Industrial Ethernet Handbook A practical guideline Planning – Installation – Start-up
Preface Preface Revision History Version 0.0 1.0 2.0 Date 10/11 11/12 Modification First edition Updated version Updated version Contact address Weidmüller Interface GmbH & Co. KG P.O. Box 30 30 32720 Detmold Klingenbergstraße 16 32758 Detmold T +49 5231 14-0 F +49 5231 14-292083 info@weidmueller.com www.weidmueller.
Contents Contents Preface Revision History Contact address 3 3 3 Contents 4 1 1.1 1.2 1.3 1.4 1.5 1.6 Introduction Objectives of the best practice guideline We value your opinion! Disclaimer Weidmüller – Partner of Industrial Connectivity Office Ethernet and Industrial Ethernet Explanation of symbols 6 6 6 6 7 7 9 2 Planning 2.1 Basic ideas on planning an Industrial Ethernet network 2.2 Planning guidelines 2.
Contents 2.14 2.15 2.16 2.17 2.18 2.19 2.20 2.21 2.22 2053260000/05/2015 2.23 2.24 Passive components: copper cabling Copper connector in acc. with (DIN) EN 50173-3 Copper connectors in acc. with PROFINET specification Copper connectors in acc.
Introduction 1 Introduction 1.1 Objectives of the best practice guideline This guideline is intended for planners, installation engineers and startup engineers for Industrial Ethernet (IE) networks. It communicates, from experience, tips, tricks and shortcuts that make the work easier. This guidelines is not an IE compendium from a basic manual. 1.2 We value your opinion! We have selected and consolidated elements of our best practices in the best possible format - it is not in a final or complete form.
Introduction 1.4 Weidmüller – Partner of Industrial Connectivity As experienced experts, we support our customers and partners around the world with products, solutions and services in the industrial environment of power, signals and data. We are at home in their industries and markets and are aware of future technological challenges. We are therefore continuously developing innovative, sustainable and value-adding solutions for their individual needs. Together we set standards in industrial connectivity.
Introduction Ethernet requirements in the office and industrial area Cabling Cont.
Introduction 1.6 Explanation of symbols The following symbols are used in this best practice guideline to highlight key sections of text: Symbol Meaning This symbol provides you with notes and tips that will help you make your work easier. This symbol indicates the danger of faults. Observing these notes will help you reduce faults.
Planning 2 Planning This chapter includes, among other things: • Planning basics, requirements and planning guidelines • Requirements for generic communication cable facilities • Fire protection and surge protection • Ethernet protocols • Description of active Ethernet components • Description of passive Ethernet components 2.1 Basic ideas on planning an Industrial Ethernet network 2.1.1 Data and control networks First decide whether you are planning a data or a control network.
Planning 2.1.2 Devices for external connection Designate the end devices and their access points (I/O modules etc.). 1 Designate the number and spatial arrangement of the I/O modules. 2 Define the terminals: exactly which terminals are required? In which protection degree: IP 20, 54, 67…? 3 Data volume of the terminals: define this at this point for the later determination of the network equipment. 4 Define the connections to external networks. 5 Define the connections to the Internet.
Planning Address areas IP address The IP address is comparable to a street address (street, house number). The IP address is used to clearly identify a PC in the network. Each IP address can only be assigned once in a network. IP-address structure An IP address consists of 4 bytes = 32 bits, each byte can adopt its own value between 0 and 254. Represented in decimal form, the IP address is divided into four octets. Example: 192.168.2.
Planning Redundancies Redundancies increase the availability of networks.Redundancy can relate to devices on the one hand, and to cabling on the other. Redundancies in the device require special components in every case. This is always vendor-specific and is not to be found in any standard. Redundancies for cabling are more common. For this you can select between the standardised redundancy methods STP, RSTP as well as vendor-specific methods.
Planning 2.1.4 Network devices Define all infrastructure components by their functionality and select the required devices. 1 Take into account the existing control cabinet and, if necessary, define additional distributions. 2 Definition of network access and partitioning of the network (router, modem …) 3 Definition of coupling elements: always plan at least 20 percent reserve on the ports for future expansions.
Planning 2.1.5 Network connection technology 1 Determine the mode of installation. • Cable routes and cable channels • Additional protective measures against mechanical damage 2 Determine the cabling requirements. • Standards • Transmission rates: the requirements for shielding and number of wires change according to transmission rate. • Cable lengths • Electromagnetic requirements (MICE): the sheath-material and shielding requirements depend on these.
Planning 2.2 Planning guidelines Planning according to the applicable standards is the basis for trouble-free and durable operation of the Ethernet network. The execution, along with later use, is defined here. • Observe the corresponding DIN regulations (safety, EMC). • (DIN) EN 50173 is vital for cabling that is not application-specific, and (DIN) EN 50174 is important for communication cables in general. • Observe the cable's minimum bending radius. • Use only suitable installation systems.
Planning 2.3 2.3.1 2.3.2 2.3.
Planning 2.3.4 Structure of generic communication cable systems Primary area (Campus Distributor) • Cabling of individual buildings together at the same site Secondary area (Building Distributor) • Vertical storey cabling Tertiary area (floor distributor / machine distributor) • Cabling to the end user • Cabling to a machine and inside a machine 2.4 N 50174-2 Information technology – Installation of E communication cabling EN 50174-2 contains requirements for planning and implementing a cabling. 2.
Planning Mechanical Protection Climate Electromagnetic Class M1 I1 C1 E1 M2 I2 C2 E2 M3 I3 C3 E3 M1 I1 C1 E1: Office, master office, office container M3 I1 C1 E1: Connection in enclosed control cabinet M3 I3 C2 E3: Connection in field area Observe special environments such as mining, petrochemicals, tunnels, pipelines etc. The MICE classification is not valid for these. 2.6 Power capability of the cabling Both IEC 11801 and EN 50173 contain a classification of symmetric copper cabling.
Planning Advantages of Gigabit Ethernet • Higher data rates for higher network performance • Full downward compatibility with the large number of installed Ethernet and Fast-Ethernet nodes Currently, more and more 10-Gigabit components are coming onto the market at prices comparable to Gigabit components. Make use of these components to make your network viable for the future.
Planning 2.7.1 Standardised components Standardised components are divided into quality categories (also Cat.).
Planning 2.7.2 Cable lengths for copper cabling Using components that meet the minimum requirements for standardised components, a length of max. 100 metres can be achieved for the entire copper connection between devices/distributors. The following applies in this case: + + = 5m 90 m 5m 100 m Connecting cables Installation cable Connecting cables Cable run length • Longer cable runs can be achieved using higher quality components. However, these are outside of the specification.
Planning 2.7.3 Cable lengths for fibre-optic cabling Determining the cable length of fibre-optic cables is more time-consuming and dependent on various factors. Put simply, all attenuations that affect the fibreoptic cable run must be lower than the power budget of the active devices.
Planning 2.8 2.8.1 Electromagnetic compatibility (EMC) Equipotential bonding and earthing system CAUTION! EMC An equipotential bonding system that meets the current standards is an absolute must for good EMC and, in particular, for an adequate protection against personal injury.
Planning 2.8.2 EMC – general Select suitable materials and make sure that installation is professionally executed, in order to ensure the compatibilty properties of the EMC.
Planning 2.9 Earthing and equipotential bonding A good earthing system and good equipotential bonding system are very important for the electrical interference immunity of PROFINET networks. Earth the PROFINET cable shields on both sides, i.e. on each of the connected devices, in order to reduce the effects of electromagnetic interference. The equipotential bonding ensures that the earth potential is equal throughout the entire PROFINET network.
Planning Since the protective earth is part of the general electrical system, it will not be described in any more detail in this document. However, the applicable regulations are to be observed in each case! Note Some PROFINET devices also have a connection for the protective earth. In particular, these are PROFINET devices that have an additional power supply with a higher voltage. Connect the protective earth in accordance with the applicable regulations. 2.9.
Planning For the earth connection of the PROFINET devices, use copper cable with a corresponding cross-section (> 2.5 mm²). As a rule, the earthing cable has a green-and-yellow insulation. In some countries the green-and-yellow marking is a regulation (in the USA only green). The functional earth is identified by the following symbol: g 2.9.3 Equipotential bonding Equipotential bonding ensures that the earth potential is equal throughout the system.
Planning Connect the installation surfaces (e.g., top-hat rails) to the equipotential bonding. Connect the system's equipotential bonding as often as possible with the building's equipotential bonding. In the case of painted parts, remove the paint from the connection point prior to connecting. After installation, protect exposed connecting points against corrosion, using zinc paint or enamel. Protect the equipotential bonding against corrosion. One option, is to paint the contact points.
Planning Install the equipotential bonding as close as possible to the PROFINET cable. Connect all individual parts of the cable raceways (metal) with each other. Use special-purpose connecting material to do this. Make sure to use the same material for the cable raceways and the connecting pieces. Appropriate material is available from manufacturers of cableways. Connect the metallic cableways as often as possible with the equipotential bonding.
Planning 2.9.4 Connect the shielding with the equipotential bonding. The shielding is an important part of the PROFINET copper cable. This shielding protects the data wires in the cable against electromagnetic interference. For the shielding to perform this function, it must be connected to the equipotential bonding of the system.
Planning 2.9.5 Connect the shielding to the equipotential bonding Various options are available to create a connection between the shielding and the equipotential bonding. The following figure shows you three such connection options. These options have been tried and proven in practice. Figure 2.1: Connections between shielding and equipotential bonding Make sure that the PROFINET cable is not pinched by the connection between the shielding and the equipotential bonding.
Planning When installing the shielding connection, observe the following: Remove the sheath of the PROFINET cable only to the extent required for the connection. The PROFINET cable is sensitive to mechanical loads in the area where the sheath was removed. Make sure you don't damage the shielding when you strip the sheath off the PROFINET cable. Do not use the shielding connection as strain-relief. This would impair the contact between the shielding and the equipotential bonding.
Planning Fasten the PROFINET cable in place before, and after, the shield laying. This protects the sensitive PROFINET cable against kinking and bending in this area. This is particularly important if the cable is subject to movement. Use only connecting materials that fit the diameter of the stripped cable. Do not mount the equipotential busbar on painted surfaces. Galvanised or chromium-plated surfaces are very suitable for mounting.
Planning 2.10 Surge protection Surge voltages are extremely high voltages that can interfere with or even destroy the insulation and function of electrical and electronic components. Your machines and systems are therefore safeguarded against: • Lightning strikes • Switching operations (direct and indirect effects) Be sure to: • Spatial separation of systems that have different rated voltages • The correct protection classes of surge protection modules 2.10.
Planning 2.11 Fire protection and fire load Fire protection The main causes of fire in electrical lines include: • Short-circuits and earth faults, e.g. on mechanical or thermally damaged cables or lines • Faulty electrical connections (loose contact) • Previous damage to insulation • Overload • Heat accumulation Note: • Install large quantities of cables in the space above suspended ceilings or the space below raised floors.
Planning IP protection class Electrical devices that are intended for use in industrial environments are subjected to influences other than household appliances. The following table shows the protection classes with the associated limit values. The protection classes are defined in the IP standard, DIN EN 60529: protection degree provided by housing (IP code). Table 2.
Planning 2.12 Quality planning Basic requirements for the quality plan and the documentation are described in (DIN) EN 50174-1. Documentation Make sure to adequately document all installations for later operation and any required changes. As-built documentation includes: • Supply information on materials used (cables, junction boxes etc.) including data sheets • Technical information (e.g., terminal diagrams, installation instructions etc.
Planning Labelling Label all connecting parts of your network on both sides. Use conventional markers and components that offer prepared labelling options. For this purpose, Weidmüller offers an extensive range of industrial markers for every situation. Do not use normal marker pens directly on the cable or the connector, as these are not durable.
Planning 2.13 Active components 2.13.1 Basic information Networks consist of two or more devices that are connected via a central point. The central node is generally a switch that manages the communication between the individual devices. IP address • Unique addressing within the network • Precise communication between the individual clients To avoid conflicts and malfunctions do not assign the same IP address twice within a network.
Planning MAC address • World-wide unique, non-interchangeable serial number for all Ethernet components • Stored permanently on the network card • Is comprised of a 48-bit long sequence, which is normally represented as six hexadecimal numbers, separated by hyphens (-) Divided into: • 3-byte vendor ID and • 3-byte device ID (consecutive number) Example: 00-15-7E-01-00-2F-vendor ID Weidmüller: 00:15:7E Subnet mask The subnet mask is used to demarcate a related address area of IP addresses.
Planning Broadcast address The broadcast address is a special address that includes every PC within a specified network. In each case the last address of the host part is used as the broadcast address of a network. Example: 192.168.0.255 Never specify a broadcast address as an address for an individual PC, otherwise various network functionalities will simply not work! Broadcast A broadcast is used to obtain recipient addresses from still unknown devices from the network.
Planning Default Gateway This is the network address the components send data packets to, if the target address is not in their own network, and no information is available as to how the target network can be reached. • It provides information on how the target network is reached or • it forwards the packets to its default gateway in the next instance. The default gateway can be compared to a standard exit.
Planning Subnets A subnet is a part of a network. A large network is divided into lots of small virtual networks in order to minimise, and thus accelerate, data traffic in a network. The sections of the entire network are called subnets. Subnets are parts of a network with their own subnet address. If devices are to communicate with each other across subnet borders you have to set the router to allow such communication. Collision domain A collision domain is a segment of a network.
Planning Virtual Local Area Network (VLAN) • Groups individual devices from different physical structures into one joint logical structure. • Changes to the network can be made with relatively little effort. • Is not subject to any geographical restriction A difference is made between static and dynamic VLANs: a) Static VLAN • Assignment of a physical port to the VLAN • A component connected to the port automatically forms part of that port's VLAN.
Planning Quality of Service (QoS) This is a method to control the data traffic and the quality of service of networks. Objective: Data from specific services reach the recipient in accordance with predefined quality parameters.
Planning Network Address Translation (NAT) Network Address Translation refers to the translation and switching between IP addresses of the local and the public domain.
Planning a) Source NAT (SNAT) Static method: • The IP address of the source is replaced. • Is used with packets • The router stores this address translation. • Is normally used for address translation between two local users only b) Destination NAT (DNAT) Dynamic method: • The IP address of the target is replaced. • Synonymous for incoming data packets • For the terminal devices involved these processes are transparent, i.e. they are not affected by this address translation.
Planning 2.13.2 Security Port security Port security ensures that an unused port is not accessed without authorisation. This is done, e.g., by software-controlled deactivation of the port. It must be possible to undo the port deactivation when the port is used again. Ports Each network component is assigned a unique IP address which is used to address this component directly. Ports enable the individual addressing of various applications using this IP address.
Planning Port mirroring Port mirroring means that the entire network traffic of the ports to be monitored is emulated to a mirror port to obtain control of the data volume and data contents. This way it is possible, e.g., to create history entries or logfiles. Fault relay (security/debugging) Many switches provide the triggering option of a programmable relay, in order to obtain information about a change of status. You can, for example, connect visual or acoustic signal transmitters to this relay.
Planning 2.13.3 Infrastructure components Industrial Ethernet switches A switch is a network component for combining several components into a local network.
Planning Global functions / operating modes Auto-Crossing: • Automatic detection of a crossing of outgoing and incoming lines on twistedpair interfaces. • Allows the connection of both a single-strand cable and a crossover cable. Auto-negotiation • Switches handle the data rate with the link partner on each port independently and automatically. • The link is established with the highest possible common data rate both partners can handle.
Planning Managed switches Owing to the numerous functions of managed switches, a configuration of the devices is essential. Programming via a Web interface or a terminal program facilitates the setting of components and allows the user to use the network to configure almost all connected PCs, even if the devices are spatially, very distant from each other. Implementation of a monitoring function for individual ports makes it easier to evaluate the fault in the event of a malfunction.
Planning Turbo-Ring V2 Turbo-Ring V2: performance characteristics • Technology protocol for redundant ring structures • Recovery time in case of a fault < 20 ms for a ring with up to 250 switches • Advanced options for coupling several "Turbo-Rings" (Dual Homing and Dual Ring) • Can be operated together with the standard redundancy protocol RSTP/STP 54 2053260000/05/2015
Planning Ring Coupling Redundant connection of 2 turbo-ring networks via 2 switches • Data exchange in normal conditions via the primary coupler • In the event that the primary coupler connection fails, the backup connection is automatically activated (recovery time < 20 ms). • Only the primary and backup coupler have to be configured for the ring coupling.
Planning Multiple Ring Coupling Connection of multiple turbo-ring networks in series • Each ring may have only one primary coupler. • Each ring may have only one backup coupler. Multiple Ring Coupling 2 Connection of multiple turbo-ring network in a hierarchical tree structure • Turbo-ring networks can also be coupled to RSTP-based network structures (e.g. to a control level).
Planning Dual Ring Connection of 2 turbo-ring networks via a common central switch • Each switch can be located in a maximum of 2 rings. • The "dual ring" switch must be explicitly configured for membership in 2 rings. Multiple Dual Ring Connection of multiple turbo-rings networks, each via a switch that is a member in 2 turbo-rings. • Each switch can be located in a maximum of 2 rings. • The "dual ring" switch must be explicitly configured for membership in 2 rings.
Planning Dual Homing Connection of 2 turbo-ring networks via a switch • Only the "dual homing" switch has to be configured for the ring connection. • The "dual homing" switch controls the primary and backup patch for the redundancy. • The "dual homing" switch can be inside the ring, but can also be operated as a stand-alone, redundantly connected switch.
Planning Multiple Dual Homing 2 Connection of multiple turbo-ring networks, in each case via a "dual homing" switch (in hierarchical tree structure) • Each switch in the control level can be operated as a "dual homing" switch.
Planning Turbo chain Turbo-chain technology • Universal "chain" network that can be connected with any number of other network structures • Recovery time of turbo chain in case of fault < 20 ms (e.g. with cable break) How does the turbo chain work? • Connection in series (daisy chain) • Chain consists of a head switch, any number of member switches and a tail switch. • Both ends of the chain are connected with a randomly structured network.
Planning Unmanaged switches Unmanaged switches allow a cost-effective entry into Industrial Ethernet engineering. They require no configuration, since they function using plug-andplay. Use • In price-sensitive applications • I f they are designed as compact plug-and-play modules •T o allow simple installation of Industrial Ethernet networks • Do not have to be configured or given parameters.
Planning Wireless LAN (WLAN) Wireless LAN refers to a local non-wired network. To use wireless technology you need an access point that acts as a gateway between the wired and wireless world. Safety features: • Current encryption standards are WPA and WPA2. • MAC address filters that only permit authorised network devices to access the wireless network The use of a WLAN network in company areas should be well thought through and be provided with best possible protection if this option is implemented.
Planning a) Types of application • Mobile connection of laptops • In motor vehicles or machines for data acquisition in storage area • In automation • For measured data acquisition or control of machines b) Frequencies Two licence-free blocks of frequencies are released for wireless network communication: Standard 802.11a Frequencies 5,15 GHz 5,725 GHz Channels Channels: 19, all overlap-free, in Europa mit TPC und DFS nach 802.11h 802.
Planning c) Channels The standard 802.11b/g is the most widely used standard and has a frequency range of 2.4 GHz to 2.4835 GHz. The frequency ranges divide as following among the individual channels: Channel 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Frequency 2.412 GHz 2.417 GHz 2.422 GHz 2.427 GHz 2.432 GHz 2.437 GHz 2.442 GHz 2.447 GHz 2.452 GHz 2.457 GHz 2.462 GHz 2.467 GHz 2.472 GHz 2.
Planning e) Data rates Take into account that all components in the network share the bandwidth for upload and download. Moreover, the specified data rates are theoretical values and refer to optimal conditions. The actually achieved data rates are several times less than the theoretical data rates. IEEE/Group 802.11 Description WLAN for1-2 Mbps on the 2.4-GHz band 802.11a WLAN for 54 Mbps on the 5-GHz band 802.11b Extension of 802.11 to 11 Mbps on the 2.4-GHz band on the 2.
Planning Wireless Distribution System (WDS) What is WDS? • A Wireless Distribution System (WDS) allows the wireless connection of access points to one another to form a wireless network (in acc. with IEEE802.11 network standard). • A WDS based wireless network-can comprise a maximum of eight wireless access points. • Integrated RSTP technology to prevent data loops (Looping Protection) • Wireless access points within the wireless network connect via MAC addresses.
Planning Modes of Operation: Access Point and Client Modes Access point mode • Allows the connection of WLAN components to a wired Ethernet network Client mode • Makes wired Ethernet components WLAN capable 2053260000/05/2015 67
Planning Mode of operation "Bridging with WDS" (WDS = Wireless Distribution System) • WLAN link between various wired networks • The “bridges” are linked to each other by means of MAC address that have to be mutually entered. • In this mode of operation the devices can be access points at the same time.
Planning Wireless network with multiple access points (scenario 1) Access Points are connected by means of the wired LAN (WDS off) • Suitable for establishing acellular radio network (which can, theoretically, be any size) • All APs have the same wireless name (SSID) for fast roaming of the WLAN clients • Connection security can be set to WEP, WPA/WPA2 (personal and enterprise) • No broadband dependency for connection of the access points to one another due to LAN Ethernet cabling 2053260000/05/2015
Planning Wireless network with multiple access points (scenario 2) Access points are connected to each other by radio link (WDS on) • Establishing a cellular radio network with only one cabling point to the wired LAN • Meshed wireless networking of up to eight access points is possible • However, there is a reduction of the bandwidth due to the twin load repeater and access point • WLAN clients can only log onto WDS based wireless networks using WEP security.
Planning Turbo-roaming performance characteristics Access points are connected to each other by radio link (WDS on) • Roaming (also called "Handover") is the ability for an interruption-free changeover of a WLAN client between two access points. • Turbo-roaming technology allows a changeover time < 50 ms (using WPA/ WPA2 encryption).
Planning Media converter Media converters connect copper cables and fibre-optic cables.
Planning Serial/Ethernet converters A serial/Ethernet converter allows you to connect a device with serial interfaces in a network. This allows trouble-free integration of an existing production facility with an RS232/422/485 interface into an Ethernet network. You can access the interface from all PCs within the network.
Planning Robust, industrial power supply units The correct power supply is a critical factor in ensuring the reliable functioning of the connected components.
Planning 2.14 Passive components: copper cabling 2.14.1 Basic information on copper cabling Copper cables are the first choice for use in the office environment and in harsh industrial environments. Advantages: • Available in many variants and lengths • Robust • Easy to assemble • RJ45 connections are the most widely available type. Raw cable/metre Industrial installation cable/horizontal cable For permanent, durable installation in cable conduits and cable trays • In Cat. 5 or Cat.
Planning Assembled cables Industrial patch cables/CabinetLine Not only for use in the office area, but also for industrial use in control cabinets • In Cat. 6 • With sheath in LSZH – low smoke and zero halogen • In the variants straight and crossover Industrial system cable Pre-assembled cable for flexible installation in machines and facilities in industrial/harsh environments • In Cat. 5 or Cat. 6 • With sheath in PUR Industrial tow-chain cable Pre-assembled cables for constant movement, e.g.
Planning Customer-specific cable production Numerous vendors offer to produce customised connecting cable; use this offer to • make your assembly easier, • make your ordering processes easier, • make your storage and your logistics work easier. In connection with this, also take a look at Weidmüller's Galaxy configuration software on the Internet at www.weidmueller.com/conf Here, you can individually create your connecting cable and directly send a request and order with at a click of the mouse.
Planning AdvancedLine CabinetLine Weidmüller's AdvancedLine offers all combinations of cables that are available with the extensive range of connectors. The new patch cable range, CabinetLine, from Weidmüller is available in various colours to distinguish between different networks. This means flexibility and robustness due to the high quality of the components used. The range is made up of standard cables and customer-specific variants. Standard cables are shown in the catalogue.
Planning 2.14.2 Normative characteristics for copper cabling Note that the transmission properties of your network depend on: • Spatial expansion of the network (conductor lengths) • Transmission properties of the components (DIN) EN 50173 also describes the characteristics: Transmission link • Transmission path between network device (switch) and connected stations • A typical transmission link consists of horizontal cabling and two connecting cables (patch cables).
Planning 2.14.3 Symmetric cable types UTP F/UTP SF/UTP Unshielded cable Cable with full foil shielding, unshielded pairs S/FTP Cable with braided shield, pairs with foil shield Cable with braided shield and foil shield, pairs unshielded 2.14.4 Special-purpose cable Use tow-chain cables in locations where the cable is subject to frequent or constant movement in an industrial environment. • SF/UTP cable • Preferably 7-core stranded Litz conductor • Cat.
Planning 2.14.
Planning 2.15 Copper connector in acc. with (DIN) EN 50173-3 In (DIN) EN 50173-3 there are two standardised connector faces: PushPull V4 with RJ45 M12 • RJ stands for "Registered Jack" (standardised socket). • The established connection technology in IT is described in IEC 60603-7 Further development of the RJ45 in the protection • degree IP 67 is described in IEC 61076-3-106 and elsewhere. • M12 has been tried and proven in automation engineering for more than 30 years.
Planning 2.16 Copper connectors in acc. with PROFINET specification In the PROFINET specification there are four standardised connector faces, which are also standardised in IEC 61158 RJ45 without tools PushPull V14 with RJ45 M12 • RJ stands for "Registered Jack" (standardised socket). • The established connection technology in IT is described in IEC 60603-7 • Further development of the RJ45 in the protection degree IP 67 is described in IEC 61076-3-117 and elsewhere.
Planning 2.16.1 PROFINET end-to-end link The PROFINET end-to-end link defines a permanent transmission link between two devices (network components or automation devices). This link is a connection between two active PROFINET components The end-to-end link itself is comprised exclusively of purely passive components. Figure 3-1 shows the basic configuration of the end-to-end link.
Planning When passive network components that comply with the PROFINET component specification are used, this guarantees that the transmission link satisfies the requirements for a proper data transmission function. Passive In terms of their mechanical and transmission structure, PROFINET components are ideally designed for the requirements in industry and especially for PROFINET. This is documented by the PROFINET Manufacturer's Declaration.
Planning Panel feed-throughs and couplings with two sockets are generally counted as two connector interfaces. The exceptions are panel feedthroughs and couplings for which the manufacturer has declared in the manufacturers declaration that these have the performance of a single socket. An additional acceptance measurement is also advisable, if such a measurement is desired for documentation purposes, for PROFINET cabling. The acceptance procedure should then be conducted as described in this document.
Planning 2.17 Copper connectors in acc. with IEC 61158 In IEC 61158, there are three standardised connector faces for EtherNet/IP: RJ45 crimp • RJ stands for "Registered Jack" (standardised socket). • The established connection technology in IT is described in IEC 60603-7 Bayonet V1 with RJ45 • Further developments of the RJ45 in the protection degree IP 67 are described in IEC 61076-3-106 and elsewhere. M12 • M12 has been tried and proven in automation engineering for more than 30 years.
Planning 2.18 Comparison of Ethernet interfaces Origin RJ45 IT M12D Automation M12X Automation IP 67 IP 67, IP 69k possible IP 67 Outer dimensions/installation size average (depending on variant) low low Wire connection up to 8 wires 4 wires 8 wires given possible possible given very good given not possible possible given very good given not possible possible given very good given given given Cat. 5 to Cat. 6A (10-Gigabit Ethernet) Cat. 5 (Fast Ethernet) Cat.
Planning 2.19 STEADYTEC® • Forward-looking connection technology for transferring data, power and signals • Created by three leading connection technology firms • Basis for reliable, user-focused solutions in line with standards – both in the office environment and in tough industrial surroundings • The modular principle is used with STEADYTEC® for many possible combinations.
Planning 2.
Planning 2.21 Passive components for fibre-optic cabling The term fibre-optic cable is used for all glass and plastic cables which are used to transfer data.
Planning Fibre-optic basics a) Fibre-optic fibres Costs (devices, cables, connection system) Range of coverage Data rates Usage, handling and packaging Fibres Plastic Optical Fibre (POF) Plastic Cladded Fibre (PCF) Multimode glass fibre Singlemode glass fibre POF/HCS low Glass high POF: up to 50 m HCS: up to 200 m up to 100 Mbit/s relatively straightforward several kilometres > 10 Gbit/s complex No additional connector One additional connector Two additional connector 50 m 43.
Planning Design of fibre-optic cables Cable sheath Sheath material DIN VDE designation Temperature range typical for market UV resistance Resistance to spread of flame Contains no halogen Oil resistance Resistance to chemicals Resistance to abrasion Applications PVC Y –40° to +115 °C yes ++ no + + + Building Water absorption Can be used outdoors Flexibility – yes + ++ very good + good – low –– very low 2053260000/05/2015 PUR 11Y –40° to +85 °C yes + yes ++ ++ ++ Industrial dragline – yes
Planning Connector Standard Media IE profile Standard Media IE profile 94 SC-Simplex SC duplex SC-RJ IEC 61754-4 MM, SM, POF IEC 61754-4 MM, SM IEC 61754-24 MM, SM, POF PROFINET ST LCD E2000 IEC 61754-2 MM, SM, POF IEC 61754-20 MM, SM EtherNet/IP IEC 61754-15 MM, SM 2053260000/05/2015
Planning 2.21.1 Routing Ethernet fibre-optic cables If the maximum permissible tractive forces are exceeded, the optical fibres can be overstretched if necessary. This can result in greater attenuation, shorter service life and/or permanent damage to the cable. Permanent or sporadic transfer faults may result. Such faults may also arise later on, sometimes years after installation. Particular attention should be paid to compliance with bending radii.
Planning 2.
Planning 2.
Planning Notes 98 2053260000/05/2015
Installation 3 Installation This chapter contains information about: • Installation guidelines • Cable routing • Connection system • Marking • Measurement and documentation 3.1 Installation guidelines During installation note the compulsory elements of the (DIN) EN 50174 series of standards. This has trans-sectoral validity. Depending on the industrial protocol specified, also refer to the associated guidelines.
Installation 3.2 Cable spacing Table 3.1 shows the minimum spacing you need to observe in accordance with IEC 61918 between Ethernet cables (shielded data cable) and other cables. The table also includes two variants with a metal isolating strip which can be used to isolate data cables from power cables. Figure 3.1: Cable spacing Generally speaking, the risk of faults (crosstalk) falls the greater the spacing between cables and the shorter the distances over which cables run in parallel.
Installation How to read the table! If you want to know the minimum spacing required between Ethernet cables and other electrical cables, proceed as follows: In the left column (Ethernet cable and cable for ...), select the electrical cable you are routing along with the Ethernet cables. In the right part of the table (spacing), select the type of cable isolation you want to use. Read the spacing for the relevant cable type off the column for the respective type of cable isolation.
Installation 3.3 Cable routing Use the following information and assistance to simplify your work and to ensure that your system runs smoothly later on. Please notice the strain relief specifications according to applicable standards. Unrolling cable With cable drums, use unwind stands to avoid harmful loading. Unreel the cable rings on the floor to avoid torsion forces on the cable. Bending radius Always note the manufacturer's details on bending radii for cables.
Installation Bundling and fixing cable Use as wide a cable tie as possible or better still use velcro ties to bundle cables or fix them to supporting parts. Ensure that the cables are stretched and that you don't squash them because this will later impair the transfer properties and ultimately result in failure during operation. Cable conduits and cable bearers Be aware that power, data and signal lines may have to be isolated to avoid data traffic faults.
Installation Cable routing within cabinets Refer to Table 3.1 for the minimum spacing between two cables of different categories. Generally speaking, the risk of faults from crosstalk decreases, the greater the spacing between the cables. If cables of different categories have to be crossed in your system, they should be crossed at right angles. Avoid routing cables of different categories in parallel.
Installation Screw a metallic cable conduit down to the rails of the frame or cabinet walls roughly every 50 cm. Ensure that there is a good conductive and flat connection between the rail and cable conduit. With coated cabinets, this can be done using lock washers for example. Another option is to remove the coating or paintwork. However, all metal parts must be sufficiently protected from corrosion.
Installation To introduce the cable into the cabinet, use suitable cable entries such as cable glands. Avoid the parallel routing of cables from the outside with PROFINET cables inside the cabinet between the cabinet entrance and shield support. This also applies to cables of the same category! 3.3.1 Routing cables inside buildings When routing cables outside cabinets and inside buildings, note the following: Refer to Table 3.1 for the minimum spacing between two cables of different categories.
Installation If the cables are routed in metallic cable conduits, the conduits can be positioned right next to one another. If there is just one shared metallic cable conduit available for all categories, the spacing stated in Table 3.1 should be observed. If there isn’t enough space, the various cable categories must be isolated using metallic partitions. The partitions must be connected to the conduit over large areas, ensuring good conductivity.
Installation 3.4 Mechanical protection for Ethernet cables Mechanical protection measures should protect Ethernet cables from wire interrupts or short-circuits or mechanical damage to the sheath and shield. Note The measures described here for mechanical safety apply equally to electrical and optical cables! Route the Ethernet cable in a plastic guard if you are routing the Ethernet cable separate from cableways. In areas with high mechanical loading, route Ethernet cables in metal reinforced tubes.
Installation In the standing areas of walk-in building and machine parts and near transport routes, route the Ethernet cable in metallic reinforced tubes or metallic cableways. Note Given the maximum length of roughly 100 metres for Ethernet copper cable, we would recommend using fibre-optic cable for connections between buildings for reasons of potential isolation and for better protection from electromagnetic faults. 2053260000/05/2015 (Source: PROFINET assembly guideline, version 1.
Installation 3.5 PROFINET/AIDA robotics cabling A coherent platform for power, signals and data in automotive construction PushPull connectors and Weidmüller’s junction boxes are the basis for this new cabling standard in the automotive industry. The new PushPull connectors are an integral part of Weidmüller’s power-signal-data installation system for AIDA* (AIDA is the Automation Initiative of the German Automotive Industry).
Installation Users can use these components to plug in and run the three basic elements of industrial automation, power, signals and data, and therefore produce an integral solution. A cable packet is used to establish the connection from the cabinet to the robot base. Hose packet 1 connects the robot base with axis 3 and hose packet 2 provides the final connection between axis 3 and the robot head.
Installation the PushPull signal connector a 10-pole hybrid insert. The result is a perfectly co-ordinated system for power, signals and data, enabling consistent cabling between the cabinet and robot (or similar applications).
Installation This installation system is suitable not only for robotics cabling, but also for all applications which require a sturdy, reliable and pluggable cabling solution. The advantages at a glance: • Quick installation/replacement • Sturdy metal housing • High transfer security • Various mounting options • Compliant with PROFINET • Compliant with the AIDA specification • Cat.
Installation 3.6 Connection system Copper connection system a) Isolating Be sure to: • Select the right tool. The cutter shape corresponds to the relevant insert and is optimised for it • Isolate vertical to the cable b) Sheath stripping To simplify the task, use a multi-stage sheath stripping tool. This removes the cable sheath at one point and the underlying shield at another point in one step. Select the right blade settings to match the cable type. 1 Insert the cable end in the tool.
Installation 3 Rotate the tool in the direction indicated by the arrow to strip insulation from the cable. 4 Open the tool before removing the cable. 5 Strip the removed cable sheath by hand.
Pin 8 5 6 8 4 7 6 7 Rx- 5 3 2 1 8 Rx+ Tx- Tx+ 1 1 2 2 8 7 4 female 3 PIN M12 X-Type 8 3 male 7 4 4 3 2 1 PIN RJ45 Pin 1 6 5 6 5 (2 pair) orange white/blue green white/blue orange brown brown white/brown white/brown blue blue green white/green orange green white/orange white/green white/orange white/orange white/green EIA/TIA T568 A EIA/TIA T568 B ETHERNET/IP RJ45 - M12: pin and colour assignment blue white orange yellow PROFINET 3 11 4 female
Installation Connection instructions • Do not remove the twist in the pairs of wires any more than necessary. • Do not add further twists to the pairs of wires. • Ensure a closed sheath film. c) Connecting RJ45 plug crimp 1 R emove sheath from cable according to assembly instructions for plug-in connector and strip the protruding braid to the rear over the cable sheath. Slide on anti-kink bushing.
Installation 4 Insert the RJ45 plug in the crimping tool and close the tool. This one step injects the contacts, braid and strain relief. Be sure to select crimping pliers to match the plug type because not all tools go with all plug. 5 Trim the protruding braid. 6 Slide the plug grommet over the assembled plug. Depending on the plug type, this protects the stop lever and ensures protection from bends and kinks.
Installation d) Connecting RJ45 plug which can be assembled on-site 2053260000/05/2015 1 emove sheath from cable according to assembly R instructions for plug-in connector. 2 ort the individual wires into the cable guides S according to the codes on the lower plug section and slide the cable as far forward as possible. 3 lose the strain relief around the cable and isolate C the protruding cable ends flush. 4 ress upper section of plug onto lower section.
Installation e) Connecting RJ45 module which can be assembled on-site 1 emove sheath from cable according to assembly R instructions for module. Slide protruding braid to rear over cable. 2 U ntwist the pair of wires. Cut the wires at an angle for simple sorting into the bottom cable guides. 3 120 lide or place the individual wires into the cable S guides of the lower module section by colour. Use one of the cable ties provided as strain relief. Isolate the protruding cable ends.
Installation 4 ress upper module section onto bottom section. P If necessary, use pliers wrench to support plug. Fix the braid with the second cable tie. f) Testing Test every cable that you route for: • correct assignment • end-to-end shield connection • short-circuit • split-pair errors Further requirements of measurements on copper cabling are defined in the PROFINET commissioning guideline. An extract can be found on the following pages.
Installation 3.7 Measurement on the copper cabling This chapter shows how the PROFINET copper cabling can be tested. Several measuring devices from the various performance classes are also mentioned by way of example. A distinction is made between: • simple cable tester (verification) • function tester (qualification) • acceptance tester (certification) 3.7.1 Cable testers Cable testers were developed to provide an easy way of testing Ethernet installations.
Installation Figure 3.2 shows the basic measurement setup for simple cable testing of PROFINET copper cabling. Basically it’s a case of testing an electrical connection, i.e. testing for connection and/or short-circuit and impermissible split pairs. The testers do not check cable parameters or whether data packets can be transferred via the cable. These testers can be used during installation to check cables for connection/short-circuit and to check for correct contact assignment on the plugin connector.
Installation 3.7.2 Function testers While the simple cable tester only tests for a correct electrical connection, the function tester checks the cabling section from the perspective of real Ethernet data transmission. Figure 3.3: Function measurement on the cabling This measuring device transmits pre-defined data packets over the cabling. The remote unit is the counterpart for responding to these packets.
Installation 3.7.3 Acceptance testers In certain cases, a simple function measurement with the function tester doesn't go far enough. A detailed measurement of cabling parameters (e.g. cable length, attenuation, crosstalk etc.) is needed. Such a measurement can be used to establish and document numerous cable parameters. After long periods of cable use, this can be useful if faults arise and the measured values from the acceptance measurement can be used by way of comparison. Figure 3.
Installation The component approach taken with PROFINET means that a compulsory acceptance test doesn't have to be run to check the cabling if using PROFINET components with a manufacturer's declaration. An acceptance measurement can however be undertaken to: • measure and document the cable length • measure and document the attenuation and other key cable parameters This gives you reference data that you can refer back to when testing the cabling later on.
Installation Using high-quality CAT. 6A components increases the distance from the permissible limit value and thereby improves the reliability of transmission. The above diagram clearly shows this distance to the red limit value curve.
Installation 3.8 3.8.1 Fibre-optic connection system POF (polymer-optical fibre) connection system a) Innovative quick-connection system for POF Standard connection system for POF Tools and aids Sheath stripping, cutting and crimping tool: IE-HTX-POF Remove the cable sheath (breakout) of the fibre-optic cable with a suitable sheath stripper. With zip-cord cables, separate the two cables slightly.
Installation 3 P lace POF inserts in tool: only close tool such that the inserts are firmly gripped. 4 Guide in fibres ntil they protrude on the other side of the tool, u then close tool all the way. 2053260000/05/2015 5 Inserts are now crimped and can be removed. 6 Slide inserts into housing. 7 You're done.
Installation 3.8.2 Glass fibre connection system a) Tools and aids Fast-cure adhesive set: The adhesive is used to fix the fibres in the plug. Select a fast-cure adhesive, which greatly simplifies and speeds up assembly. Sheath stripping tool: Remove the cable sheath (breakout) of the fibre-optic cable with a suitable sheath stripping tool. Stripping tool: Use the stripping tool to remove the cable sheath (zipcord), secondary coating and primary coating.
Installation Crimping tool: Use the crimping tool to crimp the crimp sleeve on the plug to establish a mechanical connection between the fibre-optic cable and plug. Stylus: Use the stylus to score the protruding glass fibres and then break them off. Polishing disc and polishing foils: These are used to hold the plug and polish the face end of the fibres. Microscope: You use this to check that the fibres are polished correctly.
Installation b) F ibre preparation and assembly taking the example of an SC plug on a fibre-optic glass fibre cable with the fast-cure adhesive (LC assembly is the same) Shake the bottles of adhesive and activator before using for the first time. 1 2 3 4 5 6 132 repare the cable in accordance with the P manufacturer's details. Use the metering tip to apply activator to the glass fibres and around 5 mm of secondary coating.
Installation 7 Score the protruding fibres with the stylus and break them off. 8 Hold the 30 µm (green) polishing foil in your hand, apply a little pressure and working in circular movements polish off the protruding fibres until only a little remains. 9 Place the 3 µm (pink) polishing foil on the base and evenly coat polishing foil with polishing liquid.
Installation 13 Insert plug in microscope (use adapter if necessary) and check the plug face end. If the surface quality is inadequate (scratches), the plug must be polished again. The plug must be replaced if the fibres break out. good 14 134 bad Test the photoconductivity with a source of light.
Installation Splicing Splicing is the practice of connecting two glass fibres by fusing them so that they cannot be taken apart. A special arc splicing device is used. The fibres, e.g. of the routing cables, are combined at their ends with "pigtails". The splicing device adjusts the trims of the glass fibres perfectly to one another. With modern devices, the trimming is fully automatic. The fibres are then fused (welded) with an arc.
Installation 3.9 Measurement on the fibre-optic cable This chapter describes how to assess your fibre-optic cabling. The measurement recommendations are based on the PROFINET commissioning guideline. 3.9.1 Attenuation measurement for fibre-optic cables The most important parameter to monitor on a fibre-optic cable section is its attenuation. The insertion loss process (Figure 3.5) is the easiest way to do this. The measurement process detects losses in the optical fibres and their connections.
Installation • What type of fibre has been laid (singlemode fibre, multimode fibre, hard cladded silica, plastic optical fibre)? • What plug type is used? • Roughly how long a section has been laid? Table 3.2 shows the types of glass fibre used by PROFINET and the permissible limit values for the PROFINET end-to-end link attenuation depending on the operating wavelength.
Installation The connections must feature a high-quality polish. The reference fibre may be used for no more than 500 reference measurements. Then the connections have to be polished again. Please treat the reference fibres with great care. After 2,000 reference measurements, the reference fibres should be replaced. Please also note the details provided by the manufacturer. Only special reference fibres may be used to connect the section requiring testing.
Installation 3.9.2 OTDR measurement Alongside the attenuation measurement procedure (insertion loss measurement procedure), the OTDR (Optical Time Domain Reflectometer) measurement procedure can also be used to measure fibre-optic cables. This can be used to determine faulty points in the fibre-optic cable. To do so, the device transmits a signal into the fibre-optic cable via a forerun fibre. An overrun fibre is also fitted downstream of the section.
Installation Assessment of the measurement results requires experience because the results are not displayed in plain text. The measurement results are normally produced in graph form. Figure 3.7 shows an example of the measurement results to be interpreted. Figure 3.7: Example of OTDR measurement Figure 3.
Installation Typical fibre connections are affected by various limitations which have a major impact on transmission behaviour. These limitations cause backscattering and additional attenuation. They include the various splicing connections and also the direct limitations of the fibres themselves from severe bending, fractures or cracks. Each of the limitations mentioned has its own typical reflection characteristic and can therefore be detected and analysed directly in the OTDR measurement.
Installation 3.10 Marking Ensure that the cables are marked in a clean and permanently legible way.
Installation 3.11 Measurement and documentation Cable measurements form part of the documentation required for many installations. This involves measuring the properties of the system's cables and documenting the quality of the network installed. 1 Set the measuring device to the appropriate transmission class. 2 Measure the transmission characteristics (copper) or attenuation characteristics (fibre-optic) of the cable. 3 Record the cable lengths. 4 Print out the values and add to the documentation.
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Glossary 4 Glossary Industrial Ethernet has brought with it new specialist terminology. Some of the most important terms are briefly explained here. 4B/5B A block coding diagram for FDDI and ATM. With 4B/5B coding, all data is divided into 4-bit units (a nibble) and recoded into 5-bit units (symbols) following a table.
Glossary (AWG) definition of cable diameter AWG stands for American Wire Gauge, a designation commonly used in the US for the cable diameter. It does not detail the real diameter, but a range. It cannot therefore be converted accurately into a metric measurement. For a comprehensive comparison of AWG values with the metric cable diameter, refer to http://de.wikipedia.org/wiki/American_Wire_Gauge. A brief overview is provided below AWG 28 26 24 22 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 mm2 0.
Glossary Bit rate The bit rate is also known as the speed of transmission, transmission rate or data rate. It describes the number of bits transmitted per unit of time (usually 1 second). Bridge According to their OSI definition, bridges connect sub-network protocols on layer 2 of the OSI reference model Broadcast As its name suggests, a broadcast transmission involves transmission from one point to all participants at the same time.
Glossary Ethernet Ethernet is a networking technology for local networks (LANs). Fast Ethernet Today Fast Ethernet is a very commonly used version of the Ethernet offering 100 Mbit/s via category 5 or higher twisted-pair cables. The maximum permissible range is 100 metres. Flow Control Flow Control is a function for adapting transmission to the receptiveness of the receiver.
Glossary Fibre-optic cable (FO cable) Type of cable with a glass fibre or plastic core which transports digital signals in the form of light pulses. GPRS (General Packet Radio Service) Extension of the mobile GSM standard for the packet-oriented transmission of data. Half-duplex mode The half-duplex process permits the alternating use of transmission cable in both directions. At the interfaces data can only be transmitted or received at any one time.
Glossary IPv6 The IP address range of IPv4 features a potential 4294 967 296 addresses but is barely sufficient for today’s network age. A larger Internet protocol was therefore produced a number of years ago. The address size is 128 bits compared with IPv4 which has 32 bits. IPv6 addresses are usually written in hexadecimal (IPv4: decimal) where the number is broken down into eight blocks of 16 bits each (four hexadecimal points). These blocks are listed separately using colons (IPv4: full stops).
Glossary Layer-2-Switch Data link layer. This is the level at which the unmanaged switches operate which can be incorporated in a network and only write an entry to the source address table using the MAC address and a physical port. This distinguishes the unmanaged switch from the hub.
Glossary MDI-X MDI-X stands for a crossed Ethernet connection. Transmit and receive interfaces were swapped. Auto MDI/MDI-X (autocrossing) enables the automatic adaptation of a port's transmit and receive cable, i.e. the connected Ethernet cable (crossed/not crossed) and the remote station's configuration (MDI/MDI-X) are automatically detected and the port configured accordingly. Media converter Media converters convert electrical signals into optical ones and vice versa.
Glossary PHY (Physical Layer) 1. Physical transmission layer 2. This designation is also used for a transceiver in Fast and Gigabit Ethernet. Point-to-point technology A connection variant which establishes a connection between two end devices. These point-to-point connections exist in the network environment, for wireless transmission in radio relay systems and in connections.
Glossary Remote management Remote management of a switch is undertaken by every network station fitted with Telnet or web browsers. It requires every switch to have its own IP address. Repeater A repeater is an active component which handles regeneration functions in Ethernet LANs, i.e. amplifies and processes signals.
Glossary SNMP (Simple Network Management Protocol) SNMP enables central network management for many network components. The primary goals of SNMP are reduced complexity of management functions, the extendability of the protocol and the independence of network components. SNMP is a standardised network management protocol which can be used to exchange statistics regardless of platform and set parameters. Elements of a network (e.g. router, server, switch, printer, computer etc.
Glossary Switches Switches are network components which perform switching functions. These switching functions can take the form of relaying functions in wide area networks and in local networks. Topology Structure of a network: • Line topology • Ring topology • Star topology • Tree topology Transceiver The word transceiver is made up of transmitter and receiver and describes transmission / reception equipment for fibre-optic networks.
Glossary Thanks An undertaking like the best practice guide is never the work of just a handful of people. We would like to thank the following people for their advice, input and support: André Gerlach from Bildungsinitiative der Netzwerk-Industrie (BdNI), Manfred Patzke and Jan Klüter, and the many other people working hard behind the scenes.
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