Industrial Communication: Chapter 4: Ethernet Modbus TCP/IP

Industrial Communication
Chapter 4: Ethernet Modbus TCP/IP
Ethernet Modbus TCP/IP Features
Industrial Communication Course with Unity Pro Ethernet Modbus TCP/IP Schneider Electric | Industry Business | Training | E. Pauchet V5.0 May 2010
Ethernet Is a Network
History
Developed by Xerox PARC (1973 - 1975) First standard to be published in 1980 (IEEE 802.3)
Sharing Information Network
Ethernet Modbus TCP/IP

Modbus Frames over Ethernet
Modbus Serial
Ethernet Modbus TCP/IP
Layers Used Ethernet Modbus TCP/IP

Osi Model:
APPLICATION PRESENTATION SESSION TRANSPORT NETWORK DATALINK PHYSICAL Modbus Protocol Not used Not used Ensure the transfer of the data on the network (TCP/UDP) Message Routing IP Protocol CSMA-CD (random access with collisions) Defines physical media: RJ45, Fiber Optic, Radio,
Industrial Ethernet
Used in Different Levels
Scada/HMI monitor and control multiple PLCs.
PLCs remote control the I/O devices, the speed drive, robots,
TCP (Transport Control Protocol)

Port and socket concept
Server devices may be running multiple services (Modbus, Web, Bootp,etc ) These services listen on different TCP port for a request Client device sends an IP message which includes the source port number and destination port number to establish a connection between two devices (Socket connection).
Ports
80 50
Client
Source Port number x Destination Port 502 Destination Port 80 Source Port number y
Server
502 HTTP SMTP Modbus TCP
172.16.4.2 172.16.4.1
Ports number 23 Telnet 50 SMTP 67 DHCP 80 HTTP 502 Modbus
TCP (Cont.)
Socket management multiple connections
A Client can have multiple connections to the same Server service A Server can have multiple Clients connected to the same service
Client x Client has a 2 connections to the same server. 172.16.4.1 Client y

Socket 1 Source port 3003 Dest port 502 Socket 1 2 Source port 3000 3001 Dest port 502 80
Server Server has 2 clients connected to the same service (502). 172.16.4.3
172.16.4.2
TCP Connections
Point to point messaging protocol
Uses a handshake process to establish a connection Accounts for each byte of sent and received to guarantee delivery Connection is managed by setting bits in the TCP message to request (SYN), acknowledge (ACK), terminate or abort the connection (FIN)
Request conne ction SYN
Client
to connect SYN/ACK Request acknowledged OK

Acknowledge OK sending da ta ACK / PUS H
O P E N
Server
ed ACK Acknowledged all data receiv

Done sending ction FIN closing connection FIN /ACK data close con ne
Acknowledged
Acknowledge d connection cl osing ACK

C L O S E
9
IP (Internet Protocol)
IP: Messaging Protocol Operating at OSI Layer 3 (Network layer) IP Characteristics
Responsible to transmit the message to the destination IP address to the local network or to the remote network. Fragment a packet that is larger than the maximum transmission size unit (MTU) to send as multiple packets and de-fragment the packet at the destination level. It makes no guarantee that the message will reach its destination. The reliability is done by the Transport layer
10
IP Address Assignment
Default IP Address
Derived from the factory and unique MAC address
Premium & M340 PLCs
MAC @ IP @
Quantum/Momentum/Advantys
MAC @ IP @
00 - 80 - F4 - 12 - 0C - AF = 85 . 16 . 12 . 175 - First 2 bytes are decimal 85 & 16
00 - 00 - 54 - 12 - 0C - AF = 84 . 18 . 12 . 175 - Hex to Decimal conversion of last 4 bytes
- Hex to Decimal conversion of last 2 bytes
Unique IP Addresses for Each Device

In addition to MAC Hardware addresses, each devices is assigned a logical IP address. Assignment can be static or dynamic Example : 139 . 160 . 12 . 85
The IP address contain 4 bytes and each byte has a range from 0 to 255.
11
Classful IP Address
There are 4 main address classes
Class A - Used for larger networks IP Address Range : 1.0.0.0 to 127.255.255.254 Default subnet mask : 255.0.0.0 - 16 777 216 hosts number Class B - Used for Medium networks (ex. Schneider Electric) IP Address range : 128.0.0.0 to 191.255.255.254 Default subnet mask : 255.255.0.0 65 534 hosts number Class C - Used for smaller network and individual users IP Address range : 192.0.0.0 to 223.255.255.254 Default subnet mask : 255.255.255.0 - 254 hosts number Class D - Used for Multicast groups IP Address range : 224.0.0.0 to 239.255.255.255 Devices cannot be assigned IP addresses in the multicast range The Class E is reserved for the future : 240.0.0.0 to 255.255.255.255
Industrial Communication Course with Unity Pro Ethernet Modbus TCP/IP Schneider Electric | Industry Business | Training | E. Pauchet V5.0 May 2010 12
Special IP Addresses
Loopback
IP address = 127.0.0.1 Reserved for loopback (host connecting to itself) Ex. A web browser connecting to a web server running on the same PC
Broadcast
IP address = 255.255.255.255 Used by the network management or diagnostics is addressed to all devices on the network.
13
Subnet Mask
Used to determine if the remote device is on a local or remote network
The mask separates the network portion of the IP address from the host portion of the IP address The sending device uses its configured subnet mask to perform a Boolean AND operation with both its local IP address and the IP address of the remote device to connect to
IP Address 172.16.5.20 Local device Subnet Mask 255.255.255.0 Result IP Address 172.16.4.20 Remote device Subnet Mask 255.255.255.0 Result
10101100.00010000.00000101.00010100 AND 11111111.11111111.11111111.00000000 10101100.00010000.00000101.00000000 10101100.00010000.00000100.00010100 AND 11111111.11111111.11111111.00000000 10101100.00010000.00000100.00000000
14
Troubleshoot TCP/IP
In Windows Monitoring Free Tool: WireShark
http://www.wireshark.org/
15
Troubleshoot TCP/IP
Ping Command
Used to check a connection
Launched from the DOS window (under XP)
16
Exercises
IP Address (p4-19) Find your IP address (record it for future use) Change the IP address into 192.168.0.X1 or 192.168.0.1X1 (X=Group Number) Troubleshoot TCP/IP (p4-23) Use PING command to ping your partner
17
Dynamic Assignment
IP Assignment Given By Servers
Switch
Request for IP @ Request for IP @ Server
Switch
Client
Your IP @ Your IP @
18
BootP Server
Server Has a Populated List of Devices
Devices identified with their MAC address Device #1
My MAC address is 00.80.F4.FF.00.D5, Can I get an IP Address?
Master (Server)
00.80.F4.FF.00.D5 192.168.0.23 192.168.0.81 192.168.0.40 00.80.F4.FF.44.21 00.80.F4.FF.F2.15
Sure! You are listed in my address table. Take this address: 192.168.0.23
Device #2
My MAC address is 45.80.F4.FF.33.12, Can I get an IP Address?
Sorry, you are not listed into my address table. Use your default IP address
19
BootP Server (Cont.)

Example in Unity Pro
Limitation: Device Cannot Be Changed without Reconfiguration

As each device has a unique MAC address, replacing a failed device needs a reconfiguration of the BootP Address Server table.
20
DHCP Server
Same As BootP but Based on Role Name
User configurable names used instead of MAC Addresses Device #1
My name is STBNIP2212_023, Can I get an IP Address?
Master (Server)
STBNIP2212_023 192.168.0.23 192.168.0.87 192.168.0.21 TesysT_046 ATV71_555
Sure! You are listed in my address table. Take this address: 192.168.0.23
Device #2
My name is TesysT_072, Can I get an IP Address?
Sorry, you are not listed into my address table. Use your default IP address
21
DHCP: How To Create Role Names

Depends on The Device
Using embedded HMI (ex: ATV71) Using web based applications (ex: Advantys STB) Using dedicated applications (ex: Unity Pro) Using hardware switches (ex: Tesys T, Advantys STB)
Hardware Switches Example:

Base name + Custom number derived from Switches STBNIP2212_123
22
DHCP Server
Example with Unity Pro
Advantage: Easiness of Replacement

Compared to the BootP method, replacing a faulty device with DHCP doesnt need to reconfigure the PLC application.
23
FDR Server
Additional Feature of DHCP Server.
Send the stored configuration inside a replaced device Device #1
My name is TesysT_072, Save my settings now!
Master (Server)
TesysT_072 192.168.0.87
Saved Config. of TesysT_072
Device #1
My name is TesysT_072, Can I get an IP Address?
Master (Server)
TesysT_072 192.168.0.87
New Device
Sure! You are listed in my table. Take this address: 192.168.0.87 Moreover, I found a configuration corresponding to your role name. Here is your new configuration.
Saved Config. of TesysT_072
24
ARP
Address Resolution Protocol
Request to obtain IP address Duplicate Address Check Device issues ARP for the IP address it intends to take If no response, the device assumes the IP address If there is a response, the device should not assume the IP (duplicate address)
Once the IP has been determined to be available

Device issues a Gratuitous ARP (Includes Source IP and MAC address information) Used to populate device list in the other devices and routers Advertises to others its availability on the network Allows devices wishing to communicate with it that it is available
25
UDP (User Datagram Protocol)

Transport protocol like TCP but without Acknowledgement
Provides an unreliable mechanism to transport data Messages can be lost (not acknowledgment of the packet) Retries and data integrity can be provided by the application layer
Requires less processing overhead that TCP

Without ordering messages and managing connections. it is faster than TCP The network interface does not have as much work to do as with TCP
Allows the Broadcast message, unlike TCP that requires a dedicated socket between the end device. Applications example using UDP :
Simple Network Management Protocol (SNMP) Network Time Protocol (NTP) BootP and DHCP Global Data (Real Time Publish Subscribe)
26
Software Tools
Windows PING Command Unity Pro Online View
Ping and bandwidth
Wireshark software (free)

Recording Ethernet frames
BOOTP-DHCP Server Tool (from Rockwell Automation)

Use your PC as Server to assign IP Addresses
ToolBox Ethernet Modbus TCP-IP v2.2 (from NZ TechSupport)

Send Modbus requests over TCP/IP
27
Network Design: Media

Media
Copper media Twisted pairs wires Easy to install : low cost installation
Fiber optic
Adapt different types of media Using over long distances or harsh industrial environment
28
Network Design: Copper Media

Rated by category Categories established by ANSI/EIA/TIA Committee
Industrial applications recommend Shielded media for additional protection from external sources of interference
Uses Standard 8 pin RJ-45 Connector

Cat 5 : Minimum required for 100Mbs Ethernet (unshielded cable) Cat 5e : Enhanced for 100Mbs Full Duplex operation (shielded cable) Cat 6 : New standard for 1 Gbs operation
The maximum length of one segment is 100 meters at 10, 100, 1000 Mbit/s.
29
Network Design: Fiber Optic

Glass or plastic fiber designed to guide light along its length by total internal reflection. Permits digital data transmission over longer distances and at higher data rates than other forms of wired and wireless communications (up to 20km)
SC connector
ST connector
Bayonet style connector
Keyed square connector May be coupled together
LC connector MTRJ connector Newer keyed Fiber connector Smaller form factor : higher density
Small form factor, keyed connector
30
Network Design: Wifi

Wireless Communication
Available soon in Schneider Electric (already available with partners) Main issues are security and EMC behavior
31
Network Design: Components

Hubs or switches
Hubs are not recommended for industrial application
Connexium Switch
Transceivers
Adapt different types of media Ex. 499NTR10100 : converter electrical signal to optic signal
499NTR10100
Routers
Used to route information between networks
32
Network Design: Hubs

Half Duplex (Collisions)
Each and every frame is repeated out all ports by hub All nodes listen to see if they are the receiver of the frame As more nodes are added and collisions increase, performance decreases If two devices transmit simultaneously, a collision occurs
Hub
Collision
Transmitter 1
Receiver
Transmitter 2
33
Network Design: Hubs

Full Duplex (Collisions)
Switch learn the addresses of the devices attached to them Switch full duplex can simultaneously transmit and receive a message
Switch full duplex
The Switches are extremely recommended for the Industrial application.
Transmitter 1
Receiver
Transmitter 2
34
Network Design: Routers

Routing data between different sub networks
Act as a Gateway (IP address to be defined) A router has an interface for each different networks. A table of those interfaces tells the router on which interface to send the packet
PLC
Router
172.16.4.254 172.16.4.1
172.16.5.254
172.16.5.1
Local Subnet
172.16.4.2
Each router interface is the default gateway for that subnet
Remote Subnet
Nota : If there is not a router on the local network, the default gateway can be left blank or 0.0.0.0
35
Network Design: Topologies

Bus topology Tree / Star topology
Switches in series, end devices connected to switches
Switches in a star or tee-like arrangement
Ring topology Daisy Chain topology
Switches form a ring or circle

No switches needed
36
Network Design: Point to Point Cables

Straight Cable
Connect end devices to hubs or switches
Switch or Hub
End Device
Crossed Cables
Connect hubs or switches together
Switch or Hub
Switch or Hub
37
Programming with Unity Pro
38
2 Ways of Configuration
Normal Ethernet Ports
CPU Embedded Ports (BMXp442030, TSXP572634) Ethernet Modules (BMXNOE0100, TSXETY5103)
Configuration done from project browser
DTM Compatible Ports

Converged Modules (BMXNOC0401, TSXETC101, )
Configuration done from the DTM browser

Standard Configuration
From Project Browser, Select the Network Component
Right click and create a new network
Once Created, Link it to the Module
40
Network Configuration
Options Depends on the Model
Modules Utilities
Modules Utilities
IP Configuration Messaging
Access rights from other devices.
SNMP (Simple Network Management Protocol)

Used by software monitor and manage devices on an IP network. (ConnexView)
SMTP (Simple Mail Transfer Protocol)

Parameters for sending and receiving e-mail.
IO Scanning Global Data Address Server

configures the DHCP and BOOTP services included in the module.
NTP (network time protocol)

Define the time synchronisation server
Common Words (Premium Only)

used to configure words shared on EthWay
Bandwith
estimation of the Bandwith taken by the different services.
IP Configuration
Static (Configured) Dynamic (From a server)
Assign a role name (optional)
Configuration Must Match with Rotary Switches!
43
Exercise
Ethernet Configuration (p4-38) Create a new project Create a new network Test the connection Configure the role name of the slave Configure the DHCP Test the configuration
44
Explicit Exchange Data

Function Blocks
ADDM: Address Conversion : used to provide the target address for others function blocks (M) ADDR: Address Conversion : used to provide the target address (P) CREAD_REG: Continuous Register Reading (Q) CWRITE_REG: Continuous Register Writing (Q) DATA_EXCH: Exchanging Data (M,P) MBP_MSTR: Multiple Functions (Q) READ_REG: Read Register (Q) READ_VAR: Reading variables (M, P) SEND_EMAIL: Sending Email (M) SYMAX_IP_ADDR: target address to reach legacy SquareD PLC (Q) TCP_IP_ADDR: used to provide the target address (Q) WRITE_REG: Write Register (Q) Online Help ! WRITE_VAR: Writing variables (M, P)
ADDM FB
IN:
String variable: NameOfTheNetwork{TargetIPAddress}
Out
Converted table of words, to be used in the others FB
46
READ_VAR FB
IN:
ADR: to be linked to the output of the ADDM block. OBJ: defining object to read (in the case of Modbus register: %MW) NUM: starting register to read NB: number of consecutive register to read
OUT
RECP: reception zone of the block, delivering the value read (table of words)
IN/OUT
GEST: table of 4 words to manage the communication block (errors, timeout, length, etc..)
47
WRITE_VAR FB
IN:
ADR: to be linked to the output of the ADDM block. OBJ: defining object to read (in the case of Modbus register: %MW) NUM: starting register to read EMIS: source table to write from the PLC
IN/OUT
GEST: table of 4 words to manage the communication block (errors, timeout, length, etc..)
48
Exercise
Sending Requests (p4-42) Enable Allow Dynamic Arrays in Project Settings Insert the ADDM FB Insert READ_VAR and WRITE_VAR FB Test the configuration
49
Implicit Exchange: IO Scanning

Table of Words Exchanged Automatically Between Master & Slave
Master / Client
Slave / Server
50
IO Scanning
Filling the Different Fields
51
IO Scanning (Cont.)
Debug View Online Mode (M340 and Premium Only)
IODDT Can Be Configured
52
IO Scanning Specific Integration Tool

Only with Compatible Devices
PRM / OTB / STB
53
Exercise
IO Scanning Configuration (p4-48) Configure IO Scanning Testing IO Scanning Monitoring IO Scanning Status Retrieving Process Data Values Advantys STB Integration Tool (p4-52) Create the device Test the configuration
54
FDT / DTM Configuration

Field Device Tool
Vendor tools integrated inside one tool Tools are Device Type Managers (DTM)
Benefit: Common Environment:

User Management DTM Management Data Management Network Configuration Navigation
HART
Frame Application
(Device Type Manager DTM)
HART
55
Device Tool Managers

Modbus, Ethernet, etc..
Communication DTM
Communication Driver
Gateway DTM
Gateway Driver
Device DTM
Device Driver
BTM
BTM
56
DTM in Unity Pro

DTM Browser
Integrated DTM (implemented when module added from the PLC_Bus) Dedicated DTM (devices that can interact with Unity Pro application) Third Party DTM (Unity Pro used as any other FDT frame application)
Tools DTM Browser
57
Hardware Catalog
DTM Database
Tools Menu Hardware Catalog
Update Tool
Used to add New devices inside the catalog DTM must be installed in Windows before
- DTM Config saved into STU or STA (not XEF) - DTM must be installed on the computer (otherwise project cannot be saved)
DTM Transfer
With Project Transfer
Integrated DTM
Direct Ethernet Communication

Dedicated or Third Party DTM
Field Device Switch
PLC
59
DTM Transfer for Non Integrated DTM

From DTM Browser, Select Connect then Store data to device
60
NOC0401 Configuration
Added in Unity Pro
PLC_Bus Viewer
Integrated DTM Module
DTM Browser
Add a Modbus Slave

Generic Modbus Slave DTM Installed Modbus Slave DTM
Example: Advantys STB DTM
62
Configure the Slave

Properties
Customize IODDT Variable Names
Address Setting
Enter static or dynamic IP configuration
Request Setting
IO Scanning configuration inside the module
63
Monitoring Connection
Connection Bit
Monitoring if device is present
Control Bit
Enable / Disable IO Process Data update
64
Exercises
Change the Device Role Name (p4-64) Assign new name to distinguish from previous exercise Installing the DTM (p4-65) Installing DTM & Update the hardware catalog Configuring NOC0401 and Modbus TCP/IP (p4-67) Insert BMXNOC0401 and configure it Add a Generic Modbus device and configure it Create custom variable names Test the application Do the same by configuring device from DTM
65
EtherNet Modbus TCP

Main Features Reminder:
up to 100m in 100BASE TX (RJ45 cables) at 100Mbit/s - up to 1Gbit/s Performances <10ms if 802.1Q is respected (with Connexium switches) Thousands of devices (depends on the IP config.) but IO Scanning Limitations Max 240 bytes per telegram No separate ground line Excellent error detection thanks to TCP Configuration by DTM Easy to debug (no need of additional hardware on the computer)
66

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Industrial Communication

Chapter 4: Ethernet Modbus TCP/IP

Ethernet Modbus TCP/IP Features

Sharing Information Network

Ethernet Modbus TCP/IP

Ethernet Modbus TCP/IP

Layers Used Ethernet Modbus TCP/IP

Scada/HMI monitor and control multiple PLCs.

TCP (Transport Control Protocol)

502 HTTP SMTP Modbus TCP

Ports number 23 Telnet 50 SMTP 67 DHCP 80 HTTP 502 Modbus

Client x Client has a 2 connections to the same server. 172.16.4.1 Client y

to connect SYN/ACK Request acknowledged OK

ed ACK Acknowledged all data receiv

Acknowledge d connection cl osing ACK

00 - 80 - F4 - 12 - 0C - AF = 85 . 16 . 12 . 175 - First 2 bytes are decimal 85 & 16

00 - 00 - 54 - 12 - 0C - AF = 84 . 18 . 12 . 175 - Hex to Decimal conversion of last 4 bytes

- Hex to Decimal conversion of last 2 bytes

Unique IP Addresses for Each Device

10101100.00010000.00000101.00010100 AND 11111111.11111111.11111111.00000000 10101100.00010000.00000101.00000000 10101100.00010000.00000100.00010100 AND 11111111.11111111.11111111.00000000 10101100.00010000.00000100.00000000

Launched from the DOS window (under XP)

Request for IP @ Request for IP @ Server

My MAC address is 45.80.F4.FF.33.12, Can I get an IP Address?

BootP Server (Cont.)

Limitation: Device Cannot Be Changed without Reconfiguration

My name is TesysT_072, Can I get an IP Address?

DHCP: How To Create Role Names

Hardware Switches Example:

Advantage: Easiness of Replacement

Saved Config. of TesysT_072

My name is TesysT_072, Can I get an IP Address?

Saved Config. of TesysT_072

Once the IP has been determined to be available

UDP (User Datagram Protocol)

Requires less processing overhead that TCP

Wireshark software (free)

BOOTP-DHCP Server Tool (from Rockwell Automation)

ToolBox Ethernet Modbus TCP-IP v2.2 (from NZ TechSupport)

Network Design: Media

Network Design: Copper Media

Uses Standard 8 pin RJ-45 Connector

Network Design: Fiber Optic

Bayonet style connector

Keyed square connector May be coupled together

Small form factor, keyed connector

Network Design: Wifi

Network Design: Components

Network Design: Hubs

Network Design: Hubs

The Switches are extremely recommended for the Industrial application.

Network Design: Routers

Each router interface is the default gateway for that subnet

Network Design: Topologies

Switches in series, end devices connected to switches

Switches in a star or tee-like arrangement

Ring topology Daisy Chain topology

Switches form a ring or circle

Network Design: Point to Point Cables

Programming with Unity Pro