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Planet Fieldbus:
PROFIBUS and PROFINET
Trends
Positioning drives
Electro-mechanical
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Installation ..........................................................20
Diagnostics ......................................................... 22
Training .............................................................. 27
Glossary .............................................................. 30
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Positioning and potentials of the individual bus systems on the field level
Application complexity
(sensors and actuators)
Industrial Ethernet
> 20 % regulated
Pre-processing Fieldbus
> 20 % analogue
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Networking: mounting plate with valve terminal and air preparation Pneumatics: optimised by In-house expertise: own R&D,
unit simulation labs and production
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There are five big trends which They are all ingredients for Festo’s many years of
Festo pursues with its pneu- successful automation. The experience as a market and
matics, electrical engineering most important trend with technological leader for valve
and networking concepts. regard to industrial communi- terminals provide an answer to
cation is undoubtedly the the requirements demanded by
• Networking concepts – networking concept. It directly today’s and tomorrow’s
a central prerequisite for affects, to varying degrees, the market. Reliable products in
• installation system and machine options – pneumatics and electrical
• function integration regardless of whether it’s engineering for all types of
• diagnostics about installation, function industrial communication –
• energy efficiency integration, diagnostics or worldwide! Integral solutions
energy efficiency. and universal system concepts
are the central success factors.
Valve terminals from Cycle times improved Enhanced efficiency of Up to 35 % less Reduce energy costs
Festo are very by up to 35 %! up to 60 % downtime! by up to 60 %!
adaptable!
Different levels, differ- Central, decentralised By means of the most Active diagnostics man- By means of energy
ent requirements. or hybrid machine extensive function agement and condition savings along the
concept, modular or integration, e.g. with a monitoring can save up production processes.
compact. CPX terminal to €10,000 per minute!
Industrial Ethernet
Feldbus
Operational and
management level
Cell and process level
Field level
Sensor/actuator level
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Maximum productivity will be The general advantages Control level – monitoring of Field/device level – indicates
greatly influenced by industrial The combination of PROFIBUS, production and processes on-site safety/reliability
communication in the future. To PROFINET and Ethernet:
control and analyse individual overall, the most modern type Ethernet and PROFINET PROFIBUS and PROFINET
processes with high efficiency, of automation with specific • Changing device parameters • Fast device exchange via DIP
it is mandatory that the advantages for each level. via the fieldbus network and switches (PROFIBUS) or
communication levels, which configuration tools memory card (PROFINET)
are still often separated today, Management level – holistic • Saving configurations and • Easy identification of the
be networked, using, for communication all the way parameters within PLC network status of field
example, PROFIBUS and to the office projects devices via LEDs
PROFINET. • Integration of device status • Definition of device
Ethernet and diagnostics in PLC behaviour in the event of
The “control technology • Remote diagnostics and programs or in visualisation a communication error
pyramid” shows the different maintenance of controls and systems • Setting of network and
communication requirements devices from the office • Module-oriented illustration communication attributes
on each individual level. network of device levels for adjusting machine
• Networking applications • Integration of PROFIBUS in performance
and machines PROFINET networks • Supported ProfiSafe profile
• Storage of process and • Acyclic communication via means network can be used
device information “TCP/IP” or PROFINET NRT for normal and safety-orient-
• Use of Ethernet infrastructure possible for parameters and ed communication
components (wireless LAN) diagnostics • On-site diagnostics with LEDs
and HMI
• Acyclic communication
with “DPV1” possible for
parameters and diagnostics
Management level
Control level
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The topology: Typical control platforms Schneider (PROFIBUS) Phoenix Contact (PROFINET)
networks and control Products and systems for Products, systems and services
technology Siemens automation and control for connection technology in
(PROFIBUS & PROFINET) technologies. the world of automation and
Products, systems and services for industrial communication.
for drive, control and Typical products
information technology, from Most controllers available have Typical products:
components all the way to Hilscher SyCon cards. • Controllers:
holistically integrated systems. AUTOMATIONWORX, e.g. mini
control systems from the ILC
Typical products: range
• Controllers: SIMATIC, • Software tools: PCWorX for
modular controller configuring and programming
e.g. S7-300 or S7-400 range a PROFINET network.
• Software tools: Step 7 for
configuring and programming
a PROFIBUS or PROFINET For further information
network. about the networks and
commissioning them,
go to www.profibus.org
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The communication components With 25 million devices, the Features: In PROFINET, data is trans-
PROFIBUS DP fieldbus • Line topology mitted at 100 Mbps based on a
PROFIBUS standard is the global market • Device identification based typical Ethernet mechanism
A joint research project was leader in production auto- on HW addresses in slave with twisted pair cables or fibre
started by various companies mation. • Number of I/O devices optic cables.
and institutes in Germany in limited to 127
1987 with the aim of pro- PROFIBUS PA is used in • Number of parameters Features:
pagating a bit-serial fieldbus. process technology to control restricted to a max. of • Topology: line, star, tree
This was followed in 1993 by measuring devices by means of 242 bytes • Device identification based
the specification of a simpler a process control system. This on logical names and IP
and significantly faster version is suitable for potential- addresses
protocol: PROFIBUS DP. ly explosive areas in ex zones 0 PROFINET • Number of I/O devices
and 1. The bus lines only Is the open Industrial Ethernet limited to 255
PROFIBUS DP is used to control conduct a weak current, standard from PROFIBUS & • Unrestricted parameter
field devices with sensors and ensuring an intrinsically safe PROFINET International (PI). configuration
actuators in manufacturing circuit so that even in the event PROFINET uses TCP/IP and IT
technology via a central control of a malfunction, no sparks standards, is real-time Ethernet-
system. Central to this are the capable of producing an capable and enables the
many standard diagnostic explosion occur. PROFIBUS PA integration of fieldbus systems.
options and the connecting typically has a slower data The concept is designed to be
“distributed intelligence”, that transmission rate of 31.25 modular so that users can
is, networking multiple control kbps. select their own functions.
systems with one another. These functions are essentially
Data rates of up to 12 Mbps differentiated by the type of
are possible on twisted two- data exchange required to fulfil
wire cables and/or fibre optic the speed requirements.
cables.
100 Mbps
Master 000
R R
Device Device Device Device Device Device
10 Mbps
Device Device Device
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Easy identification of the net- Definition of device behaviour Set network and communica- Online and on the spot
work status of field devices in the event of a communication tion attributes for adjusting diagnostics
• Can be very quickly error machine performance • Online: see each device
recognised via LEDs • Fail-safe: defined state of • Set the optimum update time status in plain text via, for
valves and electrical outputs for the particular field device example, Step 7 or integrate
in the event of communication in PROFINET, or the trans- it into a control program
errors and when the program mission speed in the network • Localise errors ultra-fast with
is stopped (idle mode) for PROFIBUS LEDs or device diagnostics
• Parameterise a preferred • Fast start-up with PROFINET • Get extended on-site data
actuator state depending on for fast booting maximises and detailed information
the machine concept system productivity, e.g. in without existing network
• Module-specific para- tool change applications infrastructure: with
meterisation of the • Identify the network topology CPX-MMI or CPX-FMT
diagnostic behaviour in the by configuring the LLDP
event of an error mode with PROFINET Optimum data transparency
• Fast switching over thanks to • Position and characteristics
integrated redundancy for identifying products are
management via PROFINET’s clearly recognisable thanks
ring structures to I&M function support in
• Festo products support all PROFIBUS and PROFINET
these options, thereby
enabling the optimum
utilisation of the fieldbus
network and maximising
productivity and machine
performance
CPX-MMI CPX-FMT
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Control level: Changing and saving device Integration of device status Device status and diagnostics
parameters via the fieldbus and diagnostics in PLC with network tools
network and configuration program or in the visualisation • Read out module status
tools systems or error trace of the CPX
• GSD files for including • Module and channel-specific terminal online in plain text:
device-specific information in display of errors in plain text extended diagnostic data,
software tools, such as Step 7 via the online diagnostics in e.g. with Step 7
for PROFIBUS and PROFINET the project planning software • Festo maintenance tools,
• Start-up parameterisation for • Basic status of the valve such as CPX-FMT
assigning module-oriented terminal: simply transferred
parameters during the as optional status bits within Integration of PROFIBUS in
initialisation phase the process data PROFINET networks
• Significantly reduces time • Status interface for • PROFIBUS and PROFINET can
and probability of error as additional information via coexist trouble-free (proxies)
pre-configured parameters CPX: optional via process • Controllers can work with
can be activated directly data several networks
from the controller • Targeted changing and
• With PROFINET, the TCI func- querying of parameters and
tion can be used to simplify diagnostics: optimum data
access to the appropriate access via “diagnostic
proprietary online software telegram” from PROFIBUS
(CPX-FMT in this case), and PROFINET during PLC
required for parameterisation start-up and acyclically
and online monitoring, from during the program run
the configuration interface
for Festo’s PROFINET prod-
ucts
Device status/diagnosis
via online diagnostics
Siemens Step 7
Station connection
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Management level: Remote diagnostics and Networking of applications • The CPX web monitor HTML
maintenance of controls and machines software package is
and devices from the office • Ideal, thanks to data optimised for visualising the
network bandwidth and flexibility: CPX terminal via a web
• Access via the network can Industrial Ethernet browser
be realised with CPX-FMT • For decentralised control • Fast and easy access from all
from various computers for concepts: communication computers
more transparency without with a higher-order
additional investments in the controller via PROFIBUS or Use of Ethernet infrastructure
infrastructure PROFINET thanks to the components (wireless LAN)
• Simple and cost-effective: remote control mode of the • The existing infrastructure
project planning using the CPX fieldbus node for industrial Ethernet makes
PLC Ethernet connection via integration in the auto-
the PC network Storage of process and device mation environment or of
information (documents, web special components for
sites) remote maintenance via the
• Extended device, machine Internet (via VPN, for exam-
and system information can ple) quick and inexpensive.
be stored centrally on data • CPX PROFIBUS node on
servers within an Ethernet standard Ethernet tech-
network. Status and nology is compatible with
diagnostic data can also be the infrastructure
accessed on the CPX components.
terminal with PROFINET via
an integrated web server.
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decentralised
terminals ...
CPX/MPA/MPA-F 360
Universal, modular, versatile, serial valve 700
actuation, with electrical I/O
900
CPV 400
Standard, compact, powerful 800
1600
CPV-SC
Compact, Smart Cubic 170
CPA-SC
Modular, Smart Cubic 180
MH1 10
Miniature valve
14
VTOC 10
Compact, flexible 2x 3/2-way pilot valves
MHJ, MH2/3/4 10
50 100 150 MHJ
Fast-switching valve,
Individual connection 100 200 400 MH2/3/4
CDVI
Clean Design IP65/67 650
CPI-System
Decentralized installation system. Up to 16 I/O-modules and valve terminals.
3 platforms for each I/O-module, valve terminals and master modules.
14
26
32
40
erminal)
oid coils
48
1)
56
decentralised
2)
Pressure sensor
Function integration
Multi-axes interface for electrical axes
Safety valves
Soft-start/exhaust valve
17.12.2008
Vertical stacking
2)
2)
2)
Multipin
AS-Interface
16:20 Uhr
DeviceNet
Profibus
Electrical connection
Interbus
1)
Seite 15
CANopen
1)
Communication protocol
CC-Link
1)
EtherCat
1)
1)
1)
Ethernet/IP
1)
1)
Modbus/TCP
1)
1)
Profinet/IO RT
1)
1)
Integrated controller
1)
Directly actuated
Valve
Piloted
properties
Vacuum
IP40
class
IP65
Protection
IP67
Explosion-proof
Status bit
Module-/channel oriented
Diagnostics
Preventative maintenance
210
207
251
206
211
226
213
227
210
210
210
232
243
204
248
242
244
(215,
xDKI)
such as for example: manual pressure regulators, pressure gauges, flow control plates, shut-off plates (hot-swap), compressed air supply, integrated non-return functions/back pressure flaps
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Valve terminals VTSA – modular, flexible and CPV – compact, sturdy and CPV-SC and CPA-SC –
compliant with standards! extremely powerful! small but great!
MPA – for maximum system Three valve sizes are available The perfect balance between Consistently miniaturised so
efficiency! for up to 32 standard valves on size and flow rate. The main that no space is too small for
The most modern, modular one VTSA. application of CPV is in the compact valve terminal
and robust valve technology Function integration: decentralised system concepts, range, be it the modular
in solid metal – with up to sensor valves, press valves, not least thanks to protection CPA-SC or the extremely
128 valves, thanks to unique special valves for pneumatic class IP65. Ideal for positioning compact CPV-SC.
internal serial communication! manual clamping devices and on robot arms and in handling
Combined with CPX, any kind rotary cylinders, gradual solutions. Its small size and
of electrical connection is pressure build-up. low weight permits installation
possible! Vertical stacking with in the immediate vicinity of the
Function integration: controllers, flow control valves, actuator for faster cycle times.
integrated functions, such as shut-off plates, as well as
voltage zones, pressure extensive pneumatic functions.
sensors, proportional pressure High simultaneity for valve
regulators and extensive diag- switching thanks to large
nostics capabilities guarantee exhaust cross sections.
maximum process reliability Encapsulated valves can be
and minimum installation used in a fine-dust environment.
costs. Control cabinet opti- The VTSA can be integrated
misation: pneumatic multiple into all common fieldbus
connector plate for installation networks and Ethernet via the
on the control cabinet, CPX terminal.
3/2 non-return function, Ex
approval for zone 2, 22.
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Holistic mechatronic motion From modular and compact With its controller and motor
solutions from one source: controller concepts for portfolio, Festo covers a wide
from controller to ready-to- standard pneumatics to range of servo and stepper
install handling systems. servo-pneumatic and electric motor functions, optimally
positioning all the way to adapted to all electrical drives.
sensors and compact camera
systems for process diagnos-
tics and quality assurance.
Servo motor controller Servo motor controller Stepper motor controller Motor controllers
CMMP-AS CMMS-AS CMMS-ST SFC-LAC SFC-DC
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For more performance Centralised installation Decentralised installation system Hybrid installation system
Clever machine concepts for • Control of several drives and • Individual functions on a (centralised/decentralised)
gaining new heights in terms of functions via one valve small valve terminal • Only available from Festo!
productivity and process relia- terminal • Installation-saving hybrid • Combines both systems –
bility are not only a result of • Short control loop system cable for data and power can be expanded to any size
the right portfolio, but also the (extending over only a few • Typical number of I/Os • Also ideal in a control
right machine and installation meters) between 16 and 512 cabinet or on a control
concept – for today’s and • Typical number of I/Os cabinet wall.
tomorrow’s requirements. between 16 and 128 Benefits
Festo covers nearly all possible • Space reduced by up to 70 % Benefits
options. Your system decision Benefits • Air consumption reduced by • Best mix
and its electrical aspect drasti- • Up to 60 % more efficient, up to 50 % – smaller valves • Short cycle times and high
cally influence the performance thanks to function integration possible for the same per- machine performance
of the pneumatic control loop • Channel costs reduced by up formance • System costs reduced by up
system. Three selectable to 50 % • Cycle times shortened by up to 20 % in terms of the TCO
installation concepts – • Up to 40 % better to 30 % thanks to very short • Maximum freedom of
centralised, decentralised and performance tubing lengths selection, centralised or
hybrid – will optimise your • Downtimes reduced by up to • Optimum flow rates and decentralised
cycle times and efficiency. 35 % switching times • Range of diagnostic options
• Minimised expense for • Comprehensively flexible: freely selectable
complete power supply 3 master concepts 32 to
• Minimised expense through 512 I/O; 3 valve terminals;
centralised, easy-to-access 3 I/O platforms
installation • Portable use possible thanks
• Central service point to light weight
• Teach-in function for
automatic configuration
• Simplified and shortened:
service and maintenance
Complete with fieldbus connection:
control cabinets with remote I/O
and valve terminals
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For reduced costs Valve terminals based on the • High process reliability:
An effective way to reduce your electrical CPX peripherals reduced downtimes thanks to
total cost of ownership involves Below are a few reasons for the comprehensive diagnostics
the electric and pneumatic increased efficiency and on the individual channel
function integration on valve reduced total cost of ownership levels for the electrical
terminals. The result is a (TOC): systems and pneumatics and
reduction in system costs • Installation time drops by the integrated condition
by 20 %. 60 %, sources of error are monitoring system (CMS).
eliminated and the time to Valve terminals and I/O
market is drastically systems from Festo are fully
improved. checked and pre-assembled
• Faster commissioning: thanks and offer a 100 % functional
to Festo’s plug and work©, warranty ex-works.
simpler parameterisation
using standardised interfaces Unprecedented functional
and minimised sources of integration on valve terminals
error thanks to complete • Pressure sensors
integration • Temperature measurement
• Enhanced machine • Proportional pressure
performance: shorter cycle regulators
times by up to 30 % and • Safety functions
reduced air consumption, e.g. • Integrated pneumatic and
by integrating servo-pneu- electric position controllers
matics with Smart Soft Stop. for servo-pneumatics and
electric drive technology
Savings potential
60 %
35 %
30 % 30 %
20 %
I/O channel price
Air consumption
CM/diagnostics
Advancing time
Cycle time CPi
System costs
CMPX/CMAX
Downtime
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Valve terminal
CPX/MPA:
number 1 in
diagnostics
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or
Controller FDC
or
Contribution to energy efficiency:
perfectly designed components
in combination with ready-to-
install solutions.
Industrial partners
Robust metal designs for body Fast tool change thanks to fast Compact fieldbus nodes.
assembly and welding start-up SEMI Specification compliant
3.152 and EN50170
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Simply clean – food Synergetic impulses – for more However different the sectors
and packaging industry intelligent process automation are, their objectives are
Mixing, sterilising, Centralised and decentralised nevertheless the same: Our
pasteurising, packaging, automation concepts for specialists will not only advise
handling – components as well process automation. For GMP, you on technology, reliability
as system solutions from Festo food or ATEX zones, for high and quality, but will also advise
contribute towards efficient and low temperatures, for you on how to reduce your
automation, mostly in harsh and corrosive ambient total cost of ownership in a
combination with continuous conditions. long-term and comprehensive
processes and factory auto- manner. Discover our complete
mation. Optional: FDA and HACCP product range from a single
conformity. Condition monitor- source for yourself: products,
With innovative Clean Design ing and interdisciplinary system solutions and services.
solutions, Festo ensures food diagnostics concepts based on
safety in the splash area. Festo diagnosable products reduce
will further support you with production downtime to a
individual solutions – thanks to minimum.
the sector expertise of their
sales engineers.
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100 % specially designed – Ready-to-install pneu- Festo also delivers complete Optimised and individu- Build yourself or order as a
for you matics: Built, assembled control cabinets with alised fieldbus solutions complete ready-to-install
Examples: and tested. Guaranteed remote I/Os and valve Technology: mounting plate (valves, air
• On integrated blocks performance and function. terminals. You get a • Electric preparation units, pressure
• On printed circuit boards Connect – ready. complete solution: • Pneumatic gauges): ready-to-install
• Modular control units stand-alone or with a field- • Mechatronic complete solution for a
• Under protective covers bus connection to your host • Integrated in a machine unit on the fieldbus.
system. machine profile
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Training
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I/F
Power
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PROFINET technology • IRT for Profinet IO, applica- Configuration Installation guidelines
tions in drive technology with The properties of an IO device Regardless of the network-
PROFINET is essentially divided cycle times of less than 1 ms are described in a GSD file structure, the extent of a
into Profinet CBA and Profinet (Generic Station Description). PROFINET segment must not
IO: The language used here is exceed 100 m at 100Base-TX.
• Profinet CBA (Component Profinet IO GSDML (GSD Mark-up Using switches and routers, a
Based Automation) is suit- Profinet IO describes all data Language), an XML-based network can be divided into
able for component-based exchanges between controllers language. In a development multiple segments. This makes
communication via TCP/IP. (devices with “master environment, the GSD file it possible to structure the
• PROFINET IO was created for functions”) and the devices serves as the basis for planning PROFINET network and create
real-time (RT) and synchro- (devices with “slave and configuring a Profinet IO larger network extensions. Valve
nous communication IRT functions”), as well as para- system. The GSDML for valve terminals and the CPX terminal
(IRT = Isochronous Real- meterisation and diagnostics. terminals and the CPX terminal from Festo have integrated
Time) with decentralised Profinet IO is designed for fast contains all the information switches, enabling the bus line
peripherals. data exchange between needed for the configuration to be connected through them.
Ethernet-based field devices and settings using a
Profinet CBA and Profinet IO and follows the provider/ configuration and programming You can access installation
can communicate on the same consumer model. It is well software, such as Siemens guidelines from the PROFINET
bus system at the same time. suited for data exchanges with STEP 7. user organisation (PI):
bus cycle times of a few ms. www.profibus.com
Three different protocol levels Designing an IO system is You can find the latest GSDML
have been defined: almost identical to designing a file for the CPX terminal on
• TCP/IP for Profinet and PROFIBUS system in terms of Festo’s website at:
commissioning a system with “look and feel”. www.festo.com/fieldbus
cycle times of around 100 ms
and acyclic communication
services
• RT for Profinet and Profinet
IO, cyclic I/O data exchange
in an application with 10 ms
cycle times
PROFIBUS PROFINET
Network Communication Network Communication
Communication Cable length Branch line length Communication Cable length between
speed speed the connections
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Glossary
Auto cross-over Automatically identifies whether transmitter and receiver lines are crossed or not
Baud rate Defines the amount of data transmitted per second, determines the extent of the
bus network
CPX error trace Built-in error memory of the CPX terminal, in which the 40 newest diagnostics
messages in the fieldbus node are stored
CPX-FMT PC software for the CPX terminal, access to all system data, such as parameters and
diagnostics via Ethernet or a CPX/USB adapter
CPX-MMI Handheld CPX terminal, access to all system data, such as parameters and
diagnostic CPX web monitor
HTML software for visualising the system status and diagnostics from Industrial
Ethernet CPX terminals
Free of copper Usually products which are free of copper and PTFE. Essential in the production of
and PTFE screens, for example.
DCP Discovery and Configuration Protocol; can be used to set or read the name, IP and
address and other parameters
FDA Food and Drug Administration. The drug approval authority, part of the Department
of Health in the United States
GSD(ML) files Generic Station Description file – description of a device and parameters, required
for a PROFIBUS or PROFINET configuration
HACCP The Hazard Analysis and Critical Control Points concept (HACCP) is a preventive
system which should ensure the safety of food and consumers
HMI Human Machine Interface. Components of a control or process control system which
develops and visualises information.
I&M The “Identification & Maintenance” (I&M) functions specify the standardised way in
which specific data that describes PROFIBUS devices (in accordance with a rating
plate) has to be stored in the devices.
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IRT Isochronous Real Time: the PROFINET communication channel that ensures
synchronous, time-controlled data transfer
LLDP Lower Layer Discovery Protocol: provides the basis for recording a topology and for
determining the configuration
PROFIBUS NRT PROFINET NRT (Non Real Time) was defined for applications in process automation
that are not time-critical. Achievable cycle times > 100 ms.
RoHS EC directive 2002/95/EU regulates the ban of certain substances during the
manufacture and processing of electrical and electronic devices and components,
also regulates the incorporation into respective national law
TCO Total Cost of Ownership is a calculation method with which all accrued costs for
investment goods are estimated in order to identify known cost drivers or hidden
costs.
VPN Virtual Private Network. Technology for accessing a closed network (e.g. company
networks) via the Internet or other separate networks
WEEE EC directive 2002/96/EU for reducing the increasing amount of electronic scrap from
discarded electric and electronic devices.
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Festo worldwide
2610 Rødovre Festo S.p.A 119607 Moskow Tel. ++58 (0)261/759 09 44, Fax 759 04 55
Tel. ++45 70 21 10 90, Fax ++45 44 88 81 10 Via Enrico Fermi 36/38 Tel. ++7 495/737 34 00, Fax 737 34 01 e-mail: festo@festo.com.ve
e-mail: info_dk@festo.com 20090 Assago (MI) e-mail: info_ru@festo.com
Tel. ++39 02/45 78 81, Fax 488 06 20
e-mail: info_it@festo.com