Ethernet in the Ex Area
Ethernet in an Ex area connects process data with control systems and IT systems—serving as the foundation for parallel data access, flexible network topologies, reliable communication, and high availability.
Quick read
Ethernet in Ex areas is a process automation communication technology for data transmission from areas at risk of explosion. For Zone 2, TURCK offers the excom I/O system with Ethernet, which can receive signals from Zone 1 or Zone 0. The excom Ethernet Gateway GEN transmits process, diagnostics, status, and supplementary data via a parallel data channel. For connectivity to IT and cloud systems, excom supports MQTT, OPC UA, the encrypted TURCK cloud protocol Kolibri, and open standards. TURCK Multiprotocol enables excom Ethernet to communicate via PROFINET, Modbus TCP, and EtherNet/IP. MRP for PROFINET and DLR for EtherNet/IP support ring topologies, while S2 and R2 redundancy enable additional availability concepts. The Advanced Physical Layer (APL) describes a two-wire intrinsically safe Ethernet designed to carry both communication and power over the same cable.
Ethernet in the Process Industry
Industrial Ethernet has long been known in factory automation and is now quite widespread. However, the specific requirements of the process industry—and in particular those involving potentially explosive atmospheres—have so far precluded the use of Ethernet. These requirements include intrinsic safety, configuration during operation, redundancies for maximum availability, and, last but not least, long cable lengths—which, however, are limited to 100 meters with Industrial Ethernet. When describing Ethernet in the process industry, it is important to distinguish its potential with regard to the respective zones.
Ex zone 2
For installation in Zone 2, TURCK offers its excom I/O system with Ethernet. The system can receive signals from Zone 1 or 0. When plugging in or unplugging the Ethernet connectors on the gateway during operation, you must ensure that the gateways are de-energized or that work is performed under flame light. All other components, such as power supply modules, gateways, or I/O modules, can be replaced during operation without a fire permit.
Ethernet for Zone 1
Using Ethernet in Ex zone 1 is technically more challenging. When devices are daisy-chained, it must be ensured that power levels do not add up. A consortium of automation companies has set itself the goal of overcoming these hurdles and developing a standard for a two-wire intrinsically safe Ethernet. Communication and power supply occur over the same cable. The future standard is commonly referred to as the Advanced Physical Layer (APL). However, these developments are not yet suitable for widespread industrial use in Zone 1 (as of March 2020). One day, APL is expected to enable Ethernet connections all the way down to field devices. However, traditional 4–20 mA technology and I/O systems will continue to coexist alongside APL—even after APL is fully established—solely for cost reasons.
Parallel Data Access
With the excom Ethernet Gateway GEN, TURCK is opening up the world of the process industry to digitalization and Industry 4.0. For the first time, all process, diagnostic, status, and supplementary data is transmitted at sufficient speed via a parallel data channel—without any impact on operational processes—to clouds or other IT systems for analysis and evaluation—a fast and simple path to efficient condition monitoring and predictive maintenance. Control systems and process control systems remain completely unaffected by this and are protected from unauthorized access. Data is transmitted to cloud systems via MQTT, OPC UA, TURCK’s encrypted cloud protocol Kolibri, or other open standards.
Benefits
Cloud connectivity—including on-premises
In addition to transmitting time-sensitive user data to the control system, excom can use parallel data access to transfer analytical data to any IT system on the network. However, it makes sense to first analyze the data in an edge device and then send only the results to the cloud. The cloud, in turn, can be implemented as a “private cloud” without internet access (on-premises) or in a traditional manner.
Maximum availability thanks to redundancy
The integrated Ethernet switch enables easy setup of a line topology without external switches. The line topology can be expanded to a ring topology at any time using the redundancy protocol. To do this, all devices must support the MRP (PROFINET) or DLR (EtherNet/IP) redundancy protocol. Excom also provides gateway and power supply module redundancy, which further increases the system’s reliability and supports additional redundancy concepts.
Flexible Network Topology
The gateways feature an integrated 2-port switch and can therefore be installed in a line configuration, just like traditional fieldbuses. Other standard Ethernet topologies, such as star, tree, and ring configurations, are also supported.
PROFINET redundancy concepts
Various network topologies:
In the specification, S2 redundancy refers to a system consisting of two controllers and one device—in this case, an excom gateway. The masters synchronize internally via a backbone bus and both maintain a connection to the device. TURCK also offers its IP67 IO-Link master module TBEN-L-8IOL with S2 redundancy.
excom can also support the highest redundancy standard, R2. In this configuration, two masters establish cross-connections to two gateways. This means that one of the two controllers and one of the two gateways can fail without communication being interrupted.
Multiprotocol
One gateway, Three protocols – TURCK’s multiprotocol I/O devices detect the master upon startup and automatically configure themselves for the respective protocol: PROFINET, Modbus TCP, or Ethernet/IP. excom Ethernet benefits from this proven standard and can be used right out of the box with all control systems that support Ethernet/IP, PROFINET, or Modbus TCP.
For example:
- Siemens
- Honeywell
- Rockwell
- Yokogawa
- Emerson
- Supcon
- ABB
Ethernet in the Ex area: Added Value for Your Application
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Ethernet in the Ex area at TURCK: Frequently Asked Questions
1. What is Ethernet in an Ex area, and what is it used for?
Ethernet in Ex areas is a communication technology for process automation in areas at risk of explosion. TURCK uses Ethernet with the excom I/O system to capture signals from Ex zones and transmit process data to control systems. The excom Ethernet Gateway GEN’s parallel data access capability also allows it to forward process, diagnostic, status, and supplementary data to clouds or other IT systems.
2. Which TURCK hardware supports Ethernet in Ex areas in Zone 2?
For Ethernet in Zone 2 Ex area, TURCK offers the excom I/O system with Ethernet. excom can receive signals from Zone 1 or Zone 0. According to the documentation, power supply modules, gateways, and I/O modules can be replaced during operation without the need for a flame test. Special conditions apply to Ethernet connectors on the gateway, however, because the gateways must be de-energized or the system must be operated with a flame test.
3. What role does APL play for Ethernet in the Ex area in Zone 1?
Advanced Physical Layer (APL) is designed to enable Ethernet in the Ex area all the way down to field devices in Zone 1. The approach described in the source code uses two wires for communication and power supply. The source text also clarifies that, as of March 2020, APL is not yet suitable for widespread industrial use in Zone 1, and that traditional 4-to-20-mA technology and I/O systems are intended to continue operating in parallel.
4. Which protocols does TURCK support for Ethernet in Ex areas?
For Ethernet in Ex areas, TURCK supports the PROFINET, Modbus TCP, and EtherNet/IP protocols with excom Ethernet. The multiprotocol I/O devices detect the master after startup and automatically configure themselves for the respective protocol. For parallel data access, it specifies
The source code also supports MQTT, OPC UA, the encrypted TURCK Cloud protocol Kolibri, and other open standards.
5. How is Ethernet programmed or configured in an Ex area using TURCK products?
The source text does not describe any programming and does not mention any programming tools for Ethernet in Ex areas. For TURCK excom Ethernet, it is only documented that multiprotocol I/O devices recognize the master after startup and automatically configure themselves for PROFINET, Modbus TCP, or EtherNet/IP. No information regarding engineering software, programming languages, configuration procedures, or licensing models can be derived from this source.
6. How can data from Ethernet be visualized and analyzed in Ex areas?
Ethernet in the Ex area provides process, diagnostic, status, and additional data for analysis and evaluation through the TURCK excom Ethernet gateway GEN. The parallel data channel can transmit analysis data to an IT system on the network. The source text suggests analyzing data initially in an edge device and sending only the results to a traditional or private cloud without Internet access. The source does not specify a particular visualization software.
7. How does TURCK protect data and controllers when using Ethernet in an Ex area?
In an Ex area, the TURCK excom Ethernet gateway GEN separates parallel data access from controllers and control systems. According to the source text, controllers and control systems remain unaffected by data transmission and are protected from unauthorized access. For transmission to cloud systems, TURCK cites MQTT, OPC UA, open standards, and the encrypted cloud protocol Kolibri. The source does not mention any additional security mechanisms or requirements.
8. What redundancy concepts does TURCK offer for Ethernet in Ex areas?
TURCK offers several redundancy concepts for Ethernet in Ex areas using excom. Ring topologies can use MRP for PROFINET or DLR for EtherNet/IP, provided that all participants support the respective protocol. excom also supports gateway and power supply module redundancy. In S2 redundancy, two controllers connect to an excom gateway. In R2 redundancy, two masters establish cross-connections to two gateways.
9. What are the costs and licensing requirements for Ethernet in the Ex area with TURCK?
The source text does not contain any prices, licensing costs, or licensing models for Ethernet in Ex areas using TURCK excom. It merely supports the assessment that, for cost reasons, traditional 4-to-20-mA technology and I/O systems will continue to coexist even after the establishment of the Advanced Physical Layer. Therefore, the source does not provide reliable information on hardware costs, software licenses, or recurring fees for procurement and budget planning.
10. For which practical applications is Ethernet in Ex areas suitable when used with TURCK excom?
Ethernet in Ex areas with TURCK excom is suitable for process plants that receive signals from Zone 1 or Zone 0 and transmit them via an excom I/O system installed in Zone 2. The source text also mentions Ethernet communication for skids in Ex areas, process data access in Zone 2, and a space-saving excom I/O system in the control room. The excom Ethernet gateway GEN additionally supports condition monitoring and predictive maintenance through parallel data access.