Designing Third Party

Communications
Communication Protocols
• The Communication protocols is the way to trans-receive the data with a
set of rules that sends or receives between two or more devices. The
communication protocol is the media or channel between two or more
communicating devices. By using the communication protocols, two
devices can connect and communicate with each other. Without
communication protocol, devices can only be connected but not
communicated.
• Many PLC manufacturers like Siemens, Allen-Bradley, Mitsubishi offer
proprietary networking systems that are unique and will not
communicate with another make of PLC. This is because of the different
communications protocols, command sequences, error-checking
schemes, and communications media used by each manufacturer.
Communication Protocols in PLC
• Modbus RTU
• Modbus TCP/IP
• Profibus
• Profinet
• Ethernet I/P
• Fieldbus
Modbus RTU
• Modbus RTU is an open serial protocol derived from the
Master/Slave architecture originally developed by Modicon (now
Schneider Electric).
• It is a widely accepted serial level protocol due to its ease of use
and reliability.
• Modbus RTU is widely used within Industrial Automation Systems
(IAS), Home Automation, Building Management, Robotics etc.
• Most commonly used Modbus RTU Physical media’s are
RS232
RS485
RS-232
• RS-232 is an asynchronous communications method.
• RS-232 used for point to point communication, Connects only
between 2 devices for communication.
• In RS-232 communication the distance between two devices should
be below 10 meters
RS-485
• RS-485 is one of multi-drop and two wire type communication that allows us
to communicate to multiple devices at the same time.
• According to the standard, up to 32 devices can be connected at the same
time. Maximum distance from end to end can be up to 1200 meters.

• By using repeaters, however, both the total number of devices and maximum
distance can be extended.
• RS-485 network can be used as a two-wire or four-wire network.
• The four wire network would be bidirectional (a simultaneous two
way conversation can happen) whereas the two wire network
works only in one direction.
• The RS-485 disadvantage is that it is harder to program, because it
uses the same 2 wires to send and receive data. And in any given
network, only one node can transmit data, other nodes can only
receive at that particular moment. On the advantages side, it
supports long distance communications with no problems. It also
uses lower interface signal levels than the RS-232, which makes the
interface circuit harder to damage.
Modbus TCP/IP
• Modbus TCP/IP is a simple Modbus protocol running on Ethernet over a TCP
interface. Modbus is an application protocol that assigns the ways of managing
and passing data between various layers without being affected by the
protocol used by the next immediate layer.
• TCP is Transmission Control Protocol and IP is Internet Protocol. These
protocols are used together and are the transport protocol for the internet.
When Modbus information is sent using these protocols, the data is passed to
TCP where additional information is attached and given to IP. IP then places the
data in a packet (or datagram) and transmits it.
• TCP must establish a connection before transferring data, since it is a
connection-based protocol. The Master (or Client in Modbus TCP) establishes a
connection with the Slave (or Server). The Server waits for an incoming
connection from the Client. Once a connection is established, the Server then
responds to the queries from the Client until the client closes the connection.
Profibus
• The PROFIBUS protocol is designed for high-speed
communications with distributed I/O devices
(remote I/O). A PROFIBUS system uses a bus master
to poll DP I/O devices distributed in a multi-drop
fashion on an RS485 serial bus.
• A PROFIBUS DP device is any peripheral device which
processes information and sends its output to the
master. The DP device forms a passive station on the
network (since it does not have bus access rights)
and can only acknowledge received messages or
send response messages to the master upon
request. All PROFIBUS DP devices have the same
priority, and all network communication originates
from the master.
• A PROFIBUS master forms an “active station” on the
network.
Profinet
• Profinet is a newer, Ethernet-based industrial communications protocol.
The physical interface used for Profinet is a standard RJ-45 Ethernet jack.
• Profinet cables are easily recognizable by their green color. While in
some cases a standard Ethernet cable may be used to connect two
Profinet devices, official Profinet cables should be used as they contain
robust shielding and are designed to function well in harsh industrial
environments.
• All Ethernet devices use IP addresses and MAC addresses, but the device
name is unique to Profinet devices.
• Due to its higher speed and greater flexibility, Profinet is becoming the
preferred communications protocol for industrial application.
Ethernet/IP
• EtherNet/IP (IP = Industrial Protocol) is an industrial network
protocol that adapts the Common Industrial Protocol (CIP) to
standard Ethernet.
• It is an advanced version of standard Ethernet, which is useful only
for in-home and commercial purposes; but not for industrial
applications.
• It defines all the devices on a network as a series of objects and
binds all of them to work on the same standard. This protocol was
developed by Rockwell Automation.
Foundation Fieldbus
• The idea behind field bus is to eliminate any point to point links
between the field devices like transmitter, control valves and their
controllers by a single digital connection.
• Foundation Fieldbus technology is mostly used in process
industries and power plants.
• There are 2 types.
• Foundation fieldbus H1
• Foundation fieldbus HSE
• Foundation field bus was designed to address the needs of real-
time process automation. FF was conceptually engineered as a
replacement of the normal analog 4-20 mA current loop.
Foundation Fieldbus H1
• Operates at 31.25 kbit/s and is
generally used to connect to field
devices and host systems. It
provides communication and
power over standard stranded
twisted-pair wiring in both
conventional and intrinsic safety
applications. H1 is currently the
most common implementation.
Foundation Fieldbus HSE
• Operates at 100/1000 Mbit/s and
generally connects input/output
subsystems, host systems,
linking devices and gateways. It
doesn't currently provide power
over the cable
Communication With Package Vendor PLC’s
• Every Package Vendors have their own control
system.
• In most of the sites, Package vendor PLC’s are of
different manufacturer than the main plant. In this
case we are forced to go for the open source
communication protocol gateway’s/converter’s for
the communication between these PLC’s
• If package vendor PLC’s and main PLC’s are from
same manufacturer we can able to avoid the
intermediate gateway/converter and
communicate directly with the manufacturers own
communication protocol.
• Eg: Siemens Peer to Peer communication can be done
with S7 connection on profinet interface.
Conclusion
• While designing the system we have to make sure all the control
system for the plant should be from the same manufacturer and
also the communication protocol should be same for fast and
reliable communication and troubleshooting.