This document discusses testing industrial ethernet networks like PROFINET. It defines different types of network tests: verification tests check cabling, qualification tests check signal quality, and certification tests check the entire network. The challenges of testing these networks are also examined, such as complex device configurations, bandwidth competition causing packet loss, and time pressures of on-site commissioning. Solutions discussed include portable network testers that can simplify testing and identify issues through features like one-touch health checks, cable verification, and performance monitoring.

1. A quick way to address field network issues effectively
The Field Test Challenge of PROFINET
Industrial network commissioning &
testing

2. 2PROFIBUS UK 2Editable name of event
Guidelines1
Test types2
Designers Responsibilities3
Network Diagrams4
Commissioning and testing5
© 2017
Agenda

3. 3PROFIBUS UKPROFIBUS, PROFINET and IO-Link Seminar – June 2019
Installation & Commissioning Guidelines
© 2017

4. 4PROFIBUS UKPROFIBUS, PROFINET and IO-Link Seminar – June 2019
Examples of test results
Test types - definition of terms
Verification (simple line test)*
Basic cabling structure test
Check for correct wiring
Qualification (functional test)*
Identifying performance of data transmission
Certification (acceptance test)*
Classical network acceptance tests
Assessment according to defined standards (e.g.
IEC11801 or in our case PROFINET Commissioning
Guidelines)
Troubleshooting
Typical Ethernet problems
* PROFINET Commissioning Guideline V1.36 PNO Dec. 2014
© 2017

5. 5PROFIBUS UKPROFIBUS, PROFINET and IO-Link Seminar – June 2019
Cable Verification in Practice
Qualification and Verification – PROFINET
Verification test – Wire test
Confirm accurate wiremap from plug to plug
Opens
Shorts
Crossed wires
Measure length of cable
Easy to use or cheap?
Manual or automatic?
© 2017

6. 6PROFIBUS UKPROFIBUS, PROFINET and IO-Link Seminar – June 2019
Qualification and Verification - PROFINET
Qualification test – Functional test
Determination of signal-noise-ratio (SNR)
Noise sources: NEXT *, FEXT *, echo noise, environment noise
BERT (Bit-Error-Rate-Test) or Packet-Error-Rate-Test
Sends Ethernet frames with 100Mbit/s; okay if 10s without losing frames
Evaluation based on Ethernet error tolerances according to IEEE 802.3.
Determination of runtime difference between wire pairs
Fastest pair is 0ns **
e.g. limit for 1000BASE-T: 50ns
© 2017
* NEXT: near end crosstalk
FEXT: far end crosstalk
** (PROFINET works with two wire pairs. In the ideal case both pairs should have the same runtime)
Test line

7. 7PROFIBUS UKPROFIBUS, PROFINET and IO-Link Seminar – June 2019
Near end and Far end cross talk
NEXT and FEXT
Cross talk in UTP cables is caused by
capacitive coupling between pairs. Signals on
pair A cause noise signals on pair B, and often
the cross talk noise proves to be the limiting
factor
Cross talk occurs in two ways. Nearend cross
talk (NEXT) happens when a signal from a
transmitter at one end of a cable interferes
with a receiver at the same end of the cable.
Far-end cross talk (FEXT) occurs when a signal
interferes with a receiver at the opposite end
of the cable from the transmitter
© 2017

8. 8PROFIBUS UKPROFIBUS, PROFINET and IO-Link Seminar – June 2019
Test Report – Verification and Qualification
Clear details of each
cable
Report for end
customer or
management
© 2017

9. 9PROFIBUS UKPROFIBUS, PROFINET and IO-Link Seminar – June 2019
Certification (acceptance test)*
Some of the Classical network
acceptance tests
Full System Inventory – does it match?
Network Topology – does it match?
Packet loss rate?
Network Load
© 2017

10. 10PROFIBUS UKPROFIBUS, PROFINET and IO-Link Seminar – June 2019
Designers Responsibilities
© 2017

11. 11PROFIBUS UK 11PROFIBUS, PROFINET and IO-Link Seminar – June 2019 © 2017
Designers Responsibilities

12. 12PROFIBUS UK 12PROFIBUS, PROFINET and IO-Link Seminar – June 2019 © 2017
Designers Responsibilities
12
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RGF3
40 44 39 41
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Rep
Seg 1 18m
5m 7m 5m 17m 10m 8m 7m 10m
17m 24m 56m 1m 5m 7m 4m 7m 16m 5m 9m 24m
3m 7m
45
9525
37
RGF4
16m
5m
25m

13. 13PROFIBUS UKPROFIBUS, PROFINET and IO-Link Seminar – June 2019
The change from fieldbus to Ethernet
The change -
Communication link from Fieldbus to Industrial Ethernet
Topology - linear daisy chain with limited node
devices (126) to ring, star, liner mixture with
unlimited of node devices linked.
Media - Simple twisted copper pair to copper,
fiber, wireless. Copper from one pair to four pairs
Speed - Typical Kb/s to 100Mb/s or 1Gb/s
Scale - Self contained to open flexible scaling
Complexity - Simple RS485 serial protocol (244
bytes) to complex PROFINET protocol (1440 bytes)
Control – Master/Salve to Provider/Consumer
Device – Extra network devices (switch, router,
Access Point, firewall etc.)
© 2017
Controller
I/O
#1
I/O
# N
I/O
#2
…
…
Controller
SWITCH
I/O
#1
I/O
# N
I/O
#2
AP

14. 14PROFIBUS UKPROFIBUS, PROFINET and IO-Link Seminar – June 2019
Time pressure on site commissioning test
Longer time spend on commissioning test when the nodes and
network getting bigger and complex
More time required for trouble shooting when things go wrong
due to the complexity
Shortage of high skilled person
Lack of knowledge and skilled person in shop floor to handle
Ethernet (PROFINET) communication network
Whole network access right and the risk of causing
production line down
Security concerns to share whole network access right with others
Limited budget of monitoring tool
Especially for the small network for fixed monitoring system
Limited space or difficult position to access cabinet
with laptop
© 2017
The challenge -
The field test of network communication (I)
Access Right

15. 15PROFIBUS UKPROFIBUS, PROFINET and IO-Link Seminar – June 2019
Complex node device configuration and network
trouble shooting in commissioning and maintenance
stage vs fieldbus
Multiple domains/Aspects to configure the Node Devices
comparing fieldbus
Physical layer involved different media – copper (multi cores
4-8 instead of two), fiber (bending, dirtying, mating
connector and fusion), wireless access (coverage,
interference, security)
Ethernet Link/IP layer setup – speed, duplex, MTU, protocol,
multiple switches, IP address, subnet mask, gateway, DNS etc.
Multi vendors devices’ compatibility (monitoring system,
interaction) and inter link communication
Unknown/miss configured devices connected to the existing
network
Network bandwidth competition – abnormal node device
behavior using extra bandwidth to compete with other
© 2017
The challenge -
The field test of network communication (II)
IP address
The complex node device & parameters

16. 16PROFIBUS UKPROFIBUS, PROFINET and IO-Link Seminar – June 2019
Packet loss mechanism
The network device – Switch has a unique network
behaviour.
Each I/O has built-in switch
Ethernet Link Key Performance Indicator (KPI)
Bandwidth
Delay (Latency)
Jitter
Packet Loss
Network bandwidth competition – one of the common
sources to cause packet loss, delay and jitter.
Each switch will discard received errored packets based on
FCS regardless the priority set of the traffic on packets
Controller link is the bottle neck of the bandwidth
competition causing KPI degradation.
© 2017
The challenge -
The bandwidth, packet error, delay & jitter relation
Bandwidth
Delay (Latency)Jitter
Packet Loss
When Buffer Full
Rx Error
Error Packets Dropped
I/O 1 I/O 2

17. 17PROFIBUS UKPROFIBUS, PROFINET and IO-Link Seminar – June 2019
Current available tester solutions in market
Reduce commissioning and trouble shooting time
Network health checking with easy status indication – Traffic light
Identify and locate the fault quickly
Quantified link performance check – Bandwidth, Packet error, jitter,
delay
Long term monitoring error event – know when, where what error
Comprehensive test report for the acceptance test
Simplify the test procedure for low skilled users
One key scan to know all the network status
Pass/Fail with traffic light indication of each device
Spot on the failed configuration or status location of device(s) easily
without expert on site
Risk control of limited network access right to free up
specialist time
Limited access control functions of network with monitoring only
Handing over routing job to front line operators
© 2017
The solution -
Field tester requirements (I)

18. 18PROFIBUS UKPROFIBUS, PROFINET and IO-Link Seminar – June 2019
Current available test solutions in market
Easy carry to access field test point with multiple
functions
Small form factor and light to access awkward access position
of the production line easily.
All in One – Multi-layers testing from physical layer copper,
fiber & Wi-Fi to Link/IP and PROFINET protocol layer
Non-intrusive test access via spare port or mirrored port of
switch
Support multi-protocol of industrial Ethernet production
Affordable to the majority of the automation lines
High price performance
Easy operation with less or no training
Used for multi production lines/plants
Low total ownership cost using existing file storage system
© 2017
The solution -
The field tester requirements (II)

19. 19PROFIBUS UK
How do I know which nodes are present in the network and their health status?
The scanned node list using the traffic light system gives you the answer!
Device list with
individual
health
indication
Total Nodes
and Overall
test status
Test Scenarios – Example
Field Maintenance Test – Network Health Status
…
Controller
SWITCH
I/O
#1
I/O
# N
I/O
#2
A tester view sample

20. 20PROFIBUS UK
Test Scenarios – example
Field Maintenance Test – Node Device change
How can I configure the faulty replacement/wrong device quickly to resume the production without PC?
Setup function allows device configuration without PC software instantly and no need for network specialists on site.
…
Controller
I/O
#1
I/O
# N
I/O
#2
New
I/O
#2
o Flash LED to check right device to setup
o Setup IP address, name, factory default
o Scan the network again after replacement
Sample of tester GUI
SWITCH

21. 21PROFIBUS UK
Test Scenarios – example
Field Commissioning/Acceptance Test – Cable
How can I verify that the PROFINET cable is made correctly in the field by installers?
PROFINET wiremap test is assuring the quality of cable installed during the installation and checked in commissioning.
…
Controller
I/O
#1
I/O
# N
I/O
#2
A B
PROFINET cable
under test
#1
Remote
M12 D
or X
coded
Adapter
Cable
RJ45
M12
M12 D or
X coded
Adapter
Cable
M12
RJ45
SWITCH
Sample of PROFINET cable test result

22. 22PROFIBUS UK
Test Scenarios – example
Field Commissioning Test – Network Comparison
How can I find the new commissioned production line issues in the field quickly?
The NetMAP comparison function makes verifying and troubleshooting new production line faster.
Controller
I/O
#1
I/O
# N
I/O
#2
Controller
I/O
#1
I/O
# N
I/O
#2
Dismantle, ship and reassembly
back in the plant
NetMAP A
NetMAP B
…
…
(Ref)
SWITCH
SWITCH
Sample of tester GUI

23. 23PROFIBUS UK
Test Scenarios – example
Field Commissioning Test – Bandwidth Usage
1
Controller
I/O
#1
I/O
#N
I/O
#2
How do I know the bandwidth usage of individual device as well as where the network bottle neck is?
Bandwidth measurement with PROFINET scan and mirror port link test gives you the insight.
SWITCH
…
Mirror Port 1 to 8
1
8

24. 24PROFIBUS UK
Test Scenarios – example
Field Trouble Shooting – Event log
Controller
I/O
#1
I/O
#N
I/O
#2
How can I isolate the cause of the intermittent fault quickly in a PROFINET production line?
Event log can assist you to identify what and when the error appeared on a specific device.
SWITCH
…
Sample of tester GUI

25. 25PROFIBUS UK
Test Scenarios – example
Field Network Maintenance – Network Health Trend
How can I do the preventive maintenance to minimise the down time and spare parts storage?
The live network health status comparison gives you the insight of trend on any changes.
Controller
I/O
#1
I/O
# N
I/O
#2
Controller
I/O
#1
I/O
# N
I/O
#2
A month later to test again on
the same network
Result May
Result June
…
…
May
Test
SWITCH
SWITCH
Production 7
Tested
2 May 2019
Production 7
Tested
2 June 2019
June
Test

26. 26PROFIBUS UK
How can I prove the network I commissioned is working correctly?
The PDF and CSV formatted test reports meet both the direct filing and integrated to the project report.
A sample of PDF test report summary page A sample of CSV formatted test report for easy
Test Scenarios –
Field Commissioning Test – Test Report example 1

27. 27PROFIBUS UK
Test report sample of PDF detailed test items
Test Scenarios –
Field Commissioning Test – Test Report example 2
How can I trace back to the original network commissioned setup record on specific node devices?
The comprehensive detailed test reports saves your time significantly to find a specific device’s setup.

28. 28PROFIBUS UK
Q & A
Thanks
for your
attention
All of the Documents below are available to
download on the PI Website*
PROFINET Design Guidelines
Network Load Calculation Tool
Installation Guideline for Cabling and
Assembly
Commissioning Guidelines
PROFIBUS Design Guidelines
PROFIBUS Assembly Guidelines
* You may need to be a member to access some documents
Dave Tomlin
Hitex UK Ltd 02476 692066
dtomlin@Hitex.co.uk
www.hitex.co.uk
UK Technical distributor for Softing
Industrial Automation Tools.
Xing Ye
Ideal Networks Ltd
Xing.Ye@idealnwd.com
www.idealnetworks.net