PROFIBUS Network Health
Checking and Monitoring
Andy Verwer
Verwer Training & Consultancy Ltd
and Dave Tomlin, Hitex UK
Pa...
Page 3Monitoring & Preventative Maintenance, Verwer Training & Consultancy Ltd, February 2014
PROFIBUS DP
PROFIBUS DP PROF...
Page 5Monitoring & Preventative Maintenance, Verwer Training & Consultancy Ltd, February 2014
 Permanent faults are relat...
Page 7Monitoring & Preventative Maintenance, Verwer Training & Consultancy Ltd, February 2014
PROFIBUS analysers
 PROFIBU...
Page 9Monitoring & Preventative Maintenance, Verwer Training & Consultancy Ltd, February 2014
 Health checking is an impo...
Page 11Monitoring & Preventative Maintenance, Verwer Training & Consultancy Ltd, February 2014
COMbricks
 COMbricks is a ...
Page 13Monitoring & Preventative Maintenance, Verwer Training & Consultancy Ltd, February 2014
Head
Station
Profitrace - b...
Agenda
Basics
Use Cases
Scenarios
Agenda
Types of
Diagnosis
Network
Diagnosis
Stationary
Network
Diagnosis for
PROFINET
wi...
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PROFIBUS maintenance & monitoring in Factory Automation - Andy Verwer & Dave Tomlin

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 PROFIBUS is a very reliable and cost effective technology.

 It is common to find extensive installations comprising thousands of PROFIBUS devices operating on complex networks which are connected together via industrial Ethernet.

 The reliable operation of these networks is essential to maintaining plant productivity.

 So, what can go wrong? And how do you find out? And avoid recurrance?

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PROFIBUS maintenance & monitoring in Factory Automation - Andy Verwer & Dave Tomlin

  1. 1. PROFIBUS Network Health Checking and Monitoring Andy Verwer Verwer Training & Consultancy Ltd and Dave Tomlin, Hitex UK Page 2Monitoring & Preventative Maintenance, Verwer Training & Consultancy Ltd, February 2014  PROFIBUS is a very reliable and cost effective technology.  It is common to find extensive installations comprising thousands of PROFIBUS devices operating on complex networks which are connected together via industrial Ethernet.  The reliable operation of these networks is essential to maintaining plant productivity.  So, what can go wrong? PROFIBUS
  2. 2. Page 3Monitoring & Preventative Maintenance, Verwer Training & Consultancy Ltd, February 2014 PROFIBUS DP PROFIBUS DP PROFIBUS PA Ethernet HMI PLC PC PSU Instrument or I/O failure Number 1 (90%) Wiring faults: Reflections, Wire breaks, Short circuits, connector corrosion etc. Number 2 (5%) Interference pickup. Particularly on drives and servos. Power supply failure. The Most Common Netwok Problems Software problems Page 4Monitoring & Preventative Maintenance, Verwer Training & Consultancy Ltd, February 2014  Quite often users are unaware that their system has communication errors because the robustness of PROFIBUS can hide these faults. Green light – all must be ok!  Only when the rate of data corruption reaches a critical threshold will the fault become visible. But by then it is too late! Communication faults
  3. 3. Page 5Monitoring & Preventative Maintenance, Verwer Training & Consultancy Ltd, February 2014  Permanent faults are relatively easy to fix.  Because the fault disappears when we've fixed it!  Intermittent faults can be a nightmare!  Because we cannot be sure that we have fixed it.  We may seem to have cured the problem, but then it comes back again later!  Intermittent faults require long-term monitoring to check that the fault is cured.  Statistical reporting over an extended period can be useful. Intermittent Faults Page 6Monitoring & Preventative Maintenance, Verwer Training & Consultancy Ltd, February 2014 Bus analysers  An analyser is an essential tool for fault-finding, monitoring, health-checking networks.  An analyser shows us what is going on inside a network.  Most modern analysers incorporate waveform visualisation in order to help diagnose problems at the physical level (i.e. cables and connectors).  PROFIBUS is very robust and will continue to operate in the presence of occasional errors. However, statistical measures of network performance can help you see how close you are to the “cliff edge”.
  4. 4. Page 7Monitoring & Preventative Maintenance, Verwer Training & Consultancy Ltd, February 2014 PROFIBUS analysers  PROFIBUS analysers are available from many suppliers: Page 8Monitoring & Preventative Maintenance, Verwer Training & Consultancy Ltd, February 2014 ProfiTrace
  5. 5. Page 9Monitoring & Preventative Maintenance, Verwer Training & Consultancy Ltd, February 2014  Health checking is an important part of the commissioning and maintenance strategy for your plant.  The health check will help to find non-critical and intermittent faults that are not obvious.  A health check should be carried out immediately after commissioning. We also strongly recommend repeating the health check at intervals.  How much better to integrate the health checking tools into the network?  To give permanent monitoring of system health.  Automatically report failures.  Give pre-warning of impending failures and performance degradation. System Health Checking Page 10Monitoring & Preventative Maintenance, Verwer Training & Consultancy Ltd, February 2014 Softing PROFINET monitor Permanent monitoring tools  A number of new tools have appeared on the market which are designed to be permanently connected to the network to provide 24/7 network monitoring. Softing PB Monitor DP network monitor Procentec COMbricks network monitor (multiple networks and segments, DP and PA)
  6. 6. Page 11Monitoring & Preventative Maintenance, Verwer Training & Consultancy Ltd, February 2014 COMbricks  COMbricks is a modular repeater and gateway system from Procentec with built-in ProfiTrace functionality accessible over Ethernet.  COMbricks provides:  Networking, • PROFIBUS, PROFINET, Ethernet, copper and fibre-optic.  Monitoring • ProfiTrace OE built-in and accessible over Ethernet (web based).  Control • Remote IO capability allowing low cost control and plant monitoring over the network. Page 12Monitoring & Preventative Maintenance, Verwer Training & Consultancy Ltd, February 2014 Head Station with ProfiTrace built in Repeater modules with optional ‘scope and redundancy PROFIBUS DP slave modules IO modules digital, relay, analogue etc PROFINET IO device modules Optical link modules (1 or 2 channel) mix and match to produce the required functionality The Modules available include: PA module Coupler and/or MBP monitor with ‘scope COMbricks
  7. 7. Page 13Monitoring & Preventative Maintenance, Verwer Training & Consultancy Ltd, February 2014 Head Station Profitrace - built in to head station. Can monitor all 4 segments over Ethernet. Ethernet Each of the four segments can have up to 31 devices connected. But each channel can be connected to a separate network if desired allowing up to 4 networks to be monitored simultaneously 2 chan. repeater 4 channel Repeater and Network Monitor Agenda Basics Use Cases Scenarios Agenda Types of Diagnosis Network Diagnosis Stationary Network Diagnosis for PROFINET with PN-Monitor Summary Agenda Types of Diagnosis Network Diagnosis Stationary Network Diagnosis for PROFINET with PN-Monitor Summary 14 Peter Jüngling/ Quality Assurance in PROFINET Networks by Stationary Diagnosis Stationary Diagnosis with PN-Monitor Features: • Permanent passive monitoring of the network avoids un-scheduled downtimes • Web-based system overview displays all relevant parameters at a glance • Generates alarms based on characteristic events • Snapshots of frames can be saved to find out about the event’s reason • Access to diagnosis data via SNMP SOFTING proudly present: PROFINET-Monitor • Indicates failures before they stop your network • The perfect tool for preventive maintenance NEW !
  8. 8. Agenda Basics Use Cases Scenarios Agenda Types of Diagnosis Network Diagnosis Stationary Network Diagnosis for PROFINET with PN-Monitor Summary Agenda Types of Diagnosis Network Diagnosis Stationary Network Diagnosis for PROFINET with PN-Monitor Summary 15 Peter Jüngling/ Quality Assurance in PROFINET Networks by Stationary Diagnosis Stationary Diagnosis with PN-Monitor • PN-Monitor should be inserted between PLC (Controller) and first Field Device  All frames exchanged between Controller and Device are visible from there • PN-Monitor does not disturb data exchange! Frames can pass through PN-Monitor even in powerless operation mode How to integrate PN-Monitor in your network? PN-Monitor PLC

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