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Profibus Troubleshooting Hot to Commission and Troubleshoot Profibus & Ethernet Networks Jim Ralston - Softing| Oct 24, 2019 Topics • Softing Introduction • Industrial Network Trends & Risks to Production • PROFIBUS Commissioning & Troubleshooting – Best practices for Profibus • Ethernet/PROFINET Certification, Qualification & Troubleshooting – Best practices for Ethernet • Questions? Softing Inc. ▪ Global Headquarters in Munich, Germany ▪ Founded 1979, Publicly traded since 2000 ▪ Profibus International Board Member ▪ OPC Foundation Founding Member ▪ North America headquarters in Knoxville, TN Get Connected – Stay Connected Profibus Tester - 5 dataFEED OPC Server Suite WireXpert 4500 edgeGate Ethernet Certifier mobiLink EchoCollect Network Data Diagnostics Intelligence uaGATE SI TH Link TH Scope NetXpert XG Ethernet Qualifier EPGate PN Process PNGate PA/PB Automation Industrial Networks – Media is the Foundation Cabling is Layer 1 (foundation) Proper Cabling Practices Increase Downtime • According to an ISA.org online article, industrial network failures accounted for 35% of total failures in plant automation. • Physical deterioration, electrical failure, or poor installation and maintenance practices can all lead to unreliable network performance. − loss of critical data − system downtime − even catastrophic failure The Industrial Network Speed Revolution Yesterd Today Emerging Tomorrow ay Networ Serial PROFIBUS Profinet Profinet Profinet/TS Profinet/TS Profinet/TSN k (10/100B (1000BT) N N (10GB-T) T) (2.5GB-T) (5GB-T) Data 1.2 4.8 9.6 31.2 12,000 10,000 to 1,000,000 2,500 5,000 10,000,000 Rate 5 100,000 (kbit) 10,000 5000 2500 1000 0.0012 0.0048 .0096 .03 12 55 Data Rate (mbps) Profibus Troubleshooting PROFIBUS is a Bus Topology (daisy-chain cabling) Profibus Testing Introduction Most problems in PROFIBUS networks are caused by ▪ Improper segment termination (missing, unpowered or excessive) ▪ Segments that are too long or lines that are too short ▪ Excessive number of devices in a segment ▪ Spur (drop, branch) lines ▪ Sharp cable bends ▪ Wrong type of cable ▪ Improper wiring, grounding and/or shielding ▪ Damaged cable (breaks, shorts, corrosion) ▪ Cable routing in environments subject to strong electromagnetic interference ▪ Wrong configuration of PROFIBUS parameters, GSD files, etc. PROFIBUS Tester 5 PROFIBUS Tester 5 is a powerful tool capable of performing comprehensive testing of PROFIBUS DP segments. One tool, many functions: ▪ Signal tester ▪ Cable tester ▪ Storage oscilloscope ▪ Protocol analyzer ▪ Frame recorder ▪ Trend recorder ▪ Master simulator ▪ PROFIBUS PA testing (w/optional adapter) Portable Battery-Powered with 3.5” Graphical Display Operation Modes Two modes of operation: ▪ Stand-alone mode ▪ PC mode Measurement Locations Measurement Locations Handheld: Test Function – Cable Test • Master disconnected – use when production is down or installation • Complete distance to fault results (opens, shorts, termination problems) • Quick way to determine cable faults • Similar to BT-200 function Handheld: Test Function – Bus Status • Measurement on active system • Quick determination of Diagnostic Messages (Node & Slot) Handheld: Test Function – Signal Quality • Measurement on active system • Reports Signal Quality level at each Node (note we recommend two measurements) Handheld: Test Function – Oscilloscope • Measurement on active system • Displays waveform at connection point (voltage levels, noise/ringing) Troubleshooting with the PROFIBUS Tester 5 Quick determination of Bus Communications and Bus Physics Health First indication: There is a problem ! Communication is okay => Traffic Light is green Signal quality is critical: Some nodes show bad signal quality => Traffic Light is yellow => Further Analysis required Troubleshooting with the PROFIBUS Tester 5 • Quick determination of Signal Quality at each node • Signal Quality may be trended over time Troubleshooting with the PROFIBUS Tester 5 • Oscilloscope waveform & Signal/Noise measurement • Click on each node to view (no need to move Tester) Typical Issues in a PROFIBUS Network: Sample Network Take measurements from both ends: - Master 2 - Slave 71 Master 5V 5V R 2 7 9 23 34 51 71 R R R R R Typical Issues in a PROFIBUS Network Case 1: High Line Resistance Measurements from left side (master 2) Results: Test results on the left end: - Good quality values for stations 2 – 34 - Bad quality values for stations 51 & 71 Measurements from right side (slave 71) Test results on the right end: - Bad quality values for stations 2 – 34 - Good quality values for stations 51 & 71 ➔ Reversal of Q-Levels! Typical Issues in a PROFIBUS Network Case 1: High Line Resistance Interpretation: The test result from the right side is almost a mirror image of the one from the left side. This is a clear indication of a high resistancein the network (corrosion, bent cables, long cables, etc.) In this case the problem is located between slaves 34 and 51. Master 5V 5V R 2 7 9 23 34 51 71 R R R R R Typical Issues in a PROFIBUS Network Case 2: Missing Terminator Quality is bad seen from one end only: Master 5V 5V R 2 7 9 23 34 51 71 R R R R R Take additional measurements at other locations to get a better picture of what is happening… Typical Issues in a PROFIBUS Network Case 2: Missing Terminator Results: The quality from one end declines gradually as you move to the other end: Master 2 Slave 7 Slave 23 Slave 71 Typical Issues in a PROFIBUS Network Case 2: Missing Terminator Interpretation: The problem is caused by signal reflections in the segment, due to a missing terminator at slave 71. This type of problem is normally generated at the test location that shows most stations with bad signal quality levels. You can see the reflections in the oscilloscope view for “Master 2”, seen from the “Slave 71” test point. Master 5V 5V R 2 7 9 23 34 51 71 R R R R R Termination Details Typical Issues in a PROFIBUS Network Case 3: Wire Break Results: Test result from the left end: stations 53 and 71 are timing out Test result from the right end: all stations are timing out Typical Issues in a PROFIBUS Network Case 3: Wire Break Interpretation: Devices 51 and 71 can’t be seen from the left end, and nothing can be seen from the right end. These results indicate that the problem must be a break of one or both lines between stations 34 and 51. Master 5V 5V R 2 7 9 23 34 51 71 R R R R R Troubleshooting with the PROFIBUS Tester 5 • Troubleshoot Bus Communication problems Troubleshooting with the PROFIBUS Tester 5 • Quick view of Station Statistics – identify problem nodes Troubleshooting with the PROFIBUS Tester 5 • Display Diagnostic Messages as Text not Hex Below are examples of diagnostic messages in plain text from a WAGO slave and from a Siemens Diagnose Repeater. Reading the log gives a simple indication of the problem. Diagnosis View PROFIBUS Diagnostics Suite: Frame Recording • Complete frame & data recording – with trigger options PROFIBUS Diagnostics Suite: Commissioning Report Industrial Networks – The Need for Speed! • First Generation Plant Networks - HMI/SCADA & PLC Programming - Controller Messaging (unscheduled) Simple, relatively slow speed (10Base-T) • Modern Plant Networks – an evolution - Real Time I/O - Drives/Motion - Vision Systems/Video Monitoring - More devices to monitor/collect data More complex, faster speeds needed! (1000Base-T+) Best Practices for Industrial Ethernet Testing Ethernet is a Star Topology using Switches (or hubs) Point-to-point cabling Why is Complete Cable Testing Important?…….. • As network bandwidth (data rate) increases….. − Carrier frequency increases − Impedance (attenuation) increases − Signal/noise ratios tighten − Crosstalk between pairs increase • High frequency signals traveling over copper It’s all about − Poor wiring = poor network performance (DOWN TIME) the pairing! − DC Continuity (zero baud) is not a complete test! Ethernet Standards and Cable Frequency Max Cable Speed Category • Faster networks run at higher Standard Pairs Lengt Frequency (Mbit/s) Standard frequencies h (MHz) 10BASE-T 10 Cat 3 2 100m 16 − New 2.5/5 Gbit/s bridge the gap 100BASE-TX 100 Cat 5 2 100m 100 − Will existing cable support it? 1000BASE-T 1,000 Cat 5e 4 100m 100 − Is new cabling required? 2.5GBASE-T 2,500 Cat 5e 4 100m 100 5GBASE-T 5,000 Cat 6 4 100m 250 10GBASE-T 10,000 Cat 6A 4 100m 500 40GBase-T 40,000 Cat 8 4 40m 2,000 Best Practices for Industrial Ethernet Testing Most problems in Profinet (Ethernet) networks are caused by: ▪ Poor cable/connector quality ▪ Poorly terminated Ethernet plugs/outlets (lack of installation training) ▪ Worn Ethernet RJ45 plugs – frequent insertions & machine vibration –Plugs instead of outlets/jacks being used on long runs ▪ Poorly installed cable runs – cable routing, bend radius, tie wraps.... ▪ Cable routing in environments subject to strong interference ▪ Lack of, or improper sheidling ▪ Network speed exceeds cable rated category ▪ Network/Device configuration issues Ethernet Test Levels & Types • Verifying − Basic test of conductivity (DC) − Wire map check • Qualifying − Determining Ethernet Performance (bit error rate) − Troubleshooting (distance to wiring fault) • Certifying − Standard acceptance test for networks (cert report) − Testing wire map, length & crosstalk noise levels − Location to fault/troubleshooting (wiring & pairing issues) • Active Monitoring/Alarming − Real-time network monitoring − Preventative alarming − Inventory/health − Packet level analysis Cable testers have a range of capabilities: Our focus will be on Certification and Qualification
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