Profiles Profiles
Fieldbus Message DPV0 basic functions
Application (7) Specification also DPV1, DPV2 extensions

Layers (3) to (6)

OSI not used in
model fieldbus systems

Data Link (2) Fieldbus Data Link (FDL)

Physical (1) RS485 / Fibre-Optic MBP

(IEC61158-2)

The PROFIBUS Open System Interconnection model

1.3. RS 485 Transmission

PROFIBUS RS485 uses shielded twisted pair cable allowing communication at up to
12Mbit/s. RS485 can be used to connect up to 32 devices in a single segment (piece of
cable). The allowable segment cable length depends upon the bit rate being used. The
allowable segment cable length varies from 100m maximum at high speed to 1000m
maximum at low speed (see section 4.9).

Balanced Transmission and screening

RS 485 is a balanced two-wire transmission system, which means that it is the difference
in voltage between the two wires that carries the information rather than the voltage
relative to ground or earth. Balanced transmission is much less sensitive to pickup and
interference than single-ended or unbalanced transmission. Let us see why:

Unbalanced transmission
“Unbalanced transmission” is where we use a signal wire and a zero-volt reference wire:

Transmitter Receiver
Interference

Signal

Reference
Reference is connected to low impedance ground

Electrostatic and electromagnetic interference can be picked up by both the signal and
ground wire, however since the ground wire is connected to low resistance earth, the
induced voltages and currents pass to earth and have little effect. The signal wire, on the
other hand, picks up these induced signals resulting in corrupted transmission. Unbalanced
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transmission is surprisingly common: RS232, 4-20mA, and many other transmission
technologies use unbalanced transmission.

Earthed screening can reduce electrostatic pickup, but, unbalanced transmission can give
rise to “Earth Loops” if the reference wire is earthed at both ends. Earth loops cause
variations in the reference voltage at the transmitter and receiver:

Interference

Signal

Ground

Small ground current gives rise to voltage drop

For this reason unbalanced systems are best wired with the reference and shield connected
at one end of the cable only (normally at the control room end only).

Balanced transmission
Balanced transmission is where both wires carry the signal, one positive and one negative.
The information is carried by difference between the voltages on the two wires
(differential). The term “balanced” means that the two wires have the identical electrical
characteristics and connections and so any interference that is picked up on both wires
(common mode signals) tends to cancel out. Since there is now no reference wire the
screen is totally independent from the signal. Therefore any small currents flowing in the
cable shield will have little effect (although larger screed currents and voltages can still
cause pickup):

Interference

Signal +

Signal -

Small ground current has no effect

Balanced transmission is much less prone to pickup than unbalanced transmission and
because the screen is connected at both ends of the cable it is much more effective than
screens that are earthed at one end only.

Screening balanced cables

PROFIBUS RS485 transmission is balanced to improve noise rejection. Therefore we
should earth the cable screen at both ends to ensure that it is effective at high frequencies.
This is normally done by connecting the cable screen to the device earth via the
connectors. But we must make sure that the device is correctly earthed. Poor shielding or
earthing is a very common wiring error.
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 Connector
From other Shielded, twisted-pair cable To other
devices devices

Earth the screen at

Rx Rx
every device
Data Data
Tx Tx

Device Device

But also ensure every

device is properly earthed

PROFIBUS RS 485 transmission

1.4. Segmentation
RS 485 is a multi-drop system, which means that many devices can transmit and receive
(but not at the same time), in fact only one device can transmit whilst the others receive.
An RS485 transmitter can drive the load of 31 receivers, therefore a maximum 32 RS485
devices to be connected together on a single segment (piece of cable). Note that all devices
that have an RS 485 driver count towards this 32-device limit, not just PROFIBUS
devices.

Does this mean that only 32 devices can be connected in a PROFIBUS network? No, the
RS 485 limitation of 32 devices is overcome by splitting larger networks into segments
that are electrically isolated but which communicate using repeaters or fibre-optic links.
Each segment is a separate piece of copper cable that must adhere to RS 485 rules. The
overall network can have many more devices and cover a much longer distance than the
RS 485 rules imply.

Within a segment all PROFIBUS masters, slaves, repeaters, optical link modules, and
even telegram analysers count towards the 32-device limit. This means, for example, that
when two repeaters are connected to a segment the maximum number of PROFIBUS
stations is reduced to 30. It is good practice to leave at least 10% spare capacity per
segment for future expansion and/or diagnostic tool connection; i.e. we should consider
including a repeater if the device count approaches 28.

The standard says that a maximum of 9 repeaters may be used between any master and
slave station. However many modern repeaters exhibit an increased delay meaning a
maximum of only 4 repeaters giving 5 in-line segments. Old style repeaters had a repeater
direction control signal which switched the direction of transmission (requiring an
additional wire). Most modern repeaters automatically detect the required transmission
direction and automatically switch to the correct direction. However, this introduces a

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small additional delay so restricting the number of in-line repeaters to 4 for modern
devices. This implies a maximum of 5 in-line segments from a master to the furthest slave.

1.5. Fibre-Optic Transmission

Fibre optic transmission is an alternative to copper cable. Two fibre-optic transmission
media are available: Plastic fibre which is low cost but is generally limited to distances of
less than 50m and glass fibre which can be used over distances of several kilometres. Fibre
optic transmission offers the following advantages over copper:
• Larger distances between stations are possible with fibre optics than with copper.
• Total immunity to electromagnetic interference is provided.
• Electrical isolation removes earth potential difference and ground current problems.
• Fibre optic cable has insignificant weight and is largely immune to corrosion.
Fibre-optic transmission is typically used in conjunction with RS 485 wiring to build a
network. The copper to fibre-optic interface is accomplished using Optical Link Modules,
OLMs (see section 9.1). Like repeaters, OLMs also have the effect of splitting the network
into isolated segments.

1.6. MBP Transmission

PROFIBUS PA uses Manchester Bus Powered (MBP) transmission (defined in IEC
61158-2). There are several major differences between RS 485 and MBP:
• MBP operates using current variations to transmit data.
• It operates at a fixed, data rate (31.25 kbit/s).
• MBP cable can carry both power and data
• MBP segments can be easily implemented for operation in hazardous
environments.
Typically MBP segments are implemented using DP/PA couplers or link modules (see
section 5.1). Each PA segment can connect up to 32 PA devices, however the number of
devices is significantly reduced when intrinsically safe operation is required.

2. Device Addressing
Each PROFIBUS station requires an address through which communications can be
directed. Devices such as repeaters and optical link modules simply pass the telegrams on
to the next segment and thus do not require an address.

Within a network, every PROFIBUS device or station is given an address through which
communication is directed. Every device on a PROFIBUS network must have a unique
address. If two devices have the same address then one or the other or perhaps both will
fail to operate. This is because the two devices will both attempt to respond to the master
request sent to the common address and each response will be corrupted by the other.
Sometimes the strongest device will override the weaker device and will operate
satisfactorily, whilst the weaker device is drowned-out.

2.1. Setting Addresses

The address of every station must be set by the engineer during commissioning. Station
addresses can be set in several ways:

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Physical address switch on the device
Here the device address is set by a physical switch on the device. The switch can take a
variety of forms. Seven in-line, on-off binary weighted switches, two decimally weighted
rotary switches or other forms.
9 0 1 9 0 1
8 2 8 2
1 2 4 8 16 32 64 7 3 7 3
OFF
6 5 4 6 5 4
ON x10 x1

a) Binary-weighted address switch b) Decimal-weighted address switch

In the binary-weighted switch, each switch is worth a binary digit: 1, 2, 4 … 64. If a switch
is on then the digit contributes to the address. For example figure a) shows switches 1, 4
and 16 as on, so the address would be 1+4+16 = 21. Figure b) shows the same address
(#21) set on a decimal-weighted switch.

Note that the binary switches can be labelled 0-6 or even 1-7 on different devices.
Sometimes we even find an additional switch. The eighth (or perhaps first) switch has
some other function, for example hardware or software address selection.

Note that the device power will normally need to be cycled (switched off and then on
again) for the new address to be recognised by the device.

Software setting of device address over PROFIBUS

Here the device address is set using a configuration tool (called a class 2 master). The tool
uses a “set slave address” command to effect the change. Normally devices are delivered
with the address #126, which is a reserved address for this function. Note that an option in
the addressing command is to “lock” the address, which means that it cannot be changed
again. However, there must always be a method of resetting the device back to the factory
default address.

Special software and communication link

Here the device uses special software which communicates with the device via a serial port
or perhaps Ethernet. Devices that use this method of setting the address include Human
Machine Interfaces (HMIs) devices or Programmable Logic Controllers (PLCs). This is
because these devices need the software and serial cable for downloading the program or
configuration, so it is simple to add the PROFIBUS address to this data.

2.2. Setting an address on a binary switch

To set an address on a binary weighted switch we can work down from the most-
significant switch deciding whether each should be off or on. For example, to set the
decimal address #50, the procedure starts at the most significant switch (64). Since the
required address is less that this switch value, we can see that this switch is not required
and so should be off. The next switch (32) is required so should be on. This then leaves
50 – 32 = 18 still required. The next switch (16) is required, so is on, leaving 18 – 16 = 2
still required. Thus of those switches left only the switch for (2) is required to be on. All
the other switches (8, 4 and 1) are not required and should be off.

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An alternative way to determine the settings for a binary-weighted switch is to take the
decimal address and successively divide by two. Each time we have a remainder from the
division then this becomes a digit in the binary result. Here we are working up from the
least significant bit. Taking the decimal address #50 as our example again:

50/2 = 25 remainder 0 therefore bit 0 = off. b6

25/2 = 12 remainder 1 bit 1 = on. b5
b4
12/2 = 6 remainder 0 bit 2 = off.
b3
6/2 = 3 remainder 0 bit 3 = off. b2
3/2 = 1 remainder 1 bit 4 = on. b1
Leaving a remainder of 1 bit 5 = on. b0
All remaining bits are 0 bit 6 = off. off on

PROFIBUS is a multi-master system allowing several master stations to control their

allocated slaves in parallel. In many cases, however, a single master will be used.

2.3. Reserved addresses

PROFIBUS supports 128 different addresses, numbered 0 to 127. However, some of these
addresses are reserved and recommendations should be followed in how these addresses
are allocated:
• Address 127 is reserved for global or broadcast messages.
• Address 126 is reserved for off the shelf devices whose address is set over the bus.
• Address 0 should be reserved for an engineering tool (i.e. a class-II master).
• When using a single class-I master it is recommended that its address should be set
to 1. Further class 1 masters should be allocated addresses 2, 3 … etc.
For example, when using a single master, we can have slaves at addresses 2 to 125. There
are thus 125-1 = 124 addresses available for slaves.

3. PROFIBUS RS485 Wiring

The PROFIBUS R485 wiring, employed for DP and FMS, uses shielded twisted pair cable. It
is highly recommended that only PROFIBUS cable is used with characteristics that are
optimised for RS 485 transmission (see section 6.1). DP devices can use various types of
connector or even screw terminals. However, PROFIBUS International has defined the
connections for standard 9-pin sub-D connectors, M12 plugs and sockets (tables 1 and 2) and
for hybrid connection system that can be used for fibre optic or RS485 connection with power
supply. Sub-D connectors are designed for use in clean and dry environments; M12
connectors can provide protection up to IP67.

When 9-pin sub-D connectors or M12 connectors are used, the wiring must comply with that
set down in the standard. Note that the cable shield should always be connected on every
device, even though the tables show this as optional.

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 Table 1 – Pin allocations for Sub-D PROFIBUS connectors
Pin No. Signal Function
1 Shield Ground connection Optional
2 M24 Ground for 24V supply Optional
3 RxD/TxD-P Data line plus (B-line) Mandatory
4 CNTR-P Repeater direction control signal Optional
5 DGND Data ground Mandatory
6 VP +5V supply for terminating resistors Mandatory
7 P24 +24V supply Optional
8 RxD/TxD-N Data line minus (A-line) Mandatory
9 CNTR-N Repeater direction control signal Optional
Case Shield Ground connection Optional

Table 2 – Pin allocations for M12 connectors

Pin No. Signal Function
1 VP +5V supply for terminating resistors Mandatory
2 RxD/TxD-N Data line minus (A-line) Mandatory
3 DGND Data ground Mandatory
4 RxD/TxD-P Data line plus (B-line) Mandatory
5 Shield Ground connection Optional
Thread Shield Ground connection Optional

The two wires in the twisted-pair cable carry the “Data line plus” (B-line) and “Data line
minus” (A-line) signals. The two wires in the PROFIBUS cable usually come colour coded.
Normally red and green are used, however other colours may be found. When red and green
wires are being used the following recommendations apply:

Red – B-line (RxD/TxD-P) (Aide-memoir: “B to RED” – “BREAD”)

Green – A-line (RxD/TxD-N)

3.1. Reflections and Termination

When electrical signals travel down a cable, any electrical discontinuity like additional
resistance, capacitance or the end of the wire, can cause reflections to occur. In particular,
the end of the wire is a major discontinuity where the resistance suddenly increases to
infinity.

Just like an echo, the reflected signal can cause multiple signals to appear on the line.
Reflections are bad news in high-speed communications because signals are corrupted or
distorted by the reflection.

One way of minimising reflections at the end of a cable is to terminate the end with a
specially chosen resistance that matches the cable properties. The resistance absorbs the
energy of the signal and significantly reduces the reflection (theoretically to zero). The
matching termination resistance looks to the signal like more cable and so there is no
reflection. PROFIBUS RS485 uses an active termination network that must be supplied
with 5V. This why the +5V VP and DGND pins are mandatory on PROFIBUS connectors.

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 VP (+5V)
390Ω
RxD/TxD-P
220Ω
RxD/TxD-N
390Ω
Off ÙOn
DGND (0V)

Normally built into

connector.
Can be switched in
or out.
Active termination used in PROFIBUS RS 485 wiring

To avoid reflections from the ends of the cable it is essential that each segment is
terminated at the two ends and nowhere else. RS485 Termination networks must be
powered at all times (even when devices are switched off!) otherwise reflections can
disrupt the remaining devices on the bus. It is very common to find intermittent bus
problems caused by incorrect termination. It is also common to find PROFIBUS stations or
even whole networks that never work caused by incorrect termination.

3
A properly terminated segment
2 running at 12Mbit/s
1
0
-1
-2
Powered termination on at both ends of
-3 the segment, normal reflection less than
V Differential signal
500mV peak-peak.

3
2
1
Termination at one end of the
0
-1
segment only
-2
-3
V

Effect of missing termination on RS485 waveform

Many PROFIBUS devices incorporate built-in termination resistors that can be switched in
or out. In such cases it is important that the device termination is switched out when not
required. It is common to find the device termination switch mounted on a circuit board,
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which is hidden inside the device. The switch may be left switched on after pre-delivery
tests. A common error is to have these additional termination resistors switched in giving
additional termination in the middle of a segment or double termination at the end of a
segment. Any additional termination(s) can cause reflections.

3.2. Spur lines

Spur-lines (also called stub-lines or drop-lines) should generally be avoided because they
can cause reflections. The reason for this is that they introduce additional capacitance on
the main trunk line where spur Tee junction is located. Each segment should ideally be
connected as a single linear bus. That is the cable should daisy chain from device to
device:

Tee
junction

Spur line
8 PROFIBUS
device
9PROFIBUS
device

3.3. PROFIBUS RS485 connectors and wiring tools

It is highly recommended that special PROFIBUS connectors are used when wiring a
DP/FMS network. These connectors incorporate several features that ensure reliable
operation and provide quick and robust connection. These features may include:

• Built-in termination resistors that can be switched in and out.

• Quick and reliable connection of data wires and shield.
• Connections for incoming and outgoing cables.
• Special inductors built in for operation at over 1.5 Mbit/s
• Outgoing cable isolation when termination switched in.
• Additional piggyback socket for connection of diagnostic/programming tools.

Many manufacturers produce a PROFIBUS cabling solution with cable, connector and
stripping tool. It is important that these items are compatible. One area that can cause
problems is the use of stranded and solid core PROFIBUS cable.
Solid core cables are best connected using “insulation displacement”
technology, where the core insulation is not removed, but is pierced
by a blade in the connector:

Insulation displacement technology gives a reliable airtight, low-

resistance connection to the cable core. However this type of
insulation displacement connection should not be used with stranded core cable because
the individual cable strands can be completely cut by the connector.

Reliable connections can quickly be made using special stripping tools and insulation
displacement connectors, as shown below:

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 1 2 3
Measure the length of the cable Insert the measured cable Close the stripping tool gently.
to be stripped using the template end into the stripping tool. .
on the side of the stripping tool. Use your index finger as a stop.

4 5 6
Rotate the stripping tool once With the stripping tool closed, Peel away any remaining
Close one more click and rotate pull the tool away from the cable protective film.
again. Repeat until screen is cut. removing the cable sheath.

Using the PROFIBUS stripping tool

Stranded core cable is best used in conjunction with screwed termination connectors.
The wire ends must be stripped of insulation. Ideally a bootlace ferrule should be crimped
onto the bare wire using a proper crimp tool (not pliers). Do not twist the strands together.

Connector

9 9
Screwed connectors are best for stranded cable

The bus cable should be daisy-chained from connector to connector. This allows stations
to be disconnected without interrupting bus traffic.

Modern PROFIBUS connectors normally have marked cable entries for “incoming” and
“outgoing” cables. This distinction can be important in “isolating connectors” where the
outgoing cable is isolated when the termination is switched “in”. Such isolating connectors
are useful for commissioning and testing the network. They are also useful for
maintenance, where they allow sections of a segment to be isolated whilst retaining correct
termination.

When any such connector has the termination switched “in” all the stations on the outgoing
side are disconnected, leaving a properly terminated sub-segment on the ingoing cable. For
this reason the first and last connector on a segment should only use the ingoing entry:
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 Termination
Termination
switched “on”
switched “off”

A B A B A B A B

Outgoing
connection is
From To remaining
isolated when
controlling slaves
Use incoming termination
master
entry only switched on

a) Connection for first and last b) Connections for all other

stations on the segment. stations on the segment.
Correct use of isolating connectors

Connector with
Master Slave Slave Slave Slave
termination off

Connector with
termination on Properly terminated segment Isolated slaves

Incremental commissioning and maintenance using isolating connectors

3.4. Piggy-back sockets

To allow for network analysis and troubleshooting, each segment should have at least one
connector with a “piggyback socket”. The extra socket allows monitoring or programming
devices to be plugged in without disrupting the network. Piggy-backs are best mounted at
the end of each segment. Never use a piggyback socket for adding slaves since it creates a
spur line.

At higher baud rates stub-lines must not be used

so the test tool must be directly connected to the
piggy back. Alternatively, an extra spare socket
should be provided to diagnostic tool connection.
Note that some diagnostic devices can draw up to
90mA from the socket 5V pin. In such cases you
Piggy back
should ensure that the socket is attached to a
device which can supply the required current.

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3.5. Common RS 485 wiring errors
It is common to find simple RS 485 wiring and layout errors in the field. The most frequently
occurring errors are described below:

1. Termination problems:
a. Lack of terminations at the end of a segment.
b. Double termination, caused by devices with inbuilt termination.
c. Termination in the middle of a segment (can be caused by devices with inbuilt
termination).
d. Un-powered terminations (unplugged or un-powered devices).
e. Incorrectly wired isolating connectors (only becomes a problem when
switched on).
2. Pickup and interference caused by:
a. Laying bus cables too close to electrically noisy power cables or equipment.
b. Lack of proper earthing of the cable screen at every device.
c. Screen current due to earth potential differences between areas of the network.
3. Power supply problems
a. Insufficiently rated power supply (check voltage with full load).
4. Wiring problems:
a. Wrong cable used (e.g. using PA cable for DP segments).
b. Damaged cable (including squashed, over-bent)
c. Swapped cores at a device (B-RED rule broken)
d. Un-earthed screen (not connected at every device, un-earthed devices etc.)
5. Segment rules broken:
a. Cable too long for the bit rate used.
b. Too many devices (never more than 32 RS485 drivers on a segment).
c. Use of spur lines (keep short at lower bit rates and don’t use at higher bit
rates).
6. Damaged or uncertified devices.
a. Excessive connection capacitance.
b. Faulty or poor quality RS485 driver chips

3.6. Hand-held cable test tools

Hand-held bus test tools are available from several manufacturers. Such tools can quickly
and efficiently check PROFIBUS network cabling and slave device connections and can
help to minimise wiring faults in PROFIBUS DP networks during installation and start-up.
Pre-commissioning wiring, device and address testing can save a lot of time and trouble at
the commissioning stage. The Siemens BT200 and HMS NetTest II are examples of such
hand-held tools.

Hand-held testers can typically perform the following checks on PROFIBUS cabling:

• Detection of breaks and short-circuits in wires or screens.

• Checking termination resistor settings.
• Checking the length of the installed cable (based on cable resistance for BT200 –
not very accurate; based on reflections on NetTest II – much more accurate).
• Determining the location of faults.
• Detection of reflection-generating faults.

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Hand-held testers may also perform some or all of the following checks on PROFIBUS DP
slaves:

• Check the health of the RS 485 driver.

• Check the voltage (+5V) for line termination.
• Checking slave addressing (bus scan).
• Cable impedance measurement (NetTest II only)
• Exercise slave I/O (NetTest II only).
Most hand-held testers have the useful facility of being able to store the test data obtained
whilst testing a bus segment. This data can then be downloaded onto a PC and a report
generated giving full documentation of the tests performed and the results.

3.7. Wiring Testing using the BT200

Basic cable testing

The wiring test is performed with the BT200 by connecting a special “Test Plug to one end
of the segment and switching the terminator on. All devices must be disconnected from the
cable. The BT200 is connected to each socket in turn working away from the test plug. It is
important to use a systematic procedure in testing cables so that any faults can be
accurately determined and located (at least between any two connectors). The test plug
should not be moved during testing and every socket should be checked working away
form the test plug. The cable is tested from the BT200 back to the test plug, so as soon as a
first fault is detected then the fault must be located in the section of cable just added,
between the current connector and the previously checked one.

Note that it is important to check every socket since there may be a fault local to a socket
that does not affect the rest of the cable. For example: a single socket with the A and B
wires crossed over on both the incoming and outgoing cable would not be detectable from
the end of the cable.

Cable under test

Test-Plug

termination on
BT200

Principle of the basic BT200 wiring test

Locating a short circuit

If the cable being tested has a short circuit then this will be indicated by the BT200 no
matter where the short is located. In such a case the isolating connector can be used to
isolate the rest of cable and so locate the short. Simply switch on the termination at the
BT200 connector. Always remember to switch it off again afterwards.

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 Cable under Isolated section

T T

Test- Short
Terminations

BT20

Principle of locating a short using BT200

Use of the BT200 keypad and display

Press to power device on. The display then shows Siemens copyright then an automatic
battery check is carried out. The bar-graph should extend right across the display
indicating a fully charged battery. Note that the charger is not supplied with the BT200 and
must be purchased separately.

Normal, cable test mode

After switch on the BT200 enters “normal” (cable test) mode. You are prompted to press
“TEST” to perform a test.

Battery Start Test

„„„„„„„ ÆTEST

If the BT200 cannot see the test plug, because of a cable fault, or perhaps because it is not
connected, the display will show “fix all wires”. Should the tested cable section be fault
free you will see “Cabling OK”, followd by “(1R)” which means one termination
resistor has been detected, or “(2R)” indicating two terminations found.

Cabling o.k. Fix short circ.

(2R) ÆOK B-Shield ÆTEST

Faults found include short circuit, open circuit, crossed wires etc. together with details of
the wires affected.

The BT200 menu

Other functions are available on the BT200 via a menu. To reach the menu, we must press
“Esc” and “OK” simultaneously. The most important of these additional functions are:

• “Cabeling” – same as Normal mode.

• “Station Test” – RS485 test and 5V.
• “Bus-scan” – Find slaves on the bus.

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The station test is used to check the health of a device RS485 driver and to check the
voltage supply for the termination. This test can only be done using a special multi-core
cable which is supplied with the BT200. PROFIBUS cable cannot be used since only the
two signal wires are connected to the cable.

► Cabeling ► Bus scan

Station test Station test

Note that the flashing cursor is always on the top line of the display. Thus pressing “OK”
will always select the currently showing top-most item.

Performing a Bus-Scan
After selecting “Bus scan” from the menu and pressing “OK”, you should see
confirmation that you are about to do the required test. Press “TEST” in response to the
prompt and you are then asked for a slave address.

Bus scan Slave address

ÆTEST 000 ÆOK

The default address is zero, which means the BT200 acts as a master at address 0 and scans
all slave addresses from 1 to 126 looking for slaves. (Note that if you enter any other
address, it causes the BT200 to scan for that address only.) After a delay of about 1 minute,
the display will show a list of found slaves in numerical order.

The other items on the menu include cable length measurement and a reflection test. These
measurements are not very accurate and it is recommended not to use these tests. An
oscilloscope, provides a much more accurate measurement of these characteristics,
however this is outside the scope of this document.

Wiring Testing using the HMS NetTest II

The HMS Bustest II device can also check out cable faults, however this device does not
use a separate test plug and used a different procedure based on progressive testing without
terminations, with one termination and finally with both terminations. In addition it
provides accurate cable impedance and accurate length measurement.

3.8. M12 Connector Systems

M12 screw connectors are used on DP and PA wiring. 5-pin connectors are used for
RS485 wiring (DP) and 4-pin connectors may be used for MBP wiring (PA). M12
connectors are available with screw connection or insulation displacement connection
options for cable connection. When using M12 connectors, it is most important that the
shield is connected properly and that the cable entry is sealed properly against water
ingress. You should always refer to manufacturer’s instructions.

M12 connectors are more difficult to make up on-site than 9-pin sub-D connectors and so
are often supplied pre-wired with cables. Devices that are fitted with M12 connectors often
have two sockets for incoming and outgoing PROFIBUS cables, however these make it
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difficult to disconnect a device from a working bus. Tee connectors can be used to connect
to devices via a single connection. However we should not use a spur line to connect to the
slave; just plug the tee directly into the slave socket.

Termination is normally provided by a blind termination plug connected to the last device
or tee. Power for the termination is normally provided by the device to which it is
connected (either directly or through a Tee). This is another reason for always connecting
the Tee directly to the slave, rather than via a short cable – the two-core cable cannot carry
the +5V termination supply to the terminator plug and we would end with an unpowered
termination network, causing reflections.

M12 connector systems

The manufacturer’s instructions need to be followed carefully for M12 connectors. In

particular, watch for a good screen connection which is distributed all the way around the
cable (360°) rather than via a pig-tail or drain wire connection. Also be sure to check the
security of the cable seal as it enters the plug. Water ingress through a poorly fitted seal
can cause corrosion of the terminals and further the water can travel along the cable by
capillary action to other connectors.

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4. Layout of DP segments
When laying out a PROFIBUS DP network it is important to remember the rules for RS
485 segments:

• RS 485 segments should be laid out as a linear bus, with the cable daisy chaining
from device to device. Spurs should be avoided where possible)
• Each RS 485 segment must be terminated at the ends of the segment cable and
nowhere else.
• RS 485 terminations must be powered at all times, even when the end device looses
power or is disconnected.

4.1. Ideal segment layout

When operating with a single master system, the ideal case is to have the master at one end
of the segment with the termination switched “in”. If the Master loses power, for whatever
reason, the network will fail anyway so the loss of termination power is immaterial.

At the other end a repeater may be used to extend the network to another segment. In this
way any station can be removed or replaced without upsetting bus termination. Note that it
is essential that power is always supplied to the repeater.

To further segment

Repeate
Repeater

T Slav
Slave Slav
Slave Slav
Slave Slav
Slave Slav
Slave

Piggy-back Segment 2 T
socket Galvanic isolation Repeate
Repeater
T Segment 1
T
Maste
Master Slav
Slave Slav
Slave Slav
Slave Slav
Slave Slav
Slave

Preferred arrangement for a single master network with repeaters

The piggy-back socket provided at the master allows us to examine the signals and waveforms
in the first segment. The repeater also provides a built-in piggy-back socket; however, we
must be careful because the piggy-back socket is normally connected to one segment only.
The piggy-back socket normally allows us to examine the signals on the top segment.
Therefore, it is good practice to connect the incoming master cable to the bottom segment
(usually called DP2) and use the top segment (DP1) for the outgoing cable. In this way we can
always connect to the piggy-back socket to examine the signals on the next or outgoing
segment.

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 Piggy-back socket.
Segment DP1 Connected to top
segment (DP1) only
Repeater
Repeate
Termination
switches

Segment DP2

Correct connection of the repeater and piggy-back socket

When a repeater is not used at the end of a segment, the termination must be “on” at the last
device. This means the last device needs to be powered at all times to maintain the supply to
the termination network. If you have to replace the last device, the whole network could
become unstable.

If, however, isolating connectors are used (and correctly wired) the above situation can be
avoided by switching on the termination on the penultimate device. This will isolate the last
slave but still leave a correctly terminated segment:

M S S S S S

T T
Properly terminated segment
T Isolated

Use of isolating connectors to avoid termination problems when the last slave is removed

When construction requirements force the master or repeater to be in the middle of the
segment, you need to have the terminations “on” at the first and the last device on the segment
only - not at the master or repeater.

S S M S S S

T
One segment
R

T
S S S S S S

No terminations here

As an alternative to using the terminations in the connector, a separate “active terminator”

can be used. An active terminator is simple a termination network that is separately
powered. The active terminator is connected to a power supply and needs to be powered at
all times. The advantage of this arrangement is that any slave can be disconnected and
replaced without disrupting the network. Note that additional termination (i.e. on the
connector) must not be switched on at the last device since this would result in double
termination.
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A. A. Verwer, December 2008
 AT S S M S S S

R
AT S S S S S S

No additional terminations here

Use of separate Active Terminators

4.2. Network Layout with Repeaters and OLMs

A single segment must be laid out as a linear bus. However, when using repeaters and/or
fibre-optic links to segment a network, much more freedom can be exercised. Every
repeater or fibre-optic link introduces another segment, which can itself be a branch of the
overall network. BUT, every segment must be laid out as a linear bus and must be
terminated at each end and nowhere else.

Segment 1 Segment 2

Master Slave Slave Slave Master Slave Slave Slave Slave

T T
Repeater

Repeater
Slave Slave Slave
T
T T Segment 4
T
Slave Slave Slave Slave Slave Slave Slave
T
Optical Optical Optical T
Segment 3 Link Link Link Segment 5
Module Module Module T
T
Slave Slave Slave
Slave Slave Slave
Fibre-optic cable
T = termination on
Use of Repeaters and PLMs to produce a complex network structure

4.3. RS485 Cable Length Considerations

RS 485 segments can be up to 1.0km in length; however this only applies at lower bit rates.
As the data rate increases, the maximum segment length reduces significantly as shown in
table 3.

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 Table 3 – Maximum segment lengths achievable with copper wire

Baud rate Maximum segment

length
9.6 kbit/s 1 000m
19.2 kbit/s 1 000m
45.45 kbit/s 1 000m Low speed
93.75 kbit/s 1 000m
187.5 kbit/s 1 000m
500.0 kbit/s 400m
1.5 Mbit/s 200m
3.0 Mbit/s 100m
6.0 Mbit/s 100m High speed
12.0 Mbit/s 100m

When are stub-lines allowed?

Stub-lines (also called “spur-lines” or “drop-lines”) are branches from the main segment
cable. Stub-lines can cause reflections to occur because of the additional capacitance
introduced by the spur-line cable. At low bit rates these reflections have only a small
effect, but at higher bit rates spur-lines can cause problems:

Reflections
Low bit rate

High bit rate

Reflections have a worse effect at higher bit rates

Stubs are not allowed when using higher baud rates (>1.5Mbit/s). At baud rates of
1.5Mbit/s and less, stub-lines are allowed up to the maximum capacitance shown in
table 4. Note that additional termination at the end of a stub-line should not be used.
That is we should never have more than two terminations on a segment.

Table 4 – Maximum allowable stub-line lengths

Baud rate Total allowable stub capacitance Total stub cable length*
>1.5Mbit/s None None
1.5Mbit/s 0.2 nF 6.7m
500kbit/s 0.6 nF 20m
187.5kbit/s 1.0 nF 33m
93.75kbit/s 3.0 nF 100m
19.2kbit/s 15 nF 500m
* Calculated for PROFIBUS cable type A at 30pF/m
Note that the total stub-line length shown represents the total length of all stubs attached
to a segment. Always try to avoid Spurs on DP segments where possible. Use a repeater to
create a branch segment if necessary.
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Every PROFIBUS device already has short Spur line within the casing carrying the bus
signals between the connector and RS 485 driver chip. Devices are tested for reflections as
part of the certification process; however, uncertified devices can cause reflections.

4.4. Special requirements for baud rates >1.5 Mbit/s

• Use of bit-rate (Baud rate) greater than 1.5 Mbit/s requires special connectors with
built in inductors.
• Spur-lines are not allowed when using baud rates greater than 1.5 Mbit/s.
• The maximum segment length is 100m.
• A minimum cable length between any two stations of 1m is recommended.

This minimum cable length requirement is because stations that are closely connected can
together cause reflections even though they individually meet the PROFIBUS certification
requirements. Separating stations with 1m of cable introduces a small delay between the
devices, so the reflections don’t add.

25pF 25pF 25pF 25pF

Oscilloscope
trace:-

Effect of adding 1m of cable between closely spaced devices

5. Layout of PA segments
Manchester Bus Powered (MBP) transmission, which is defined in IEC61158-2, is used for
PROFIBUS PA. This is identical to the transmission system used for Foundation Fieldbus
(FF), however, PROFIBUS and FF devices cannot share the same cable.

Spur lines are common in MBP segments where field-mounted junction boxes are often
used to route cable branches to individual devices. There are, however, limitations on the
length/number of spurs. A total of up to 1900m of cable can be used in a MBP segment,
however the characteristics of the cable (see section 6.2) and/or requirements for intrinsic
safety (see section 5.4) can reduce this significantly.

Up to 32 devices can be connected to a PA segment; however the particular characteristics

of the segment power supply and/or requirements for intrinsic safety can again reduce this
significantly.

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5.1. Coupler and link technology

Simple DP/PA couplers

PA slaves are controlled by DP masters and so we must use a DP/PA coupler to connect
PA segments to DP segments. The coupler converts between RS485 and MBP signals, in
addition it provides power for the PA segment. Intrinsically safe couplers also incorporate
a protection barrier (Zenner barrier) to limit the current and voltage supplied to
intrinsically safe segments.

Up to 32 devices can be connected to a PA segment, however power supply limitations or

intrinsically safe requirements may reduce this number significantly. Simple couplers,
when used on their own, do not have a PROFIBUS address; telegrams are simply
translated and passed through from segment to segment. When using a simple coupler,
each PA slave is allocated an address which is unique on the network, however, the DP
segment must run at low speed (45.45 or 93.75 kbit/s - depending on the coupler
manufacturer).

#1 #0 #10 #11
#12

DP segment running at 45.45 or 93.75 kbit/s

DP/PA Power supply for PA segment
coupler
PA segment running at 31.25 kbit/s
(no address)

#17
#16
#15
#13 #14
Use of a simple DP/PA coupler

Siemens DP/PA Link Module

A Siemens DP/PA link module acts like a slave on the DP side and a master on the PA
side. Thus a link module must have a slave address through which the DP master can
access the PA segment. The PA devices are therefore strictly a new network. So the
addressing of the PA devices can overlap the addresses on the rest of the network. A link
module allows the DP segment to run at high speed (up to 12 Mbit/s), independently of the
PA bit rate. Typically a link module will incorporate several plug-in couplers to drive PA
segments.

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 #1 #0 #10 #11
#12

DP segment running at up to 12 Mbit/s

Siemens
Couplers
DP/PA link
PA segment 2
module at DP
PA segment 1
address #13

#14

#13
#12
#10 #11
Use of a Siemens Link Module with Couplers

Pepperl+Fuchs Modular Coupler

Pepperl+Fuchs offer a modular coupler that behaves in a similar way to the Siemens link
module. Like a link module, the P+F Modular coupler allows the DP segment to run at up
to 12Mbit/s, however it does not take a DP address and appears transparent on the
network. Like a simple coupler, the PA addresses must not overlap the DP addresses.
Unfortunately the nomenclature is rather confusing: The P+F modular coupler consists of a
“head station” plus a number of “power-link” modules, each of which can drive a PA
segment.
#10 #11
#1 #0
#12

DP segment running at up to 12 Mbit/s

Pepprl+Fuchs
Plug- in “power link modules”
Modular
PA segment 2
coupler
PA segment 1
(no address)

#1 7

# 16
#1 3 #1 5
#1 4
Use of a P+F Modular Coupler with Power Link Modules

5.2. MBP Spur Lines

The length of the individual spur-lines on a PA segment depends upon the total number of
spurs used. Table 5 shows the recommended length of individual MBP spur-lines. Notice
that intrinsically safe installation requirements provide an additional restriction on stub-
line length.

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 Table 5 – Recommended IEC61158-2 stub-line lengths

Number of Maximum spur length Maximum spur length

spur-lines non-intrinsically safe installation intrinsically safe installation
25 to 32 1m 1m
19 to 24 30 m 30 m
15 to 18 60 m 60 m
13 to 14 90 m 60 m
1 to 12 120 m 60 m
Note that the maximum cable length of 1900m includes cable used for spurs.

Devices can be installed and removed with power applied to the cable, however care must
be exercised to ensure that the leads do not short which would mean loss of power to the
other devices on the segment. Fused spurs and hubs can be useful to avoid such problems.

5.3. MBP termination

Terminations should be used on PA segments for the same reasons as described for DP
segments, that is to stop reflections from the end of the main trunk line. However the
termination network for MBP segments is very different to that for RS 485 wiring. An
MBP termination consists of a capacitor and resistor in series connected between the two
wires. The resistor matches the characteristic impedance of PA cable and the capacitor is
included to block DC, otherwise significant current would flow through the resistor from
the power supply.
100Ω±2%
PA cable
1µF ±20%

MBP Termination

Note that MBP terminators are not powered. Terminators are mounted at the ends of the
main cable run only (i.e. not at the ends of spur lines). Most segment couplers incorporate
a built-in terminator, which should be at one end of the line. The other terminator is
normally mounted on the last or furthest device, or sometimes in the last junction box.

PA slave PA slave PA slave PA slave

DP PA slave
junction
boxes
DP/PA T PA slave
coupler T

T PA slave
Power
supply PA slave PA slave PA slave

Termination Termination Alternative location

normally built in to in last junction for termination in last
coupler box device
PA segments can use spurs and tree structures

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Note that the position of the terminator determines how many spurs we have. For example
when the terminator is in the last junction box then we have one more spur then if the
terminator is mounted in the last device. Terminators in junction boxes are preferred
because of the availability of off-the-shelf solutions. These junction boxes can be obtained
with a single spur, or with multiple spurs, with and without terminations and protection.

Tee junction boxes

for PA spurs

Typical PA Installation using junction boxes

5.4. Intrinsic Safety Considerations

When electrical equipment operates in a potentially explosive atmosphere (a hazardous
environment) special precautions must be taken to ensure that it will not cause an
explosion. Several protection methods are available, however “intrinsically safe
protection”, EEx i, has many advantages for instrumentation. Intrinsically safe protection
is based upon limiting the current and voltage (and hence power) available to the field-
mounted device. Capacitance and inductance are also controlled to limit the stored energy
available for a spark. Different classes of protection are provided: EEx ib which is safe in
the event of a single fault and EEx ia which remains safe in the event of a double fault.
EEx ia equipment can be used in a “zone 0” application where the threat of explosion is
permanent or sustained. The gas group is considered since some gasses are easier to ignite
than others. Gas group IIC has the most stringent requirements. Finally the surface
temperature must be limited to below the gas or vapour ignition temperature. Temperature
class T4 has the lowest requirement.

From To
Power hazardous
supply area

Typical protection barrier circuit limits current and voltage even in the presence of faults

Special “barriers” that incorporate voltage and current limiting devices are placed in the
circuit. Certified devices must be used that meet the capacitance and inductance

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requirements for the protection category. Also the cable length and spur lengths must be
limited. This means that when used to protect a PA segment, the number of devices and
maximum cable length are significantly less than the IEC61158-2 specification would
allow for non-hazardous applications.

PROFIBUS PA segments can be designed to be intrinsically safe by ensuring all devices

are certified for intrinsic safety and that the cable and terminations meet the requirements.
Traditionally the “entity concept” was used for designing intrinsically safe applications,
however a relatively new method called the “Fieldbus Intrinsically Safe Concept”, FISCO,
has been introduced to simplify system design. FISCO power supplies for intrinsic safety
limit the available output power to a segment, however, in addition, the voltage is limited.
This allows greater current to be delivered to the segment (hence more devices).
Intrinsically safe DP/PA couplers incorporate barriers that provide current and voltage
limiting. A typical coupler certified for EEx ia gas group IIC might provide 110mA at a
voltage of 13V which would limit the number of devices to 7 or 8 per segment (compared
to 32 devices for a non-hazardous application).

The FISCO model enforces the following restrictions:

• Each segment has only one source of power.
• Every field device consumes a constant basic current.
• The field devices act as passive current sinks.
• Device capacitance and inductance limited to Ci < 5nF, Li < 10µH.
• Total cable length limited to 1000m maximum. (including spurs)
• Individual spur line lengths limited to 60m maximum.

The detailed design of an intrinsically safe PA segment is beyond the scope of this
document and the reader is referred to the PROFIBUS – MSB Technical Guideline.

6. Cables for PROFIBUS

6.1. Cables for PROFIBUS RS485 segments

The standard IEC61158 specifies a “type A” cable for use with PROFIBUS RS485 as
shown in table 6.

Table 6 – Cable specification for PROFIBUS RS485 type A cable

Parameter
Impedance 135 to 165 Ω at a frequency of 3 to 20 MHz
Capacitance < 30 pF / m
Resistance ≤ 110 Ω/ km
Wire diameter > 0.64 mm
Conductor area > 0.34 mm2

In order to fit the cable into standard connectors, the cable needs to have a sheath diameter
of 8.0 +/- 0.5 mm.

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The term “Type-A” is rather confusing because it really means “Quality-A”, i.e. “best
quality”. Several different forms of Type A cable are available:

• Standard PROFIBUS solid-core cable.

• Stranded-core cables for flexibility.
• Cables with special sheaths for use in the food and chemical industries.
• Armoured cables for protection against rodent and other damage.
• Zero Halogen (Low Smoke) cables for use in confined spaces.
All can be obtained as “Type-A” cable.

6.2. Cable for PROFIBUS PA

IEC 61158-2 specifies four different types of cable for use in PA segments (table 7). PA
type A cable (not the same as RS485 Type A cable) is a two-core shielded twisted pair
cable which gives the best performance in terms of signal attenuation and hence cable
length.
Table 7 – Cable specification for PROFIBUS PA cables

Conductor Max DC loop Max total

Pairs Shield area resistance cable length
Type A Single Yes (90%) 0.8 mm2 44 Ω/km 1900 m
Type B Multi Overall shield 0.32 mm2 112 Ω/km 1200 m
Type C Multi None 0.13 mm2 264 Ω/km 400 m
Type D Multi None 1.25 mm2 40 Ω/km 200 m

When using IEC61158-2 type A cable, the total segment length can be up to 1.9km
including all branches or stub-lines. Intrinsically safe requirements will give significantly
reduced segment length (see section 5.4).

The recommendation is to use type A cable for new installations. However, the ability to
use other types of cable is useful when fieldbus devices are being fitted to an existing plant
which already has cable installed.

7. Installing PROFIBUS cables

7.1. General Guidelines

Bus cables should ideally be installed in their own steel cable channels or conduits. Plastic
trunking provides no screening whatsoever: it is just a cable tidy. Basket type cable trays
also do not provide screening.

8 8 9
Solid steel channelling with a lid or steel conduit
provides electrostatic and electromagnetic screening
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If not installed in conduit bus cables should be brightly coloured and installed where they
are clearly visible and separate from all other cables in order to improve any interference
pickup and to avoid accidental damage.

When installing, it is important not to distort or damage bus cables since this can cause
reflections to occur in the network. In particular, do not twist or stretch bus cables, do not
squash or crimp them and adhere to the recommended minimum bend radius (typically
for solid core: 75mm minimum, for stranded cables: 45mm for a single bend and 65mm for
repeated bending).

Use cable pulleys to avoid damage and excessive bending during installation

7.2. Cable Segregation

To reduce the chances of interference pickup, it is important that bus cables are run
separately from other types of cable. It is useful to categorise various cable applications as
follows:
Category I:

• Fieldbus and LAN cables (e.g. PROFIBUS, ASi, Ethernet etc.).

• Shielded cables for digital data (e.g. printer, RS232 etc.).
• Shielded cables for low voltage (≤25V) analogue and digital signals.
• Low voltage power supply cables (≤60V).
• Coaxial signal cables

Category II:

• Cables carrying DC voltages >60V and ≤400 V

• Cables carrying AC voltages >25V and ≤400 V

Category III:

• Cables carrying DC or AC voltages >400 V

• Cables with heavy currents.
• Motor/drive/inverter cables.
• Telephone cables (can have transients >2000V).

Category IV:

• Cables of categories I to III at risk from direct lightning strikes (e.g. connections
between components in different buildings)

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 ≥20 cm

Cable ≥10 cm Cable ≥ 10 cm

Cable
Category Category Category
I II III

≥50 cm
≥ 50 cm ≥50 cm
Cable
Category
IV
Separation distances for cables of different category

Sometimes it is impossible to adhere to the separation distances. Where cables have to

cross, they should cross at right angles and should never run in parallel even for short
distances.

7.3. Use of cable trays and channels

Cables from the same category can be bundled together or laid directly beside each other
in the same cable trays. Cables of different category must be separated by at least the
distances shown.

10cm 10cm

Cat III Cat II Cat I

Cables mounted on a cable tray, rack or ladder

must be separated by the recommended clearances

When separated by earthed steel partitions with a steel lid, the bundles can be placed next
to each other. All channels and partitions must be properly earthed using flexible bonding
links protected against corrosion. Note that braided straps are better than solid metal for
high-frequency EMC protection.
Cat II

Cat III Cat I

Cable groups separated in steel compartments can be placed next to each other

7.4. Cabling Within Wiring Cabinets

The braided shields of all PROFIBUS cables entering the wiring closet should be earthed
with metal clamps as close as possible to the point of entry to the cabinet. This is because
the cable screen can carry pick-up into a cabinet where it can disrupt sensitive electronic
equipment. Earthing the screen close to the point of entry minimises this problem.

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 Close as possible

Strain Cable
Earth cable shield
relief entry
Enclosure or cabinet

Earthing the cable screen close to the pint of cabinet entry

A more robust solution is to use M12 bulkhead adaptor. These have the additional
advantage that they also allow the internal wiring to be completed and tested off-site.

M12
connectors

Enclosure or cabinet
Bulkhead connector
provides earthing

A more robust solution using earthed bulkhead connectors

Try to avoid parallel routing of PROFIBUS cables and internal cabinet wiring, even with
cables of the same category. Try to maintain separation distances, but where cables of
different categories must cross, they should do so right angles. If the separation distances
cannot be maintained, use earthed metallic channels with bonded partitions to separate
cables.

Remember to observe the minimum cable length requirement of 1m between devices for
networks running at over 1.5 Mbit/s. The excess cable can be easily looped out of the way,
but do remember the minimum bend radius requirement for the cable being used. Even
when using rates of 1.5 Mbit/s or less, it is good practice to observe this 1m cable length
between devices. You may wish to upgrade the bus speed at some later date.

7.5. Potential Equalisation

In order for the screen to be effective at high frequencies, the screen must be earthed at
both ends of the cable. Sometimes, however the local earth at different parts of the plant
can be at significantly different potential, which can lead to current passing along the cable
screen. Such screen current is to be avoided since it can lead to interference pickup.

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Earth potential problems are common where:

a) The network cable covers a large area or extends over a long distance.
b) Power is supplied to different sites from different sources (i.e. sub stations).
c) Heavy electrical currents are present (e.g. arc furnaces, power stations etc).

One solution is to install a potential equalisation cable between the different earth
potentials. The potential equalisation cable can carry significant current and should be
sized accordingly (16 mm2 is not uncommon). Finely stranded cable, with a large surface
area, should be used to ensure that effectiveness at high frequencies. Potential equalisation
cable should be laid parallel to and as close as possible to the network cable to minimise
the area enclosed between the two.

Cabinet 1 Cabinet 2

Local Potential Local

ground equalisation cable ground

Bus cable Close as possible

Figure 20 – Installation of a potential equalisation line

NOTE: The network cable screen must never be used for potential equalisation.

An alternative to running heavy potential equalisation cables is to use capacitive shield

grounding at one end of the cable. This technique provides a good path to ground for high
frequency signals that can cause pickup, yet will not allow DC current to pass along the
PROFIBUS cable shield. A repeater should be used in such cases to also isolate the data
lines (A and B):

Repeater
Don’t short to ground!

C < 10nF, Capacitive

V > 1500V grounding
Different earth
potentials

Capacitive grounding

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Remember that optical-fibre segments provide total isolation from one end to the other.
They also are totally immune to any electrical interference and can be used over long
distances.

8. Repeaters
An RS 485 repeater amplifies the data signals on bus lines and provides isolation between
individual bus segments. A repeater is required, when:

a) there is a need to connect more than 32 devices to the bus, or

b) there is a need to isolate sections of the bus, or
c) the segment exceeds the maximum permissible cable length for the bit-rate used.

Repeaters can also be useful to create branch segments in your network.

Some older repeaters do not incorporate automatic bit-rate detection and hence the baud
rate must be explicitly set using a switch provided on the device.

9. Fibre Optic Components

An optical fibre cable transfers data signals using light which travels along a glass or
plastic fibre. Several types of fibre-optic transmission media are available:

• Plastic fibre which is low cost, simple to make up, but is generally limited to
distances of less than 50m.
• Multi-mode glass fibre which can be used over distances of up to 2km.
• Single-mode glass fibre which can be used over distances of up to 50km.
Glass-fibre cable requires special techniques and tools for making up and testing. Plastic
fibre transmission is less expensive and can easily be made up on-site.

9.1. Optical Link Modules

Fibre-optic PROFIBUS transmission requires the use of RS 485 to fibre optic conversion
called Optical Link Modules (OLMs). OLMs are available from various manufacturers.
Each optical channel on an OLM requires two optical connections: one for transmission
and one for reception. Some OLMs have duplicate optical channels (i.e. 2 in plus 2 out)
allowing two optical segments or redundant fibre optic paths to be implemented. Like
repeaters, OLMs also have the effect of splitting the network into isolated segments.

When using OLMs to connect two segments, two fibre optic cables are required; one for
the signal in each direction. Other, more complex topologies are possible using more
OLMs.
Single channel OLMs
Segment 1
Segment 2

OLMs connecting two segments

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Optical segments are normally arranged as ring using multiple single-channel OLMs.

Ring

OLMs can be used to give tree, star and even redundancy.

Tree Star

Segment 1 Segment 2
OLM OLM

Redundant fibre optic connection using two channel OLMs

10. Bibliography

Documents available from PROFIBUS International ([Link])

PROFIBUS Standard - DP Specification
Implementation Guideline IEC 61158/61784, Type 3, PROFIBUS
Fibre optical data transfer for PROFIBUS
Handbook PROFIBUS Installation Guideline
Installation Guideline for PROFIBUS DP/FMS
Installation Guideline PROFINET Part 2: Network Components
PROFIBUS Interconnection Technology
PROFIBUS PA User and Installation Guideline
PROFIBUS RS485-IS User and Installation Guideline
PROFIsafe - Environmental Requirements

Other documents and publications

SIMATIC NET PROFIBUS networks manual.
Siemens ET 200 Distributed I/O System manual.
Siemens BT200 operator manual.
HMS Bustest II user guide.
Berge J: “Fieldbuses for Process Control”, ISA, 2002.
IEC61000-5-2: 1997: Electromagnetic compatibility (EMC) – Part 5: Installation and
mitigation guidelines, Section 2: Earthing and cabling.

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Index
9-pin sub-D connectors, 8 intrinsic safety, 27
active termination, 9 isolating connector, 20
active terminator, 20 isolating connectors, 13
address setting, 6, 7 junction boxes, 26
balanced transmission, 3 line length, 28
binary switch, 7 M12 connector, 8, 18
BT200, 14, 15 M12 connectors, 17
Bus scan, 17 MBP, 6, 23
Bustest II, 14 modular coupler, 25
cabinets, 31 multi-drop, 5
cable categories, 30 Net Test II, 17
cable channels, 32 network layout, 19
cable length, 21 OLM, 21, 34, See optical link module
cable specification, 28, 29 optical link module, 6, 34
cable test tools, 14 Pickup, 1
cable trays, 31 Pickup Reduction, 2
capacitive coupling, 1 Piggy back, 19
channels, 31 potential equalisation, 32
connectors, 11 reflections, 9, 22
crossing cables, 31 repeater, 5, 6, 20, 21, 33, 34
decimal switch, 7 repeaters, 5
device addressing, 6 reserved addresses, 8
DP/PA Coupler, 24 RS 485, 2
DP/PA Link Module, 24 screening, 2
drop-line. see stub-line, see stub-line Screening, 4
ducting, 2 segment, 5, 21
Earth loops, 4 segment length, 21, 29
earthing, 32 Segmentation, 5
Earthing, 4, 31 Segregation, 30
Electromagnetic pickup, 1 Shielding, 2
Electrostatic pickup, 1 solid core cable, 11
fibre optic, 2, 34 spur length. See stub length
fibre-optic, 6 Spur line, 11
FISCO, 28 spur lines, 25, 26
FO. See fibre optic spur-lines. see stub-line
Foundation Fieldbus, 23 stranded cable, 11
H1. See IEC 61158-2 stripping tool, 11
H2. See RS 485 stub length, 26
hand held test tools. See cable test tools stub-line, 11, 22, 29
hazardous environment, 27 stub-line length, 22
High speed requirements, 23 termination, 9, 22, 26
IEC 61158-2, 2, 6, 29 Twisted pair, 2
inductive coupling, 1 Unbalanced transmission, 3
installing cables, 29 wiring, 8
insulation displacement, 11 wiring faults, 14
insulation displacement connectors, 11 Zenner barrier, 24
interference, 1

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