Industrial Ethernet, Part 1: Technologies

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Purpose and Learning Objectives

• Identify the Telecommunications Infrastructure Standard for Industrial Premises to choose the proper cabling infrastructure for a particular network environment

• Identify the Ethernet features required for particular network protocols and environment

• Identify the best network topology for a particular plant layout.

• Examine the 2013 Ethernet trends in CE’s “Mobility, Ethernet and Wireless” report

• Look at trends from other Ethernet research

Technical Questions and SupportTechnical problems?

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Speakers

• Mike Robbins, Network Engineering Manager, TriCore Inc.

• Moderator: Mark T. Hoske, Content Manager, Control Engineering, CFE Media, covering industrial networking, among other topics, since 1994

Industrial Ethernet, Part 1: Technologies

Mike RobbinsNetwork Engineering Manager

TriCore Inc.

Industrial Ethernet Technologies

• TIA standards for Ethernet copper cabling• The categories and how to choose.• Best practices

• Industrial Ethernet networks• Type of networks

• Ethernet switch features• IGMP snooping• VLAN’s

• Ethernet topologies

TIA Twisted-pair cable categoriesCategory Makeup Data rate

Network compatibility

Cat-1 2 pair 1 Mbps Analog voice

Cat-3 4 twisted pairs 10 Mbps – 2 pair 10BaseT

Cat-5 4 twisted pairs10 Mbps – 2 pair100 Mbps – 2 pair

10BaseT100BaseTX

Cat-5e 4 twisted pairs10 Mbps – 2 pair

100 Mbps – 2 pair1 Gbps – 4 pair

10BaseT100BaseTX

1000BaseTX

Cat-6 4 twisted pairs1 Gbps – 4 pair

10 Gbps – 4 pair (55m)1,000BaseTX

10,000BaseTX

Cat-6a 4 twisted pairs 10 Gbps – 4 pair 10,000BaseTX

Fixed cabling & patch cables

• Patch cables typically use stranded conductors• Can extend up to 10 meters (33 ft)• Terminated at the factory

• The cabling between patch panels and jacks are referred to as fixed or “horizontal” cabling

• Can extend up to 90 meters (295 ft)• Normally solid conductors• Terminate with modular jacks or punch down

Ethernet over copper cable is limited to 100m

CAT5e100Mb max

24/26 AWG

CAT6a10Gb max23 AWG

Center spline

CAT61Gb max23 AWG

Categories for Industrial Applications

TIA-568 Commercial Building Telecommunications Cabling Standard

• The TIA 568 standard defines these areas:

• Backbone• Connecting hardware• Cords and jumpers• Horizontal (solid wires) cables• Stranded (patch) cables • Optical fiber

• Type of fiber, transceivers, and

supported distances

TIA-1005 Telecommunications Infrastructure Standard for Industrial Premises

• In contrast to the TIA-568 standard, which addresses commercial buildings, the central concept of this standard is the potential exposure to hostile environments in the industrial space.

• A prime design principle of the standard is the special cabling system requirements for industrial operations.

•Category 6 or better cabling shall be used for the Automation Islands.

TIA-1005: MICE definition

M1I1C1E1 - Worst case commercial environment

M2I2C2E2 - Worst case light industrial environment

M3I3C3E3 - Worst case industrial environment

Telecommunications Room• Control Room• Typical MICE Range 1• (commercial grade)

Factory Floor• Network Distribution• Typical MICE Ranges 1-2 from• commercial grade to light industrial

Work Area• Consolidation points• Typical MICE Ranges 1-2 from• commercial grade to light industrial

Automation island• Control Panels, On Machine

(distributed)• MICE Ranges 1-3 from commercial

grade to harsh environment rated

Cabling best practices

• Planning is key• Include cable

management• Color coded cabling• Patch panels• Naming scheme

• Label!

Network documentation

• Understanding of critical network dependencies

• Assists with troubleshooting

• Point of reference for expansion

Industrial networksWhat is the role of your network?

• SCADA• Systems that collect data from PLCs.• Use explicit (unicast) communications

• Control network Controls drives, I/O, servos, etc.

• EtherCAT• EtherNet/IP• Modbus TCP• Profinet• etc.

Multicast: Group Communication

consumer

producer

producer

producer

Industrial Ethernet switchesIGMP Snooping

HMI

HMI

Industrial Ethernet switchesBroadcasts

Broadcast

192.168.1.0 192.168.5.0

Industrial Ethernet switchesRouter

Broadcast Domain 1 Broadcast Domain 2

Router

BroadcastBroadcast

192.168.1.0 192.168.5.0

Industrial Ethernet switchesVLAN (virtual local area network)

Broadcast Domain 1 Broadcast Domain 2

Router

BroadcastBroadcast

192.168.1.0 192.168.5.0

Switch w/VLAN’s

VLAN 1 VLAN 2

Industrial Ethernet switches

VLAN 2VLAN 2

VLAN 3VLAN 3

VLAN 3

VLAN 2

VLAN 3

Industrial Ethernet switchesHow fast are they?

10ms

10ms

2.5µs 2.5µs 2.5µs

Total latency = 7.5µs

Ethernet topologiesStar

Ethernet topologiesTree

Ethernet topologies - Ring

Ring requirements:• Managed switches• Ring protocol enabled

Ethernet topologiesRedundant star

Industrial Ethernet Technologies

• Use the TIA-1005 standard to select the proper infrastructure for your industrial network.

• Document your network in detail.

• If you have a control network with Ethernet/IP, make sure you use managed switches and enable IGMP snooping.

• Ethernet topologies commonly used for industrial Ethernet networks

Mobility, Ethernet and Wireless Research

Mark T. Hoske, Content Manager, Control Engineering, CFE Media

Introduction and methodologyObjectiveControl Engineering performed this research to better understand more about integration, use, and spending for mobility, Ethernet, and wireless technologies and how they help users of automation, controls, and instrumentation to be more productive.

SampleThe sample was selected from recipients of Control Engineering for whom email addresses were available.

MethodSubscribers were sent an email asking them to participate in this study. The email included a URL linked to the questionnaire.

Data collected: Oct. 11, 2013, through Oct. 29, 2013 Respondents were asked about the technologies or services they buy or specify that use, connect with, or

support mobility, Ethernet, or wireless technologies. Those responding positively were asked about specific products, spending trends, use of mobility devices, integration, protocols, security, and mobile applications.

Number of respondents: 200 Margin of error: +/- 6.9 at a 95% confidence level

Incentive: Survey participants were offered the opportunity to enter a drawing for a $150 VISA gift card.

CE Ethernet research topics• Ethernet products specified• Future spending and productivity resulting from Ethernet use• Products and services spending comparison• Servicing and integrating Ethernet products• Where Ethernet technologies are used in the workplace• Ethernet protocols used. (An Ethernet protocol is the software that runs over the Ethernet physical layer.)• How integrated is Ethernet?• How easily was Ethernet implemented?• Ethernet adoption benefits• Ethernet adoption challenges

Ethernet products specified

Q: Identify the specific products you use, buy, or specify, or expect to within the next 12 months for business/professional purposes. (n=200)

Switches, wire or cable, networks, connectors and routers are the most common products specified.

Switches

Wire or cable

Networks

Connectors

Routers

Cordsets

Gateways

Other infrastructure hardware

Other infrastructure software

Services for infrastructure

64%

59%

54%

52%

49%

40%

35%

31%

19%

19%

Future spending and productivity

Q: Complete the following statements by estimating: (n=200)

Analysis

9%

40%

41%

4%8%

Productivityoutlook

9%

40%

43%

6%3%

Products and servicesspending outlook

Not sure

Decrease

Remain the same

Increase

Significantly increase

Products and services budget

Q: For the products and services you purchase, what do you spend more money on for Ethernet and wireless? (n=200)

By a three-fold margin, products get more budget than Ethernet services, said respondents.

Products; 59%

Services,16%

About the same; 25%

Servicing and integrating

Q: For the following, indicate who most often works on, services, and integrates these devices at your location: (n=200)

Operations or engineering and business IT were evenly split among those working on, servicing, and integrated Ethernet devices.

30% 19% 31% 14% 4% 4%

Operations or engineering Manufacturing IT Business ITSystem integrator Consultant Other

Servicing and integrating (continued)

Q: Where do you interface with the industrial mobility, Ethernet, or wireless technologies mentioned above? (n=200)

Where Ethernet, industrial mobility, and wireless technologies are used...

Place

of b

usin

ess

(pla

nt flo

or/o

pera

tions

)

Place

of b

usin

ess (

reac

hing

into

ent

erpr

ise)

Other

com

pany

loca

tions

Custo

mer

loca

tions

Home

With

serv

ice p

rovid

ers o

r sys

tem

inte

grat

ors

With

pro

duct

supp

liers

, ven

dors

77%

50%39% 36% 35%

21% 19%

Ethernet protocols

Q: Which Ethernet protocols are used in your facility? (n=200)

Most-used Ethernet protocols are EtherNet/IP, TCP/IP and UDP, Modbus TCP, and Profinet.

EtherN

et/IP

TCP/IP a

nd UDP

Modbus

TCP

Profin

et

EtherC

AT

HART IP

Ethern

et Powerlin

k

BACnet

Foundation H

SE

SERCOS II

I

Oth

er Eth

ernet p

roto

col

CC-Lin

k IE

Profin

et IRT

VARAN

Mech

antrolin

k III

FL-Net (

OPCN-2

)

SynqNet

None

72%67%

42%

28%

19% 16%10% 9% 8% 7% 6% 6% 5% 2% 2% 2% 1% 1%

Integrated technologies

Q: Currently, how integrated with controls, automation, instrumentation are following technologies? (n=200)

46% of respondents see Ethernet as highly integrated with controls, automation and instrumentation, and 40% see Ethernet as somewhat integrated.

46% 40% 12% 3%

Highly integrated Somewhat integrated Not very integrated Not integrated

Integration experience

Q: How was the integration experience in the last 12 months? (n=200)

Most respondents said Ethernet was relatively easy to install.

42% 37% 14% 3%5%

Easy (plug and play)More challenging (plug, configure, and play)Difficult (plug, configure, unplug, call someone)Tried, but didn't have resources (tried, gave up)Knew better than to even try

Ethernet technology benefits

Q: What are the primary benefits of industrial use of Ethernet technologies at your location (or company)? (n=200)

By far, the primary Ethernet benefit is greater data access. Next benefits are ease of use and productivity increases, followed by cost savings.

Data

acce

ss

Ease

of u

se

Produ

ctivit

y inc

reas

es

Cost s

aving

s

Time

savin

gs (s

peed

)

Bette

r ass

et m

anag

emen

t

Less

dow

ntim

e

Mor

e ef

fecti

ve m

ainte

nanc

e

Mor

e ac

cura

te d

ecisi

ons o

r pro

cess

es

Accou

ntab

ility

Great

er se

curit

y

Easier

train

ing

Other

63%

37% 37%28%

23% 22% 20% 20% 17% 14% 14%5% 3%

Ethernet adoption challenges

Q: What challenges do you see with adoption (or additional use) of these technologies in your business? (n=200)

Security and lack of training and education and support are among major adoption challenges.

Security issues

Lack of training/education/processes to support adoption or integration

No budget, lack of investment for capital investments

No budget, lack of investment for system integration or services investments

23%

22%

18%

17%

Lack of knowledge of use cases or benefits

Lack of business case to support investment

Safety issues

No need for these technologies

14%

13%

9%

5%

Summary of CE Ethernet research• Most common products: Switches, wire or cable, networks, connectors and routers• 40% of respondents expect to spend more on Ethernet and increase productivity.• Around 60% of what’s spent on Ethernet goes to products. Services get less.• Operations or engineering and business IT were evenly split: Ethernet workers• Ethernet, industrial mobility, and wireless technologies are used 77% on the plant floor or operations areas.• Most used Ethernet protocols: EtherNet/IP, TCP/IP and UDP, Modbus TCP, Profinet, and EtherCAT.• 46% of respondents see Ethernet as highly integrated with controls, automation and instrumentation, and 40% see Ethernet as somewhat integrated.• Most respondents said Ethernet was relatively easy to install.• Data access is the greatest technology benefit of Ethernet by 63% of respondents. • Security and lack of training, education and support are among major adoption challenges.

Industrial Ethernet switches, routers

Industrial Ethernet components

Ethernet is gaining on fieldbus

Ethernet growth for motion controlUse of Ethernet with motor drives and motion controllers will more than triple in 2016 from 1.8 million new connected nodes in 2011, IHS said.

Ethernet for process industriesUse of Ethernet as an industrial communications technology in motion control to more than triple by 2016, IHS said.

Ethernet switches get a boost• Industrial Ethernet (IE) switches, driving by discrete automation, will get a boost from increased use in process and infrastructure applications, said ARC Advisory Group in May 2013.• IE differs from commercial switches: ruggedized enclosures, high IP ratings, mounting and connector types, ability to withstand extended temperature ranges, redundant components, and conformance to industrial infrastructure standards, among others. • Infrastructure applications include smart grid and intelligent rail. • The mix of form factors, point counts, port speeds, media types, and other device characteristics continues to expand.• Availability of switches that meet requirements such as IEC 61850-3 for substation automation and EN 50155 for rail only further enhances Ethernet’s suitability in infrastructure applications.

Ethernet research from others• IHS commented recently on decline in growth of stand-alone industrial routers, as use of managed switches is expected to grow steadily over five years.• While annual fieldbus connections still outpace industrial Ethernet connections, IHS believes that within 10 to 15 years industrial Ethernet will be the dominant networking technology in industrial environments and almost all components will offer Ethernet connectivity as standard. • Use of Ethernet as an industrial communications technology in motion control will more than triple by 2016, IHS said.• Industrial Ethernet nodes in process industries are projected to rise to 8.7 million units in 2016, up a 96% from 4.4 million in 2011, IHS said.• Industrial Ethernet switches, driving by discrete automation, will get a boost from increased use in process and infrastructure applications, said ARC Advisory Group.

Submitting Questions, Exit Survey and Archive Question?Type your question in the “Ask a Question” box on the Webcast console andclick “Send.” We will get to as many questions as we have time for. Questionsthat are for today’s presenters will be answered verbally during the Q&Asession at the end of the webcast.

Exit Survey:Please take a moment to answer a few questions on our exit survey that will pop up on your screen at the conclusion of thewebcast. We use the answers to help make improvements to our webcast program.

Archive:• Within 7 days, an archive with Q&A will be posted• We will send an email to registered attendees with hyperlink• Can also access from www.controleng.com home page

Speakers

• Mike Robbins, Network Engineering Manager, TriCore Inc. www.tricore.com

• Moderator: Mark T. Hoske, Content Manager, Control Engineering, CFE Media, covering industrial networking, among other topics, since 1994 www.controleng.com

Thanks to Today’s Webcast Sponsors

Industrial Ethernet, Part 2: Case Study Applications will be held on Thursday,

November 21, 2013

Click here for more information and to register for part 2 of this Webcast series.

Industrial Ethernet, Part 1: Technologies

Sponsored by: