Networking PLCs with Profibus (and TCP/IP)

Introduction
✓An industrial control network is a system of
interconnected equipment used to monitor and control
physical equipment in industrial environments.
✓ The role of the communication is exchanging of
connection with a common computer in order to
create and transmit the program to PLC and to
transmit data to superior levels for operator’s control of
technology
✓Industrial networks cover mainly production control,
so it is very important to ensure high reliability,
deterministic mode of communication and high power.
✓These networks differ quite significantly from
traditional enterprise networks due to the specific
requirements of their operation.
 Introduction cont..
✓ Typical differences between industrial and conventional networks
Industrial Conventional
Primary Function Control of physical Data processing and
equipment transfer
Applicable Domain Manufacturing, processing Corporate and home
and utility distribution environments
Hierarchy Deep, functionally Shallow, integrated
separated hierarchies with hierarchies with uniform
many protocol and physical
protocols and physical standard utilization
standards
Failure Severity High Low
Reliability Required High Moderate
Round Trip Times 250 μs - 10 ms 50+ms

Data Composition Small packets of periodic Large, aperiodic packets

and aperiodic traffic
Temporal Consistency Required Not Required
General Network Hierarchies
AS-I Networking
✓AS- stands for actuator/sensor interface.
✓It is a connection system for the lowest process level(i/o
level) in process automation
✓ All as-I interface product compile with
Sensor /Actuator level

AS-I device
 AS-I Networking cont…
✓ AS-Interface is a system that requires four basic
components:
1. Exactly one network master, in most cases in the form
of a Gateway to a higher level industrial network or a
PLC backplane card,
2. A number of network slaves, in most cases input and
output modules,
3. Exactly one power supply used to power the network
slaves and enabling communication with the network
master, and
4. The wiring infrastructure, in most case accomplished
using the yellow flat cable. Connecting plugs –
Vampires.
 AS-I Networking cont…
AS-I Master/ Slave system

AS-I Master

AS-I Slave
Organization of access procedure AS-I Networking cont…

As-interface message=As-master call + Slave response +

delay

1 bit=6μs, There for the total duration of AS-interface

is 152μs +2/-1μs, i.e more than 6500 As-interface
message can be exchanged in one second.
AS-interface power supply AS-I Networking cont…
▪ Data and power are transmitted over the same line
▪ Has special design

▪ Four function are performed by As-I power supply

Provide the network with a nominal voltage of
30VDC
Safe isolation
Data decoupling
Network balancing
 AS-I Networking cont…
AS-I Networking Technology
Topology Open tree
Bus medium Unshielded two-wire cable for data and power
Cable length 100m,200m with extender 300m with repeater
Number of 31(62)per As-I line
slave
Number of i/o 124(248)input +124 output
Access Master-slave , single master operation
Addressing Unique address in the slave, addressing via
master or addressing device
Cycle Time max.5(10)ms
Error protection identification and repetition of faulty message
frames
Data rate 156-166kbit/s
Signal level power supply 21.5-31.6VDC, Data signal 3-8VSS
 AS-I Networking cont…
As-I master configuration
✓ Switch PLC to stop mode (disconnect master from
profibuse
✓ Set profibus address
✓ Store and run
✓ Diagnostic comminication
✓ Start PLC
Configuration conflict
✓ Failure of station/defect
✓ Slave with network 0
✓ two slave with the same address on the network
✓ Slave with wrong address
✓ Conventional station on the bus
 AS-I Networking cont…
Programming unit
 AS-I Networking cont…
Advantage of AS-I networking
✓ Easy connection(piercing technology)
✓ Free from electromagnetic interface (EMF)
✓ Small , cost effective slave interfacing
✓ Easy installation work for programming including
modification and extension