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A Holistic approach to PROFIBUS health monitoring - Dale Fittes

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Key Points for Successful Health Monitoring on PROFIBUS Networks …

Key Points for Successful Health Monitoring on PROFIBUS Networks

Take a holistic approach i e 360 Take a holistic approach i.e. 360˚ view

May require inter-departmental collaboration

e g.. Production Maintenance IT QA Production, Maintenance, IT, QA.

Combine continuous monitoring with “point-and-shoot” diagnostics

Requires a combination of tools and skillsets

Published in: Technology

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  • 1. A HOLISTIC APPROACH to PROFIBUS DIAGNOSTICS Dale Fittes Hitex UK dfittes@hitex.co.uk www.hitex.co.uk 024 7669 2066
  • 2. Key Points for Successful Health Monitoring on PROFIBUS Networks  Take a holistic approach i.e. 360 view i e 360˚  May require inter-departmental collaboration  e g Production Maintenance IT QA e.g. Production, Maintenance, IT, QA.  Combine continuous monitoring with “point-and-shoot” diagnostics  Requires a combination of tools and skillsets www.hitex.co.uk 024 7669 2066
  • 3. PROFIBUS Diagnostics Suite  Universal diagnostic software supports multiple tools www.hitex.co.uk 024 7669 2066
  • 4. PROFIBUS Diagnostics Suite Functionality with supported buscheck tools Standard tests Expert tests         in prep. prep   PROFIBUS Inspektor BC-502-PB/CL Output Protocol Analyzer BC-4x0-PB BC 4 0 PB Input Frame an nalysis Oscillogr ram analysis Trigger Test repo ort Critical eve ents Signal qua ality Trend mulator Master sim Topology Signal Ana alysis A Protocol Analysis Overview phys. & comm. Quick and long-term test Permanen bus status nt Test functions Stand-alo operation one Network status  PROFIBUS Tester 4 BC-600-PB BC 600 PB PROFIBUS Tester 3 PB-T3                www.hitex.co.uk      024 7669 2066 
  • 5. PROFIBUS Tester 4 ► Very powerful all-in-one PROFIBUS DP tester which simultaneously analyses data communication and monitors bus quality. ► Integrated master simulator allows bus testing without having a PLC connected, and pinpoints faults on individual bus devices. devices ► Stand-alone mode - allows testing without connecting to a laptop PC ► Extremely easy to use: Just one click starts a full bus test. “Traffic light” status indication. ► Rapid, accurate and reproducible test results www.hitex.co.uk 024 7669 2066
  • 6. PROFIBUS Tester 4 Features and applications ► Allows full testing of live PROFIBUS DP segments with minimum impact on bus ll f ll t ti f li O S t ith i i i t b operation. ► U i Universal t l f l tool for: – – – – – – – Setup and commissioning Documentation Acceptance Tests Preventive maintenance Optimization Troubleshooting Field device testing www.hitex.co.uk 024 7669 2066
  • 7. PROFIBUS Tester 4 Stand-alone mode ►Live t t ►Li status of all bus devices f ll b d i ►Quick test* of network status (10 memory locations) ►Trend* ►Master simulator • * Display and detailed analysis of test results on the PC using the PROFIBUS Diagnostics Suite www.hitex.co.uk 024 7669 2066
  • 8. PROFIBUS Tester 4 Main Benefits ► Reduces commissioning times ► Down-time prevention due to regular preventive tests p g p ► Effective and quick trouble-shooting reduces unscheduled downtimes www.hitex.co.uk 024 7669 2066
  • 9. PROFIBUS Diagnostics S it Di ti Suite Bus and network status ► The Bus Status Display continually shows the bus status whether or not the test has begun: ► :The Network Status Overview displays the overall diagnostic result and provides a brief overview of the bus physics and bus communication www.hitex.co.uk 024 7669 2066
  • 10. PROFIBUS Diagnostics Suite Network status – Protocol tab ► Select segment, master or slave levels: www.hitex.co.uk 024 7669 2066
  • 11. PROFIBUS Diagnostics Suite Network status – Protocol tab ► If the correct GSD files are available for identified devices, the device type, error messages, configuration and parameters can be displayed in plain text other tools reading hexadecimal  only PB‐DIAG‐SUITE reads clear text ► All state changes of masters + slaves are logged with time stamp www.hitex.co.uk 024 7669 2066
  • 12. PROFIBUS Diagnostics Suite g Network status - Signal Quality tab ► The Signal Quality tab provides an overview of the bus physics by indicating the quality index measured for all bus devices – Even transient physical faults that occur only sporadically will be detected and displayed reliably ► Si Signal d t il available f each b d i can b l details il bl for h bus device be displayed optionally: www.hitex.co.uk 024 7669 2066
  • 13. PROFIBUS Diagnostics Suite Network Status - Topology tab ► The topology scan determines the sequence and distances of all passive bus devices www.hitex.co.uk 024 7669 2066
  • 14. PROFIBUS Diagnostics Suite Trend Analysis ► The trend analysis is used for finding rare or sporadic faults over a prolonged period of time. ► C Covers b th bus communication and signal quality. both b i ti d i l lit www.hitex.co.uk 024 7669 2066
  • 15. PROFIBUS Diagnostics Suite Test report ► Based on the network status, a detailed test report including all graphics can be generated from an active test tool, or from a file. ► The test report can be printed or exported as a PDF or an E l fil t d Excel file www.hitex.co.uk 024 7669 2066
  • 16. PROFIBUS Diagnostics Suite Expert functions - Oscilloscope ► The signal can be analyzed with the integrated oscilloscope www.hitex.co.uk 024 7669 2066
  • 17. PROFIBUS Diagnostics Suite Expert functions - Frames ► The frame analysis function provides powerful trigger and filter settings for analyzing individual frames www.hitex.co.uk 024 7669 2066
  • 18. PROFIBUS Tester 4 Optional Accessories ► The D-sub adapter cable BC-600-PB-CB-DSUB-1 is optimized for reduced influence on live PROFIBUS DP segment operation for testing of running plants. The risk of critical influences on bus operation which can cause a plant standstill is significantly ti hi h l t t d till i i ifi tl reduced. ► Using the M12 adapter set BC-600-PB-CB-M12, y can connect the g p , you PROFIBUS Tester 4 to field devices with M12 connectors. ► BC-MOST-PB mobile electric power supply offering up to 4 hours of operating time includes charging station 230V 50/60Hz with Power time, Plug Euro Type C / CEE 7/16only) and carrying bag www.hitex.co.uk 024 7669 2066
  • 19. PROFIBUS Monitor® Features and Applications ► Alerts if PROFIBUS DP maintenance is required l f d ► ► ► Preventing of loss of production due to fieldbus faults Permits scheduling of b maintenance P it h d li f bus i t – Best use of the often scarce maintenance resources – Efficient utilization of system downtimes Easy-to-use via integrated web interface – Status of all bus devices at a glance www.hitex.co.uk 024 7669 2066
  • 20. PROFIBUS Monitor® Functionality ► ► ► ► ► ► ► ► ► Permanent monitoring of the health of the PROFIBUS and alerting of operational staff if operator intervention is required Supports PROFIBUS DP, DPV1, FMS and MPI – Auto baud rate detection 9 6 kbit/s … 12 Mbit/s 9,6 One Inspektor per bus line is all that is needed (no matter how many physical segments) No bus address or changes to the PLC program are required for setup and commissioning Non-proprietary functionality allows use across all controller and bus device types Monitoring f bus M it i of b cycle ti l times and occurrence of critical events d f iti l t – Corrupt telegrams – Telegram repetition – Device drops and restarts – Device errors ( (internal/external diagnostics) ) – Bus faults Alarm list Frame snapshots Bus status report www.hitex.co.uk 024 7669 2066
  • 21. PROFIBUS Monitor® Alerting via PLC/process controller www.hitex.co.uk 024 7669 2066
  • 22. PROFIBUS Monitor® Central server for data and analysis (option) PROFIBUS DP Other fieldbus CAN , e.g. On request Ethernet The image cannot be display ed. Your computer may not hav e enough memory to open the image, or the image may hav e been corrupted. Restart y our computer, and then open the file again. If the red x still appears, y ou may hav e to delete the image and then insert it again. :  PROmanage Server Central event and alarm database for up to 80 Monitors www.hitex.co.uk  Office PC 024 7669 2066
  • 23. PROFIBUS Monitor® Web interface – main overview www.hitex.co.uk 024 7669 2066
  • 24. PROFIBUS Inspektor® Parameterization ► Settings for thresholds, alerts and snapshots in one go or separately for each device ► On error detection: – The ERR LED turns red – The potential-free contact closes, the relay clicks audibly – Visualization via integrated web interface sua at o a teg ated e te a e ► Unique feature: Alerting for error frames and bus cycle time deviations www.hitex.co.uk 024 7669 2066
  • 25. PROFIBUS Monitor® Extended analysis functions ► Alarm li t of th l t 100 critical events l list f the last iti l t ► Snapshots with 500 frames from the last 8 critical events – – Downloadable from web interface to PC Detail D t il analysis with PB-DIAG-SUITE (F l i ith PB DIAG SUITE (Frames and d i d P t d derived Protocol) l) www.hitex.co.uk 024 7669 2066
  • 26. PROFIBUS Monitor® Optional Accessories ► Active connection cable BC-131-PB – – Allows remote tests at a distance of 3 m without disturbing effects of a spur cable hassle-free integration into existing or running installations w/o changing cabling g ► Starter Package BC-502-PB-START – – Complete set for quick commissioning Everything included to start measuring at running systems immediately ► Comfort Line license BC-502-PB/CL 5 – Enables full featured protocol analyzer via USB and PROFIBUS Diagnostics Suite ► Premium Line license BC-502-PB/SNMP – Enables SNMP features for central data management www.hitex.co.uk 024 7669 2066
  • 27. PB-USB Universal PROFIBUS Interface with High-Speed USB Port Optimised for :‐ Network Configuration,  Device Parameterization  PLC programming  PLC programming Plant maintenance  Data acquisition.  www.hitex.co.uk 024 7669 2066
  • 28. PROFIBUS EASY-ACCESS TEST POINT Provides easy access where there is no D‐SUB connector available www.hitex.co.uk 024 7669 2066
  • 29. PROFIBUS Current Clamp Meter Ideal for finding earth faults etc. www.hitex.co.uk 024 7669 2066
  • 30. And finally....consult the experts for:        Application Notes l White Papers Tech Tips Training Consultancy Design Services g Friendly advice! www.hitex.co.uk 024 7669 2066
  • 31. Thank you! Hitex UK Ltd Millburn Hill Road Warwick University Science Park Coventry CV4 7HS Tel: 02476 692066 Fax: 02476 692131 Email: info@hitex.co.uk www.hitex.co.uk www hitex co uk www.hitex.co.uk 024 7669 2066