Webinar on PROFIBUS Network Maintenance

Speaker’s for today
Nirmal Tony Joseph Angadh Lambert

Agenda
Section-2
3. Physical and Logical Problems
2. PROFIBUS Communication Technology, Standards, Quality parameters
1. Introduction to PROFIBUS & PROFINET International (PI),
5. How to detect Logical & Physical parameters in PROFIBUS
4. Permanent monitoring Solution
6. Exercise – Real time failure scenario in PROFIBUS
7.PROFIBUS Vs PROFINET
8. PROFIBUS to PROFINET Advantage, Architecture Planning in PROFINET
Section -1
Section - 3

Company Overview
Germany
500+
PROFESSIONALS USA
Japan
12
HQ & Development Centre:
Bangalore India
SERVICES SOLUTIONS
Product FOCUS
Engineering IIoT, Cloud & Big
Data Analytics
Embedded
Software
& Hardware
Digital
Services
Solutions
Quality
Engineering
Application
Software
Engineering
Process
& Factory
Power &
Utilities
Data
Connectivity
& Integration
Solutions
Custom
Solutions

Network Specialist
• Controlling networks.
• Localizing weaknesses.
• Ensuring system availability.
We offers you a comprehensive product of tailored solutions to
improve the reliability and stability of your automation networks

Industry Associations
 Part of various Special Interest Groups
(Technical Specifications, Architecture, Test
& Certification and Marketing)
 Involved in reference Application
Architecture, Design and Development
 Technology Outsourcing Partner
 PROFIBUS and PROFINET Competency
Center
 FDT Test & Certification Center
 Part of Global Expert/Certified Community
https://opcfoundation.org/about/opc-
foundation/experts/
https://www.profibus.com/pi-
organization/certified-people/

About PROFIBUS and PROFINET International (PI)

PROFIBUS topics – Maintenance level perspective
 What is PROFIBUS PROTOCOL?
 PROFIBUS Address Range
 PROFIBUS Communication
 PROFIBUS Signal
 PROFIBUS Communication standards
 PROFIBUS Terminations and Impedance

PROFIBUS
 PROCESS FIELD BINARY UNIT SYSTEM (PROFIBUS)
 PROFIBUS – PROFIBUS DP & PROFIBUS PA
 RS-485 Technology
 Master Slave Principle
Decentralized peripheral (DP)
Call
Response
SlaveMaster

PROFIBUS address range
 Some configuration tools block the special addresses 0 and 126 for slaves
 Address 126 is the standard address for slaves whose address is assigned by software (manufacturer's delivery
state)
 Address 127 is a broadcast address that is simultaneously destined for multiple nodes (visible on a bus monitor, e.g.
PB-INspektor)
Actual number of PROFIBUS slaves that can be connected is 124 to a single Master(Controller)

10
A
. . .
Master
Slave Slave Slave
B
Slave
31
2
1213
2 22
2
10 31 12 13
Telegram traffic – Master slave communication
No. 02 to no. 10 request output information
No. 10 to no. 02 response input information
No. 02 to no. 31 request output information
No. 31 to No. 02 response input information
No. 02 to No. 12 request output information
No. 02 to No. 13 request output information
PROFIBUS communication

The PROFIBUS Signal
 The PROFIBUS signal consists
In Profibus communication a bit signal is split into 16 parts and the 8/16th part is considered
to interpret if the bit transmitted is logical 0 or 1 of a differential voltage signal
Signal cable A
Signal cable B
2.5 V
-2.5 V
2.5 V – (-2.5V)
= 5V
 For successful PROFIBUS communication, PI recommends the
voltage >2.2V and the slope must be < 5/16.
8/16th

PROFIBUS communication standards
 The topological structure in the PROFIBUS is a line structure.
 A maximum of 32 stations can be accommodated in a copper segment (RS 485).
 10 transmission speeds are specified for the PROFIBUS (RS 485)
 Transmission speed depends on the distance

Quality parameters in PROFIBUS communication
 PROFIBUS 90% Problems are Physical

Physical problems
 Shielding/Grounding
 Missing/Faulty terminations
 Exceeded cable length according to baud rate
 Short circuit
 Exceeded number of nodes(Slaves)
 Wrong cable types (150ohms)
 Improper Segmentation
 Electro-magnetic Interferences
Termination
Shield Contact

Logical problems
 Repeat telegram
 Error telegram
 Diagnostic telegrams
 Missing Telegram
10
A
. . .
Master
Slave Slave Slave
B
Slave
31
2
1213
2 22
W
10 31 12 13
2

Repeater connections
 How a 2 channel normal repeater can be connected
Even if 2 connections are there this is a Single
Segment – Segment1
Segment2
 In a single segment PROFIBUS Master can communicate to max 32
nodes
 For Instance:
We have observed in plants L1 will be connected to 20 nodes and L2 will
be connected to 20 nodes ie total in a single Segment >32nodes.
 Results in intermittent failures in communication
L1
L2

Advantage of MULTIrep
 Extension of your PROFIBUS project, up to 126 stations (star structure possible)
 Signal stabilization / regeneration for trouble-free data communication
 Reporting of logical and physical anomalies in PROFIBUS data traffic
 Error isolation on individual segments through automatic filtering
 Simplified diagnosis and accelerated troubleshooting through segment delimitation
with error status
 Clearly visible LED status
 Available in 2 channel, 5 channel and 7 channel

Physical Problems
 For instance:
How improper shielding gradually affecting the PROFIBUS Communication
Improper
Shielding
proper
Shielding

Physical Problems
 For instance:
Small Stubs creating
Impedance changes in the
PROFIBUS cable. 1-meter rule followed
to reduce EMI as per PI
stand

Permanent Network Monitoring
“INspektor Pinpoints minor deviations in the Network ”
(<2.5v in PROFIBUS communication is not recommended, PLC will only give indications if the V is <1.8v)
Logical evaluation – online – Permanent Monitoring Solution
Logical test in PROFIBUS with PROFIBUS-INspektor®
Telegram analysis
 Error telegrams
 Telegram repetition
 Module failure
 Diagnosis data and
cycle times

Web analysis and evaluation
 Web-based display – network overview, 24/7 Permanent Monitoring
 Troubleshooting made easy – No software and no internet required
 For 1 master 1 dedicated PROFIBUS - INspektor
 Reports can be saved in Word/PDF, Time stamping and History of events

How do we capture the quality values?
10
A
. . .
Master
B
31
2
1213
2 22
2
10 31 12 13
 Physical evaluation – online
 Signal test (bit form) in the PROFIBUS
with the PB-QONE
 Flanks, harmonics, levels
 Measurement at both ends of the segment
 Provide accessible measurement point

Plug n Play

Quality values
 Quality Values as recommended.
For successful PROFIBUS communication, PI recommends the voltage >2.2V and the slope must be < 5/16

Quality values
 For Instance: Harmonics and PROFIBUS communication voltage
Disturbance in the oscilloscope
Traffic signal for each nodes
 PROFIBUS Communication voltage is 2.37 and slope is 7/16 which is below the recommended standards

Pinpointing the Exact error

Automatic Topology display
 Cable length also will be measured automatically

How to detect PROFIBUS Cable Parameters?
Physical evaluation – offline
• Line test in PROFIBUS with PROFtest II
 Determination of reflection spots/impedance discontinuities
 Shielding discontinuity
 Cable impedance measurement
 Cable length measurement
 Correct termination
Typical error message
Example:

PROFIBUS Cable Parameters?
How to detect Impedance?
10
A
. . .
B
31
2
1213
2 22
2
10 31 12 13
Physical evaluation – offline
• Line test (reflection test) in
PROFIBUS with PROFtest II
• 1. Disconnecting the master
• 2. Turn terminating resistor of the active
measuring point PBMA IP20 OFF
• 3. Connect PROFtest II

Multirepeaters are more efficient than repeaters in a line structure

Looking backward and forward
32
PROFIBUS
 adresses
 Master-Slave-communication
 One cable and two wire
 Line topology
 terminations
 Measurement points
 example:
(0 till 125)
(150 Ohm)
(on both ends)
2  18 2  18
2  100 2  100
error!
Which device drop out?
Why?
Which device are changed?
2  101 + Reflexion
2  101
Master
Slave
Slave
SlaveSlave
X
Slave
Slave
Failure
PROFIBUS
INspektor
PBQ-one

Permanent Monitoring Solutions
 The complete package

System concept permanent network monitoring
 Central monitoring of all fieldbuses and networks

 Network monitoring software PROmanage® NT
Centralized network monitoring

PROFINET – Industrial EtherNET
 PROCESS Field Bus vs PROCESS Field Network
Protocol PROFIBUS PROFINET
Serial Field bus Industrial Ethernet Standard
Physical Layer Rs485 (2wire) Ethernet (4wire)
Speed 12mb/s 100mb/s & 1Gbit/s
Topology Serial Tree,star,ring,line
Address Space 126 255
Technology Master/Slave Provider/ consumer-Broadcast
Connector Type DE9 Connector RJ45 connector

PROFIBUS to PROFINET Migration
 Architecture planning in PROFINET
Source : Siemens Website
Quality Parameters in PROFINET

PROFINET Architecture
 For Instance: PROFINET Architecture developed according to the standards
PROmesh P9 & P20
Managed Switches
 Get port statics
 Ensure high network availability
 Logical and physical control
 Leakage current monitoring
 Deterministic data transmission
 PROFINET packets has priority
 Capacity to sustain 20% Netload
PROFINET-INspektor

Conclusion
Objective is a stable network
This can be achieved by:
• Good advance planning of the network
• High-quality installation
• Inclusion of an (intelligent) network access
• Verification of the compliance of the (planned) network structure

Utthunga Technologies Pvt. Ltd.
No. 8, 27th Cross, 2nd Stage,
Banashankari, Bangalore – 560 070
Phone: +91-80-68151900
Mail: contact@utthunga.com

Webinar on PROFIBUS Network Maintenance

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