Ethernet Peter Thomas Control Specialists Ltd...PROFINET Applying the Ethernet Standard to...

PROFINET

Applying the

Ethernet

Standard to

Industrial

Automation

Peter Thomas

Control Specialists Ltd

www.controlspecialists.co.uk

PROFINET - Applying the Ethernet Standard - V1.0 - July 2014

Automation SeminarCoventry – July 2014

2

Objectives


• A review of PROFIBUS• PROFINET the natural evolution of PROFIBUS• Connecting to existing Fieldbus systems• Control System Configuration• Network Monitoring Considerations


PROFINET - Applying the Ethernet Standard to Industrial Automation.

Review of PROFIBUS

• PROFIBUS is a multi-drop network where many devices are connected to one cable.

• Every PROFIBUS device must have a unique address which is set by the engineer during set up

• Up to 126 PROFIBUS devices can be connected together in a single network.

• However only 32 devices can be connected on a segment.• Segments are formed using repeaters, hubs, optical links or couplers.

• DP devices run on RS485 cabling using shielded twisted pair cable terminated at the ends to stop reflections.

• PA devices run on Manchester Bus Powered (MBP) cable.

PROFINET - Applying the Ethernet Standard - V1.0 - July 2014 www.controlspecialists.co.uk

Review of PROFIBUS

• A PROFIBUS network must have a Class-1 master. The Class-1 master must be configured to communicate with its allocated slaves.

• Each device has a GSD file which describes its characteristics, options, diagnostics etc.

• A Class-2 master can optionally be connected to the network for engineering functions such as parameter setting, calibration or diagnostics etc.

• DP devices can run at a bit rate from 9.6kbit/s up to 12Mbit/s (all devices at the same bit rate).

• PA devices always run at 31.25kbit/s.


Review of PROFIBUS

• The protocol is a simple master slave communication with token passing between masters.

• Only one device can talk at a time and communicational is one way at a time (half duplex).

• Device start up is standardised and checks include:• ID number, unique identification for each type of device (check configured ID=device ID)

• IO configuration (check modules present=modules configured)

• Standardised diagnostics.• Communication errors and peripheral errors.

• Standardised profiles• PA devices, drives, encoders, safety etc.


What is PROFINET?

• PROFINET is an open Industrial Ethernet standard developed by the PROFIBUS Organisation.

• It is NOT PROFIBUS over Ethernet.• PROFINET uses completely standard modern Ethernet (IEEE802.3). However, some features of PROFINET require additional standards to operate.

• Ethernet is not a multi drop network. Each cable only connects two devices. Switches are used to branch from device to device with a maximum cable length between devices of 100m

• Ethernet uses four core twisted pair screened cable• Termination (to stop reflections) is provided in every device and is no longer in the hands of the user.


PROFINET

• PROFINET is not a master/slave protocol. Full duplex communication is used which means that devices can read and write at the same time.

• PROFINET operates at 100Mbit/s or faster.• PROFINET makes use of Existing IT standards but, unlike IT systems, is “real-time” and deterministic.

• PROFINET is very well thought out to meet all the requirements of automation and control systems incorporating:

• High speed time communication with a range of real-time performance classes.

• Standardised communication and peripheral diagnostics.• Profiles for a wide range of applications.


Ethernet

IO-Controller

� Configuration� Control/monitoring� Alarms

� Diagnosis� Status/Control� Parameters IO-Device

PROFINET IO devices

PROFINET SupervisorE.g. PLC running

application program.E.g. PC or laptop running

engineering tool application.

E.g. Field device with inputs/outputs

(Compare with PROFIBUS Class-1 master)

(Compare with PROFIBUS Class-2 master)

(Compare with PROFIBUS Slave device)


PROFIBUS and the OSI model

physical (1)

application (7)

OSImodel

User layer

(3) to (6)

data link (2)

MBP(IEC61158-2)

Not used

MBP interface

Fieldbus MessageSpecification (FMS)

FMS profiles DP profiles

DP basic functions DPV0

DP extensions DPV1, DPV2

Fieldbus Data Link (FDL)

RS485/Fibre optic

FMS DP PA

PA profiles


ProfilesUser layer Profiles

PROFINET and the OSI model

Application Layer (7)

Presentation Layer (6)

Session Layer (5)

Transport Layer (4)

Network Layer (3)

Data Link Layer (2)

Physical layer (1)

IP

PROFINET Real-time channel

TCP/UDP

PROFINET Application Layer

Standard fast Ethernet.

Non time critical communications

Real time communications

Not used Not used


PROFINET IO

• Many features that have been developed for PROFIBUS devices have been directly incorporated into PROFINET:

• Standardised module and channel-related diagnostics,• Alarm and status information,• Identification and Maintenance (I&M) functions,• Time stamping,• Device description file (GSD) with configuration data for the device and available modules – PROFINET based on XML (called GSDML)

• Highly deterministic process cycle timing.


Real-Time Operation

• What does “Real-Time” mean?• A real-time control system responds in a deterministic manner within a time which is short compared to the plant response time.

• i.e. it depends on the application!• Standard communications (IT)

• requires a response in the order of ~100ms.• Factory automation

• requires a response time in the order of 1 to 10ms.• Multi axis motion control

• requires a response time in the order of 0.1 to 1ms with a jitter of less than 1µs.


Real-Time Operation

• PROFINET makes use of:• TCP/IP for standard communications, achieving response times typically less than 100ms.

• A Real-Time, RT, channel for I/O communications, achieving cycle times between 1 and 10ms.

• Isochronous Real-Time, IRT, channel for highly deterministic performance (drives and servos), achieving cycle times down to 32µs with <1µs jitter.

• RT and IRT communications are totally compatible with TCP/IP.

• Because they are encapsulated inside a standard Ethernet frame.


Real-Time Operation

• PROFINET IRT complies with IEEE 1588 – “Precision clock synchronization protocol for networked measurement and control systems”.

• However this not always good enough!• PROFINET extensions to IEEE 1588 provide better accuracy with:

• Automatic determination and compensation of the network transmission time.

• Giving less than 1µs jitter.


Isochronous Real-Time Operation

IRTchannel

IRTchannel

Non real-timechannel

IRTchannel



Cycle times down to 32µs possible

Cycle 1 Cycle 2 Cycle 3

IRTSyncOpen channeli.e. TCP/IP

RT NRT


IRT traffic

• IRT traffic uses a reserved time slot at the beginning of each cycle. This is always delivered on time.

• RT traffic has higher priority than standard TCP/IP traffic.

• TCP/IP must wait for RT to finish.

Reserved for IRT IRT

TCP/IP

TCP/IPRT

RT

TCP/IPRT

TCP/IP

TCP/IP

RT

RT

RT

RT

RT

IRTIRTIRTIRTIRTIRTIRT

Overtaking lane

Normal lane


IRT performance

• Cycle time 1 ms, IRT phase less than 200µs, leaving ~80 % for RT and standard communication.

Central control with motion control and operator panel

Multi-axis drives Single-axis drives

Open factory network

RouterE.g. 24 axes with1000byte I/O

PROFIdrive

profile


Functional Safety with PROFINET

• PROFINET also offers safety oriented communication that allows for integrating safety oriented components.

• A second 'safety fieldbus' is not necessary. • PROFIsafe V2 can be used in functional safety systems up to EN954 cat 4, PL e or SIL3.

• PROFIsafe is a profile that can be used in PROFIBUS and PROFINET.

• However, PROFINET has a significant advantage that safe and standard IO can be mixed in a single device.

www.controlspecialists.co.ukPROFINET - Applying the Ethernet Standard - V1.0 - July 2014

Functional Safety with PROFINET

Standard PROFINET I/O

protocol

Standardapplication

Safetyapplication

Ethernet

PROFISAFElayer

Standard PROFINET I/O

protocol

Standardapplication

Safetyapplication

PROFINET “Black-channel”

PROFIsafe Profile

• PROFIsafe V2 provides functional safety for both PROFIBUS and PROFINET systems.

• Suitable for use in SIL3 applications.

PROFISAFElayer


Other innovations on PROFINET

• Time synchronisation and time stamping.• The IRT facilities allow accurate time stamping to be implemented using IRT clock synchronisation.

• Configuration in Run• The ability to change the configuration of a device without stopping the control application.

• Standardised, scalable redundancy• High availability using redundant ring architecture and standard Media Redundancy Protocol, MRP.

• Standardised energy saving using the PROFIenergy profile.• Intelligent shutdown and start-up from power save.


Integration with Fieldbus

• Over 3000 different products are available on PROFIBUS from over 300 different manufacturers.

• There are currently far fewer devices available for PROFINET. So integration of PROFIBUS and PROFINET is very desirable.

• PROFINET provides a transparent interface with PROFIBUS via a standardised gateway or “Proxy”.

• The Proxy is a PROFINET IO device on one side and a PROFIBUS master on the other.

• PROFIBUS Configuration is integrated into the PROFINET configurator and is downloaded via Ethernet.


PROFIBUS

PROFINET

Integration with Fieldbus

PROFIBUS DP

PROXY

PROFIBUS PA

INTERBUS-S

PROXY

PROFINET

Other fieldbusses:AS-i, Modbus, DeviceNet,and others being developed.

PROXY

www.controlspecialists.co.ukPROFINET - Applying the Ethernet Standard - V1.0 - July 2014

Hardware Configuration

• Configuring a PROFINET system is very similar to configuring a PROFIBUS system.

• The configuration is usually done using the programming tool of the hardware vendor e.g. Siemens Step 7 Rockwell RS Logix 5000 etc.

• Before you begin make sure that you have the GSDML files for each device on the network.

• For each device you add, you assign a user-friendly device name and an IP address.


24

Siemens – Hardware Configuration


Network Diagnostics

• The use of PROFINET diagnostic tools and devices willallow you to monitor the live status of your PROFINETNetwork.

• During the design phase, careful consideration has to begiven as to how these tools will connect to the network.

• Connecting a device or tool to the wrong point in thenetwork can result in misleading, or even missing,diagnostic information.


Network Monitoring Considerations

• There are three preferred ways of connecting adiagnostic tool to a PROFINET network:-

• Via a Mirrored Port on a managed switch.• Using a TAP in series with the with the IO Controller and its IOdevices.

• Using a permanently connected diagnostic device.

• However, very often, the first two of these methodsonly allow communications in one direction, i.e. to themonitoring software.

• This can lead to certain functions of the tool notworking.


Diagnostic Monitoring using a Managed Switch

WAGO 750-340

RACK03DEV1192.168.0.31

00-0E-8C-9B-94-BD

SIEMENS ET200S

RACK03DEV2192.168.0.32

00-1B-1B-25-B7-1D

MURR IMPACT20

RACK03DEV3192.168.0.33

00-0F-9E-08-7F-DE

MOXA ETS-5055-PORT SWITCH

00-90-E8-0C-B6-29

SIEMENS X208 8-PORT

SWITCH

192.168.0.1 (WEB)00-0E-8C-9B-94-BD

SIEMENS CP315-2 DPPN CPU

MASTERRACKCPU192.168.0.2

00-0E-8C-FE-75-E2

Let us consider the monitoring all PROFINET communications between the IO Controller and the 3 IO Devices by connecting to the 8-port switch.


Ethernet Switches

• PROFINET networks make extensive use of switches.

• Simply plugging in a diagnostic tool into a spare port on the switch will not work because switches only send messages to the port to which the intended receiving device is connected.

• To overcome this we set up one port as a mirrored port (usually a feature of managed switches).

• But note, that some mirrored ports are NOT bi-directional which can prevent certain diagnostic functions working


Diagnostic Monitoring using a Managed Switch

WAGO 750-340

RACK03DEV1192.168.0.31

00-0E-8C-9B-94-BD

SIEMENS ET200S

RACK03DEV2192.168.0.32

00-1B-1B-25-B7-1D

MURR IMPACT20

RACK03DEV3192.168.0.33

00-0F-9E-08-7F-DE


00-90-E8-0C-B6-29

SIEMENS X208 8-PORT

SWITCH

192.168.0.1 (WEB)00-0E-8C-9B-94-BD



00-0E-8C-FE-75-E2

The solid line connects the laptop to a mirrored port the dashed line is a second connection to a spare port –this is only required when the mirrored port is NOT bi-directional AND the diagnostic software needs to transmit data


Softing EchoTap

• If you do not have a switch that supports port mirroring, an alternative is to use a TAP.

• Taps have two RJ45 ports and are connected in series with the device(s) that you want to monitor.

• The PC connects to the Tap via a USB interface.

• By definition, the installing of a tap requires you to disrupt the network when installing it.

IN OUT

USB


Diagnostic Monitoring using a Softing EchoTap

WAGO 750-340

RACK03DEV1192.168.0.31

00-0E-8C-9B-94-BD

SIEMENS ET200S

RACK03DEV2192.168.0.32

00-1B-1B-25-B7-1D

MURR IMPACT20

RACK03DEV3192.168.0.33

00-0F-9E-08-7F-DE


00-90-E8-0C-B6-29

SIEMENS X208 8-PORT

SWITCH

192.168.0.1 (WEB)00-0E-8C-9B-94-BD



00-0E-8C-FE-75-E2

USB

Connection to spare port


WAGO 750-340

RACK03DEV1192.168.0.31

00-0E-8C-9B-94-BD

SIEMENS ET200S

RACK03DEV2192.168.0.32

00-1B-1B-25-B7-1D

MURR IMPACT20

RACK03DEV3192.168.0.33

00-0F-9E-08-7F-DE


00-90-E8-0C-B6-29

SIEMENS X208 8-PORT

SWITCH

192.168.0.1 (WEB)00-0E-8C-9B-94-BD



00-0E-8C-FE-75-E2

Connection to web server

Permanent Monitoring – Softing BC502 PN


WireShark

• Wireshark® is a network protocol analyser. Itlets you capture and interactively browse thetraffic running on a computer network.

• It is not dedicated to PROFINET and as suchcannot be compared to ProfiTrace.

• It is free to download and available fromwww.wireshark.org


WireShark

• Wireshark® can be used to capture andanalyse the following PROFINET traffic:-

– Start-Up Checks / IP Assignment etc.– Data Exchange– Loss of Module– Loss of Communications– Duplicate Device Name – SNMP / LLDP traffic


Using a Managed Switch with WireShark

WAGO 750-340

RACK03DEV1192.168.0.31

00-0E-8C-9B-94-BD

SIEMENS ET200S

RACK03DEV2192.168.0.32

00-1B-1B-25-B7-1D

MURR IMPACT20

RACK03DEV3192.168.0.33

00-0F-9E-08-7F-DE


00-90-E8-0C-B6-29

SIEMENS X208 8-PORT

SWITCH

192.168.0.1 (WEB)00-0E-8C-9B-94-BD



00-0E-8C-FE-75-E2

Connection to mirrored port


Using an EchoTap with WireShark

WAGO 750-340

RACK03DEV1192.168.0.31

00-0E-8C-9B-94-BD

SIEMENS ET200S

RACK03DEV2192.168.0.32

00-1B-1B-25-B7-1D

MURR IMPACT20

RACK03DEV3192.168.0.33

00-0F-9E-08-7F-DE


00-90-E8-0C-B6-29

SIEMENS X208 8-PORT

SWITCH

192.168.0.1 (WEB)00-0E-8C-9B-94-BD



00-0E-8C-FE-75-E2

USB

Connection to spare port


37

Questions?

Peter ThomasControl Specialists Ltd

[email protected] – http://www.linkedin.com/company/2198880


Tel +44(0)1925 824003Mob +44(0)7971 405871


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