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1 Industrial Communication for Automation and Drives Overview automation s

2 Open communication at a glance Data communication Data communication is used for data interchange between programmable controllers or between programmable controller and intelligent peers (such as PCs, computers, etc.). Network communication The communication link can be established using integrated interfaces in the programmable controller (CPU) or by using communications processors (CPs/TIMs). Data transmission is event-controlled, and is initiated by calling a communication block. SIMATIC S7 and SIMOTION provide multipoint interface (MPI), PROFIBUS and Industrial Ethernet for data communication. Industrial mobile communication The basis for industrial mobile communication are worldwide networks such as WLAN, GSM or, in the near future, UMTS which implement simple, secure solutions for local or worldwide company networks. The basis for secure global data communication is TCP/IP. Point-to-point Multi-point Interface PROFIBUS Industrial Ethernet Process or field communication Process or field communication is used to interface actuators/sensors to a programmable controller by means of distributed I/O. The link can be established via integrated interfaces on the CPU or by means of interface modules (IMs, CPs). The exchanging of process signals from the actuators/sensors can take place cyclically via the process image or individually via control command. SIMATIC provides PROFIBUS DP and AS-Interface for process or field communication. It also provides EIB, which forms the link between production automation and building services automation. AS-Interface PROFIBUS 2

3 Pages Data communication is implemented using MPI, PROFIBUS and Industrial Ethernet. General High-availability and fail-safe communication Network interfaces Transmission media Totally Integrated Automation PROFInet Manufacturing Execution Systems Glossary In point-to-point communication, two stations interchange data with one another. The point-to-point structure represents the simplest form of communication. The multi-point interface (MPI) is an integrated interface on programmable controllers such as SIMATIC or SIMOTION as well as on SIMATIC PCs, PGs and Panels. PROFIBUS is for data communication between programmable controllers made by different manufacturers. Industrial Ethernet (IEEE and 802.3u) is the international standard for area networks, and is currently the number one network in the LAN landscape worldwide. Data communication systems Point-to-point communication Multi-point interface (MPI) PROFIBUS Industrial Ethernet Worldwide communication Network performance and power Typical practice-related data (Table) Process or field communication 5 PROFIBUS DP/PA -PROFIBUS DP master -PROFIBUS DP slaves Typical practice-related data (Table) As low-cost alternative to a wiring harness, AS-Interface connects sensors and actuators using a two-wire cable. PROFIBUS (IEC 61158/EN 50170) is the international field standard, and is the world market leader among field buses. AS-Interface -AS-Interface master 8 8 -AS-Interface slaves 9 Process or field communication is supported by the AS-Interface and PROFIBUS DP networks. DP/AS-Interface link Safety at work Typical practice-related data (Table)

4 Industrial communication This brochure provides an overview of Siemens products for industrial communication in automation. The following criteria are available as selection assistance: 4 Types of communication: process or field communication and data communication with typical applications. Sample configurations which demonstrate a wide variety of possible solutions. Comparisons between the technical specifications for the various bus systems. Totally Integrated Automation Totally Integrated Automation (TIA) stands for a complete line of automation components providing the very highest level of integration: three-fold integration. An integrated software toolset supports all project phases, from hardware selection over programming and operation to diagnostics and maintenance. All tools access a common database, saving configuring overhead and ensuring project-wide data consistency. Communication within TIA is integrated from the field level to the process control level: Industrial Ethernet, PROFIBUS with AS-Interface as extended arm (for interfacing switching and installation technology), For information on Component based Automation and PROFInet, see page Protocol applications (e.g. PROFIBUS DP). Allocation of products (e.g. CP) to automation systems (e.g. controllers) in the relevant bus system (e.g. Industrial Ethernet). Navigation assistance for obtaining more detailed information. A glossary of the most important abbreviated terms. The configurations shown in the brochure must be regarded as sample configurations for informative purposes only. EIB (for integrating building services automation). Centralized and distributed I/O are configured in the exact same way. SIMATIC IT Siemens recently expanded the Totally Integrated Automation solution platform to include Manufacturing Execution Systems (MES). SIMATIC IT forms the bridge between automation level and corporate management level. Component based Automation based on PROFInet Component based Automation is the TIA concept for modular plant and machine construction. It utilizes the benefits of component technology, which has already successfully established itself in the software world. PROFInet, the communication standard developed by PROFIBUS International, is used for communication. Integrated communication plays a decisive role As economically-priced alternative to the cable harness, AS-Interface connects sensors and actuators over a two-wire cable. The basis for building services automation is the international EIB standard (EN 50090, ANSI EIA 776). The multi-point interface (MPI) is an interface integrated in SIMATIC S7 /C7 programmable controllers, SIMOTION, and SIMATIC PCs, PGs and OPs/PPs/TDs. The MPI makes it possible to set up shortdistance communication networks. PROFIBUS (IEC 61158/EN 50170) is the international standard for the field level, is the world market leader among field buses, and provides powerful process or field communication. Industrial Ethernet (IEEE and 802.3u) is the international standard for area networks. At present, Industrial Ethernet is the number one network in the LAN landscape, with a market share of over 80%. Industrial Ethernet is used to set up powerful long-distance communication networks. Industrial Mobile Communication Industrial Mobile Communication is the term used for industrial mobile communication products (such as MOBIC) from SIMATIC NET which use wireless communication. The basis for Industrial Mobile Communication are worldwide networks such as WLAN (to IEEE b), GSM, or the networks of the future, UMTS. Thanks to the growing versatility of information technology, Industrial Mobile Communication is being used with increasing frequency in the world of automation. Network interfaces are implemented via programmable controllers or links.

5 The various bus systems are divided into buses for: Process or field communication Process communication or field communication is used to interface sensors and actuators to a programmable controller. These devices can be linked via integrated interfaces on the CPU or by means of interface modules (IMs, CPs). SIMATIC and SIMOTION provide PROFIBUS DP and AS-Interface for process or field communication, as well as EIB, which serves as bridge between production automation and building services automation. Integrated interface For PROFIBUS DP and AS-Interface (SIMATIC S7 only), integrated interfaces are available on the CPUs for SIMATIC S7/C7 programmable controllers, SIMOTION, the SIMATIC PCS 7 process control system, and SIMATIC PCs and PGs. Integrated interfaces provide a costoptimized DP interface for fieldbus communication. Using communication processors In today's powerful programmable controllers, it is often more practical to interface multiple PROFIBUS DP lines to programmable controllers by means of communications processors. This not only enables the connection of a larger number of I/O devices, but also the separate handling of individual production areas. Data communication Management Enterprise level Process or fieldcommunication Control level Field level Automation level Performance/ transmission rate Data communication Data communication is used for data interchange between programmable controllers or between programmable controllers and intelligent peers (PCs, computers, etc.). SIMATIC and SIMOTION are equipped with multi-point interface (MPI), PROFIBUS and Industrial Ethernet for use in data communication. Integrated interface For Industrial Ethernet and MPI, integrated interfaces are available on SIMATIC S7 programmable controllers, PCs, PGs, and SIMOTION systems. Bus system allocation and performance range coverage Using communications processors High-performance CPs are available for Industrial Ethernet which are already equipped with communication software, thus off-loading the stations by making it unnecessary for them to perform communication tasks (e.g. flow control, blocking, etc.). 5

6 Industrial networks The graphic shows connection of different automation systems to the standardized networks Internet Pad PC Access Point HMI systems Notebook PC Controller Converter Field devices Link 6 Sensors

7 Mobile telephone Telecontrol and substation control and protection Internet Pad PC Motion Control Systems Teleservice Controller Controller Controller Link Field device for hazardous areas Link MOTION Control Drives MOTION Control System Link Actuator Controller Power supply Sensors 7

8 Process or field communication AS-Interface Valves, actuators, drives many different components are used at the field level. All of these actuators/sensors must be interfaced to an automation system. Today, distributed I/O are being used at the field level as intelligent on-site outposts, so to speak. Process or field communication is supported by the AS-Interface and PROFIBUS DP networks AS-Interface At the field level, one finds numerous sensors and actuators. As price-efficient alternative to the cable harness, AS-Interface connects these components using a two-wire cable. AS-Interface is used where individual actuators/sensors are spatially distributed throughout the machine (e.g. in a bottling plant). AS-Interface is the open international EN Standard. All over the world, leading manufacturers of actuators and sensors support AS-Interface. Interested companies have full access to the electrical and mechanical specifications for this interface. SIMATIC C7-621 ASi SIMATIC ET 200X SIMATIC S7-300 SIMATIC C7 SIMATIC S7-200 DP/AS-Interface Link 20E Integrated interface (Specification V2.0) CP CP CP P CP Safety at work Standard PLC/standard master Standard slave Power supply Safety monitor Signal evaluation Fail safe slave/safety monitor Fail safe slave with Emergency Stop The 'safety at work' concept enables the integration of fail-safe components such as Emergency Stop switches, safety door switches or fail-safe light grid in an AS-Interface network. These components are fully compatible with familiar AS-I components (such as master, slaves, power supply, repeaters, etc.), are based on EN and are jointly operated on the yellow AS-i cable. Master information (through regular I/O transfer) 8

9 AS-interface is a single-master system. Communications processors (CPs) are available for SIMATIC families which serve as master for controlling processor or field communication. Extended AS-Interface Specification V2.1 permits interfacing of up to 62 slaves. Thanks to the integration of analog-value processing in the masters, accessing analog values is just as easy as accessing digital values. A DP/AS-Interface Link is used to interface the SIMATIC S7-400 to the AS-i network. DP/AS-Interface Link 20E in IP20 is available for connecting the AS-Interface network directly to PROFIBUS DP, making it possible to use AS-i as PROFIBUS DP subnetwork. This is how you save costs AS-Interface replaces high-overhead cable harnesses and connects binary actuators and sensors such as proximity switches, valves and indicator lights to a programmable controller, for example SIMATIC. In practice, this means problemfree installation, since data and power are transported over a single cable. Thanks to a specially developed cable and cable-piercing technology, the AS-Interface cable can be tapped at any point. This concept gives you enormous flexibility and is exceptionally cost-saving. Special knowledge of installation and commissioning are unnecessary. In addition, easy cable installation, a clear cable structure and the special design of the AS-i cable not only greatly reduce the risk of errors, but also the overhead for service and maintenance. Power supply LOGO! Standard sensor, e.g. inductive BERO AS-i panelboard (without AS-interface chip) Signal column Annunciator K45 (with AS-interface chip) for connection of standard sensors User submodule K60 IP 65 motor starter AS-i panelboard Ultrasonic BERO with integrated AS-interface Standard encoder, e.g. position switch You will find the technical specifications for AS-Interface 14 9 on page

10 Process or field communication PROFIBUS DP/PA PROFIBUS links field devices such as distributed I/O or drives with automation systems such as SIMATIC S7 programmable controllers, SIMOTION or PCs. PROFIBUS, which is based on the IEC 61158/EN Standard, is a powerful, open, rugged fieldbus system with short response times. The following protocols are available for process or field communication with PROFIBUS: PROFIBUS DP (distributed peripherals) PROFIBUS DP is used to connect distributed field devices such as SIMATIC ET 200 or drives with very fast response times. PROFIBUS PA (Process Automation) PROFIBUS PA is an expanded version of PROFIBUS DP which offers intrinsically safe data and power transmission (e.g. measuring transducers in the food industry) in conformance with International Standard IEC PROFIBUS DP/PA is used when actuators/sensors in the machine or plant (e.g. at the field level) are widely distributed and can be spatially combined in a single station (such as the ET 200). In this case, the actuators/sensors are connected to the field devices, which are supplied with output data as per the master/slave principle and provide the controller or PC with input data. At SIMOTION's drive interface, the isochrone PROFIBUS is supported by PROFIdrive's "drive engineering" profile. S7-400 S7-300 SIMATIC C7 S7-400 S7-300 SIMATIC TDC SIMATIC C7 CPU 41x -2/3 FM DP CPU 317T-2 DP 31xF-2 DP 31x-2 DP 31xC-2 DP C7-633 DP C7-634 DP C7-635 C7-626 C7-636 CP Extended IM 467/467 FO CP 342-5/CP FO CP 50M0 CP 342-5/CP FO SIMOTION C/P/D Integrated interface 10

11 Powerful tools such as STEP 7, COM PROFIBUS and SIMATIC PDM are available for configuring and assigning parameters to the I/O devices. In STEP 7, centralized I/O and distributed I/O are configured in exactly the same way. PDM (Process Device Manager) is the parameter assignment tool for intelligent field devices (parameter assignments, diagnostics), and is called from STEP 7. STEP 7 can be used to make changes in user programs as well as to test and commission SIMATIC programmable controllers interfaced via PROFIBUS DP from any point in the plant. Drive ES also makes it possible to engineer the drives from any point in the plant. The S7-PDIAG/S7-GRAPH and ProAgent diagnostic tools make it possible to carry out process diagnostics without the need for additional diagnostic instruments. Power PG Field PG Rack WinAC Box Panel Device basis for WinAC WinAC RTX Box PC 620/840 Rack PC 840/IL40 Panel PC IL70/670/870 Field PG Power PG FI 45 V2 CP 5511/CP 5512 CP 5611 CP 5613/CP 5613 FO CP 5614/CP 5614 FO WinAC Slot 412/416 (with integrated interface) WinAC MP (with integrated interface) CP 5613/CP 5613 FO WinAC basis WinAC PN CP 5611 CP 5613/CP 5613 FO integrated interface PC/PG Device basis for WinAC PC For information on Component based Automation and PROFInet, see page CP 5511/CP 5512 CP 5611 CP 5613/CP 5613 FO CP 5614/CP 5614 FO S7-400 CP Extended IM 467/467 FO S7-300 ProTool/Pro CP 342-5/CP FO CP 5511/CP 5512/CP 5611 CP 5613/CP 5613 FO CP 5614/CP 5614 FO CPU PN/DP (i.v.) 11

12 Process or field communication PROFIBUS DP/PA Lateral data communication on the PROFIBUS DP Lateral communication on the PROFIBUS DP makes communication even faster and easier. The master sends a message containing setpoint values to the first slave. The slave responds by sending its actual values in a broadcast message, which is heard by all the other nodes on the bus. Recipients are mainly intelligent devices with their own data preprocessing capability (distributed intelligence), such as drives or distributed PLCs. Lateral communication requires no additional message. Master/slave and lateral communication relationships can be combined as needed. Isochrone mode (equidistance) can be set to a µs! Ideal for closed-loop control! A precisely reproducible bus cycle time is a requirement for sophisticated closedloop control, positioning and motion control applications. Every deviation can result in instable processes. Reproducibility with jitter of < 1 µs satisfies the very strictest requirements, e.g. for applications involving synchronism. Drives, CPUs and modular slaves are synchronized to a common clock pulse, not only making it possible to perform motion control tasks, but also enabling precise execution of distributed generalpurpose closed-loop control and measuring tasks. Acyclic data interchange In addition to the cyclic exchange of user data, PROFIBUS DP also enables acyclic messages. This makes it possible to send event-controlled data to the slave, e.g. drives can be easily assigned new parameters dynamically while the plant or machine is in operation. SIMATIC S7 Power PG Notebook ET 200X SIMATIC C7 ET 200M Field PG ET 200S ET 200L SINAMICS SIMOVERT MASTER- DRIVES MOBY ASM MICROMASTER SINUMERIK 840 Di SIMOTION C/P/D SIMOREG 12

13 For PROFIBUS DP/PA technical specifications, see page Openness all along the line Thanks to PROFIBUS DP's openness, it goes without saying that it is possible to interface standardized components from different manufacturers. The IEC 61158/EN ensures investment security for the future. More than 2,000 products and services from around 300 member companies all over the world offer a wide range of fieldlevel products with PROFIBUS DP interface. Siemens itself offers a complete palette of programmable controllers, network components, communication software and field devices. And if you are a manufacturer of field devices, we can supply you with virtually everything related in any way to the PROFIBUS interface, such as ASICs, training, certification, and much more. SIMATIC HMI VS 710 Vision Sensor ET 200iS DP/PA coupler/link Customer-specific solutions with ASICs Customer-specific solutions with ASICs Mobile Panel SITRANS F US SITRANS P SIMATIC PC DP/EIB Link EIB (EN 50090, ANSI EIA 776) is the internationally standardized building installation system and the basis for building services automation. 13

14 Process or field communication Typical practice-related data The table below contains empirical values which are intended to serve as recommendation for the selection of the optimum network. AS-Interface PROFIBUS DP PROFIBUS PA 1 2 Connectable Binary inputs/outputs Binary inputs/outputs Field devices in Zone 1 field devices Analog inputs/outputs Analog inputs/outputs hazardous area Intelligent field devices, (type of protection: [EEx ia], e.g. drives, measuring explosive group: IIC) sensors, slaves with data Non hazardous area preprocessing (such as (measuring transducer, ET 200X or S7-300, actuators or valves) SIMOTION ) Programming/ -Via PROFIBUS DP Via PROFIBUS DP commissioning with STEP 7 and PDM and PROFIBUS PA with the SIMATIC PDM (Process Device Manager) tool 3 Number of slaves Max. 62 Max DP/PA links 15 typ. 20 to 30 typ 31 field devices per DP/PA link AS-i cycle time Max. 5 ms for 31 slaves -- Max. 10 ms for 62 slaves Bus cycle time -2 ms at 12 Mbit/s typ. 200 ms at kbit/s typ. 10 ms at 1.5 Mbit/s typ. Network capacity Electrical: Electrical: up to 9.6 km Hazardous area: max. 1.0 km With/without repeater 100 m Optical: up to 90 km Non-haz. area: 1.9 km Topology Line, tree, star Line, tree, ring, star Line, tree, star Transmission media Unshielded two-wire cable Shielded two-wire cable Shielded two-wire cable Available degrees IP 20 IP 20 IP 20 of protection IP 65 to IP 67 IP 65 to IP 67 IP 65 to IP 67 [EEx ia] Standard EN IEC 61158/EN IEC Power supply via bus Yes No Yes Bus interface CP, integrated interface CP/IM, integrated inter-link or segment coupler or link face or link 14

15 Process or field communication Typical practice-related data 1 A list of the field devices which can be interfaced to the relevant networks for the purpose of process or field communication. 2 Configuring and commissioning can be done anywhere on the network. The freely selectable communication relationships are thus extremely flexible, easy to convert, and easy to change. 3 Slaves are network nodes on the PROFIBUS which send data back to the master at the master's request AS-i is a single-master system with cyclic polling. The AS-i cycle time is the time it takes for the master The bus cycle time is understood to mean the time it takes for each master (active bus nodes) to receive When using electrical components, local networks can extend over the distance defined in the standards. The method of cabling used between the stations is referred to as the network topology. to poll the slaves, which is done at precisely predetermined intervals. the token (the right to send) precisely once. Greater distances can be bridged using optical components Transmission media are either two-wire cables or fiber- The degree of protection is shown as IPxy, whereby the first digit (x) refers to shock-hazard protection as well as protection against solid bodies. Standards are international norms or guidelines In some networks, the power supply for the bus nodes The term 'interface' or 'interfacing' is understood to mean the physical method of connecting bus nodes to the bus cable. optic cables. The second digit (y) indicates protection against water. The higher the digit, the greater the protection. stipulating product properties and characteristics. is also supplied by means of the bus. 15

16 Data communication Industrial Ethernet, PROFIBUS The decision as to whether multi-point interface (MPI), PROFIBUS or Industrial Ethernet should be used for data communication depends mainly on the size of the area that must be covered by the network, the amount of data involved, the number of nodes involved and the network's expandability. A basic contingent of communication functions on the networks ensures consistency, that is to say, the functions show virtually the same performance capability over all of these networks. The following communication functions/services are available for data communication: PG/OP communication These are integrated communication functions which allow SIMATIC and SIMOTION systems to communicate with every HMI device (TD/OP) and SIMATIC PG (STEP 7). PG/OP communication is supported by all networks (with the exception of MPI), e.g. commissioning (coexistent interface). S7 communication For S7-400, S7 communication is the integrated communication function SFB (System Function Block), and for S7-300 it is loadable FBs optimized in the SIMOTION and SIMATIC S7/C7 systems. It also makes it possible to interface PCs and workstations. The amount of useful data per request may not exceed 64 kbytes. S7 communication provides simple, powerful communication services as well as a network-independent software interface. Data communication is implemented by way of MPI, PROFIBUS and Industrial Ethernet MOBIC Access Point, e.g. RLM S7-300 S5-compatible communication (SEND/RECEIVE) S5-compatible communication (SEND/RECEIVE) enables SIMATIC S7/C7 to communicate with existing systems, above all with SIMATIC S5, as well as with PCs via PROFIBUS and Industrial Ethernet. SIMATIC TDC For information on the functionality of the communication functions, see page SIMATIC C7 Third-party device 16

17 MOBIC SINAUT Fetch and Write are also made available via Industrial Ethernet, ensuring that software created for SIMATIC S5 can continue to be used without any modification. Standard communication Mobile telephone PC Standard communication actually consists of standardized protocols for data communication, such as FTP. PROFInet S7-300 S7-400 SIMOTION C/P/D PROFInet communication services are used for data interchange between PROFInet components via Ethernet, and are configured graphically using a vendor-independent engineering tool called SIMATIC imap. OPC SIMATIC WinAC PN S7-200 Power PG (OLE for Process Control) OPC is a standardized, open, vendorindependent interface, and is used to interface OPC-capable Windows applications to S7 communication and S5-compatible communication (SEND/RECEIVE). Vision Sensor VS 72x Information Technology (IT) with and Web technology S7-400 PC S7-300 S7-400 Field PG SIMATIC WinAC This form of standard communication links SIMATIC to IT via Industrial Ethernet. In office environments, and Web browsers have become widely-used communications resources.the most widely accepted communication path is Ethernet, although telephone lines and the Internet are also popular. Socket interface for Industrial Ethernet SIMATIC C7 Field PG Power PG This interface enables data communication with computers via TCP/IP. Users can program their own protocols for this interface, which is widely used in the PC world as well as in the UNIX world. In the SIMATIC S7, the SEND/RECEIVE (S/R) blocks are used as portal to TCP/IP. PROFIBUS FMS PROFIBUS FMS is used for data communication between non-identical automation systems from different manufacturers. 17

18 Data communication MPI (multi-point-interface) Supported communication functions Controllers can be connected to the MPI by way of interfaces integrated in the CPUs of various automation systems (e.g. SIMATIC, SIMOTION); PCs/PGs can be connected to the MPI via integrated interface/communications processor. Basic S7 communication Data are transmitted on an eventcontrolled basis by calling a communication block (SFC) in the CPU (basic S7 communication for S7-300, S7-400, C7). The advantage is that no space in user memory is required. The amount of user data per request may be up to 76 bytes (small amounts of data). S7-300 SIMOTION C/P/D S7-400 SIMATIC TDC SIMATIC C7 S7-200 OP/TD/PP S7 communication PG/OP communication SIMATIC PC Field PG SIMATIC WinAC SIMATIC TDC SIMATIC C7 S7-400 Integrated interface on all SIMATIC S7/C7/TDC CPUs or SIMATIC PCs S7-200 S7-300 WinAC Basis/RTX/PN WinAC Slot 412/416 WinAC via integrated interface or CP 5611/CP 5613 SIMATIC WinAC Integrated interface SIMOTION C/P/D 18

19 Data communication PROFIBUS TD/OP The table contains the functions supported by the integrated interfaces, communications processors (CPs) and relevant communications software. Integrated interface PG/OP Communication functions S7 S5- comm. comp. Comm. FMS OPC The objective of OPC is to standardize the interface between programmable controllers and applications. OPC is being used more and more frequently for data interchange between automation applications. PROFIBUS is a powerful, open, rugged bus system. PROFIBUS is fully standardized in accordance with the IEC 61158/EN Standard, providing excellent investment security now and for the future. Siemens itself has a complete product line of associated network components! S7-400 S7-300 C7 HMI CP CP FO CP Integrated interface CP Basic CP Extended ProTool Pro WinCC Thanks to the openness of PROFIBUS, it can, of course, accommodate standardized components from different manufacturers. You can do your configuring, commissioning and troubleshooting anywhere on the bus. The freely selectable communication relationships are exceptionally flexible, easy to convert, and easy to modify. Supported communication functions The following communication functions are available for data communication via PROFIBUS: SIMATIC WinAC WinAC PN WinAC Basis WinAC RTX WinAC Slot 412/416 WinAC MP 1) 1) Without PC PG/OP communication S7 communication S5-compatible communication (SEND/RECEIVE) Standard communication (FMS). Box Panel Integrated interface 1) Rack PG/PC CP 5511 CP 5611 CP 5613/ CP 5613 FO CP 5614/ CP 5614 FO 1) 1) 1) 1) Technical specifications for data communications, see page 1) Contained in STEP 7 19

20 Data communication Industrial Ethernet For information on Component based Automation and PROFInet, see page Industrial Ethernet is a powerful area and cell network based on the IEEE (ETHERNET) Standard. Ethernet is also the technology on which the Internet is based, and offers many possibilities for worldwide networking. The many possibilities provided by intranet, extranet and Internet already available in today's office environments can also be utilized in production and process automation. Ethernet technology, which has been successful over many years, in combination with switching, full-duplex mode and autosensing allows you to match your network's performance to your requirements. You can choose your data throughput rate to suit your particular needs, since integrated compatibility makes it possible to introduce the new technology in stages. With a market share of over 80%, Ethernet is number one in today's LAN landscape worldwide. Ethernet provides important properties and performance characteristics which can mean many important benefits for your application: Fast commissioning thanks to simple yet sophisticated connection systems. High availability, since existing plants can be expanded without perturbation. Virtually unlimited communication capabilities due to scalable performance through switching technology. Networking of widely varied types of applications, such as office and production applications. Company-wide communication thanks to WAN (Wide Area Network) link-ups such as ISDN or Internet. Investment security thanks to retention of compatibility in future development. SIMATIC NET depends on this timetested, reliable technology. Siemens has already supplied hundreds of thousands of components and connections for rugged and EMC-stressed industrial sites. SIMATIC NET provides important additions to traditional Ethernet technology for rugged industrial environments: Network components for use in rugged industrial environments. Fast on-site cable preparation thanks to the FastConnect cabling system with RJ45 technology. Fail-safe networks thanks to highspeed redundancy. Constant monitoring of network components thanks to a simple but effective signalling concept. PROFInet-capable products on the Ethernet SIMATIC imap engineering tool, the configuration editor based on the PROFInet Standard, for the graphical configuration of communication links. SIMATIC WinAC PN PC-based control as software PLC. SIMATIC NET IE/PB Link, compact network interface between Industrial Ethernet and PROFIBUS. PROFInet-capable CP PN for interfacing the S7-300 to the Ethernet. PROFInet OPC server for accessing data in PROFInet devices from PC applications. Visualization via OPC All visualization products which represent OPC clients can be used, such as SIMATIC ProTool/Pro, SIMATIC WinCC, third-party HMI systems. CPU PN/DP with integrated Ethernet interface (available soon). SIMATIC S7-200 SIMATIC S7-300 SIMATIC S7-400 SIMATIC TDC SIMOTION C/P/D SIMATIC PC Field PG Power PG PC-based Automation MOBIC SIMATIC PCS 7 SIMATIC C7 PC Notebook WinAC PN WinAC Basis, WinAC RTX WinAC Slot 412/416 WinAC MP PC 20 Vision Sensor VS 72x

21 1) Integrated interface available soon 2) SIMOTION P 3) With Industrial Databridge 4) PG communication only Product PG/OPcommunication S7- communication S5-compatible communication PROFInet Standard Protocol OPC CP CP IT CP CP PN CP IT CPU PN/DP 1) IT S/R to socket S/R to socket IT+S/R to socket TCP/IP TCP/IP TCP/IP TCP/IP TCP/IP TCP/IP CP CP IT S/R to socket IT+S/R to socket ISO+TCP/IP ISO+TCP/IP CP 5100 TCP/IP Integr. interface TCP/IP 2) Integr. interface CP 1613 CP 1612/1512 CP 1515 DCOM IT+S/R to socket DCOM IT+S/R to socket DCOM IT+S/R to socket DCOM IT+S/R to socket TCP/IP ISO+TCP/IP ISO+TCP/IP TCP/IP CP 1512/1612 CP 1613/1512/1612 CP 1613/1612/1512 Integr. interface 3) 3) DCOM IT+S/R to socket DCOM IT+S/R to socket DCOM IT+S/R to socket ISO+TCP/IP ISO+TCP/IP ISO+TCP/IP TCP/IP ProTool Pro WinCC WinAC TCP/IP TCP/IP TCP/IP Integrated interface or Wireless via CP Internet Browser + JVM Thin Client TCP/IP CP 1613 CP ) 4) S/R to socket S/R to socket ISO+TCP/IP ISO+TCP/IP Integr. interface TCP/IP 21

22 Data communication Worldwide communication Today, cross-network communication and worldwide communication are based on TCP/IP. This Standard is used in both local Ethernet network and on the Internet or intranet, simplifying communication and system interfacing. Communication using information technology (Web, ) are becoming increasingly important in the automation world. Communications processors transmit event-controlled messages over IT communication pathways by to both local and global recipients. They are able to provide simple visualization using Web technology and file processing (FTP): CP IT for SIMATIC S7-200 CP IT for SIMATIC S7-300 CP IT for SIMATIC S7-400 Industrial Mobile Communication This term is used for the industrial mobile communication products for wireless communication from SIMATIC NET. Industrial Mobile Communication is based on worldwide networks, such as WLAN (to IEEE b), GSM or, in future, UMTS. Thanks to enormous growth in the diversity of information technology, Industrial Mobile Communication is being used with increasing frequency in the automation world, making global communication in automation environments possible while at the same time creating the possibility of problemfree links to the planning and office worlds through the following products: MOBIC Internet Pad for wireless access to intranet and Internet as well as Thin Client applications The CP 1515 communications processor and RLM Radio Link Modules for setting up a wireless IEEE b network and for linking mobile nodes to that network. Teleservice Progressive plant automation and increasingly extensive globalization of companies are requiring more and more frequent access to teleservice systems via stationary or radio networks. SIMATIC teleservice The MPI interface on SIMATIC S7/C7, SIMOTION automation systems and OPs is extended by means of the public telephone network. This requires nothing more than a TS adapter and a modem. The Teleservice engineering tool establishes a connection with the machine or plant, and has at its disposal the well-known functionality of STEP 7, Drive ES, SIMOTION SCOUT and the diagnostic tools. Teleservice functions just as though you were actually at the machine or in the plant. No additional PC/PG is required. TS 980 / TS-MOBIC teleservice Is used for telecontrol of a PC or PG integrated in the plant by way of Industrial Ethernet. In addition to the TS client, all software tools that are to be used must be installed on the PC or PG in question (e.g. diagnostic software such as STEP 7 or ProTool/Pro). Only the TS 980 software executes on the remote PC/PG. Telecontrol The SINAUT telecontrol system makes it possible to set up complex, widely distributed networks using narrow-band transmission media. This makes it possible to use not only private lines or wireless connections in communication projects, but also leased lines or public networks such as ISDN, GSM or the analog telephone network, and to combine them as needed. 22

23 Data communication Network performance and capacity Network performance The differences in the performance capabilities of multi-point interface, PROFIBUS and Industrial Ethernet depend on certain marginal conditions, such as the number of nodes or the length of the data frames. One important marginal condition is the required network access time, which is the length of time a node must wait before it can send a frame. The shorter the network access time, the more the networks differ in their performance. At 100 Mbit/s, Industrial Ethernet can send 150 times the number of frames that MPI can send in a given amount of time. New technologies, used in combination, can enhance Industrial Ethernet's performance by a factor of 50 or more. These technologies are: Fast Ethernet with 100 Mbit/s: Frames are transported much faster, and therefore reserve the bus for a much shorter period of time. Full Duplex excludes collisions; the data throughput increases enormously, since the usual retries are unnecessary. Between two stations, data can be sent and received at the same time. The data throughput over a Full Duplex Fast Ethernet connection thus increases to 200 Mbit/s. Switching enables parallel communication. Dividing a network into segments using a switch off-loads that network. Local data traffic in each segment is completely independent of the traffic in other segments, making it possible for several frames to be in transport at the same time. Frames (200 byte/sec) 1,000, ,000 10,000 1, Network/value throughout for 5 nodes 1 ms 10 ms The performance enhancement therefore stems from the fact that multiple frames are underway at the same time. Autosensing is the term used for network nodes (data terminals and network components) which can automatically detect the transmission rate of a signal (10 Mbit/s or 100 Mbit/s) and support autonegotiation (the configuration protocol for Fast Ethernet). 100 Mbit/s 10 Mbit/s 100 ms Max. network access time Industrial Ethernet with switching and full duplex Industrial Ethernet PROFIBUS with 1.5 Mbit/s MPI 23

24 Data communication Typical practice-related data The table contains empirical values whose purpose is to serve as recommendation for selecting the optimal network. MPI PROFIBUS Industrial Ethernet 1 Interfaceable systemes SIMATIC S7/C7 SIMATIC TDC SIMATIC PG/PC SIMATIC HMI SIMATIC WinAC SIMOTION SIMATIC S7/C7 SIMATIC PG/PC SIMATIC HMI SIMATIC WinAC SIMATIC TDC SIMATIC S7/C7 SIMATIC PG/PC SIMATIC HMI Workstation, computer SIMATIC WinAC SIMATIC PCS 7 SIMATIC TDC SIMOTION 2 Number of nodes Typical Maximum 2 to to to 100 Over Typical data length per frame 64 bytes 120 bytes 250 bytes 4 Network capacity Local network WAN Electrical: up to 100 m Electrical: up to 9.6 km Optical: up to 90 km Electrical: up to 1.5 km Optical: up to 200 km Worldwide with TCP/IP Wireless with Wireless LAN 5 Topology Line Line, tree, single-fiber ring, redundant ring, star Line, tree, redundant ring, star 6 Engineering e.g. bus parameters Default/settable default/settable No settings required 7 Available communication functions PG/OP communication Basis S7 communication S7 communication S5-compatible communication (SEND/RECEIVE) Standard communication PROFInet 5) 5) 5) 2), 3), 4), 5) 1), 5) 5) 4), 5) (IT, socket) 4) 2), 4), 5) 8 Use of communications processors 24 1) SIMATIC PCS 7: PG communication only 2) SIMATIC S7-300, SIMATIC WinAC PN, IE/PB Link 3) Interface to PROFInet, Ethernet via PROFInet proxy device 4) Not SIMOTION 5) Not SIMATIC TDC

25 1 Here is a list of automation systems which can be interfaced to the relevant networks and implement data communication. The decision as to whether to use multi-point interface (MPI), PROFIBUS or Industrial Ethernet for data communication depends mainly on requirements relating to network size, amount of data, number of nodes and network expandability. 2 The typical number of nodes cites empirical values from many applications. 3 A factor important to network performance is the amount of data per frame. The worse the network performance, the shorter the frames should be in order to prevent a single node from usurping the available performance capacity. If long frames, e.g. program blocks or data blocks, have to be transmitted, they are first segmented. 4 5 Electrically, local networks can be extended to the limits defined in the Standards. The use of optical components makes it possible to bridge longer distances without violating the Standards, but the The way the cables between the nodes are laid is referred to as topology. configuration rules regarding execution time must be observed. 6 7 Network operation requires that certain specifications (e.g. addresses) be made by the stations in the network. In Industrial Ethernet networks, all parameters except the station address are preset, enabling easy expansion. No bus parameters are required. Flexibility is attained through the use of the appropriate network components. A number of basic communication functions are available on all the networks for the purpose of uniformity. S5-compatible communication (SEND/RECEIVE) enables communication between SIMATIC S5 and SIMATIC S7 or a PC. By making appropriate settings (e.g. network speed, monitoring times), PROFIBUS can be adapted to the required network size, number of nodes, and time response. The settings themselves can be easily made using the available configuring tools. MPI has default settings for all parameters, but some of these can be changed. The PROFInet communication services are used for data interchange between PROFInet devices, and are configured graphically using the vendorindependent SIMATIC imap engineering tool. 8 In a system such as SIMATIC S7, for example, additional performance capabilities can be implemented through the use of auxiliary components. This is the reason why e.g. SIMATIC S5s, S7s and PCs can be interfaced to PROFIBUS and Industrial Ethernet using communications processors (CPs). 25

26 High-availability communication and redundancy Process or field communication Production plants are designed and calculated for around-the-clock shifts. When a plant fails, the results are cost-intensive downtimes, high re-start costs, and the loss of valuable materials. Redundant control systems such as the SIMATIC S7-H system protect against such failures. High-availability systems The S7-400H is a high-availability programmable controller. Handling, programming, configuring and communication are the same as for standard systems. Depending on the network topology, redundant communication links are created which become automatically available, without loss of data, in the event of a problem. The I/O are interfaced by means of redundant PROFIBUS DP lines. Redundant networks S7-REDCONNECT ensures problem-free communication between PC applications (such as WinCC ) and the S7-400H over redundant networks. PC applications which already use S7 communication (e.g. over the OPC interface) may continue to be used without any modifications. Industrial Ethernet networks and PROFIBUS networks can be set up as redundant networks with OSM, ESM and OLM. Thanks to ring topology, the network continues to function when one transmission path fails; failure of a network component affects only the nodes in that segment. PC with 2 x CP 1613 and S7-REDCONNECT S7-400H S7-400H H-CPU in Single mode S7-300 H system PC H system PC OSM S7-400 S7-200 Host system 26

27 Fail-safe communication S7-300F with standard I/O and F I/O ET 200M with standard I/O Operator Panel The "PROFIsafe" protocol profile, developed for PROFIBUS DP, is used for communication between a fail-safe S7 CPU and the failsafe signal module. PROFIsafe features PROFIsafe was the first communication standard based on IEC to allow standard communication and fail-safe communication on the same bus. With SIL 3 (Safety Integrity Level 3), Category 4 (EN 954-1), it fulfills the highest demands for the production and process industries, and with the PA version (IEC ), PROFIBUS DP expands the integrated distributed automation into the process world. PROFIsafe thus supports the different communication requirements of both the production and process industries. ET 200M with F I/O ET 200S with standard I/O, F I/O and F motor starter Laser scanner Light curtain PROFIsafe functionality PROFIsafe counters the possibility of transmission errors due to problems such as address falsification, loss, delay, etc. with four different measures: Sequential numbering of the PROFIsafe data Time monitoring "Password"-based authenticity monitoring and An optimized version of CRC. Using slave nodes, fail-safe encoder signals from a PROFIBUS station are transmitted to the fail-safe CPU. When these encoder signals have been logically gated, an appropriate output signal is transmitted to a fail-safe PROFIBUS slave. Single-channel transmission is used, and there is no redundant transmission path. Fail-safe data Standard data Fail-safe data Standard data PROFIsafelayer Standard PROFIBUS DP protocol Standard PROFIBUS DP protocol Black channel= standard PROFIBUS The fail-safe SIMATIC components are part of Safety Integrated, the Siemens safety program based on SIGUARD, SIMATIC and SINUMERIK / SIMODRIVE products. The PROFIsafe protocol profile is used for failsafe communication on the PROFIBUS. 27

28 Network interfaces Network interfaces between Industrial Ethernet, PROFIBUS, AS-Interface and EIB are implemented through links, programmable controllers (PLCs) or PCs. In the latter two cases, integrated interfaces and communications processors (CPs) can be used to interface networks. When a link is used to implement a network interface, the data are forwarded without changes of any kind from one network to the other. The DP/EIB Link, the DP/AS-Interface Link or the IE/PB Link can be used as network interface between EIB, AS-i, PROFIBUS and Industrial Ethernet networks. When PLCs such as SIMATIC S7-200, S7-300 or S7-400 are used, data are exchanged between the networks via communications processors or integrated interfaces. The data are preprocessed using a controller (PLC or PC-based) before being forwarded to the other network. PROFInet network interface with Proxy functionality S7-200 IE/PB Link (Proxy) PC with PN OPC server PC with SIMATIC WinAC (Proxy) SIMOTION P S7-400 S7-300 SIMOTION C S7-300 PROFIBUS segments can be interfaced to Industrial Ethernet by means of devices with a representative function, so-called PROFInet proxies. This can be done using a solution involving SIMATIC WinAC PN or via a SIMATIC NET IE/PB Link. This allows all standard PROFIBUS slaves to be used without any changes for Component based Automation. S7-300 SIMATIC C7 S7-200 PC DP/AS-Interface Link 20E PG Intelligent devices on the PROFIBUS SIMATIC ET 200X and ET 200S with their own CPUs as intelligent slaves Compact S7-300 CPUs as intelligent slaves Standard slaves Master interface modules for ET 200X (integrated) and ET 200S (auxiliary module). S7-300 DP/EIB Link 28

29 Transmission media AS-Interface One feature of AS-Interface technology is the use of a common two-wire cable for data transmission and for the distribution of auxiliary power to the sensors/actuators. For this purpose, an AS-Interface power supply unit is used which fulfills the requirements of the AS-Interface transmission method. The mechanically coded and therefore non-interchangeable AS-Interface profiled cable is available for wiring purposes. The repeater/extender is used to extend an AS-Interface segment. PROFIBUS For PROFIBUS, different transmission media are available for a wide variety of applications. Electrical data transmission The standard solution for this form of data transmission is a shielded, twisted pair cable with circular cross section. These cables are available with PE or PUR sheath, in a halogen-free version, designed for underground installation or as dragline, or in a special version for use in hazardous areas. The PROFIBUS FastConnect system (FC) allows the PROFIBUS copper cables to be prepared quickly and easily on site. Optical data transmission This solution is based on fiber-optics. The FO cables are available with glass or plastic fibers for indoor or outdoor use, in a dragline version, and in a halogenfree version. Wireless data transmission This form of transmission is based on ILMs (Infrared Link Modules) with a reach of 15 meters. Industrial Ethernet Electrical data transmission FC twisted pair The FC twisted pair cabling system is ideal for structured cabling in the plant itself. The FastConnect(FC) connection system for Industrial Ethernet not only "industrializes" the structured cabling system from the office area for use in the plant. FastConnect cables can also be prepared extremely quickly right on site, thus making standard RJ45 cabling technology available in an industry-standard version suitable for structured cabling (patch, patchfield, interior, outlet, service cabling). Thanks to integrated insulation displacement contacts (such as ELS TP40), a connection is possible between two nodes up to 100 meters apart using FC TP cables without additional patching. If electrical isolation and EMC protection are the primary concerns, however, then optical data transmission would be the right solution. Optical data transmission Glass fibers The optimum technology, even for setting up redundant ring networks. Futuristic fiber-optics cables, which are completely impervious to electromagnetic interference, are used as transmission medium. These cables are also completely free from potential dependencies. The advantage: absolutely no need to invest in expensive equipotential bonding. Wireless data transmission To allow wireless data transmission, a local radio network for wireless communication can be set up with just an Access Point, such as RLM, and a radio card, e.g. the CP These transmission media can also be used in any combination. 29

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