PROFINET Diagnostics
Software and Tools
Dr. Xiu Ji
Content
www.mmu.ac.uk/profibus
Static wiring test, diagnostics
Live system diagnostics
Basics of PROFINET
PROFIBUS - PROFINET User Conference, June 29 30, 2010, Stratford
PROFINET Diagnostics by Dr. Xiu Ji, Page 2
What is PROFINET?
www.mmu.ac.uk/profibus
PROFINET is Standard Ethernet (IEEE 802.3).
PROFINET is based on the Fast Ethernet or 100 BASE
TX/FX.
PROFINET is an Industrialised Ethernet, optimised for
speed, determinism and durability.
PROFIBUS - PROFINET User Conference, June 29 30, 2010, Stratford
PROFINET Diagnostics by Dr. Xiu Ji, Page 3
Important IEEE 802.3 specs
www.mmu.ac.uk/profibus
1000 Base X - Gigabit Ethernet
PROFIBUS - PROFINET User Conference, June 29 30, 2010, Stratford
PROFINET Diagnostics by Dr. Xiu Ji, Page 4
www.mmu.ac.uk/profibus
PROFINET is based on
100BASE-TX/FX, i.e. Fast Ethernet
Fibre optic medium
Twisted 2-pair copper Cat 5 cable
Max. cable length of 100m between devices
100 mbps
X: means any medium, copper or fibre, but redundant with T or F.
100BASE can also use un-twisted enhanced Cat 5 cable, i.e. Cat 5e.
STP: Shielded Twisted Pair, e.g. 100BASE-TX, STP. PROFINET
only uses STP cables.
UTP: Unshielded Twisted Pair, e.g. 100BASE-TX, UTP.
PROFIBUS - PROFINET User Conference, June 29 30, 2010, Stratford
PROFINET Diagnostics by Dr. Xiu Ji, Page 5
What is Industrial Ethernet?
www.mmu.ac.uk/profibus
Is this fit ?
- High temperatures
- Rugged and metal housing
- Rack mount designs
- Withstand vibrations
- Electrical Noise Immunity
PROFIBUS - PROFINET User Conference, June 29 30, 2010, Stratford
PROFINET Diagnostics by Dr. Xiu Ji, Page 6
www.mmu.ac.uk/profibus
IP20 RJ45
Connectors
IP65 RJ45
IP65 M12
Customised
heavy-duty
PROFIBUS - PROFINET User Conference, June 29 30, 2010, Stratford
PROFINET Diagnostics by Dr. Xiu Ji, Page 7
4 wires or 8 wires?
www.mmu.ac.uk/profibus
PROFIBUS - PROFINET User Conference, June 29 30, 2010, Stratford
PROFINET Diagnostics by Dr. Xiu Ji, Page 8
Half Duplex
www.mmu.ac.uk/profibus
Half duplex Mode
Data transmission can take place only in one
direction at the same time
uses two wires, twisted
PC A
PC B
2 wires
Transmit
010
Transmit
TX+
TX+
TX-
TX-
0110
Receive
Receive
RX+
RX+
RX-
RX-
PROFIBUS - PROFINET User Conference, June 29 30, 2010, Stratford
PROFINET Diagnostics by Dr. Xiu Ji, Page 9
Full Duplex
www.mmu.ac.uk/profibus
Full duplex mode, 4 wires
Transmission of data in two directions simultaneously
Use of 4 wires and switching technology
i.e. telephone
PROFIBUS - PROFINET User Conference, June 29 30, 2010, Stratford PROFINET Diagnostics by Dr. Xiu Ji, Page 10
Straight and Crossover Cables
www.mmu.ac.uk/profibus
Ethernet devices must be connected so that the
transmitter in one device is connected to the receiver in
another.
When connecting one device directly to another (e.g. a
PC to a field device), a cross-over cable is required:
Device
Transmit
Device
Crossover
cable
Transmit
Receive
Receive
PROFIBUS - PROFINET User Conference, June 29 30, 2010, Stratford PROFINET Diagnostics by Dr. Xiu Ji, Page 11
Straight and Crossover Cables
www.mmu.ac.uk/profibus
When using a switch or hub to connect devices, the switch normally
provides the crossover for us.
Therefore, when using switches, straight cables are used to
connect the device to the switch:
Device
Transmit
Receive
Straight
cable
Switch with
crossover
Transmit
Receive
Modern switches provide auto-crossover, where they are able to
automatically provide crossover as required.
PROFIBUS - PROFINET User Conference, June 29 30, 2010, Stratford PROFINET Diagnostics by Dr. Xiu Ji, Page 12
Cable Test Tools
www.mmu.ac.uk/profibus
There are many different cable test tools available for checking
Ethernet cables.
These range in price from less than 100 pounds to over 3000.
PROFIBUS - PROFINET User Conference, June 29 30, 2010, Stratford PROFINET Diagnostics by Dr. Xiu Ji, Page 13
Stripping Tools
www.mmu.ac.uk/profibus
3cm
PROFIBUS - PROFINET User Conference, June 29 30, 2010, Stratford PROFINET Diagnostics by Dr. Xiu Ji, Page 14
Insulation Displacement Connectors
www.mmu.ac.uk/profibus
PROFIBUS - PROFINET User Conference, June 29 30, 2010, Stratford PROFINET Diagnostics by Dr. Xiu Ji, Page 15
Cable Tester
www.mmu.ac.uk/profibus
Connect the test plug at one end and the tester at the
other end.
Detect many wiring faults:
Wire break
Short circuit
Swapped wires
PROFIBUS - PROFINET User Conference, June 29 30, 2010, Stratford PROFINET Diagnostics by Dr. Xiu Ji, Page 16
Good wiring
www.mmu.ac.uk/profibus
Pin 1
Yellow (TD+)
Pin 3
White (RD+)
Pin 2
Orange (TD-)
Data 2
Pin 6
Blue (RD-)
Select this Mode
Shield present
Upper line: Connector at the tester
Lower line: Connector at the plug
PROFIBUS - PROFINET User Conference, June 29 30, 2010, Stratford PROFINET Diagnostics by Dr. Xiu Ji, Page 17
Wiring faults
www.mmu.ac.uk/profibus
1
2
3
6
sh
1
2
3
6
sh
1
2
3
6
sh
1
2 Wire break and
3
Effected pins
6
sh
No shield or
Shield broken
PROFIBUS - PROFINET User Conference, June 29 30, 2010, Stratford PROFINET Diagnostics by Dr. Xiu Ji, Page 18
Wiring faults
www.mmu.ac.uk/profibus
1
2
3
6
sh
1
2
3
6
sh
1
2
3
6
sh
1 Yellow and White
2
swapped
3
6
sh
Short circuit,
Second
line indicated
as --
PROFIBUS - PROFINET User Conference, June 29 30, 2010, Stratford PROFINET Diagnostics by Dr. Xiu Ji, Page 19
Practical Exercise
www.mmu.ac.uk/profibus
Make up a cable and test on a live system.
Watch for the connectivity indicators on the switch.
PROFIBUS - PROFINET User Conference, June 29 30, 2010, Stratford PROFINET Diagnostics by Dr. Xiu Ji, Page 20
Configuration:
PROFINET IO Systems
www.mmu.ac.uk/profibus
IO-Controller
PROFINET Supervisor
E.g. PLC running
application program.
E.g. PC or laptop running
engineering tool application.
(Compare with PROFIBUS
Class I master)
(Compare with PROFIBUS
Class II master)
Ethernet
Configuration
Configuration
Control/monitoring
Control/monitoring
Alarms
Alarms
IO-Device
Diagnosis
Diagnosis
Status/Control
Status/Control
Parameters
Parameters
E.g. Field device with
inputs/outputs
(Compare with PROFIBUS
Slave device)
PROFIBUS - PROFINET User Conference, June 29 30, 2010, Stratford PROFINET Diagnostics by Dr. Xiu Ji, Page 21
A PROFINET IO System
www.mmu.ac.uk/profibus
Siemens S7-300 CPU 315-2 PN/DP Controller
Siemens managed switch, SCALANCE X204-2
Westermo 5-port unmanaged switch, SDW-500
PROFIBUS - PROFINET User Conference, June 29 30, 2010, Stratford PROFINET Diagnostics by Dr. Xiu Ji, Page 22
Step 1
www.mmu.ac.uk/profibus
S7-300
IO Controller
192.168.0.1
255.255.255.0
SCALANCE
X204-2
Westermo
Switch
192.168.0.100
255.255.255.0
IO Supervisor
192.168.0.11
255.255.255.0
Computer name:
MMUPC2
Siemens ET 200S
4 2-in and 4 2-out
WAGO 750-340
2 4-in and 2 4-out
PROFIBUS - PROFINET User Conference, June 29 30, 2010, Stratford PROFINET Diagnostics by Dr. Xiu Ji, Page 23
Drag & Drop and
Assign Device Name
www.mmu.ac.uk/profibus
IO Controller automatically assign IP addresses based on its domain
addresses.
Configuration is similar to PROFIBUS!
PROFIBUS - PROFINET User Conference, June 29 30, 2010, Stratford PROFINET Diagnostics by Dr. Xiu Ji, Page 24
Addressing
www.mmu.ac.uk/profibus
Device addresses are NOT set by DIP switch. Instead, Device Name
concept is used.
IO devices much have a device name.
Every device has a unique MAC address. (Media Access Control)
MAC Address must be printed on every IO device.
MAC Address is used for real-time communication.
IP Address is used only for non-real-time data exchange, e.g. configuration
and parameterisation.
IP addresses are allocated by IO Controller every time during start-up or
restart.
PROFIBUS - PROFINET User Conference, June 29 30, 2010, Stratford PROFINET Diagnostics by Dr. Xiu Ji, Page 25
Addressing
www.mmu.ac.uk/profibus
Start-up always takes place over the non-real-time
TCP/UDP/IP channel.
MAC addresses and device names (at default or if
assigned) are revealed at this stage.
IP addresses are then allocated based on their MAC
addresses.
The device name is vital in setting up IP addresses.
Device name must be set correctly.
Once the device name and IP address are correct the IO
controller can initiate communication with the device.
PROFIBUS - PROFINET User Conference, June 29 30, 2010, Stratford PROFINET Diagnostics by Dr. Xiu Ji, Page 26
Download or change device name
www.mmu.ac.uk/profibus
There are tools
available for changing
device names.
Changing device names
within a configuration tool
stores the names
within the project.
PROFIBUS - PROFINET User Conference, June 29 30, 2010, Stratford PROFINET Diagnostics by Dr. Xiu Ji, Page 27
Initial Communication
www.mmu.ac.uk/profibus
Communication between Controller and Supervisor
via LAN
Supervisor: Laptop with Siemens S7 HW-Config application
Controller: Siemens S7-300 CPU with RJ45 interface
Scan or Browse Network: MAC address and device name are revealed.
PROFIBUS - PROFINET User Conference, June 29 30, 2010, Stratford PROFINET Diagnostics by Dr. Xiu Ji, Page 28
MAC address and device name
www.mmu.ac.uk/profibus
Assign IP Address manually or
via Controller automatically.
PROFIBUS - PROFINET User Conference, June 29 30, 2010, Stratford PROFINET Diagnostics by Dr. Xiu Ji, Page 29
Step 2
www.mmu.ac.uk/profibus
S7-300
Westermo
Switch
SCALANCE
X204-2
IO Controller
192.168.0.4
255.255.255.0
00-30-DE-01-50-89
IO 2
192.168.0.1
255.255.255.0
00-0E-8C-89-5E-39
192.168.0.100
255.255.255.0
00-0E-8C-A1-59-17
192.168.0.2
255.255.255.0
08-00-06-6C-02-90
192.168.0.3
255.255.255.0
00-30-DE-01-50-92
IO Supervisor
ET200S IO 1
WAGO IO 1
192.168.0.11
255.255.255.0
Siemens ET 200S
4 2-in and 4 2-out
WAGO 750-340
2 4-in and 2 4-out
PROFIBUS - PROFINET User Conference, June 29 30, 2010, Stratford PROFINET Diagnostics by Dr. Xiu Ji, Page 30
Step 3a: Write a program
www.mmu.ac.uk/profibus
Write a simple program in OB1 and download it to
Controller.
L
INC
T
T
T
T
T
T
QW0
1
QB0
QB1
QB2
QB6
QB7
QW8
L
QW4
INC 1
T
QW4
//load Output Word 0
//increment it with 1
//write it to Output Byte 0
//write it to Output Byte 1
//write it to Output Byte 2
//write it to Output Byte 3
//write it to Output Byte 4
//load Output Word 4
//load Output Word 4
//increment it with 1
//write it to Output Word 4
PROFIBUS - PROFINET User Conference, June 29 30, 2010, Stratford PROFINET Diagnostics by Dr. Xiu Ji, Page 31
Step 3b: Write a program
www.mmu.ac.uk/profibus
Program:
PROFIBUS - PROFINET User Conference, June 29 30, 2010, Stratford PROFINET Diagnostics by Dr. Xiu Ji, Page 32
Learning MAC Addresses
www.mmu.ac.uk/profibus
Switch knows which device is on which port and hence directs
traffic/data to where is intended to be rather than flooding the
network.
PROFIBUS - PROFINET User Conference, June 29 30, 2010, Stratford PROFINET Diagnostics by Dr. Xiu Ji, Page 33
Switching Technology
www.mmu.ac.uk/profibus
A switch remembers the ports:
If swapping plugs, it takes time to re-figure out the ports
Power off a device first, swap plugs if required, and then power on the
device.
PROFIBUS - PROFINET User Conference, June 29 30, 2010, Stratford PROFINET Diagnostics by Dr. Xiu Ji, Page 34
Diagnostics
www.mmu.ac.uk/profibus
PROFINET provides fast and thorough diagnostics
covering almost every component of a PROFINET
network.
Diagnostics are structured hierarchically, starting with
the device information and moving down to the ladder to
the module and channel diagnostics.
Network and system status are also available.
In case of a fault, the station name, module number,
channel number, channel type, and information about
the error itself are displayed and can be accessed.
Diagnostics are similar as in PROFIBUS!
PROFIBUS - PROFINET User Conference, June 29 30, 2010, Stratford PROFINET Diagnostics by Dr. Xiu Ji, Page 35
Communication faults
www.mmu.ac.uk/profibus
Mainly caused by poor network wiring or layout or
cable/connector deterioration.
Can be permanent or intermittent.
SF
BF
ET200S IO 1
PROFIBUS - PROFINET User Conference, June 29 30, 2010, Stratford PROFINET Diagnostics by Dr. Xiu Ji, Page 36
Peripheral faults
www.mmu.ac.uk/profibus
Caused by sensor/actuator failure or wiring faults.
Again faults can be intermittent.
System Fault light
shows peripheral
errors
Note: Bus Fault shows
communications is OK.
Modules have individual indication
SF
BF
ET200S IO 1
Sensor
PROFIBUS - PROFINET User Conference, June 29 30, 2010, Stratford PROFINET Diagnostics by Dr. Xiu Ji, Page 37
Diagnostics
www.mmu.ac.uk/profibus
The switch passes on the
PROFINET diagnostics of an IO
device to CPU.
CPU evaluates and report the
diagnostics
IO-Controller
The switch reports network
disturbances as PROFINETdiagnostics to the IO-Controller (1)
Configuration of the Switch as IODevice (GSDML)
Additional SNMP channel, e.g. for
reporting on a Supervisor (2)
IO-Controller
IO-Device3
IO-Device1
IO-Device2
IO-Device1
IO-Device2
PROFIBUS - PROFINET User Conference, June 29 30, 2010, Stratford PROFINET Diagnostics by Dr. Xiu Ji, Page 38
A lost station
www.mmu.ac.uk/profibus
PROFIBUS - PROFINET User Conference, June 29 30, 2010, Stratford PROFINET Diagnostics by Dr. Xiu Ji, Page 39
Diagnostics using analysers
www.mmu.ac.uk/profibus
Free tool, Wireshark.
The alarms are captured.
PROFIBUS - PROFINET User Conference, June 29 30, 2010, Stratford PROFINET Diagnostics by Dr. Xiu Ji, Page 40
Port Mirroring
www.mmu.ac.uk/profibus
Port Mirroring is used on a switch to send a copy of network
packets seen on one switch port (or an entire VLAN) to a network
monitoring connection on another switch port.
Defining a mirror port duplicates all traffic on the mirror.
incoming and outgoing traffic
Useful for monitoring the switch traffic on a certain port, the monitor
port for diagnostic reasons.
e.g. with Ethereal / Wireshark analyser
Available in managed switches or as a dedicated device.
PLC
Device
PC
PROFIBUS - PROFINET User Conference, June 29 30, 2010, Stratford PROFINET Diagnostics by Dr. Xiu Ji, Page 41
Setup Switch for Monitoring
www.mmu.ac.uk/profibus
PROFIBUS - PROFINET User Conference, June 29 30, 2010, Stratford PROFINET Diagnostics by Dr. Xiu Ji, Page 42
Monitoring
www.mmu.ac.uk/profibus
Hubs should NOT be used
In PROFINET!
Only useful for
monitoring purpose.
PC with
analyzer
PROFIBUS - PROFINET User Conference, June 29 30, 2010, Stratford PROFINET Diagnostics by Dr. Xiu Ji, Page 43
Monitoring
www.mmu.ac.uk/profibus
Mirror port
Monitor port
PC with
analyzer
PROFIBUS - PROFINET User Conference, June 29 30, 2010, Stratford PROFINET Diagnostics by Dr. Xiu Ji, Page 44
Mirror and monitor ports
www.mmu.ac.uk/profibus
PROFIBUS - PROFINET User Conference, June 29 30, 2010, Stratford PROFINET Diagnostics by Dr. Xiu Ji, Page 45
Non-monitoring Port
www.mmu.ac.uk/profibus
On non-monitoring port of a switch, only multicast or
broadcast messages are captured.
PROFIBUS - PROFINET User Conference, June 29 30, 2010, Stratford PROFINET Diagnostics by Dr. Xiu Ji, Page 46
Recording
www.mmu.ac.uk/profibus
Select a network interface to record telegrams/data
exchange.
PROFIBUS - PROFINET User Conference, June 29 30, 2010, Stratford PROFINET Diagnostics by Dr. Xiu Ji, Page 47
Normal Data
www.mmu.ac.uk/profibus
Priority 6, relatively low.
PROFIBUS - PROFINET User Conference, June 29 30, 2010, Stratford PROFINET Diagnostics by Dr. Xiu Ji, Page 48
Alarms
www.mmu.ac.uk/profibus
VLAN must be used. Alarms are Priority 5, higher than normal data.
PROFIBUS - PROFINET User Conference, June 29 30, 2010, Stratford PROFINET Diagnostics by Dr. Xiu Ji, Page 49
Conclusion
www.mmu.ac.uk/profibus
Static wiring test handheld tools.
Configuration errors MAC addresses, device names
and IP addresses.
Live system diagnostics
Software supplied with IO Controller
Analysers, e.g. comprehensive and easy to use Wireshark
PROFIBUS - PROFINET User Conference, June 29 30, 2010, Stratford PROFINET Diagnostics by Dr. Xiu Ji, Page 50
