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Getting Started with PROFIBUS
Tester 4
By
BlueBox Communication
1
www.BlueBoxComm.com
Table of Contents
Topic Page No
Introduction 3
Scope of delivery 5
Installation 7
Strategy for analyzing networks with PROFIBUS Tester 4 11
Stand-alone mode 12
The PROFIBUS Diagnostic Suite (PB-DIAG-SUITE) software 14
Topology Scan 31
Typical Network Issues in a PROFIBUS Network 35
Best-Practice for a stable PROFIBUS network 47
2
Introduction
Here is a list of issues commonly found in PROFIBUS networks
Missing, unpowered, or surplus bus-
terminations
Bus cable too long
Dead-end branches Wrong cable types
Damaged or defective bus drivers
(RS 485 components)
Aging/corroding connectors and cables
causing excessive transmission
resistance
Cable-routing in environments
subject to strong interference
EMC impacts
Network and node configuration
errors
Wrong GSD Files, and more…
3
Introduction
The Profibus Tester is a Mobile Testing unit. It is a powerful diagnostic and
troubleshooting tool for testing cables, measuring signals and analyzing
communication of any LIVE Profibus networks.
Key Features:
Comprehensive network tests in stand-alone mode without requiring a notebook
The Long-Term Trend view is for detecting sporadic faults
Combines all in one device Signal Tester, Protocol Analyzer & Storage
Oscilloscope
The PROFIBUS Tester 4 supports you to
reduce network downtime
increase network reliability
reduce maintenance costs of your PROFIBUS networks
4
Scope of Delivery
Standard
What„s in the box:
 Power cable for external 24 V power supply
 USB cable to connect PB-T4 with PC
 DSUB standard connection BC-600-PB-CB-
DSUB2
 Power supply 100-240 V AC in / 24 V out
 PROFIBUS Tester 4
 Connector for oscilloscope trigger output
 Not shown:
– CD-ROM with PROFIBUS Diagnostic
Suite software
– Manuals 5
Scope of Delivery
Optional
Optional Accessories:
DSUB service connector interface for
connecting the tester to the network
Low impact connector cable for sensitive
and safety critical networks
M12 service connector interface with cable,
T-junction and termination
 M12 Connector cable
 Current leakage clamp meter LSZ-CHB3
6
Installation
 Supported operating systems: Windows XP, VISTA (32-bit) and Win 7 (32-bit and 64-bit).
 Before installing the PROFIBUS Diagnostics Suite, please ensure that your PC or
notebook meets the following minimum hardware requirements:
– RAM:
≥ 500 MB for Windows XP
≥ 1 GB for Windows VISTA and Windows 7 32-bit
≥ 2 GB for Windows 7 64-bit
– Screen resolution ≥ 1024x768 pixels (XGA)
– USB interface 2.0
– For data- recording at baud rates up to 1.5 Mbit/s: Processor speed ≥ 1 GHz
– For data-recording at baud rates over 1.5 Mbit/s: Processor speed ≥ 2 GHz
 The above system requirements are general guidelines and assume that the operating
system is not burdened by additional CPU intensive applications.
System requirements
7
Installation
 Installation of PB-Diag-Suite from the Supplied CD-ROM
Note: Install PB-DIAG Suite software prior to connecting PROFIBUS Tester 4 to PC!
Setup should normally start automatically when you insert the CD-ROM supplied with your test
tool. If it doesn't, the “start.exe” file provided on the CDROM needs to be run manually. A dialog
box appears where you can choose a language for the installation by selecting the
corresponding national flag.
The CD-ROM also includes the “.NET-Framework” and the Microsoft Installer, which will be
installed on Windows XP systems, if required, before installation of the PB-DIAG-Suite starts.
Also, if needed you may install Acrobat Reader manually from the CD-ROM to display user
manuals and test reports that have been exported as pdf files.
(For further details read page 8 of manual)
 Installation of latest software update from Softing's Web Site
Please install the software from your CD-ROM first before downloading and installing any
updates.
Use following link to download the update of latest version of PB-DIAG Suite Software:
http://www.softing.com/home/en/industrial-automation/downloads/updates/profibus-dp.php
How to install the software
8
DSUB cable to connect PB-T4 to a
PROFIBUS network
100-240V in; 24 V out power supply
USB cable to connect to PC
(not required in Stand-Alone-Mode)
Please note:
Install PB-DIAG-SUITE software prior to
connecting PROFIBUS Tester 4 to PC!
How to connect the PROFIBUS Tester 4
Installation
9
Installation
Basic settings of PROFIBUS Tester 4
Normally, the GUI of your PROFIBUS-Tester 4 is set to English.
If not, you can easily change the settings of the PB-T4 as follows:
Change language from German to English:
Connect PB-T4 to the power supply, no PC connected!
Press 5x to see “EINST. & BEDIEN.“ menu
Press 2x to “Akt. Sprache“
Press to change from German to English
Press 2x to return to the main menu
Change Limit for Quality-Level:
Connect PB-T4 to the power supply, no PC connected!
Press 5x to see “Settings & HELP“ menu
Press 3x to “Cur. Q-Limit“
Press to change to 2500 (recommended value)
Press 2x to return to the main menu
EINSTELLUNGEN
Akt. SPRACHE:
DEUTSCH
ENGLISH ?
SETTINGS
Curr. Language:
ENGLISH
GERMAN ?
SETTINGS
Cur, Q-Limit:
250
Change ?
SETTINGS
Cur, Q-Limit:
2500
Change ?
English
main menu
(default setting)
function keys
10
Analyzing Profibus Networks
We recommend the following initial steps:
 Step 1:
- Perform a “Live-Status“ test with PB-T4 in “Stand-Alone-Mode“ (without PC)
- Always (!) execute the “Live-Status“ on both ends of your network
Case 1: Your network is OK (no further actions required) if
- all quality levels test good in both tests`
and
- if there are no error frames or frame repetitions in both tests
Case 2: your network needs service if there are
-bad signal levels,
-error frames or
-frame repetitions in one or in both measurements
 Step 2:
-Connect PB-T4 again to that end of the network that displayed problems
-Connect PB-T4 to the USB-port of your PC and start PB-DIAG-SUITE software
-Perform a “Quick Test“ from your PC
-The “Overview Window“ will help you to determine whether your are faced with
electric and/or communication problems
-Select “Protocol“ and/or “Signal Quality“ views for further diagnostic details
11
Stand-Alone-Mode
Rapid network analysis without a PC
DP Segment
R=0 Qmin = 4248
E=0 Qmax = 4942
Bus device(s) ->
DP Segment
R=0 Qmin = 217
E=0 Qmax = 4942
Bus device(s) ->
Bus : ERROR
Comm. : ERROR
Phys. : Warning
Details 
Bus : OK
Comm. : OK
Phys. : OK
Details 
Step 1:
Connect PB-T4 to one end of your PROFIBUS network
Press - button once to the “Live-Status“ menu
Press - button to start “Live-Status“ test
Read the results (in this case everything OK)
Press for details
All details are good from this end
Step 2:
Connect PB-T4 to other end of your PROFIBUS network
Perform the “Live-Status“ test
Read the results (in this case there are problems)
Press for details
There are poor electrical signals while testing from this end
Use the Live-Status function of the Stand-Alone-Mode for a first, simple test of the
- communication (R= frame repetitions, E= error frames)
- signal quality (Qmin and Qmax of total network)
from both ends of a network
12
Stand-Alone-Mode
Rapid network analysis without a PC
Bus : OK
Comm. : OK
Phys. : OK
Details 
Conclusion:
If you get this result from both ends of your network, your segment is OK.
There are no error frames and frame repetitions.
 There is no need for further tests!
Bus : ERROR
Comm. : ERROR
Phys. : Warning
Details 
DP Segment
R=3 Qmin = 217
E=0 Qmax = 4942
Bus device(s) ->
If your network test results in an error message on one or both ends of your
network you will need to further investigate
 Continue your tests at the location with the worst result.
 Connect your PB-T4 with your PC and start PB-DIAG-SUITE for further tests
Bus : ERROR
Comm. : ERROR
Phys. : OK
Details 
DP Segment
R=0 Qmin = 4248
E=0 Qmax = 4942
Bus device(s) ->
Here is a unique case:
- Communication indicates „ERROR“
- R=0, E=0, all signals are OK
Interpretation:At least one PROFIBUS node is down but the rest of the network
is working perfectly.
 Connect your PB-T4 with your PC and start PB-DIAG-SUITE to identify the
missing node(s)
13
PROFIBUS Diagnostic Suite
Getting Started
 Check if your PB-T4 is recognized
by PB-DIAG-SUITE
 Click on “Quick test“ to start a comprehensive
network test.
Once the test has finished the results are
automatically displayed in the
“Overview Window“
 Connect PB-T4 to the PROFIBUS network at the location that indicated a network issue (as
described in the previous 2 slides)
 Connect PB-T4 to your PC using the USB cable
 Follow the installation wizzard for the hardware istallation (first time only)
After a successful hardware installation start the PB-DIAG-SUITE software by clicking on
14
PROFIBUS Diagnostic Suite
Overview Window
 The Overview Window indicates:
- Is the network OK from this side?
- If not, the problem is either related to communications or electrical problems
Result:
The test result from this end indicates bad signal quality. Click on “Signal Quality“ (link or tab) for more details
Green light indicates:
“Communication is OK“
Yellow light indicates:
“Problems with the
electrical signal quality“
All critical values are
marked by red ink:
In this case 5 out of 7
Stations show bad quality
=> Traffic light is yellow
All values are OK
=> Traffic light is
green
First indication:
or
4 tabs for easy operation:
• Overview
• Protocol,
• Signal Quality
• Topology
15
PROFIBUS Diagnostic Suite
Signal Quality Window
 As indicated in the „Overview Window“ there are electrical issues in our demo network.
 For more details open the „Signal Quality“ display.
It displays the signal quality level for all stations as a bar graph and provides an
oscilloscope view for a selected station.
16
PROFIBUS Diagnostic Suite
Signal Quality Window: Name test locations
Why should you name your test locations?
As already stated in the “Stand-Alone-Mode“ slides, test results may vary depending on the test location.
In order to easily compare the results later-on we recommend to associate a symbolic name with each
test location.
Click on settings button to open menu for
“Signal Analysis Settings”
Click on button “Test Locations“
Highlight “Default Test loc, then double click, then
type in a name and the respective bus address
It is recommended to define and test at least the
two end-locations of your network
17
PROFIBUS Diagnostic Suite
Signal Quality Window: Sorting of bar graphs
Manual sorting of bar graph:
Click on “Signal Analysis
Settings“ for sorting bar graph
Click on “Stations“
By default the signal quality bars are sorted by node address. However, most of the time the physical
location of a node with a specific address on the network does not follow this rule. To make the
interpretation easier it is highly recommended to sort the bars according the correct topology (their
correct physical order).
This can be achieved
- manually as described below
- or automatically by a topology scan
De-select (!) this check mark
Mark a station and change
position in the list with these
buttons
18
PROFIBUS Diagnostic Suite
Signal Quality Window: making further measurements
For a clearer picture of your network health you
should run the same test at multiple test
locations.
Click on “Start Test“ for starting and wait
until all stations have been scanned
Click on “Stop Test“ to stop the test
Select test location
19
PROFIBUS Diagnostic Suite
Signal Quality Window: Oscilloscope
A double click on any bar opens
the oscilloscope view for this node
strong reflections
as seen from rear end
smaller reflections as
seen from front end
Visualize Reflections:
Poor signal quality is mainly caused by
- Reflections (e.g missing termination, wrong cable type)
- High transition-resistance (e.g. defect cable, corrosion)
- EMC impacts
Once open, a single click on any
bar displays the signal of the
respective node
20
PROFIBUS Diagnostic Suite
Signal Quality Window: Oscilloscope
Click on bar for node #2
Increase zoom to 62,5 ns
Place cursor 1 to rising flank
Place cursor 2 to distortion
=> Now you can read the distance
between the test location named
“Busende 15“ and the location of
the reflection: In our case 22,8 m
Localize the problem with the
Oscilloscope:
Distance 22,8 m
21
PROFIBUS Diagnostic Suite
Signal Quality Window: Oscilloscope
Next, you can compare the
distance between the
reflection and other nodes:
Click on bar of node #12
Place cursors
Now distance is only 12,5 m
Click on bar of node #15 (Busend)
Now distance is 0 m and no
distortion
Result: the reflection is caused by (or is close to)
node #15 (e.g. missing terminator).
Consequently no reflections can be seen there.
Click on bar of node #2
Place cursors
Now distance is 22,8 m
22
PROFIBUS Diagnostic Suite
Protocol Window
Click on “Protocol“
Life List
Green = data exchange okay
Yellow = slave reports diagnose
Orange = config or param failure
Red = no answer, station is dead
Blue = station not configured in
Master
Click on Segment
Log for main communication events
between master and slaves (e.g.
communication start-up, etc.)
Number of Retries, Diagnostic
Frames, Restarts are and indicator for
developing problems in the network
Bus cycle time
In case of data communication problems open the “Protocol Window“.
Typically, communication issues are caused by wrong PROFIBUS parameters settings in the master.
23
PROFIBUS Diagnostic Suite
Protocol Window
Check GSD-file configuration:
Expected GSD = real GSD ?
If not => configuration failure
Configuration can be seen under
configuration bookmark
Large variation of Station Delay Times
indicates a problem of the station
Clicking on a node (or station) will
display its specific information.
Log file of the selected station
Click on “Diagnosis“ to read
diagnostic messages of selected
slaves in plain text (not only hex
strings)
24
If you prefer the matrix overview, you may use this as well:
- Click on segment
- Select „Station Statistics“
- You can display all events or select „retries“, „diagnose“, „set parameters“
for each station
PROFIBUS Diagnostic Suite
Protocol Window
25
PROFIBUS Diagnostic Suite
The Frame Window
Click on the “Start Test“
button to start recording
Click on the “Frames” tab to
open the frame display
Detailed Information for Professionals:
The Frames display allows you to record and analyze
the entire communication down to a single bit:
- Decode all frames
- Analyze timing by time stamps
- Trigger for frames or specific bits to catch sporadic
events
Click on the “Stop Test“ button
to stop recording
26
Define individual color coding
for each type of frame
Click on a single frame to get
the decoded contents
PROFIBUS Diagnostic Suite
The Frame Window
27
The “Project Window“ offers an easy
filing of your records
You will find additional record files for
demo purposes in the “Project View“
- Place the cursor on “projects“ tag:
=>The project view opens
- You may lock the window to avoid
automatic closing
- Open “Projects“-folder to view saved
frame recordings
28
PROFIBUS Diagnostic Suite
The Project Window
PROFIBUS Diagnostic Suite
Automatically generated Test Report
Click on:
Test / Create Report
Click on „continue“ to create the
report
Click on „Cover Page“ to type in
your company data
29
Signal Quality Report:
- min, max, mean value per station
- bar graphs from all test locations
- oscilloscope charts
Toggle between protocol and
signal quality report by
selecting page 1 or page 2
Protocol Report:
- life list and status of stations
- retries, diagnose, set parameter
for each station
PROFIBUS Diagnostic Suite
Automatically generated Test Report
30
Topology Scan
Step 1: Start with a Quick-Test to scan all devices
For best-results, the network should be “healthy” before
starting the topology scan. Please verify the health of your
network by using the this suite as shown on the previous
slides.
As a first step you need to scan for all slave devices in
your network (if not already done).
•Connect your PB-T4 to a running network
•Start Quick Test with a click
•After completing the Quick Test open the window for
topology scan
 PB-T4 shows all detected devices in the
numerical sequence of the PROFIBUS addresses
(most of the time the physical sequence is different)
31
Topology Scan
Step 2: Disconnect masters & connect PROFIBUS Tester 4
A true and correct Topology Scan can only be done
with no active PROFIBUS master attached to the
network.
Therefore you need to disconnect any masters in
your network and then connect PB-T4 as shown.
Please only use BC-600-PB-CB-DSUB-2 cable that
is included in the standard scope of supply.
Disconnect every single active device (PLC, MPI
and, if necessary, diagnostic repeaters) from the
power supply or the bus.
Connect the PROFIBUS Tester 4 to one end of your
network. Typically, you would remove the connector
for your PLC and plug it directly into the Tester 4.
The PROFIBUS Tester 4 will provide the necessary
power for the bus termination.
32
Topology Scan
Step 3: Activate Master Simulator in PB-DIAG-Suite on your PC
• Click on this button to activate the “Master Simulator”
• Accept manual setting of baudrate
• Select the correct baud rate for your network
33
Topology Scan
Step 4: Perform the topology scan
• Start topology scan by clicking on the
„Start-Test“ button
• Wait until progress of scan has reached 100% for
all stations
• Since the master (typically, the PLC) is
diconnected it cannot be located.
Double click on master´s „Distance (m)“ and
enter „0“ to locate the master correctly.
34
Typical Network Issues
Sample Network
Master
2 7 9 23 34 51 71
RR
R
R R
R
5V
Note: The termination resistors are integrated in the connectors of station 2
and 71; the 5V supply for the termination is provided by the respective
device.
5V
The following network issues were
recorded on this sample network.
35
Typical Network Issues
Case 1: Reversal of results from both ends of the system
 Case 1:
 Step 1:
 Connect and test from left end side (Master 2)
 Step 2:
 Connect and test from right end side (Slave 71)
 Result:
 Test results from the left end:
 - Good quality values for stations 2 - 34
 - Bad quality values for stations 51 – 71
 Test results from the right side:
 - Bad quality values for stations 2 – 34
 - Good quality values for stations 51 – 71
  Reversal of Q-Levels !
measurement from right side
(Slave 71)
measurement from left side
(Master 2)
36
2 7 9 23 34 51 71
RR
R
R R
R
5V 5V
Master
R
Reason: High Line Resistance between two Stations
(#34 and #51)
Interpretation:
The test result from the right side is the reversal (!) of the test results from the left side and
vice versa.
This kind of reversal is a clear indication for an high resistance in the network.
In this case the problem is caused somewhere between slave 34 and slave 51
e.g. corrosion, sharply bent cable, etc.
Typical Network Issues
Case 1: Reversal of results from both ends of the system
37
Typical Network Issues
Case 2: Q-level becomes worse from one measuring point to other
Case 2:
- Step 1: perform test at left end (Master 2)
- Step 2: perform test at right end (Slave 71)
- Step 3: perform tests at random stations located in the middle of the network
Result:
- No reversion of Q-level between left and right side
- Instead, the Q-level for all stations generally declines from one station to the other.
Master 2 Slave 7 Slave 23 Slave 71
38
Interpretation:
- The problem is not caused by resistance problems (corrosion, cable too long, etc…
- The problem is caused by signal reflections in the network,
in this case by a missing termination resistance at Slave 71.
Typically, the problem is located at the test point that shows most stations with a bad Q-
level.
2 7 9 23 34 51 71
RR
R
R R
R
5V 5V
Master
You can see the reflections in the oscilloscope
display of master 2 while connected
at test point Slave 71.
Typical Network Issues
Case 2: Q-level becomes worse from one measuring point to other
39
Typical Network Issues
Case 3: Some stations are “missing”
Case 3:
- Step 1: perform test at left side (Master 2)
- Step 2: perform test at right side (Slave 71)
(Note: make sure that Timeout is not caused by the
time-out setting in PB-T4: => Tools / settings)
Result:
- Test at left end: Slave 53 and 71 are missing
- Test at right end: all stations are missing
40
 Interpretation:
 The fact that some devices can be seen from one end but not from the other
indicates that the problem is not be caused by the devices themselves.
 The test result at the left end shows that the Q-levels are good until slave 34.
After slave 34 the Q-levels are not testable. This indicates that the problem
must be in the line between slave 34 and 51.
 Conclusion:
 The problem is caused by a break of one or both signal lines.
Master
2 7 9 23 34 51 71
RR
R
R R
R
5V 5V
?
Typical Network Issues
Case 3: Some stations are “missing”
41
Typical Network Issues
Case 4: Quality Level of one device is bad
 Case 4:
 Step 1: perform test at left side (Master 2)
 Step 2: perform test at right side (Slave 123)
 Step 3: perform test at Slave 23
 Result:
 The Q-level of slave 23 is bad. All others are good. The result of all three measurements is basically
identical.
 Interpretation:
 The voltage level of RS485 driver of station 23 (and only station 23) is too low.measurement from left side (master 2)
measurement directly from slave 23
measurement from right side (slave 123)
42
Typical Network Issues
Case 5: Bus-termination is not powered correctly
 An idle voltage of approx. 0,6 Volts indicates that only one bus-termination is powered correctly
 communication may work, sporadic failures likely
 An idle voltage close to 0 Volts (both terminations not correctly powered or one termination missing/one
not correctly powered  PROFIBUS will not start
Indication of idle voltage:
The correct idle voltage is supposed to be
between 0.8 and 1.4 V.
An idle voltage lower than that indicates that one
or both bus-terminations are not powered
correctly.
In addtion, you can detect a low
idle-voltage in the oscilloscope
(in this case approx. 0.5 V)
1V
43
Typical Network
Case 6: Too many bus-terminations or electrical resistance
R
R
R
2 7 9 23 34 51 71
RR
R
R R
R
5V 5V
Master
44
Typical Failure Cases
Case 6: Too many bus-terminations or electrical resistance
Note: The test results get worse the closer the PBT-4 is connected to the location of
the problem (Master #2).
However, the signal quality level of the problematic station (Master #2) might be one
of the best.
Unfortunately, the test results do not change as strikingly when dealing with tool
many bus-terminations as they do with missing bus-terminations. Additional
resistance usually affects all stations.
signal blurred
only some drops in signal due to reflections
bad signal flanks
45
Typical Network Issues
Case 7: Cable too long for selected baud rate
Note:
Here the built-in Master functionality of the PB-
T4 comes in very handy.
Without changing the PLC-program, the
network can be tested at different baud rates
(e.g. 1.5Mbaud).As shown above, running the
same network at a baud rate of 1,5 Mbaud is
perfectly acceptable.
Note 1:
A cable length of 144m is too long for 12 Mbaud
(100m permissible).
Therefore, the quality levels / signal level of the
stations measured at the master drop with the
distance to the referring slave.
Note 2:
A test performed at the opposite end of the
network (station #17) will show a “mirrored
image”. In contrast to high line resistance the
signal quality degrades gradually.
12 Mbaud, 144m 1.5 Mbaud, 144m
46
Best-Practice for PROFIBUS
Cable type, number of stations, cable length
 PROFIBUS RS-485
 Layout: terminated line, branch (or stub) lines < 0.3 m (1 foot) !!
 Cable type: shielded twisted pair cable acc. to PROFIBUS specification
 Number of stations: max. 32 w/o repeater, 127 using repeaters
 Max. cable length (applies to cable type A only):
Baud Rate Max. Cable Length
9.6, 19.2, 31.25, and 45.45Kbit/s 1200 m (3940 ft)
93.75 and 187.5 Kbit/s 1000 m (3280 ft)
500 Kbit/s 400 m (1310 ft)
1500 Kbit/s 200 m (656 ft)
3000, 6000, and 12000 Kbit/s 100 m (328 ft)
47
Best-Practice for PROFIBUS
Correct line topology, setting of bus termination
Rt Rt
S S SS
M
S No ! Avoid branch lines !
termination„on“
termination„on“
termination„off“
termination„off“
termination„off“
termination„off“
termination„off“
Copper cable 0.22 mm2, twisted pair, shielded, AWG 24*
Max. 32 stations (Masters and Slaves) in one segment without repeater
48
Best-Practice for PROFIBUS
Correct line topology with repeaters
Rt Rt
S SS
Rt Rt
S SS
M
31 Stations
+1 Rep
30 Stations
+2 Rep
30 Stations
+2 Rep
Rt Rt
S SS
Rt Rt
S SS
31 Stations
+ 1 Rep
Rep
Rep
Rep
…
…
…
…
49
Best-Practice for PROFIBUS
Grounding and mounting of PROFIBUS RS-485
PROFIBUS
GND Cable to balance the Potentials, approx. 16 mm2,
Best: Same Routing as PROFIBUS Cable (parallel)
Slave Slave
Master
Equipotential Rail
PROFIBUS
Planar Connection of the PROFIBUS Cable Shielding to the Ground
Potential, e.g. through special Clamps
Equipotential Rail Equipotential Rail
50
www.BlueBoxComm.com
Thank You 
BlueBox Communication
443, Nana Peth, Kirad Villa,
Shop No. 5B, Pune- 411002,
Maharashtra, India.
+91 7875218696
+91 7875440101
sales@BlueBoxComm.com
51

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Getting Started with PROFIBUS Tester 4

  • 1. Getting Started with PROFIBUS Tester 4 By BlueBox Communication 1 www.BlueBoxComm.com
  • 2. Table of Contents Topic Page No Introduction 3 Scope of delivery 5 Installation 7 Strategy for analyzing networks with PROFIBUS Tester 4 11 Stand-alone mode 12 The PROFIBUS Diagnostic Suite (PB-DIAG-SUITE) software 14 Topology Scan 31 Typical Network Issues in a PROFIBUS Network 35 Best-Practice for a stable PROFIBUS network 47 2
  • 3. Introduction Here is a list of issues commonly found in PROFIBUS networks Missing, unpowered, or surplus bus- terminations Bus cable too long Dead-end branches Wrong cable types Damaged or defective bus drivers (RS 485 components) Aging/corroding connectors and cables causing excessive transmission resistance Cable-routing in environments subject to strong interference EMC impacts Network and node configuration errors Wrong GSD Files, and more… 3
  • 4. Introduction The Profibus Tester is a Mobile Testing unit. It is a powerful diagnostic and troubleshooting tool for testing cables, measuring signals and analyzing communication of any LIVE Profibus networks. Key Features: Comprehensive network tests in stand-alone mode without requiring a notebook The Long-Term Trend view is for detecting sporadic faults Combines all in one device Signal Tester, Protocol Analyzer & Storage Oscilloscope The PROFIBUS Tester 4 supports you to reduce network downtime increase network reliability reduce maintenance costs of your PROFIBUS networks 4
  • 5. Scope of Delivery Standard What„s in the box:  Power cable for external 24 V power supply  USB cable to connect PB-T4 with PC  DSUB standard connection BC-600-PB-CB- DSUB2  Power supply 100-240 V AC in / 24 V out  PROFIBUS Tester 4  Connector for oscilloscope trigger output  Not shown: – CD-ROM with PROFIBUS Diagnostic Suite software – Manuals 5
  • 6. Scope of Delivery Optional Optional Accessories: DSUB service connector interface for connecting the tester to the network Low impact connector cable for sensitive and safety critical networks M12 service connector interface with cable, T-junction and termination  M12 Connector cable  Current leakage clamp meter LSZ-CHB3 6
  • 7. Installation  Supported operating systems: Windows XP, VISTA (32-bit) and Win 7 (32-bit and 64-bit).  Before installing the PROFIBUS Diagnostics Suite, please ensure that your PC or notebook meets the following minimum hardware requirements: – RAM: ≥ 500 MB for Windows XP ≥ 1 GB for Windows VISTA and Windows 7 32-bit ≥ 2 GB for Windows 7 64-bit – Screen resolution ≥ 1024x768 pixels (XGA) – USB interface 2.0 – For data- recording at baud rates up to 1.5 Mbit/s: Processor speed ≥ 1 GHz – For data-recording at baud rates over 1.5 Mbit/s: Processor speed ≥ 2 GHz  The above system requirements are general guidelines and assume that the operating system is not burdened by additional CPU intensive applications. System requirements 7
  • 8. Installation  Installation of PB-Diag-Suite from the Supplied CD-ROM Note: Install PB-DIAG Suite software prior to connecting PROFIBUS Tester 4 to PC! Setup should normally start automatically when you insert the CD-ROM supplied with your test tool. If it doesn't, the “start.exe” file provided on the CDROM needs to be run manually. A dialog box appears where you can choose a language for the installation by selecting the corresponding national flag. The CD-ROM also includes the “.NET-Framework” and the Microsoft Installer, which will be installed on Windows XP systems, if required, before installation of the PB-DIAG-Suite starts. Also, if needed you may install Acrobat Reader manually from the CD-ROM to display user manuals and test reports that have been exported as pdf files. (For further details read page 8 of manual)  Installation of latest software update from Softing's Web Site Please install the software from your CD-ROM first before downloading and installing any updates. Use following link to download the update of latest version of PB-DIAG Suite Software: http://www.softing.com/home/en/industrial-automation/downloads/updates/profibus-dp.php How to install the software 8
  • 9. DSUB cable to connect PB-T4 to a PROFIBUS network 100-240V in; 24 V out power supply USB cable to connect to PC (not required in Stand-Alone-Mode) Please note: Install PB-DIAG-SUITE software prior to connecting PROFIBUS Tester 4 to PC! How to connect the PROFIBUS Tester 4 Installation 9
  • 10. Installation Basic settings of PROFIBUS Tester 4 Normally, the GUI of your PROFIBUS-Tester 4 is set to English. If not, you can easily change the settings of the PB-T4 as follows: Change language from German to English: Connect PB-T4 to the power supply, no PC connected! Press 5x to see “EINST. & BEDIEN.“ menu Press 2x to “Akt. Sprache“ Press to change from German to English Press 2x to return to the main menu Change Limit for Quality-Level: Connect PB-T4 to the power supply, no PC connected! Press 5x to see “Settings & HELP“ menu Press 3x to “Cur. Q-Limit“ Press to change to 2500 (recommended value) Press 2x to return to the main menu EINSTELLUNGEN Akt. SPRACHE: DEUTSCH ENGLISH ? SETTINGS Curr. Language: ENGLISH GERMAN ? SETTINGS Cur, Q-Limit: 250 Change ? SETTINGS Cur, Q-Limit: 2500 Change ? English main menu (default setting) function keys 10
  • 11. Analyzing Profibus Networks We recommend the following initial steps:  Step 1: - Perform a “Live-Status“ test with PB-T4 in “Stand-Alone-Mode“ (without PC) - Always (!) execute the “Live-Status“ on both ends of your network Case 1: Your network is OK (no further actions required) if - all quality levels test good in both tests` and - if there are no error frames or frame repetitions in both tests Case 2: your network needs service if there are -bad signal levels, -error frames or -frame repetitions in one or in both measurements  Step 2: -Connect PB-T4 again to that end of the network that displayed problems -Connect PB-T4 to the USB-port of your PC and start PB-DIAG-SUITE software -Perform a “Quick Test“ from your PC -The “Overview Window“ will help you to determine whether your are faced with electric and/or communication problems -Select “Protocol“ and/or “Signal Quality“ views for further diagnostic details 11
  • 12. Stand-Alone-Mode Rapid network analysis without a PC DP Segment R=0 Qmin = 4248 E=0 Qmax = 4942 Bus device(s) -> DP Segment R=0 Qmin = 217 E=0 Qmax = 4942 Bus device(s) -> Bus : ERROR Comm. : ERROR Phys. : Warning Details  Bus : OK Comm. : OK Phys. : OK Details  Step 1: Connect PB-T4 to one end of your PROFIBUS network Press - button once to the “Live-Status“ menu Press - button to start “Live-Status“ test Read the results (in this case everything OK) Press for details All details are good from this end Step 2: Connect PB-T4 to other end of your PROFIBUS network Perform the “Live-Status“ test Read the results (in this case there are problems) Press for details There are poor electrical signals while testing from this end Use the Live-Status function of the Stand-Alone-Mode for a first, simple test of the - communication (R= frame repetitions, E= error frames) - signal quality (Qmin and Qmax of total network) from both ends of a network 12
  • 13. Stand-Alone-Mode Rapid network analysis without a PC Bus : OK Comm. : OK Phys. : OK Details  Conclusion: If you get this result from both ends of your network, your segment is OK. There are no error frames and frame repetitions.  There is no need for further tests! Bus : ERROR Comm. : ERROR Phys. : Warning Details  DP Segment R=3 Qmin = 217 E=0 Qmax = 4942 Bus device(s) -> If your network test results in an error message on one or both ends of your network you will need to further investigate  Continue your tests at the location with the worst result.  Connect your PB-T4 with your PC and start PB-DIAG-SUITE for further tests Bus : ERROR Comm. : ERROR Phys. : OK Details  DP Segment R=0 Qmin = 4248 E=0 Qmax = 4942 Bus device(s) -> Here is a unique case: - Communication indicates „ERROR“ - R=0, E=0, all signals are OK Interpretation:At least one PROFIBUS node is down but the rest of the network is working perfectly.  Connect your PB-T4 with your PC and start PB-DIAG-SUITE to identify the missing node(s) 13
  • 14. PROFIBUS Diagnostic Suite Getting Started  Check if your PB-T4 is recognized by PB-DIAG-SUITE  Click on “Quick test“ to start a comprehensive network test. Once the test has finished the results are automatically displayed in the “Overview Window“  Connect PB-T4 to the PROFIBUS network at the location that indicated a network issue (as described in the previous 2 slides)  Connect PB-T4 to your PC using the USB cable  Follow the installation wizzard for the hardware istallation (first time only) After a successful hardware installation start the PB-DIAG-SUITE software by clicking on 14
  • 15. PROFIBUS Diagnostic Suite Overview Window  The Overview Window indicates: - Is the network OK from this side? - If not, the problem is either related to communications or electrical problems Result: The test result from this end indicates bad signal quality. Click on “Signal Quality“ (link or tab) for more details Green light indicates: “Communication is OK“ Yellow light indicates: “Problems with the electrical signal quality“ All critical values are marked by red ink: In this case 5 out of 7 Stations show bad quality => Traffic light is yellow All values are OK => Traffic light is green First indication: or 4 tabs for easy operation: • Overview • Protocol, • Signal Quality • Topology 15
  • 16. PROFIBUS Diagnostic Suite Signal Quality Window  As indicated in the „Overview Window“ there are electrical issues in our demo network.  For more details open the „Signal Quality“ display. It displays the signal quality level for all stations as a bar graph and provides an oscilloscope view for a selected station. 16
  • 17. PROFIBUS Diagnostic Suite Signal Quality Window: Name test locations Why should you name your test locations? As already stated in the “Stand-Alone-Mode“ slides, test results may vary depending on the test location. In order to easily compare the results later-on we recommend to associate a symbolic name with each test location. Click on settings button to open menu for “Signal Analysis Settings” Click on button “Test Locations“ Highlight “Default Test loc, then double click, then type in a name and the respective bus address It is recommended to define and test at least the two end-locations of your network 17
  • 18. PROFIBUS Diagnostic Suite Signal Quality Window: Sorting of bar graphs Manual sorting of bar graph: Click on “Signal Analysis Settings“ for sorting bar graph Click on “Stations“ By default the signal quality bars are sorted by node address. However, most of the time the physical location of a node with a specific address on the network does not follow this rule. To make the interpretation easier it is highly recommended to sort the bars according the correct topology (their correct physical order). This can be achieved - manually as described below - or automatically by a topology scan De-select (!) this check mark Mark a station and change position in the list with these buttons 18
  • 19. PROFIBUS Diagnostic Suite Signal Quality Window: making further measurements For a clearer picture of your network health you should run the same test at multiple test locations. Click on “Start Test“ for starting and wait until all stations have been scanned Click on “Stop Test“ to stop the test Select test location 19
  • 20. PROFIBUS Diagnostic Suite Signal Quality Window: Oscilloscope A double click on any bar opens the oscilloscope view for this node strong reflections as seen from rear end smaller reflections as seen from front end Visualize Reflections: Poor signal quality is mainly caused by - Reflections (e.g missing termination, wrong cable type) - High transition-resistance (e.g. defect cable, corrosion) - EMC impacts Once open, a single click on any bar displays the signal of the respective node 20
  • 21. PROFIBUS Diagnostic Suite Signal Quality Window: Oscilloscope Click on bar for node #2 Increase zoom to 62,5 ns Place cursor 1 to rising flank Place cursor 2 to distortion => Now you can read the distance between the test location named “Busende 15“ and the location of the reflection: In our case 22,8 m Localize the problem with the Oscilloscope: Distance 22,8 m 21
  • 22. PROFIBUS Diagnostic Suite Signal Quality Window: Oscilloscope Next, you can compare the distance between the reflection and other nodes: Click on bar of node #12 Place cursors Now distance is only 12,5 m Click on bar of node #15 (Busend) Now distance is 0 m and no distortion Result: the reflection is caused by (or is close to) node #15 (e.g. missing terminator). Consequently no reflections can be seen there. Click on bar of node #2 Place cursors Now distance is 22,8 m 22
  • 23. PROFIBUS Diagnostic Suite Protocol Window Click on “Protocol“ Life List Green = data exchange okay Yellow = slave reports diagnose Orange = config or param failure Red = no answer, station is dead Blue = station not configured in Master Click on Segment Log for main communication events between master and slaves (e.g. communication start-up, etc.) Number of Retries, Diagnostic Frames, Restarts are and indicator for developing problems in the network Bus cycle time In case of data communication problems open the “Protocol Window“. Typically, communication issues are caused by wrong PROFIBUS parameters settings in the master. 23
  • 24. PROFIBUS Diagnostic Suite Protocol Window Check GSD-file configuration: Expected GSD = real GSD ? If not => configuration failure Configuration can be seen under configuration bookmark Large variation of Station Delay Times indicates a problem of the station Clicking on a node (or station) will display its specific information. Log file of the selected station Click on “Diagnosis“ to read diagnostic messages of selected slaves in plain text (not only hex strings) 24
  • 25. If you prefer the matrix overview, you may use this as well: - Click on segment - Select „Station Statistics“ - You can display all events or select „retries“, „diagnose“, „set parameters“ for each station PROFIBUS Diagnostic Suite Protocol Window 25
  • 26. PROFIBUS Diagnostic Suite The Frame Window Click on the “Start Test“ button to start recording Click on the “Frames” tab to open the frame display Detailed Information for Professionals: The Frames display allows you to record and analyze the entire communication down to a single bit: - Decode all frames - Analyze timing by time stamps - Trigger for frames or specific bits to catch sporadic events Click on the “Stop Test“ button to stop recording 26
  • 27. Define individual color coding for each type of frame Click on a single frame to get the decoded contents PROFIBUS Diagnostic Suite The Frame Window 27
  • 28. The “Project Window“ offers an easy filing of your records You will find additional record files for demo purposes in the “Project View“ - Place the cursor on “projects“ tag: =>The project view opens - You may lock the window to avoid automatic closing - Open “Projects“-folder to view saved frame recordings 28 PROFIBUS Diagnostic Suite The Project Window
  • 29. PROFIBUS Diagnostic Suite Automatically generated Test Report Click on: Test / Create Report Click on „continue“ to create the report Click on „Cover Page“ to type in your company data 29
  • 30. Signal Quality Report: - min, max, mean value per station - bar graphs from all test locations - oscilloscope charts Toggle between protocol and signal quality report by selecting page 1 or page 2 Protocol Report: - life list and status of stations - retries, diagnose, set parameter for each station PROFIBUS Diagnostic Suite Automatically generated Test Report 30
  • 31. Topology Scan Step 1: Start with a Quick-Test to scan all devices For best-results, the network should be “healthy” before starting the topology scan. Please verify the health of your network by using the this suite as shown on the previous slides. As a first step you need to scan for all slave devices in your network (if not already done). •Connect your PB-T4 to a running network •Start Quick Test with a click •After completing the Quick Test open the window for topology scan  PB-T4 shows all detected devices in the numerical sequence of the PROFIBUS addresses (most of the time the physical sequence is different) 31
  • 32. Topology Scan Step 2: Disconnect masters & connect PROFIBUS Tester 4 A true and correct Topology Scan can only be done with no active PROFIBUS master attached to the network. Therefore you need to disconnect any masters in your network and then connect PB-T4 as shown. Please only use BC-600-PB-CB-DSUB-2 cable that is included in the standard scope of supply. Disconnect every single active device (PLC, MPI and, if necessary, diagnostic repeaters) from the power supply or the bus. Connect the PROFIBUS Tester 4 to one end of your network. Typically, you would remove the connector for your PLC and plug it directly into the Tester 4. The PROFIBUS Tester 4 will provide the necessary power for the bus termination. 32
  • 33. Topology Scan Step 3: Activate Master Simulator in PB-DIAG-Suite on your PC • Click on this button to activate the “Master Simulator” • Accept manual setting of baudrate • Select the correct baud rate for your network 33
  • 34. Topology Scan Step 4: Perform the topology scan • Start topology scan by clicking on the „Start-Test“ button • Wait until progress of scan has reached 100% for all stations • Since the master (typically, the PLC) is diconnected it cannot be located. Double click on master´s „Distance (m)“ and enter „0“ to locate the master correctly. 34
  • 35. Typical Network Issues Sample Network Master 2 7 9 23 34 51 71 RR R R R R 5V Note: The termination resistors are integrated in the connectors of station 2 and 71; the 5V supply for the termination is provided by the respective device. 5V The following network issues were recorded on this sample network. 35
  • 36. Typical Network Issues Case 1: Reversal of results from both ends of the system  Case 1:  Step 1:  Connect and test from left end side (Master 2)  Step 2:  Connect and test from right end side (Slave 71)  Result:  Test results from the left end:  - Good quality values for stations 2 - 34  - Bad quality values for stations 51 – 71  Test results from the right side:  - Bad quality values for stations 2 – 34  - Good quality values for stations 51 – 71   Reversal of Q-Levels ! measurement from right side (Slave 71) measurement from left side (Master 2) 36
  • 37. 2 7 9 23 34 51 71 RR R R R R 5V 5V Master R Reason: High Line Resistance between two Stations (#34 and #51) Interpretation: The test result from the right side is the reversal (!) of the test results from the left side and vice versa. This kind of reversal is a clear indication for an high resistance in the network. In this case the problem is caused somewhere between slave 34 and slave 51 e.g. corrosion, sharply bent cable, etc. Typical Network Issues Case 1: Reversal of results from both ends of the system 37
  • 38. Typical Network Issues Case 2: Q-level becomes worse from one measuring point to other Case 2: - Step 1: perform test at left end (Master 2) - Step 2: perform test at right end (Slave 71) - Step 3: perform tests at random stations located in the middle of the network Result: - No reversion of Q-level between left and right side - Instead, the Q-level for all stations generally declines from one station to the other. Master 2 Slave 7 Slave 23 Slave 71 38
  • 39. Interpretation: - The problem is not caused by resistance problems (corrosion, cable too long, etc… - The problem is caused by signal reflections in the network, in this case by a missing termination resistance at Slave 71. Typically, the problem is located at the test point that shows most stations with a bad Q- level. 2 7 9 23 34 51 71 RR R R R R 5V 5V Master You can see the reflections in the oscilloscope display of master 2 while connected at test point Slave 71. Typical Network Issues Case 2: Q-level becomes worse from one measuring point to other 39
  • 40. Typical Network Issues Case 3: Some stations are “missing” Case 3: - Step 1: perform test at left side (Master 2) - Step 2: perform test at right side (Slave 71) (Note: make sure that Timeout is not caused by the time-out setting in PB-T4: => Tools / settings) Result: - Test at left end: Slave 53 and 71 are missing - Test at right end: all stations are missing 40
  • 41.  Interpretation:  The fact that some devices can be seen from one end but not from the other indicates that the problem is not be caused by the devices themselves.  The test result at the left end shows that the Q-levels are good until slave 34. After slave 34 the Q-levels are not testable. This indicates that the problem must be in the line between slave 34 and 51.  Conclusion:  The problem is caused by a break of one or both signal lines. Master 2 7 9 23 34 51 71 RR R R R R 5V 5V ? Typical Network Issues Case 3: Some stations are “missing” 41
  • 42. Typical Network Issues Case 4: Quality Level of one device is bad  Case 4:  Step 1: perform test at left side (Master 2)  Step 2: perform test at right side (Slave 123)  Step 3: perform test at Slave 23  Result:  The Q-level of slave 23 is bad. All others are good. The result of all three measurements is basically identical.  Interpretation:  The voltage level of RS485 driver of station 23 (and only station 23) is too low.measurement from left side (master 2) measurement directly from slave 23 measurement from right side (slave 123) 42
  • 43. Typical Network Issues Case 5: Bus-termination is not powered correctly  An idle voltage of approx. 0,6 Volts indicates that only one bus-termination is powered correctly  communication may work, sporadic failures likely  An idle voltage close to 0 Volts (both terminations not correctly powered or one termination missing/one not correctly powered  PROFIBUS will not start Indication of idle voltage: The correct idle voltage is supposed to be between 0.8 and 1.4 V. An idle voltage lower than that indicates that one or both bus-terminations are not powered correctly. In addtion, you can detect a low idle-voltage in the oscilloscope (in this case approx. 0.5 V) 1V 43
  • 44. Typical Network Case 6: Too many bus-terminations or electrical resistance R R R 2 7 9 23 34 51 71 RR R R R R 5V 5V Master 44
  • 45. Typical Failure Cases Case 6: Too many bus-terminations or electrical resistance Note: The test results get worse the closer the PBT-4 is connected to the location of the problem (Master #2). However, the signal quality level of the problematic station (Master #2) might be one of the best. Unfortunately, the test results do not change as strikingly when dealing with tool many bus-terminations as they do with missing bus-terminations. Additional resistance usually affects all stations. signal blurred only some drops in signal due to reflections bad signal flanks 45
  • 46. Typical Network Issues Case 7: Cable too long for selected baud rate Note: Here the built-in Master functionality of the PB- T4 comes in very handy. Without changing the PLC-program, the network can be tested at different baud rates (e.g. 1.5Mbaud).As shown above, running the same network at a baud rate of 1,5 Mbaud is perfectly acceptable. Note 1: A cable length of 144m is too long for 12 Mbaud (100m permissible). Therefore, the quality levels / signal level of the stations measured at the master drop with the distance to the referring slave. Note 2: A test performed at the opposite end of the network (station #17) will show a “mirrored image”. In contrast to high line resistance the signal quality degrades gradually. 12 Mbaud, 144m 1.5 Mbaud, 144m 46
  • 47. Best-Practice for PROFIBUS Cable type, number of stations, cable length  PROFIBUS RS-485  Layout: terminated line, branch (or stub) lines < 0.3 m (1 foot) !!  Cable type: shielded twisted pair cable acc. to PROFIBUS specification  Number of stations: max. 32 w/o repeater, 127 using repeaters  Max. cable length (applies to cable type A only): Baud Rate Max. Cable Length 9.6, 19.2, 31.25, and 45.45Kbit/s 1200 m (3940 ft) 93.75 and 187.5 Kbit/s 1000 m (3280 ft) 500 Kbit/s 400 m (1310 ft) 1500 Kbit/s 200 m (656 ft) 3000, 6000, and 12000 Kbit/s 100 m (328 ft) 47
  • 48. Best-Practice for PROFIBUS Correct line topology, setting of bus termination Rt Rt S S SS M S No ! Avoid branch lines ! termination„on“ termination„on“ termination„off“ termination„off“ termination„off“ termination„off“ termination„off“ Copper cable 0.22 mm2, twisted pair, shielded, AWG 24* Max. 32 stations (Masters and Slaves) in one segment without repeater 48
  • 49. Best-Practice for PROFIBUS Correct line topology with repeaters Rt Rt S SS Rt Rt S SS M 31 Stations +1 Rep 30 Stations +2 Rep 30 Stations +2 Rep Rt Rt S SS Rt Rt S SS 31 Stations + 1 Rep Rep Rep Rep … … … … 49
  • 50. Best-Practice for PROFIBUS Grounding and mounting of PROFIBUS RS-485 PROFIBUS GND Cable to balance the Potentials, approx. 16 mm2, Best: Same Routing as PROFIBUS Cable (parallel) Slave Slave Master Equipotential Rail PROFIBUS Planar Connection of the PROFIBUS Cable Shielding to the Ground Potential, e.g. through special Clamps Equipotential Rail Equipotential Rail 50
  • 51. www.BlueBoxComm.com Thank You  BlueBox Communication 443, Nana Peth, Kirad Villa, Shop No. 5B, Pune- 411002, Maharashtra, India. +91 7875218696 +91 7875440101 sales@BlueBoxComm.com 51