Particularly relevant to people responsible for the design of PROFINET networks, highlighting the common errors and assumptions made that could make on-going support of the network rather difficult.

1. Network Design
Webinar
Peter Thomas
Control Specialists Ltd
May 2020
www.controlspecialists.co.uk

2. PROFINET Network Design © Control Specialists Ltd – May 2020 Page 2
Control Specialists Ltd
 Established in 1989, we are an organisation
with ongoing experience in the design,
commissioning and support of programmable
industrial automation systems and the
communication networks used by them.
 Our experience includes utilities (water and
gas), pharmaceutical, logistics, waste disposal
to name but a few,
 We also provide training courses on several
areas of industrial automation, we are a
PROFIBUS and PROFINET International Training
Centre (PITC) and a member of PI UK.

3. PROFINET Network Design © Control Specialists Ltd – May 2020 Page 3
PI UK Webinars - 2020
This webinar the second of a series of webinars being delivered
on behalf of PI UK.
 11th May 2020 – EMC Awareness for Industrial Automation
 20th May 2020 – PROFINET Network Design
 27th May 2020 – PROFINET Diagnostics
 3rd June 2020 – PROFINET Gateways
 10th June 2020 – PROFIBUS Lightning Surge Protection
All webinars are being recorded and will be uploaded to our
YouTube Channel.
You will receive a .pdf copy of any presentation you attend.

4. PROFINET Network Design © Control Specialists Ltd – May 2020 Page 4
What is PROFINET ?
PROFINET is an example of an Industrial Ethernet communications
protocol that is based on 100 Mbps, Fast Ethernet as defined in
IEEE802.3 and uses copper, fibre or wireless.
It is primarily associated with communications between PLC’s (IO
controllers) and plant-based devices (IO Devices) in an industrial
environment.
Source: PROFIBUS and PROFINET International – May 2020

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5
PROFINET
HTTP SNMP Socket
IP
TCP / UDP
Sensor system
PC
SNMP/OPC server
PROFINET
IRT Field devicesPC
Internet Explorer
Real-Time
RT IRT
Ethernet
PROFINET
RT Field devices
PROFINET in Operation
Source: PROFIBUS and PROFINET International – May 2020

6. PROFINET Network Design © Control Specialists Ltd – May 2020 Page 6
PROFINET Network
Components
PROFINET Networks consist of several discrete items
of apparatus:-
 IO Controllers (IOC’s) – The devices actually
controlling the communications – these are
usually PLC’s.
 IO Devices (IOD’s) – These are the plant-based
devices that the IOC is communicating with.
They may be remote IO, Invertor drives,
encoders etc.
 Switches – These are used to connect the IOC’s
with the IOD’s.
 Gateways – These are used to connect to other
network types, e.g. PROFIBUS, AS-I, CAN or IOT
(OPC-UA/MQTT)
 Monitoring Tools – Essential for the qualification
and support of your network

7. PROFINET Network Design © Control Specialists Ltd – May 2020 Page 7
VSD
(0.70)
(FIBRE)
IO LINK
MASTER
MODULE
4 * IOL
DEVICES
PROCENTEC
office.sw1
5
6
7
8
5
6
8
(M)
‘CSL PN TRAINING’
192.168.1.X
FIXED: 1.1 – 1.29
NAT: 1.5 – 1.29
DHCP: 1.30 – 1.254
(0.7)
(0.1)
(0.2)
IOC.1
IOC.2
PROCENTEC
ATLAS
SIEMENS
KTP700
PROCENTEC
ETHERMIRROR
HMI.1
1
2
3
4
IOC.1
SIEMENS
factory.sw1
(0.3)
(0.4) ETHERTAP
PROCENTEC
1
4
2
7
MIRROR PORTX
3
(1.1)
REMOTE ACCESS
USB
RACK 2
0.20-
0.23
RACK 4
0.40-
0.43
RACK 5
0.50-
0.53
RACK 6
0.60-
0.63
RACK 3
0.30-
0.33
RACK 1
0.10-
0.13
4 4 9
8 8 9
PROFINET IO RACKS / LAPTOP RACKS (1 to 6)
(1.2)
PROFIBUS
TRAINING
NETWORK
CANOPEN
TRAINING
NETWORK
(0.212)
PN / CAN
(HELMHOLZ)
ROUTER
(HELMHOLZ)
(0.214)(0.213)
DP/PN
(HELMHOLZ)
(0.201)
PN / PA
(SOFTING)
(0.211)
LOCAL PA
TRANSMITTERS
IOT
GATEWAY
(0.215)
(80)
PHOENIX
factory.s
w3(0.6)
PHOENIX
factory.s
w2
(0.5)
RC
RC
1 5
5
(0.5)
(0.6)
IOC.1 FACTORY
SWITCH RACK
6
2
1
8
8
2
(MRP)
RM
(MRP)
(0.101) (0.102) (0.103)
(0.104 (0.105) (0.106)
Control Specialists Network

8. PROFINET Network Design © Control Specialists Ltd – May 2020 Page 8
PROFINET Network Design
 The ease in which PROFINET networks can be configured can
lead to a false sense of security in terms of robustness, support
and future expansion.
 Poorly designed networks present the risk of underlying
network-related issues that may only become apparent after
several months or even years
 A PLC absent of bus faults does not indicate a healthy network.
 This presentation will bring your attention to the things that
need to be considered to ensure that you have a reliable
network that meets your needs both now and in the future.

9. PROFINET Network Design © Control Specialists Ltd – May 2020 Page 9
Network Design Considerations
Choice of
Components
Topology and
Redundancy
IIoT
Requirements
Training and
Support
Qualification
Connectivity to
other Networks
Network
Security
Device Naming
Conventions /
Cycle Times
Equipotential
Bonding
Application
Profiles

10. PROFINET Network Design © Control Specialists Ltd – May 2020 Page 10
IO Controllers (IOC’s)
 IO Controllers are responsible for the overall
communications in a PROFINET network.
 Whilst most networks will only have one IOC, it is
permissible to have several IOC’s in a single
network.
 The total number of IOD’s, including any for
suture expansion, should be determined as some
IOC’s have an upper limit on the number of
devices they can communicate with.
 PROFINET can co-exist with conventional ethernet
devices but the hardware configuration will only
show you the PROFINET devices.
 If your network will consist of conventional
ethernet devices that send / receive large
payloads you would be advised to put these on a
dedicated network via a communications
processor on the same PLC.

11. PROFINET Network Design © Control Specialists Ltd – May 2020 Page 11
IO Devices (IOD’s)
 PROFINET is a vendor-independent
network that is supported by all of the
major manufacturers involved in
industrial automation.
 Most devices come with two RJ45
ports and act as a 2-port switch.
 Some devices use M12 connectors.
 Each IOD will need to be assigned a
unique device name that must match
that in the IOC.
 The support and diagnostic
capabilities of IOD’s can differ from
one another and should be checked.
 Each IOD must have a device-specific
GSDML file to allow it to be
incorporated into the hardware
configuration of an IOC.

12. PROFINET Network Design © Control Specialists Ltd – May 2020 Page 12
Switches
 In principle, a PROFINET network could consist of just
one IOC and several IOD’s in a ‘Line Topology’, similar
to PROFIBUS DP, and thereby avoid switches altogether.
However this approach has some limitations.
 PROFINET networks will work with unmanaged
switches, as long as they support Quality of Service
(QoS).
 However, from a support and qualification point of
view, you are strongly advised to use PROFINET
Conformance Class B switches for PROFINET RT.
 Conformance Class B switches are industrial-grade,
managed switches with a web interface that supports
many of the features and protocols essential to the
support and qualification of a network, such as port-
mirroring, SNMP (Simple Network Management Protocol
and LLDP (Link Layer Discovery Protocol)
 They also have GSDML files for incorporating into the
IOC Hardware Configuration.

13. PROFINET Network Design © Control Specialists Ltd – May 2020 Page 13
Device Naming Conventions
 All PROFINET devices need a device name to
identify themselves on the network.
 The device name must match that entered in the
hardware configuration instance of the device.
 On power-up, the IOC will search for the device by
name and on finding it will allocate a unique IP
address to the device.
 Device names need to be unique on the network,
conform to the PI criteria for device naming and
ideally be related to the location and/or function
they perform in the process.
 There are several free-to-download tools available
to perform the initial device naming.
 Automatic naming of a replacement device is a
feature that can be enabled in the IOC but is
dependent on the topology feature being used. This
is a very useful feature and will minimise downtime.
Siemens - PRONETA

14. PROFINET Network Design © Control Specialists Ltd – May 2020 Page 14
Device Cycle Times
 All PROFINET Networks run at 100 Mbps.
 The cycle time of each IOD can be set independent of each other in
the hardware configuration of the IOC.
 There are two variations of PROFINET, PROFINET RT (Real Time) and
PROFINET IRT (Isochronous Real Time).
 PROFINET RT can typically support cycle times as low as 1ms whilst
PROFINET IRT can go as low as 32µs.
 The polling rate for a device should be set as high as necessary NOT
as a high as possible.
 The polling rate is one adjustable parameter available for the control
of network loading which should ideally be <= 20%
 Some IOD’s have a minimum cycle time.
 Communications between an IOC and an IOD are monitored by a
“watchdog” that is set to 3 times that of its polling rate by default.
 The destination must receive at least one valid telegram withing this
time period to maintain the link.

15. PROFINET Network Design © Control Specialists Ltd – May 2020 Page 15
Connectivity to other
Networks
 Very few industrial automation networks exist in complete
isolation.
 There may be other PROFINET Networks to connect to.
 There may be legacy networks in operation such as
PROFIBUS DP / PA.
 There may be a need to connect to CAN, IO-Link or AS-i.
 Gateways / Couplers exist for all of these.
 Each gateway would appear as an IOD on the PROFINET side.
PN / PB (DP)
HELMHOLZ
PN / PB (PA)
SOFTING
PN / CAN
HELMHOLZ
PN / IO-LINK
SIEMENS
PN / AS-I
IFM

16. PROFINET Network Design © Control Specialists Ltd – May 2020 Page 16
IIOT Requirements
 The Industrial Internet of Things (IIoT)
refers to sensors and instruments that
are networked together with
computerised industrial applications,
e.g. including manufacturing and energy
management.
 This connectivity provides data
collection, exchange, and analysis, that
can lead to improvements in
productivity and efficiency and other
commercial benefits.
 Many IOC and IOD manufacturers are
incorporating two of the most popular
IIoT protocols in their products. These
being OPC-UA(Unified Architecture) and
MQTT (Message Queuing Telemetry
Transport)
 It is also possible to get dedicated IIoT
gateways.
PROFINET – OPC-UA
ADFWEB

17. PROFINET Network Design © Control Specialists Ltd – May 2020 Page 17
Security
 The fact that PROFINET is an
ethernet-based network makes
Security an important aspect of
design.
 PI have specific guidelines on
Security that cover a wide
range of solutions.
 The eventual solution for a
given network will have several
aspects to it but one common
aspect is the use of Firewalls.
 These support features such as
packet filtering and Network
Address Translation (NAT)
amongst other things.
WALLIE
HELMHOLZ

18. PROFINET Network Design © Control Specialists Ltd – May 2020 Page 18
Topology
 Topology defines the physical interconnection of network
devices.
 PROFINET supports Line, Star, Tree and Ring topologies.
 Each one has its benefits and disadvantages from a support
and availability point of view.
Line
Star
Tree
Ring

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Wireless Transmission
Wireless technology for PROFINET is now supported by many of the
leading automation companies:

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Wireless Devices
 All wireless solutions require a wireless device at either end of
the transmission link, one called a wireless master, the other
called a wireless slave.
 The simplest application will use one wireless master and one
wireless slave to allow wireless communications with up to 7
conventional PROFINET IO devices over a distance of 100m
(indoors) or 300m (outdoors) and at cycle times as low as 30ms.
100 – 300m
IOC IOD IOD IOD IOD IOD
Master Slave
Up to 7 IO devices per wireless slave

21. PROFINET Network Design © Control Specialists Ltd – May 2020 Page 21
PROFINET Design Tools
 A number of software-tools are available to assist in
determining the most appropriate topology for your
application.
 They help identify potential communication “bottle-necks”
and allow you to try out “what-if” scenarios.
SINETPLAN - Siemens

22. PROFINET Network Design © Control Specialists Ltd – May 2020 Page 22
System Redundancy
 PROFINET caters for system redundancy at the Controller level
and device level.
No Redundancy Controller Redundancy
Controller + Device Redundancy

23. PROFINET Network Design © Control Specialists Ltd – May 2020 Page 23
EMC and Equipotential
Bonding
 The shields of all PROFINET cables must be connected to a low
impedance bonding infrastructure at both ends.
 A conventional safety-related bonding system may not meet the
low-impedance requirements for EMC.
 EN 50310 recommends moving towards a Type D Mesh Common
Bonded Network.
 When implemented correctly, such a bonding system will provide
a low impedance (< 1Ω) at the “Frequencies of concern.
 Equipment and tools are available to assist you in this task
MWMZ II Impedance Clamp
Indu-Sol
EM-CLOT SYSTEM
Indu-Sol

24. PROFINET Network Design © Control Specialists Ltd – May 2020 Page 24
PROFILES
 Whilst the PROFINET protocol provides a way to move data across a
network, it does not give the data any structure or meaning.
 The use of Application Profiles provide a standard framework (data
structure) for the device application to talk to the controller
application.
 There are several Application Profiles, the most common being:
PROFIDRIVE – For Variable Speed Drive Applications
PROFISAFE – For Functional Safety Applications
PROFIENERGY – For Energy Conservation on large processes

25. PROFINET Network Design © Control Specialists Ltd – May 2020 Page 25
Diagnostic Tools
 Whilst the diagnostic capabilities of PLCs
are improving all of the time they are
generally associated with high-level
connectivity or device-specific diagnostics.
 PLC’s cannot generally be relied upon to
provide low-level indication of network
functionality.
 PROFINET diagnostic tools are essential for
the qualification and support of PROFINET
networks and take two forms:-
 Active Analysers – These “actively” poll the
network devices for diagnostic information.
 Passive Analysers – These ‘passively’
monitor the telegrams on the network –
usually between the IOC and first switch.
 Note – Active analysers will be constrained
by the use of unmanaged switches.
ATLAS / ETHERTAP
PROCENTEC
PROFINET INSPEKTOR
INDU-SOL

26. PROFINET Network Design © Control Specialists Ltd – May 2020 Page 26
Qualification
 Qualification is the performing of a
series of pre-written tests to
establish the installation and
operational aspects of a PROFINET
network.
 They will be completely separate
from the usual application-specific
testing.
 PROFINET Diagnostic tools are an
essential part of this and very often
produce reports of their own to
assist in providing evidence.
 A PLC with no bus faults is no
guarantee that there aren’t
underlying network issues.

27. PROFINET Network Design © Control Specialists Ltd – May 2020 Page 27
Training
Control Specialists provide the following PROFINET-related
training:
 Face-to Face
 Certified PROFINET Installer (1-day)
 Certified PROFINET Engineer (3 ½ days)
 Online / Instructor-Led (Half-day)
 PROFINET Commissioning and Maintenance (½ day or 1 day)
 EMC Awareness for Industrial Automation Systems (1 day)

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Questions ?

29. PROFINET Network Design © Control Specialists Ltd – May 2020 Page 29
Peter Thomas
Chairman of PI Training Centres and Technical Officer – PI UK
www.linkedin.com/in/petermthomas
peter.thomas@controlspecialists.co.uk
Control Specialists Ltd
www.controlspecialists.co.uk
Tel +44(0)1925 824003