COMMUNICATION PROTOCOLS

What is Protocol?

A set of rules and regulations that allow two electronic devices to connect to
exchange the data with one and another.

Types of Electronic Communication Protocols:

There are two types of communication protocols which are classified below:
1. Inter System Protocol
2. Intra System Protocol

1. Inter System Protocol: The inter system protocol using to communicate the two different
devices. Like communication between computer to PLC. The communication is done through
a inter bus system.

2. Intra System Protocol: The Intra system protocol is used to communicate the two devices
within the circuit board.

Here we are going to see widely used industrial automation protocols and its pros and cons.
Below I have name the protocols,
1. CC-Link Industrial Networks
2. ControlNet
3. DeviceNet
4. EtherCAT
5. EtherNet/IP
6. FOUNDATION Fieldbus
7. HART Protocol
8. MECHATROLINK
9. Modbus
10. Profibus
11. PROFINET
1. CC-Link Industrial Networks

CC-Link is an open-architecture network that was originally developed by the

Mitsubishi Electric Corporation in 1997. In 2000 the non-profit organization CLPA (CC-Link
Partner Association) was formed to manage and oversee the network technology and support
manufacturer members.
CC-Link is open industrial network that enables devices from numerous
manufacturers to communicate.
Technical specification of CC-Link:

The maximum number of occupied

4 stations
stations

Maximum Number of Devices per

64 Devices
network

10M / 5M / 2.5M / 625k /

Communication speed
156kbps
Communication system Broadcast Polling system
Communication medium Shielded twisted 3-Wire
Synchronization system Frame synchronization system
Encoding system NRZI

Bus format (EIA RS485

Transmission path format
conformance)

Transmission format HDLC conformance

Error control system CRC (X16+X12+X5+1)

Other user features include:

High immunity to electromagnetic interference (EMI)

Standby network master assumes network control if the primary master goes
off-line
Bypasses faulty network devices without disrupting network traffic
Hot swapping of master and slave devices
Allows automation controllers to be programmed and monitored over the
network
Simple communication programming
2. ControlNet

ControlNet is an open industrial network protocol for industrial automation

applications, also known as a Fieldbus. ControlNet was earlier supported by ControlNet
International, but in 2008 support and management of ControlNet was transferred to ODVA,
which now manages all protocols in the Common Industrial Protocol family.

ControlNet is a serial communication system for communication between devices that

wish to exchange time-critical application information in a deterministic and predictable
manner. ControlNet is a member of a family of networks that implements the Common
Industrial Protocol (CIP) at its upper layers. ControlNet, which adapts CIP to Concurrent
Time Domain, Multiple Access (CTDMA) Technology. Why adapt CIP to CTDMA?
CTDMA allows for users to achieve deterministic, high-speed transport of I/O and peer-to-
peer interlocks in applications that are time-critical.

Technical Features:
High-speed deterministic network used for the transmission of time-critical
application information
Real-time control and messaging services for peer-to-peer communication
Multicast of inputs
Multicast of peer-to-peer data
Allow users to graphically view and configure the entire network
Distances of 30 km or more using repeaters (star, tree, or bus)
Several cable options—including fiber optic for use in a wide range of applications
and environments

3. DeviceNet

DeviceNet is a network system used in the automation industry to interconnect control

devices for data exchange. It utilizes the Common Industrial Protocol over a Controller Area
Network media layer and defines an application layer to cover a range of device profiles.

It is an application layer protocol on top of the CAN (Controller Area Network)

technology, developed by Bosch. DeviceNet adapts the technology
from the Common Industrial Protocol and takes advantage of CAN, making it low-cost and
robust compared to the traditional RS-485 based protocols.

Technical Features:

Network in addition to the signal, but also including power, self-powered

support network function
Allows three bit rates: 125 Kbit / s, 250 Kbit / s and 500 Kbit / s, the main trunk
under different bit rates (trunk) is inversely proportional to the length and bitrate
Flat cable network can be used
Single network can have up to 64 nodes
Duplicate node address detection function
Supports master-slave and end-to-end (peer-to-peer) communication architecture
Multiple network allows a single master function
Can be used in high-noise environments

4. EtherCAT

EtherCAT - Ethernet for Control Automation Technology is an Ethernet-based

fieldbus system, invented by Beckhoff Automation. The protocol is standardized in IEC
61158 and is suitable for both hard and soft real-time requirements in automation technology.
The goal during development of EtherCAT was to apply Ethernet for automation applications
requiring short data update times (also called cycle times; ≤ 100 µs) with low communication
jitter (for precise synchronization purposes; ≤ 1 µs) and reduced hardware costs.

The EtherCAT Device Protocol functional principle is an important differentiator to

other Ethernet solutions: with EtherCAT, the Ethernet packet is no longer first received, then
interpreted and copied as process data at every connection. Instead, the Ethernet frame is
processed on the fly the EtherCAT Slave Controller chip in each slave node reads the data
addressed to it, while the frame is forwarded to the next device. Similarly, input data is
inserted while the frame passes through. The frames are hardly delayed at all. The frame sent
by the master is passed segment (or branch). The last device detects no additional devices
connected to the downstream port and therefore sends the frame back to the master.
Technical Features:

As made clear through the publishing of the IEEE 1588 Precision Time Protocol
standard, synchronization has gained importance in the Industrial Networking
industry. Synchronization is another advantage of EtherCAT systems.
The “processing on the fly” principle of EtherCAT has another advantage in
addition to speed. EtherCAT networks can be configured in many types of
topology.
High Speed.

5. EtherNet/IP

EtherNet/IP was introduced in 2001 and today is the most developed, proven and
complete industrial Ethernet network solution available for manufacturing and process
automation. EtherNet/IP is a member of a family of networks that implements the Common
Industrial Protocol (CIP) at its upper layers.
EtherNet/IP, like other CIP Networks, follows the Open Systems Interconnection
(OSI) model, which defines a framework for implementing network protocols in seven
layers: physical, data link, network, transport, session, presentation and application.
Networks that follow this model define a complete suite of network functionality from the
physical implementation through the application or user interface layer. As with all CIP
Networks, EtherNet/IP implements CIP at the Session layer and above and adapts CIP to the
specific EtherNet/IP technology at the Transport layer and below.
Technical Features:
Complete producer-consumer services let you simultaneously and seamlessly control,
configure and collect data from intelligent devices over a single network or use a
single network as a backbone for multiple distributed CIP Networks
 Compliance with IEEE Ethernet standards provides users with a choice of network
interface speeds — e.g., 10, 100 Mbps 1 Gbps and beyond
Options for industrially rated devices incorporating IP67-rated connectors (RJ45 or
M12) with module and network status
With the optional QuickConnect feature, EtherNet/IP minimizes power-up delays for
applications where devices must connect and be ready to communicate with minimal
delay
Support for functional safety with CIP Safety implemented in devices
Synchronization of clocks across a system of interconnected devices using CIP Sync
Support of high-speed motion control applications with CIP Motion

6. FOUNDATION Fieldbus
FOUNDATION Fieldbus is an all-digital, serial, two-way communications system
that serves as the base-level network in a plant or factory automation environment. It is an
open architecture, developed and administered by the Fieldbus Foundation. It is targeted for
applications using basic and advanced regulatory control, and for much of the discrete control
associated with those functions.
FOUNDATION fieldbus was originally intended as a replacement for the 4-20 mA
standard, and today it coexists alongside other technologies such as Modbus, Profibus, and
Industrial Ethernet. FOUNDATION fieldbus today enjoys a growing installed base in many
heavy process applications such as refining, petrochemicals, power generation, and even food
and beverage, pharmaceuticals, and nuclear applications.
1. H1 link (31.25kbps) interconnects field equipment (Sensors, Actuators & I/O).
2. HSE (High Speed Ethernet, 100mbps) provides integration of high speed controllers,
subsystems (via Linking Device) and data servers and workstation.
Technical Features:
Reduced number (or size) of:
o Wires and marshaling panels. o
Intrinsic safety barriers.
 o Input/output Converters.
o Power Supplies and Cabinets. o
Equipment Rooms.
Remote configuration of devices.
More information available for Operations and Maintenance, due to more information
coming from sophisticated devices. Device diagnostics enable predictive maintenance
programs.
“Control in the field” due to standardized function blocks.

Disadvantages:
Limitations in intrinsic safety applications.
Not really accepted for safety systems.
Devices require interoperability testing with host system.
Extra design effort required (segment calculations, additional configuration data
required for control system).

7. HART Protocol

The HART stands for Highway Addressable Remote Transducer is a hybrid

analog+digital industrial automation protocol. Its most notable advantage is that it can
communicate over legacy 4-20 mA analog instrumentation current loops, sharing the pair of
wires used by the analog only host systems.
The protocol was developed by Rosemount Inc.
There are two main operational modes of HART instruments:
Point to Point (analog/digital) mode
Multi-drop mode.
Point to Point
In point-to-point mode the digital signals are overlaid on the 4-20 mA loop current.
Both the 4-20 mA current and the digital signal are valid signalling protocols between the
controller and measuring instrument or final control element.
Multi-drop
In Multi-drop mode the analog loop current is fixed at 4 mA and it is possible to
have more than one instrument on a signal loop.
Technical Features:
simple design
easy to maintain and operate
compatible with conventional analog instrumentation
simultaneous analog and digital communication
option of point-to-point or multidrop operation
flexible data access via up to two master devices
supports multivariable field devices
sufficient response time of approx. 500 ms
open de-facto standard freely available to any manufacturer or user

8. MECHATROLINK
MECHATROLINK is an open protocol used for industrial automation, originally
developed by Yaskawa and presently maintained by Mechatrolink Members Association
(MMA).
Mechatrolink protocol has two major variants:

MECHATROLINK-II—Defines protocol communication schemes through serial link

equivalent to RS485 with a maximum speed of 10Mbit/s and maximum 30 slave nodes.
MECHATROLINK-III—Defines protocol communication schemes over Ethernet with a
maximum speed of 100Mbit/s and maximum 62 slave nodes.

Function Specification MECHATROLINK-Ⅱ MECHATROLINK-Ⅲ

Physical Layer Equivalent to RS-485 Ethernet

Baud Rate 10 Mbps 100 Mbps

Transmission Cycle Time 250 μs to 8 ms 31.25 μs to 64 ms

17 bytes or 32 bytes 8/16/32/48/64 bytes

(Both string sizes cannot (Different string sizes
String Size
be used at the same can be used as the same
time) time)

Number of Slaves 30 max. 62 max.

Maximum Transmission 50 m total 100 m between stations

Distance (100 m with Repeater) 0.5 m
Minimum Distance between
50 cm 20 cm
Stations

Cascade, star, or point-

Topology Bus
to-point

Cyclic and event-driven

Cyclic/Event-driven Cyclic communications
communications
Communications possible
supported.

Message Communications None Available

Technical Features:

Ultra-high-speed communications at a baud rate of 100 Mbps and a minimum

transmission cycle of 31.25 μsec.
Connects up to 62 slave stations.
Supports large- and small-scale systems with a maximum node-to-node distance of
100 m and a minimum station-to-station distance of 20 cm.
Replace or add slaves while the machine is running.
Allows combining the use of different data sizes (8, 16, 32, 48, and 64 bytes), making
it possible to select the optimum size for each device.
Use the multi-slave function to control multiple slaves with a single communication
ASIC.

9. MODBUS

Modbus is a serial communications protocol originally published by Modicon (now

Schneider Electric) in 1979 for use with its programmable logic controllers (PLCs). Simple
and robust, it has since become a de facto standard communication protocol, and it is now a
commonly available means of connecting industrial electronic devices.

Modbus RTU — This is used in serial communication & makes use of a compact,
binary representation of the data for protocol communication. The RTU format
follows the commands/data with a cyclic redundancy check checksum as an error
check mechanism to ensure the reliability of data. Modbus RTU is the most common
implementation available for Modbus. A Modbus RTU message must
 be transmitted continuously without inter-character hesitations.
Modbus messages are framed (separated) by idle (silent) periods.
Modbus ASCII — This is used in serial communication and makes use of ASCII
characters for protocol communication. The ASCII format uses a longitudinal
redundancy check checksum. Modbus ASCII messages are framed by leading colon
(':') and trailing newline (CR/LF).
Modbus TCP/IP or Modbus TCP — This is a Modbus variant used for
communications over TCP/IP networks, connecting over port 502. It does not require
a checksum calculation as lower layers already provide checksum protection.

Technical Features:
developed with industrial applications in mind
openly published and royalty-free
easy to deploy and maintain
moves raw bits or words without placing many restrictions on vendors
Easy connection to Modicon or Honeywell systems
Suitable for small-to medium volumes of data (<= 255 bytes)
Acknowledged data transfer

Disadvantages:
Great amount of configuration and programming required
Protocol is not common in the SIMATIC family

10. PROFIBUS
PROFIBUS (Process Field Bus) is a standard for fieldbus communication in
automation technology and was first promoted in 1989 by BMBF (German department of
education and research) and then used by Siemens. It should not be confused with the
PROFINET standard for Industrial Ethernet. PROFIBUS is openly published as part of IEC
61158.

There are two variations of PROFIBUS in use today; the most commonly used
PROFIBUS DP, and the lesser used, application specific, PROFIBUS PA:
PROFIBUS DP (Decentralised Peripherals) is used to operate sensors and actuators
via a centralised controller in production (factory)
 automation applications. The many standard diagnostic options, in particular, are
focused on here.
PROFIBUS PA (Process Automation) is used to monitor measuring equipment via a
process control system in process automation applications. This variant is designed for
use in explosion/hazardous areas (Ex-zone 0 and 1). The Physical Layer (i.e. the
cable) conforms to IEC 61158-2, which allows power to be delivered over the bus to
field instruments, while limiting current flows so that explosive conditions are not
created, even if a malfunction occurs. The number of devices attached to a PA
segment is limited by this feature. PA has a data transmission rate of 31.25 kbit/s.
However, PA uses the same protocol as DP, and can be linked to a DP network using
a coupler device. The much faster DP acts as a backbone network for transmitting
process signals to the controller. This means that DP and PA can work tightly
together, especially in hybrid applications where process and factory automation
networks operate side by side.

Technical Features:
Easy to use and universal
Efficient and productive
Proactive
Innovative

11. PROFINET

PROFINET acronym for Process Field Net is an industry technical standard for data
communication over Industrial Ethernet, designed for collecting data from, and controlling,
equipment in industrial systems, with a particular strength in delivering data under tight time
constraints (on the order of 1ms or less). The standard is maintained and supported by
Profibus & Profinet International, an umbrella organization headquartered in Karlsruhe,
Germany.
Every module within a PROFINET network has three addresses:

MAC address
IP address
Device name, a logical name for the module within the total
configuration
Function classes of PROFINET
In PROFINET, we can distinguish two function classes that are independent of each other,
the PROFINET IO and the PROFINET CBA (Component Based Automation) .
PROFINET IO is concerned with distributed I/O (Input/Output) and PROFINET CBA is
concerned with distributed automation.
PROFINET IO: The distributed field devices are connected through the PROFINET IO. If
you are familiar with PROFIBUS, you will find considerable similarity between these two
systems; for example, process data from the
field devices is transmitted into the control system
Periodically.

PROFINET IO uses three different communication channels to exchange data with

the control systems and other devices. The standard TCP/IP channel is used for
parameterization, configuration and acyclic read/write operations. NRT (Non-Real Time)is
used for non-time-critical processes. The RT channel (Real Time) is used for standard cyclic
data transfer and alarms. The third channel, IRT (Isochronous Real Time) is the high-speed
channel used for Motion Control applications. The technical characteristics of the field
devices are described by the so-called GSD file (General Station Description) which is based
on XML (eXtensible Markup Language).

PROFINET CBA: This concept is designed for distributed industrial automation

applications. The PROFINET CBA is built on the standard DCOM (Distributed Component
Object Model) and RPC (Remote Procedure Call) technologies. DCOM is an object oriented
mechanism that structures how a Client can locate, request and receive data from a Server.
DCOM was originally developed by Microsoft. The DCOM objects, which are disconnected
from the PROFINET CBA, are called technological components. These components act
independently and coordinate their activities among themselves autonomously. The
encapsulated technological components are called PROFINET components, which are
described by PCD (PROFINET Component Description). You can imagine them as a black
box with the interfaces on the outside. They communicate with each other over these
uniformly defined interfaces. This also allows us to connect them as we wish.

Technical Features:
1. Ease of Use
2. Flexible network topology
3. Integrated Diagnostics
 4. Integrated safety
5. High availability
6. Scalable real time
7. Expanded system structure
8. Everything on one cable

Comparison PROFIBUS with PROFINET

FEATURES PROFIBUS DP PROFINET IO
Master class 1 IO controller
Master class 2 IO supervisor
Slave IO device
Wired PROFIBUS over copper Industrial Ethernet over copper
transmission or fiber- or fiber-optic
technology optic cable cable
Wireless Infrared transmission Industrial WLAN (Wireless Local
transmission is possible Area Network)
technology is possible

Once an IO device is
Data exchange By requesting parameterized, it can work
by itself. Data can be exchanged
cyclically or
acyclically (by requesting)

One exactly defined

Data channels data channel Several data channels between
between Master and
Slave. Controller/Supervisor and Device

Number of
devices 126 devices maximum Arbitrary, depends on network.

IT services Not possible Can be integrated

Device XML based with schema

description Keyword based definition

Data priority Same priority Different priorities can be set

Access of a field Read only from several Read and write from several
device users. users possible.
 Assignment of IP addresses to IO
controller with Engineering tool
Assignment of IP addresses to IO
devices by IO controller Assignment of
device name to IO device with
Engineering tool Assignment of IP
Coding of the addresses by using web
PROFIBUS address over
Address a DIP-switch or 100 Mbit/s with full duplex
assignment Engineering tool
Data transfer Max. 12 Mbit/s Standard: line
rate
Possible: tree and ring
Topology Standard: star and tree
Possible: bus and ring