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problem of breakage of communication at random intervals

Created by: JD_techflirt at: 2/11/2011 2:14 PM (12 Replies)

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2/11/2011 2:14 PM	Rate (0)
JD_techflirt Posts: 95 Rating: (1)	Deep Bhatt I have 6ES7416-2XN05-0AB0 cpu. It is working on 1.5 mbps speed of profobus communication. sometimes it goes out of communication with drive and if I change the speed of data rate from 1.5 mbps to 128 kbps or slower than 1.5 mbps its working properly.. I have checked profobus and fiber optic cable physically there is no problem with it..and all communications are as per standrd rule with 2 OLM. I am facing this problem twice in 15 days.. Can any one give solution for that??? Hi , We are also facing the same problem. Wehave CPU 417H as master redundantr system which is communicating to C240PN drive controller located at various distances 1) First RIO station at2km from CPUconnected via OLM 1300 ; This station has drive fed conveyor controlled by C240PN communicating via Profibus. 2) Second station at 2.7 Km from station i.e 4.7km from CPU connected via OLM 1300; This station also has drive fed conveyor controlled by C240PN communicating via Profibus. 3) Third station at 4 km from 2nd station i.e 9km from CPU connected via OLM 1300. This station also has drive fed conveyor controlled by C240PN communicating via Profibus.. our profibus speed is 1.5Mbps and we are facing the same problem of breakage of communication at random intervals. We are unable to find any solution. Hope anybody can suggest any solution to come out of it. Regards, JD Splitted from 6ES7416-2XN05-0AB0 communication problem faced.
JD_techflirt Posts: 95 Rating: (1)	Last edited by: O_Moderator at: 2/11/2011 2:40 PM new subject after splitting
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2/11/2011 4:08 PM	Rate (0)
J_Bell Posts: 5822 Rating: (412)	Hello, well, the by you mentioned behavior is really rough to diagnose. Personally I would say that this may be caused, because of its sporadic appearance, by either a sporadic failure in some part of the system or by certain circumstances that cause a timeout during the runtime... especially as the system is asrampant as yours. For the beginning I would like to check if you entered the size of the network within your network configuration in HW Config or NetPro. This adjustment changes some values in the bus parameter set ... which may have caused the problem you see. Have you ever tried to run the PROFIBUS on a lower baud rate, like 500 kBit/s? Could you monitor any faults at the OLMs you use? Was it possible to monitor something on the bus? Sorry for all these questions... but it is hard to have any idea if you are far way of the system. Best regards J_Bell
J_Bell Posts: 5822 Rating: (412)
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2/11/2011 10:30 PM	Rate (0)
fritz Diamond Expert Joined: 10/7/2005 Last visit: 3/20/2025 Posts: 3042 Rating: (1061)	Hello JD_techmania I fully agree with J_Bell's advise,sporadically appearing network dropouts can be tough to troublehoot and have numerous causes (e.g. interference, poor connections, power supply issues etc. etc.). I suggestthat you get hold of aProfibus monitoring toolthat allows you to evalute the physical signal levels as well as monitoring of the data traffic and my choice for this would be Procentec's Profitrace 2. Disclaimer: Since the company I work for is also a partner of Procentec, this advise may appear to be biased, I can tell you though that I haven't come across a Profibus poblem that I couldn't solve with the help of this tool. I hope this helps and good luck
	Cheers fritz The advice and opinion given in this thread is that of the author and does not necessarily reflect the views of I S Systems Pty Limited. To find out how I S Systems can help you with your automation needs please visit www.issystems.com.au.
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3/4/2011 6:22 AM	Rate (0)
JD_techflirt Posts: 95 Rating: (1)	Thanks all for reply. As suggested I have put distances in Hardware Configuration of Step7, till now the communication breakages have drastically reduced. We are monitoring the system i ll update u with the progress. I have a question?? Why we mostly designe our systems with profibus communication and not with ethernet communication ...is it because of cost, or speed or no of nodes capacity or Y?? Regards, JD
JD_techflirt Posts: 95 Rating: (1)
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3/4/2011 6:30 AM	Rate (0)
playerslight Posts: 1064 Rating: (72)	I agree with Fritz the profitrace tool he mentioned is well worth the investment to help trouble shoot profibus and have used it quite alot .It helps find noise on the line and loose connections
playerslight Posts: 1064 Rating: (72)
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3/4/2011 3:56 PM	Rate (0)
J_Bell Posts: 5822 Rating: (412)	Hello JD_techmania, your question is well worth the discussion, in my opinion the PROFIBUS is still in favour because it is well known. The durability and functionality is well tested. Most people are still convinced that Ethernet is not capable of being as robust and reliable as PROFIBUS is... there is a lot to do to convince everybody. Best regards J_Bell
J_Bell Posts: 5822 Rating: (412)
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3/7/2011 6:45 AM	Rate (0)
JD_techflirt Posts: 95 Rating: (1)	Hi J_Bell, As u said Profibus is well tested but still occurrance of communication breakage problem persists widely in case of profibus for which we have designed special resistance connectors and it is too prone to interference. In case of Drive PLC systems there is always a problem of communication breakage. Whereas incase of ethernet we dont have to take so many precautions of sheilding and resistance and other things but it works quite robust and itsaccessories, switches etc are cheap and readily available. I am novice in this field but we are involved into designing high end mining systems I need opinions wheather can we go for ethernet as our main system bus instead of Profibus.. Regards, JD
JD_techflirt Posts: 95 Rating: (1)
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3/7/2011 10:13 AM	Rate (0)
J_Bell Posts: 5822 Rating: (412)	Dear JD, you are surely aware of the distance limitation you have to face with industrial Ethernet. Your wiremay not exceed 80 to 100 m in length as long as you do not put a switch in between. PROFIBUS may reach, depending on the Baud rate, up to 1000 m on copper. Especially if I think mining... this is a rather good argument. On the other side the possible potential differences on such distances... I fear Ethernet is much more sensitive on this... than PROFIBUS is. Just to mention some points. Best regards J_Bell
J_Bell Posts: 5822 Rating: (412)
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4/9/2011 8:52 PM	Rate (0)
JD_techflirt Posts: 95 Rating: (1)	Hi all, I thinkmy communication damon has returned . One more RIO (remote input/output) staion is coming in our plant and wewill hook it to our main plant bus....and I tried to do so....consequence....reappearance of communication failure in drive fed conveyors. Our main plantProfibus Bus consists of 1) CPU S7 417-H with 2) 14 redundant IM153 ET staions. 3) 12 Y- Couplers communicating to Siprotech relays. 4) 6 Y- Couplers communicating to Drive controllors. ( C240PN ). Ourfuture RIO station will have 1) 3 redundant IM153 ET staions, and 2) 5 y-couplers for relays. In our old configuration to maintain bus and no communication failurewe have put 5 OLMs and 10km distance in Hardware configuration. But now when I add thefuture configuration with same OLM and distance the drive conveyors stop communicating ( WatchDog Time of system went up from 372825 to 512118 ) I tried by putting different bus speeds, distances and OLMs but still communication failure occurs. I think there is some heart beat monitor in drives which stops due to slow response time and brings the Drives to complete halt. Can anybody suggest what to do...??? Waiting for your suggestions. Regards, JD
JD_techflirt Posts: 95 Rating: (1)	Last edited by: JD_techmania at: 4/9/2011 8:55 PM
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4/14/2011 7:12 AM	Rate (0)
JD_techflirt Posts: 95 Rating: (1)	Hii Allll can sombody helpp...????
JD_techflirt Posts: 95 Rating: (1)
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