PI UK Seminar (Nov 2021) - PROFINET Implementation and Testing
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The document discusses the process of certifying a PROFINET network and diagnostics. It describes various test types including verification, qualification, and certification tests to assess the network according to standards. Cable verification ensures accurate wiring while qualification testing identifies data transmission performance. Network acceptance tests check the inventory, topology, packet loss rate, and load. Designers are responsible for port numbers, cable labels, device names, and locations. Troubleshooting examines common issues like wiring faults, interference, configuration errors, and device failures.
PI UK Seminar (Nov 2021) - PROFINET Implementation and Testing
- 1. The process of certifying a new PROFINET network and Diagnostics Dave Tomlin – Hitex UK Ltd
- 2. 2 PROFIBUS UK 2 Introduction 1 Industrial Network Installation and Commissioning Guidelines 2 Test Types 3 Qualification, Verification & Certification 4 Designers Responsibilities 5 Network Acceptance Tests 6 Troubleshooting 7 © 2017
- 3. 3 PROFIBUS UK Installation & Commissioning Guidelines © 2017
- 4. 4 PROFIBUS UK Examples of test results Test types - definition of terms Verification (simple line test)* Qualification (functional test)* Certification (acceptance test)* Assessment according to defined standards (e.g. IEC11801 or in our case PROFINET Commissioning Guidelines) * PROFINET Commissioning Guideline V1.36 PNO Dec. 2014 © 2017
- 5. 5 PROFIBUS UK Cable Verification in Practice Qualification and Verification – PROFINET Verification test – Wire test Confirm accurate wire map from plug to plug Opens Shorts Crossed wires Measure length of cable Easy to use or cheap? Manual or automatic? © 2017
- 6. 6 PROFIBUS UK Qualification and Verification - PROFINET Qualification test – Functional test Identifying performance of data transmission Determination of signal-noise-ratio (SNR) Noise sources: NEXT *, FEXT *, echo noise, environment noise BERT (Bit-Error-Rate-Test) or Packet-Error-Rate-Test Sends Ethernet frames with 100Mbit/s; okay if 10s without losing frames Evaluation based on Ethernet error tolerances according to IEEE 802.3. Determination of runtime difference between wire pairs Fastest pair is 0ns ** e.g. limit for 1000BASE-T: 50ns © 2017 * NEXT: near end crosstalk FEXT: far end crosstalk ** (PROFINET works with two wire pairs. In the ideal case both pairs should have the same runtime) Test line
- 7. 7 PROFIBUS UK Test Report – Verification and Qualification Cable Qualification Report • Report for end customer or management © 2017 PROFIBUS, PROFINET and IO-Link Seminar – June 2019
- 8. 8 PROFIBUS UK Test Report – Verification and Cable Certification 1 Page per cable rather than a few Much more detail about the cable Expected and Achieved throughput rather than pass/fail for pairs © 2017
- 9. 9 PROFIBUS UK Near end and Far end cross talk Some TLA’s - NEXT and FEXT Cross talk in UTP cables is caused by capacitive coupling between pairs. Signals on pair A cause noise signals on pair B, and often the cross talk noise proves to be the limiting factor Cross talk occurs in two ways. Nearend cross talk (NEXT) happens when a signal from a transmitter at one end of a cable interferes with a receiver at the same end of the cable. Far-end cross talk (FEXT) occurs when a signal interferes with a receiver at the opposite end of the cable from the transmitter © 2017
- 10. 10 PROFIBUS UK Acceptance test Some of the Classical network acceptance tests Full System Inventory – does it match? Network Topology – does it match? Packet loss rate? Network Load © 2017
- 12. 12 PROFIBUS UK 12 © 2017 Designers Responsibilities Port Numbers marked Cable Labels marked Device Names General Location
- 13. 13 PROFIBUS UK 13 © 2017 Designers Responsibilities
- 14. 14 PROFIBUS UK Inventory List – Firmware Check PROFINET 4.3.4 of PROFINET Commissioning Guideline V1.36 Check the firmware revision levels of the PROFINET devices and document them. If the firmware revisions installed in the plant deviate from the planning, contact the person responsible for the planning of the system. PROFINET Devices are usually “hot Swappable” assuming correct FW versions are available. © 2017
- 15. 15 PROFIBUS UK 5.4.1 of PROFINET Commissioning Guideline V1.36 Network Topology - PROFINET Checking for Line Depth and Structure for load calculation and update time. © 2017 Maximum line depth with update time* 1ms 2ms 4ms 8ms 7 14 28 58 *Store and forward Switches
- 16. 16 PROFIBUS UK Lost Packets – PROFINET There should be no lost packets/retries on fiber or Copper connections, if there are then this suggests there may be trouble ahead. © 2017
- 17. 17 PROFIBUS UK PROFINET and “IT” traffic sharing the network Network Load - PROFINET 5.4.3 of PROFINET Commissioning Guideline V1.36 A small change of hardware implementation can have a serious effect on network load © 2017 Network Load Recommendation <20% No action required 20-50% Check planned network load >50% Take measures to reduce network load
- 18. 18 PROFIBUS UK Example of network load evaluation Checking the loading for each device Usually the highest load will be from the first link to PROFINET Controller Run your analysis at a time and duration to capture representative results. © 2017
- 19. 19 PROFIBUS UK Example Report © 2017 Example Report
- 20. 20 PROFIBUS UK PROFIBUS, PROFINET and IO-Link Seminar – June 2019 Conclusion Commissioning and Trouble Shooting PROFIBUS/NET Read and understand the guidelines before even designing the system Ensure that the cabling is installed, TESTED and signed off by suitably experienced people Ensure the Network Acceptance tests have been done based on PNO recommendations Install monitoring devices that can alert you before a major breakdown occurs There are cable testing tools and there are cable certification tools they are not the same Network diagrams are still really handy, but they are a lot easier to produce automatically than with PROFIBUS Having a reference to last known good state can save hours of troubleshooting, “who changed that device”, “why was that plugged into a different port” etc etc. © 2017
- 21. 21 PROFIBUS UK PROFINET - typical failures Troubleshooting of typical PROFINET failures Poor segmentation/planning of network Use of wrong / outdated device description files (GSDML files) Configuration errors (wrong name) Cable errors, EMC – See Peters Presentation Device diagnostics Decrease of communication quality (aging) © 2017
- 22. 22 PROFIBUS UK PLC Ethernet PSU PROFIBUS DP PROFIBUS DP HMI PROFIBUS PA Common PROFIBUS Problems Number 1 - Wiring faults: Reflections, Wire breaks, Short circuits, connector corrosion or failure etc. Number 2 - Interference, Particularly from drives and servos. Configuration faults. Addressing faults. Power supply failure. Instrument or I/O failure
- 23. 23 PROFIBUS UK For PROFIBUS or PROFINET Troubleshooting in a Nutshell Have a PLAN! Who is going to deal with a problem? What tools do they need? Do they have the documentation? Network Diagrams Permit to work? Plan for accessibility, can you access the network? Can you physically get to the network while its running? Have you got piggyback connectors PB, or Spare (mirror) ports/fixed TAP PN? © 2017 Breakdown Plan: 1. Maintenance teaM view logs in the “network Monitor” to see what has failed. 2. collect network diagraMs and tester and go to relevant area 3. insPect the ProBleM 4. rePair ProBleM 5. test rePair 6. schedule any further Maintenance required 7. review Breakdown to see if it is PossiBle to avoid in future
- 24. 24 PROFIBUS UK 24 © 2017 Trouble shooting aid 45 12 17 22 27 26 31 28 24 18 25 5 7 5 17 10 3 Clear Address’ and lengths
- 25. 25 PROFIBUS UK 25 Editable name of event © 2017 War Stories Pt1 – Carpet bombed resistor Odd dropouts Poor signal quality but works 8 Links <1m but… (replaced) Halve the problem, and again What was the problem?
- 26. 26 PROFIBUS UK 26 Editable name of event © 2017 War Stories Pt2 – Room for Reflection Process stops from time to time.. Look at signal quality Look at oscilloscope What's the problem
- 27. 27 PROFIBUS UK 27 Editable name of event © 2017 Lots of short spurs PLC Factory The Solution
- 28. 28 PROFIBUS UK PROFIBUS, PROFINET and IO-Link Seminar – June 2019 Free Tools (not exhaustive) PRONETA – useful diagnostic and configuration tool Wireshark – useful but complex packet analysis tool IP Scanner – useful for finding devices © 2017
- 29. 29 PROFIBUS UK PROFIBUS, PROFINET and IO-Link Seminar – June 2019 Paid for Tools (not exhaustive) Softing, PROCENTEC, Indu-SOL are the major players represented today. Others like Fluke etc are available but not PROFINET Specific. Tools for Monitoring, Analysis, Cable testing, Acceptance testing & topology viewing. © 2017
- 30. 30 PROFIBUS UK PROFIBUS, PROFINET and IO-Link Seminar – June 2019 Important Things All of the Documents below are available to download on the PI Website* PROFINET Design Guidelines Network Load Calculation Tool Installation Guideline for Cabling and Assembly Commissioning Guidelines PROFIBUS Design Guidelines PROFIBUS Assembly Guidelines * You may need to be a member to access some documents Thanks for listening Dave Tomlin Hitex UK Ltd 02476 692066 dtomlin@Hitex.co.uk www.hitex.co.uk UK Technical distributor for Softing Industrial Automation Tools. © 2017
- 31. Please come take a look during the break Editable name of event © 2017