Best Practices for Troubleshooting Industrial Networks ProfinetEthernet Profibus

Best Practices for Troubleshooting Industrial Networks Profinet/Ethernet & Profibus March 2018 Jim Ralston

Topics • Softing Introduction & Solutions • Industrial Network Trends • Risks to Operation: Poor/Degrading Cabling Infrastructure • PROFIBUS Commissioning & Troubleshooting – Best practices for Profibus • Ethernet/PROFINET Certification, Qualification & Troubleshooting – Best practices for Ethernet • Advanced Network Monitoring Tools (Profinet/Profibus) – Preventive maintenance • Questions? © 2016 Softing Inc. All Rights Reserved.

Softing Inc. § Global Headquarters in Munich, Germany § Founded 1979, Publicly traded since 2000 § Siemens Industrial Automation Technology Partner § Rockwell Automation Global Encompass partner § North America headquarters in Knoxville, TN Copyright © 2017 Softing Industrial. All rights reserved. 3

Softing Worldwide Softing AG Munich, Germany Softing Inc. Boston, MA Sales/Service Knoxville, TN Headquarters

Solutions for Industrial Automation & Networking Test & Monitor Networks Qualify/Certify Cables Move Data

Proper Cabling Practices Reduce Downtime • According to an ISA. org online article, industrial network failures accounted for 35% of total failures in plant automation. • 80% + Industrial Network failures are due to cable problems! • Physical deterioration, electrical failure, or poor installation and maintenance practices can all lead to unreliable network performance. − loss of critical data − system downtime − even catastrophic failure © 2016 Softing Inc. All Rights Reserved.

The Network Speed Revolution Yesterday Network Data Rate (kbit) Today Serial 1. 2 PROFIBUS 4. 8 9. 6 31. 25 12, 000 Emerging Tomorrow Profinet (10/100 BT) Profinet (10 GBT) 10, 000 to 100, 000 1, 000, 000 10, 000 0. 0012 0. 0048 . 0096 . 03 12 Data Rate (mbps) © 2016 Softing Inc. All Rights Reserved. 55 1000

Industrial Network Monitoring & Testing Tools • Cable Certification/Qualification during cable installation (before startup) – Test to ensure cabling meets TIA category/Profibus standards & speed requirements • Network Commissioning during start-up – Detect problems before production begins – Document network devices & conditions • Network Monitoring during operation (preventative & live troubleshooting) • Cable troubleshooting – identify problems for quick repair © 2016 Softing Inc. All Rights Reserved.

Best Practices for Profibus Testing • Commissioning & Troubleshooting with the PROFIBUS Tester 5

Profibus Testing Introduction Most problems in PROFIBUS networks are caused by § Improper segment termination (missing, unpowered or excessive) § Segments that are too long or lines that are too short § Excessive number of devices in a segment § Spur (drop, branch) lines § Sharp cable bends § Wrong type of cable § Improper wiring, grounding and/or shielding § Damaged cable (breaks, shorts, corrosion) § Cable routing in environments subject to strong electromagnetic interference § Wrong configuration of PROFIBUS parameters, GSD files, etc. © 2016 Softing Inc. All Rights Reserved.

PROFIBUS Tester 5 is a powerful tool capable of performing comprehensive testing of PROFIBUS DP segments. One tool, many functions: § Signal tester § Cable tester § Storage oscilloscope § Protocol analyzer § Frame recorder § Trend recorder § Master simulator § PROFIBUS PA testing (w/optional adapter) Portable Battery-Powered with 3. 5” Graphical Display © 2016 Softing Inc. All Rights Reserved.

Operation Modes Two modes of operation: § Stand-alone mode § PC mode © 2016

Measurement Locations © 2016 Softing Inc. All Rights Reserved.

Troubleshooting with the PROFIBUS Tester 5 Quick determination of Bus Communications and Bus Physics Health First indication: There is a problem ! Communication is okay => Traffic Light is green Signal quality is critical: Some nodes show bad signal quality => Traffic Light is yellow => Further Analysis required © 2016 Softing Inc. All Rights Reserved.

Troubleshooting with the PROFIBUS Tester 5 • • Quick determination of Signal Quality at

Troubleshooting with the PROFIBUS Tester 5 • • Oscilloscope waveform & Signal/Noise measurement Click

Typical Issues in a PROFIBUS Network: Sample Network Take measurements from both ends: -

Typical Issues in a PROFIBUS Network Case 1: High Line Resistance Measurements from left side (master 2) Results: Test results on the left end: - Good quality values for stations 2 – 34 - Bad quality values for stations 51 & 71 Measurements from right side (slave 71) Test results on the right end: - Bad quality values for stations 2 – 34 - Good quality values for stations 51 & 71 Reversal of Q-Levels! © 2016 Softing Inc. All Rights Reserved.

Typical Issues in a PROFIBUS Network Case 1: High Line Resistance Interpretation: The test result from the right side is almost a mirror image of the one from the left side. This is a clear indication of a high resistance in the network (corrosion, bent cables, long cables, etc. ) In this case the problem is located between slaves 34 and 51. 5 V R R Master 2 7 R © 2016 Softing Inc. All Rights Reserved. 9 23 34 51 71 5 V R R R

Typical Issues in a PROFIBUS Network Case 2: Missing Terminator Quality is bad seen from one end only: 5 V R R R Master 2 7 9 23 34 51 71 5 V R R R Take additional measurements at other locations to get a better picture of what is happening… © 2016 Softing Inc. All Rights Reserved.

Typical Issues in a PROFIBUS Network Case 2: Missing Terminator Results: The quality from one end declines gradually as you move to the other end: Master 2 © 2016 Softing Inc. All Rights Reserved. Slave 7 Slave 23 Slave 71

Typical Issues in a PROFIBUS Network Case 2: Missing Terminator Interpretation: The problem is caused by signal reflections in the segment, due to a missing terminator at slave 71. This type of problem is normally generated at the test location that shows most stations with bad signal quality levels. You can see the reflections in the oscilloscope view for “Master 2”, seen from the “Slave 71” test point. 5 V Master R R R © 2016 Softing Inc. All Rights Reserved. 2 7 9 23 34 51 71 5 V R R R

Typical Issues in a PROFIBUS Network Case 3: Wire Break Results: Test result from the left end: stations 53 and 71 are timing out Test result from the right end: all stations are timing out © 2016 Softing Inc. All Rights Reserved.

Typical Issues in a PROFIBUS Network Case 3: Wire Break Interpretation: Devices 51 and 71 can’t be seen from the left end, and nothing can be seen from the right end. These results indicate that the problem must be a break of one or both lines between stations 34 and 51. 5 V R Master 2 7 9 23 34 51 71 5 V R R R © 2016 Softing Inc. All Rights Reserved.

Typical Issues in a PROFIBUS Network Case 4: Low RS-485 Driver Voltage Results: Measurements from any location are almost the same, showing bad quality on one station. Interpretation: The voltage level of the RS-485 driver of station 23 is too low. Test location: left end side, Master 2 Test location: Slave 23 Test location: right end side, Slave 123 © 2016 Softing Inc. All Rights Reserved.

Troubleshooting with the PROFIBUS Tester 5 • Troubleshoot Bus Communication problems © 2016 Softing

Troubleshooting with the PROFIBUS Tester 5 • Quick view of Station Statistics – identify

Troubleshooting with the PROFIBUS Tester 5 • Display Diagnostic Messages as Text not Hex Below are examples of diagnostic messages in plain text from a WAGO slave and from a Siemens Diagnose Repeater. Reading the log gives a simple indication of the problem. Diagnosis View © 2016 Softing Inc. All Rights Reserved.

PROFIBUS Diagnostics Suite: Frame Recording • Complete frame & data recording – with trigger

PROFIBUS Diagnostics Suite: Commissioning Report © 2016 Softing Inc. All Rights Reserved.

Best Practices for Industrial Ethernet Testing Ethernet is a Star Topology using Switches (or

Why is Complete Cable Testing Important? ……. . • As network bandwidth (data rate) increases…. . − Carrier frequency increases − Impedance (attenuation) increases − Signal/noise ratios tighten − Crosstalk between pairs increase • High frequency signals traveling over copper − Poor wiring = poor network performance (DOWN TIME) − DC Continuity (zero baud) is not a complete test! © 2016 Softing Inc. All Rights Reserved. It’s all about the pairing!

Best Practices for Industrial Ethernet Testing Most problems in Profinet (Ethernet) networks are caused by: § Poor cable/connector quality § Poorly terminated Ethernet plugs/outlets (lack of installation training) § Worn Ethernet RJ 45 plugs – frequent insertions & machine vibration –Plugs instead of outlets/jacks being used on long runs § Poorly installed cable runs – cable routing, bend radius, tie wraps. . § Cable routing in environments subject to strong interference § Lack of, or improper sheidling § Network speed exceeds cable rated category § Network/Device configuration issues © 2016 Softing Inc. All Rights Reserved.

Test Levels & Types • Verifying − Basic test of conductivity (DC) − Wire map check • Qualifying − Determining Ethernet Performance (bit error rate) − Troubleshooting (distance to wiring fault) • Certifying − Standard acceptance test for networks (cert report) − Testing wire map, length & crosstalk noise levels − Location to fault/troubleshooting (wiring & pairing issues) • Active Monitoring/Alarming − − Real-time network monitoring Preventative alarming Inventory/health Packet level analysis Cable testers have a range of capabilities: Our focus will be on Certification and Qualification

What Certification is All About • Ensuring that the cable infrastructure MEETS the CAT standards − • • The network DEPENDS on Layer One! Reducing start-up time Reducing “finger pointing” when network problems arise − 80+% of industrial network problems are cabling oriented! • • A REQUIREMENT for the manufacturers warranty (Belden, Panduit, etc. ) Certification is PART of the TIA 568 standard Certification is the NORM for commercial installations – why not industrial? Certifiers also make excellent troubleshooting tools – reduce downtime Cable vendors will warranty their wiring and connections for periods up to 25 years if installations are Certified with approved equipment © 2016 Softing Inc. All Rights Reserved.

What Certification is All About • TIA 568 defines Certification currently for commercial Structured Network Cable systems: • • Permanent Link Channel Test 10 m max The Channel = Permanent Link plus patch cords A and B – What is most common in Industrial? © 2016 Softing Inc. All Rights Reserved. 10 m max

What Certification is All About • TIA 568 defines Certification currently for commercial Structured Network Cable systems: • • Permanent Link Channel Test 10 m max The Channel = Permanent Link plus patch cords A and B – What is most common in Industrial? • 100 meter “home run”! © 2016 Softing Inc. All Rights Reserved. 10 m max

What is required to Certify a cable? 190, 000 measurements needed to Certify one Cat 6 A cable! Measurement Description Dynamic Wiremap Accurately detects Open/Short and “Distance to Fault” from both ends of the cable Loop Resistance The resistance between the two conductors of a twisted pair which is looped back at the far end Cable Length The length of the cable under test Near End Crosstalk (NEXT) The interference at the near end of a pair caused by signal on another pair Power. Sum NEXT The sum of the individual NEXT effects on each pair by the other three pairs Insertion Loss (Attenuation) The decrease in signal strength from one end of the cable to the other ACR-N The difference between insertion loss and near-end crosstalk (NEXT) Power. Sum ACR-N The sum of the individual ACR-N effects on each pair by the other three pairs Return Loss (RL) Signal loss caused by structural imperfections in the cable ACR-F (ELFEXT) The interference at the far end of a pair caused by signal on another pair, with the insertion loss subtracted Power. Sum ACR-F The sum of the individual ACR-F effects on each pair by the other three pairs Propagation Delay Time it takes for a signal to travel from one end of a cable to the other Delay Skew The difference in time between the fastest and slowest pairs within a cable © 2015 Softing Inc. All Rights Reserved.

Cabling standards and frequency bandwidth

Wire. Xpert 4500 Advanced Cable Certifier • Industrial Ethernet: Supports RJ 45 & M 12 D-code/X-code testing • CAT 5 e, CAT 6 A & new CAT 8 support • Optional MM & SM fiber testing/certification • Fast: Auto-Test in less than 9 seconds • Endorsed: By leading cable manufacturers • Accurate: Exceeds ISO level IV; V and TIA level IIIe • Measures cable length & distance to fault • x. Port software included for documentation © 2016 Softing Inc. All Rights Reserved.

Wire. Xpert 4500 Advanced Cable Certifier • Industrial Ethernet: Supports RJ 45 & M 12 D-code/X-code testing • CAT 5 e, CAT 6 A & new CAT 8 support • Optional MM & SM fiber testing/certification • Fast: Auto-Test in less than 9 seconds • Endorsed: By leading cable manufacturers • Accurate: Exceeds ISO level IV; V and TIA level IIIe • Measures cable length • x. Port software included for documentation © 2016 Softing Inc. All Rights Reserved.

Wire. Xpert 4500 Advanced Cable Certifier • Excellent troubleshooting tool with TDR – – – TDR = Time Domain Reflectometer – like RADAR Reports cable length Wiring issues Distance to fault (opens/shorts) Distance to attenuation problems Distance to crosstalk/noise (damaged pairs) © 2015 Softing Inc. All Rights Reserved.

Wire. Xpert 4500 Advanced Cable Certifier • Excellent troubleshooting tool – – – Reports cable length (copper TDR) Wiring issues Distance to fault (opens/shorts) Distance to attenuation problems Distance to crosstalk/noise (damaged pairs) © 2015 Softing Inc. All Rights Reserved.

x. Port Software • Included with Wire. Xpert – Not needed for testing/set-up –

What Does Certification Measure?

Example Cable Certification Report

Wire. Xpert 4500 Fiber Optic Certifier • Supports Fiber Types (head options): • Multimode (using Encircled Flux standard) • Single Mode • MPO (12 fiber data center) • Performs Optical Length & Loss (Tier 1 certification) • Not an OTDR

Wire. Xpert 4500 Advanced Cable Certifier Kit

Fiber. Xpert OTDR - New! Optical Time Domain Reflectometer • Smart. Link and OTDR trace analysis • Automatic Pass/Fail detection • Automatic Macro bend recognition • Light Source and Power Meter function • Lightweight • Unlimited memory using a USB stick • 8 -hour battery Smart. Link and OTDR trace analysis

Fiber. Xpert OTDR Smart. Link Display Mode – quick summary • Zone 1: Graphical overview with icons representing events • Zone 2: Results for each wavelength (color coded) • Zone 3: Alarms table (if any)

Net. Xpert Gigabit Cable Qualifier and Network Diagnostic Tool • Qualifies data cabling for IEEE 802. 3 compliance at transmission rates of up to 1 Gbit/s (BERT) • Determines signal-to-noise ratio (SNR) • Measures delay skew • Performs full TDR for pair length and distance to fault measurements • Full-color wire map shows opens, shorts, mis-wires, and split pairs • Results can be saved in the unit and standards-based reports generated Does NOT certify – but performs some of the same tests

Net. Xpert – Connection Tests • Passive Cable Test – – – – Graphical Wiremap display Measures and displays length Improperly terminated cables are clearly displayed Detects Length to Opens and Shorts Displays Crossings, Swaps and Split Pairs Measures Signal/Noise Ratio Bit Error Rate Test (BERT) up to 1 Gbps © 2016 Softing Inc. All Rights Reserved.

Gigabit Cable Qualifier and Network Diagnostic Tool • Qualifies data cabling for IEEE 802. 3 compliance at transmission rates of up to 1 Gbit/s (BERT) • Determines signal-to-noise ratio (SNR) • Measures delay skew • Performs full TDR for pair length and distance to fault measurements • Full-color wire map shows opens, shorts, miswires, and split pairs • Results can be saved in the unit and standardsbased reports generated © 2016 Softing Inc. All Rights Reserved.

Net. Xpert – Active Testing and Troubleshooting • Active Network Tests and Diagnosis – Active Port – Link Capability & status – Po. E/Po. E+ – Detects voltage and performs load test for voltage drop – – – – Network scan (list and duplicate address alarm) VLAN Discovery Ping Table Link Light flashing DHCP Client Discovers CDP and LLDP Protocols Traceroute • Test results stored in PDF/CSV files © 2016 Softing Inc. All Rights Reserved. Net. Xpert Test Results

Net. Xpert Products Product Description Net. Xpert 1400 network/cabling qualifier; IEEE 802. 4 testing up to 1 Gbit/s; Tests ethernet, coax, audio; security cables; w report sw Net. Xpert RJ 45 to M 12 cable 1 meter, RJ 45 to M 12 D-Code © 2016 Softing Inc. All Rights Reserved.

TH Scope and TH Link Overview • TH Scope with TH Link(s) are intended to inform users of network health in an easy-tounderstand manner • TH Link modules connect directly to networks and their built in webservers provide basic network info • TH Scope is a software package that enables additional monitoring beyond the built-in webservers Industrial Ethernet © 2016 Softing Inc. All Rights Reserved.

TH Link - Network Monitoring Solution Network Monitoring & Alarming using Web Browser • • • Early network error detection and correction Network device inventory list Logs network failures/errors (recorded to SD with time stamp) Email & Relay Alarm in case of problem or fault No “IT Expertise” required © 2016 Softing Inc. All Rights Reserved.

TH Link - Network Monitoring Solution TH Link Network Inventory © 2016 Softing Inc.

TH Link - Network Monitoring Solution TH Link Diagnostic List – Timestamped Events ©

TH Link Connection Options Separate subnet with no “routing/switching” between Ports Industrial Ethernet model also supports Modbus TCP & PROFINET devices Note 1: There must be no firewall between the TH LINK and the Ether. Net/IP devices. Note 2: The TH LINK does not provide any switch or router functionality. © 2016 Softing Inc. All Rights Reserved.

TH Scope Network Monitoring Advanced Diagnostics with TH SCOPE (optional) Additional Features Trend Topology - PROFINET © 2016 Softing Inc. All Rights Reserved. • • • Trend view (back 30 days) Topology diagram Export all reports to Excel Reference report for start-up & comparison OPC server for HMI/Alarm integration SNMP Agent for IT management tools

TH Scope Network Monitoring & Analytics Advanced Diagnostics with TH SCOPE Software (optional) PC-Software for monitoring and maintaining industrial networks Inventor y • Advanced analytics (trend view, reference comparison, data export, printing) Visualizes collected data from multiple TH LINK gateways • Embed into existing applications (OPC Server for HMI, SNMP Agent, web link) • Cross-protocol information analysis, PROFINET, standard Ethernet TCP/IP, Modbus TCP, Ethernet/IP • Reference network comparison report © 2016 Softing Inc. All Rights Reserved.

TH Link & TH Scope Comparison Chart Feature TH LINK Device TH SCOPE Software Network list & Device List + + Network and device status + + Timestamped Event Log (SD) + + Network & Error Statistics + + Device Inventory + + Email alarms + + Topology (list) + + Topology (graphical) – Profinet Only - + Data export (Excel) - + Report Creation (Print & PDF) - + Reference Comparison (PDF) - + Trend Analysis - + OPC Server DA - + SNMP Agent - + © 2016 Softing Inc. All Rights Reserved.

TH LINK PROFIBUS § Ethernet-PROFIBUS gateway § Passive listener to PROFIBUS DP (requires coupler for PA) § Acyclic master for Asset Management applications § Configurable threshold monitoring for telegram repeats (gradual deterioration, sudden effects) § Automatic error detection (Email alerts) enable early reaction before significant damage happens Copyright © 2016 Softing Industrial. All rights reserved. 70

TH Scope & TH Link Products • Models & Options Part Number Product Description GDA-JA-003034 TH LINK PROFINET Module for Continuous Monitoring of PROFINET Networks GDA-JY-003037 TH LINK Industrial Ethernet Module for Continuous and Simultaneous Monitoring of PROFINET, Ether. Net/IP and Modbus TCP Networks. Also Supports Standard Ethernet TCP/IP Diagnostics GEA-JN-003006 TH Link Profibus Module for Continuous Monitoring of PROFIBUS Networks LRA-JY-003024 TH SCOPE Software for Accessing and Diagnosis of PROFIBUS, PROFINET, Ether. Net/IP and Modbus TCP Networks Requires TH LINK Component Within Appropriate Network © 2016 Softing Inc. All Rights Reserved.

Resources • Web – Softing Industrial US website: – To place an order – Service Request • Phone & FAX – In the US: 800 -625 -8678 – International: +1 -865 -251 -5252 – FAX: +1 -865 -579 -4740 • Address Softing Inc. 7209 Chapman Hwy Knoxville, TN 37920 Jim Ralston 724 -554 -8498 Jim. Ralston@softing. us © 2016 Softing Inc. All Rights Reserved. http: //www. softing. us/sia

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