PROFINET Diagnostics Software and Tools
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1 PROFINET Diagnostics Software and Tools Dr. Xiu Ji Static wiring test, diagnostics Live system diagnostics Basics of PROFINET Content PROFINET Diagnostics by Dr. Xiu Ji, Page 2
2 What is PROFINET? 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. PROFINET Diagnostics by Dr. Xiu Ji, Page 3 Important IEEE specs 1000 Base X - Gigabit Ethernet PROFINET Diagnostics by Dr. Xiu Ji, Page 4
3 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. PROFINET Diagnostics by Dr. Xiu Ji, Page 5 What is Industrial Ethernet? Is this fit? - High temperatures - Rugged and metal housing - Rack mount designs - Withstand vibrations - Electrical Noise Immunity PROFINET Diagnostics by Dr. Xiu Ji, Page 6
4 IP20 RJ45 Connectors IP65 RJ45 IP65 M12 Customised heavy-duty PROFINET Diagnostics by Dr. Xiu Ji, Page 7 4 wires or 8 wires? PROFINET Diagnostics by Dr. Xiu Ji, Page 8
5 Half Duplex Half duplex Mode Data transmission can take place only in one direction at the same time uses two wires, twisted PC A PC B Transmit TX+ Transmit wires TX+ TX- 10 Receive RX+ RX- TX- RX- Receive RX+ PROFINET Diagnostics by Dr. Xiu Ji, Page 9 Full Duplex Full duplex mode, 4 wires Transmission of data in two directions simultaneously Use of 4 wires and switching technology i.e. telephone PROFINET Diagnostics by Dr. Xiu Ji, Page 10
6 Straight and Crossover Cables 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: Transmit Device 1 2 Crossover cable 1 2 Device Transmit Receive Receive PROFINET Diagnostics by Dr. Xiu Ji, Page 11 Straight and Crossover Cables 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: Transmit Device 1 2 Straight cable 1 2 Switch with crossover Transmit Receive Receive Modern switches provide auto-crossover, where they are able to automatically provide crossover as required. PROFINET Diagnostics by Dr. Xiu Ji, Page 12
7 Cable Test Tools There are many different cable test tools available for checking Ethernet cables. These range in price from less than 100 pounds to over PROFINET Diagnostics by Dr. Xiu Ji, Page 13 Stripping Tools 3cm ❶ ❷ ❸ ❹ PROFINET Diagnostics by Dr. Xiu Ji, Page 14
8 Insulation Displacement Connectors ❺ ❻ ❼ ❽ PROFINET Diagnostics by Dr. Xiu Ji, Page 15 Cable Tester Connect the test plug at one end and the tester at the other end. Detect many wiring faults: Wire break Short circuit Swapped wires PROFINET Diagnostics by Dr. Xiu Ji, Page 16
9 Data 2 Pin 1 Yellow (TD+) Pin 2 Orange (TD-) Good wiring Pin 3 White (RD+) Select this Mode Pin 6 Blue (RD-) Shield present Upper line: Connector at the tester Lower line: Connector at the plug PROFINET Diagnostics by Dr. Xiu Ji, Page 17 Wiring faults sh sh No shield or Shield broken sh sh Wire break and Effected pins PROFINET Diagnostics by Dr. Xiu Ji, Page 18
10 Wiring faults sh sh Short circuit, Second line indicated as sh sh Yellow and White swapped PROFINET Diagnostics by Dr. Xiu Ji, Page 19 Practical Exercise Make up a cable and test on a live system. Watch for the connectivity indicators on the switch. PROFINET Diagnostics by Dr. Xiu Ji, Page 20
11 Configuration: PROFINET IO Systems E.g. PLC running application program. (Compare with PROFIBUS Class I master) IO-Controller Ethernet PROFINET Supervisor E.g. PC or laptop running engineering tool application. (Compare with PROFIBUS Class II master) Configuration Control/monitoring Alarms IO-Device E.g. Field device with inputs/outputs (Compare with PROFIBUS Slave device) Diagnosis Status/Control Parameters PROFINET Diagnostics by Dr. Xiu Ji, Page 21
12 S7-300 IO Controller SCALANCE X204-2 Step 1 Westermo Switch IO Supervisor Computer name: MMUPC2 Siemens ET 200S 4 2-in and 4 2-out WAGO in and 2 4-out PROFINET Diagnostics by Dr. Xiu Ji, Page 23 Drag & Drop and Assign Device Name IO Controller automatically assign IP addresses based on its domain addresses. Configuration is similar to PROFIBUS! PROFINET Diagnostics by Dr. Xiu Ji, Page 24
13 Addressing 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. PROFINET Diagnostics by Dr. Xiu Ji, Page 25 Addressing 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. PROFINET Diagnostics by Dr. Xiu Ji, Page 26
14 Download or change device name There are tools available for changing device names. Changing device names within a configuration tool stores the names within the project. PROFINET Diagnostics by Dr. Xiu Ji, Page 27 Initial Communication 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. PROFINET Diagnostics by Dr. Xiu Ji, Page 28
15 Assign IP Address manually or via Controller automatically. MAC address and device name PROFINET Diagnostics by Dr. Xiu Ji, Page 29 Step 2 S7-300 IO Controller SCALANCE X204-2 Westermo Switch DE E-8C-89-5E-39 IO Supervisor E-8C-A C ET200S IO 1 Siemens ET 200S 4 2-in and 4 2-out IO DE WAGO IO 1 WAGO in and 2 4-out PROFINET Diagnostics by Dr. Xiu Ji, Page 30
16 Step 3a: Write a program Write a simple program in OB1 and download it to Controller. L QW0 //load Output Word 0 INC 1 //increment it with 1 T QB0 //write it to Output Byte 0 T QB1 //write it to Output Byte 1 T QB2 //write it to Output Byte 2 T QB6 //write it to Output Byte 3 T QB7 //write it to Output Byte 4 T QW8 //load Output Word 4 L QW4 //load Output Word 4 INC 1 //increment it with 1 T QW4 //write it to Output Word 4 PROFINET Diagnostics by Dr. Xiu Ji, Page 31 Program: Step 3b: Write a program PROFINET Diagnostics by Dr. Xiu Ji, Page 32
17 Learning MAC Addresses Switch knows which device is on which port and hence directs traffic/data to where is intended to be rather than flooding the network. PROFINET Diagnostics by Dr. Xiu Ji, Page 33 Switching Technology 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. PROFINET Diagnostics by Dr. Xiu Ji, Page 34
18 Diagnostics 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! PROFINET Diagnostics by Dr. Xiu Ji, Page 35 Communication faults Mainly caused by poor network wiring or layout or cable/connector deterioration. Can be permanent or intermittent. SF BF ET200S IO 1 PROFINET Diagnostics by Dr. Xiu Ji, Page 36
19 Peripheral faults 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. SF BF Modules have individual indication ET200S IO 1 Sensor PROFINET Diagnostics by Dr. Xiu Ji, Page 37 Diagnostics 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 IO- Device (GSDML) Additional SNMP channel, e.g. for reporting on a Supervisor (2) IO-Controller 1 2 IO-Device3 IO-Device1 IO-Device2 IO-Device1 IO-Device2 PROFINET Diagnostics by Dr. Xiu Ji, Page 38
20 A lost station PROFINET Diagnostics by Dr. Xiu Ji, Page 39 Free tool, Wireshark. The alarms are captured. Diagnostics using analysers PROFINET Diagnostics by Dr. Xiu Ji, Page 40
21 Port Mirroring 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 PC Device PROFINET Diagnostics by Dr. Xiu Ji, Page 41 Setup Switch for Monitoring PROFINET Diagnostics by Dr. Xiu Ji, Page 42
22 Hubs should NOT be used In PROFINET! Only useful for monitoring purpose. Monitoring PC with analyzer PROFINET Diagnostics by Dr. Xiu Ji, Page 43 Monitoring Mirror port Monitor port PC with analyzer PROFINET Diagnostics by Dr. Xiu Ji, Page 44
23 Mirror and monitor ports PROFINET Diagnostics by Dr. Xiu Ji, Page 45 Non-monitoring Port On non-monitoring port of a switch, only multicast or broadcast messages are captured. PROFINET Diagnostics by Dr. Xiu Ji, Page 46
24 Recording Select a network interface to record telegrams/data exchange. PROFINET Diagnostics by Dr. Xiu Ji, Page 47 Priority 6, relatively low. Normal Data PROFINET Diagnostics by Dr. Xiu Ji, Page 48
25 Alarms VLAN must be used. Alarms are Priority 5, higher than normal data. PROFINET Diagnostics by Dr. Xiu Ji, Page 49 Conclusion 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 PROFINET Diagnostics by Dr. Xiu Ji, Page 50
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