Industrial Comunications and Control Protocols
Industrial Comunications and Control Protocols
Copyright ©2016
Updated 2022
Index
Introduction 3
Protocol: A definition 3
Digital Data Basics 3
Differences in Controller Types 5
Diversity in the PLC/DCS/PAC market and its problems 5
Networks, Nodes, and Topologies 6
The OSI Model and its importance 12
Hardware and Connecting Cables 12
Communication methods 16
Deterministic communications 17
Interface standards and devices 17
Common Features in Protocols 20
Some Notable Automation Companies 21
Proprietary and Open Protocols 21
The HART protocol 22
TCP/IP 23
Control protocols 24
Modbus and two of its variants 24
Rockwell / Allen-Bradley Protocols 25
Some Important Open Protocols 26
The Fieldbus Foundation and its work 26
FOUNDATION Fieldbus H1 26
FOUNDATION Fieldbus HSE 28
The PROFIBUS Standards 28
PROFIBUS DP 29
PROFIBUS PA 29
PROFINET 29
Communications between Controllers and HMIs 30
Windows OS and OPC 30
PLC/DCS and HMI Programming Software 32
Transmitters, actuators and protocols 32
Disadvantages of using protocols 32
Summary 33
Appendix A: Overview of the Modbus RTU Protocol 34
Appendix B: Some programming software by PLC/DCS providers 35
References 36
Endnotes 37
Introduction
Readers who have experience with, or some knowledge about one or more of the
following technologies will benefit most from this course: Programmable Logic
Controllers (PLCs); Distributed Control Systems (DCSs); or Programmable Automatic
Controllers (PACs).
This course also discusses networks in some detail. Protocols are best explained
along with a discussion about some basic features of networks.
Protocol: A definition
Protocol: The author's definition of a protocol is a method for digital data
communications between two or more devices in different locations, or on a network.
There are many protocols in use around the world. This course focuses on protocols
used by PLCs, DCSs, PACs, and devices existing on the same network as industrial
controllers. Some protocols used with controllers are for data communications only,
usually by sensors and transmitters. Others are used for both data communications
and control applications.
Almost all transmitted data is at least one byte long. A byte consists of 8 consecutive bits,
or binary digits. A byte can have up to 256 (28) values. In reality, data is frequently
communicated in 2, 4 or 8 byte units. A data unit with 2 bytes (16 bits) is often called a
Word.
Measurements that mean something in the real world - levels, pressures, temperatures,
etc. - can easily be represented with 2 or 4 bytes. So can the ranges of set points.
Likewise the On or Off state of a device like a motor. Within computers and
microprocessors, arithmetic operations on data that has a digital equivalent is readily
done. They can easily manipulate data in binary, or base 2.
Digital data communications through protocols has the advantages that it is inherently
more stable, reliable, and less susceptible to electrical noise than analog signals.
Over time, the two technologies became more alike. That has led some manufacturers to
call their industrial controllers Programmable Automation Controllers, or PACs. There are
many applications which can be met by either a PLC or DCS, but usually a PLC will be
less costly.
By the late 1980s it was evident there was too much diversity in this market. Devices from
one OEM could be used with the same OEM's equipment, but not with comparable
equipment from other companies. The need to standardize similar controllers and field
Better data communications methods were also developed. Ethernet, first developed in
1973, is a good example. As networks grew in size and the Internet spread in the 1990s,
the advantages of using Ethernet and its native protocols, including TCP/IP, with industrial
controllers became apparent. So Ethernet and TCP/IP variations are now widely used by
industrial controller OEMs.
The Bus topology is the simplest. Figure 1A shows a simple bus network. Note the
presence of resistors at the ends of the bus. Each node is exposed to data traffic on the
bus, but it will only respond if data is directed to it. Otherwise the data is ignored. A bus
topology has the disadvantage that failure of the bus cable will stop communications. End
resistors with identical resistances are used to improve signal quality on the bus.
In a Star topology (Figure 1B), individual nodes are connected to a central node. Very
often the central node is a Switch. Switches allow temporary pathways to be made so any
node on the network can communicate with any other node. In a star topology, an
individual node can be disconnected without affecting communications on the rest of the
network. It’s more reliable than a bus topology. All data traffic stops if the central node
fails. However, switches are built for high reliability, and often, Uninterruptible Power
Supplies are connected to provide temporary backup power in event of loss of line power.
Sometimes redundant switches are used for improved reliability. In that case, each node
has two ports, with separate cables attached to each distributed node.
Figures 1C-1 and 1C-2 illustrates the Ring topology. The ring doesn’t need to have a
master device, but usually it does. Each node can both send and transmit data. Data
sent from one node to another is forwarded around the ring from the originating node to
the destination node to which it is addressed. If a segment fails, data can be sent in the
reverse direction. A double ring provides enhanced reliability.
Many different types of devices besides computers, controllers and switches can be can
be part of a network – such as printers, scanners, barcode readers, TV cameras, etc.
In reality, networks are interconnected in many different ways. Some networks consist
of combinations of one or more of the three basic networks. In a properly set-up
network, data can get from one node to another as long as a path for data transmission
exists. Many readers may have seen or worked with networks much more complex than
those shown in this course. See References 5 and 6 for information on other types of
networks.
Most networks have a central computer known as a Server. Servers are computers
which meet higher standards for dependability, durability, and speed of access to data
than ordinary desktop computers. Typically they also have far larger data storage
capacity. Servers are frequently set up in redundant pairs. Computers in a network
which act only as "dumb terminals" - which operators can use for monitoring and
control, but don’t directly interact with controllers or perform processing tasks - are
referred to as Clients. A server processes requests from its clients and interacts with
controllers. Servers are often referred to as Thick Clients, and client PCs are
sometimes called Thin Clients. Such networks are usually called Client-Server
Networks.
Many plants and facilities have multiple client PCs and controllers in various locations.
So use of servers in process control applications is sensible for 4 reasons: first, to
centralize key databases used to monitor the site in one reliable computer (or redundant
pair of computers). Second, historical data can be stored on servers. Third, use of
servers simplifies access to shared resources such as printers. Last, a Client-Server
network allows appropriate delegation of roles and tasks to different entities. Each local
controller - a PLC, DCS, or PAC - can execute control over systems in a specific area of
a site, and report the status of its inputs and outputs to the server. And client operator
terminals that are networked with a server can access the server's database(s) for
several purposes:
1
For such purposes, the server passes on commands from client PCs to the appropriate local controller.
Some communication cables have one group of conductors or fibers for communication
in one direction, and another group of conductors or fibers for communication in the
other direction. Regarding such cables, two communications terms sometimes used are
Half-duplex and Full-duplex. Half-duplex refers to the transmission of data in only
one direction at a time on a cable or other data link. Full-duplex refers to the
transmission of data in two directions simultaneously. Typical copper Ethernet cable has
separate pairs of conductors for data transfer in opposite directions.
The OSI, or Open Systems Interconnect model, is the next topic. The OSI model is a
theoretical model of how communications occur on a network. It has 7 layers. It’s helpful
to refer to the OSI model to explain features of protocols, hardware and networks. The
layers are:
Layer 1 (Physical): This layer considers only the physical aspects of a network; the
cables, converters, interconnecting devices, etc.
Layer 2 (Data-link): This layer concerns itself with how Layers 1 and 3 work together.
Layer 3 (Network): This layer provides an addressing scheme for routing of data and
messages, and includes methods for reliable data communications
Layer 4 (Transport): This layer makes sure that messages get to their correct
destination.
Layer 5 (Session): This layer handles the actual connections between systems.
Layer 6 (Presentation): This layer deals with the way different systems represent data.
Layer 7 (Application): This layer concerns itself chiefly with the software applications
used on a computer screen.
Use of protocols involves both software and hardware, and it's hard, but sometimes
necessary, to differentiate between functions performed by hardware devices, and
functions performed by software. So it's helpful to refer to the OSI model sometimes.
Readers may wonder which parts of the OSI Model are used by Communications and
Control protocols. The answers are : generally layers 1, 2, and 7. A protocol sets the
rules for, among other things, how data is read from and written to the input and output
registers of a PLC or DCS. PLC and DCS software is developed to be interoperable
with one or more protocols. The same is true of HMI software (page 26).
are listed in Tables 1 and 2 on page 12. Table 3 on page 13 lists some network
communications cables.
Communication methods
The last topic to be covered before interface standards and protocols are discussed in
detail is communication methods. Three common methods for communications between
networks are Master-Slave, Token-Ring, and Ethernet.
Token-Ring networks rely on token passing for data communications. As the name
suggests, token-ring communications is used on ring networks. "A special message,
called the token, is passed from one machine to another around the ring, and each
machine can transmit only while it is holding the token." 1 Token-ring networks never
became prevalent in business and industry. However, token-passing doesn’t require a
ring network for use – it can be, and is, used on networks of other topologies.
So, some protocols rely on token-passing but don’t use a ring network.
why the Internet uses Ethernet. And use of the Ethernet method has become common
among industrial controllers. Furthermore, communication speeds on Ethernet networks
are fast – typically 100 megabits per second (Mbps) or higher.
Peer-to-peer communications
When any network can transmit data to any other node on the network, the network is
called a peer-to-peer network. Peer-to-peer capability is only possible if the application
layer protocol supports it. Peer-to-peer networks can be implemented on networks with
many different topologies. A master-slave network is not a peer-to-peer network.
Deterministic communications
Communications that occur within predictable and repeated time intervals are referred
to as deterministic. In controllers, deterministic communications capability is vitally
important. Most programmable controllers check and see if any inputs from field devices
have changed many times per second. If any have, the controller responds rapidly.
Deterministic communications is also referred to as cyclic communications.
USB: USB, or Universal Serial Bus, is an interface standard. It is used for point-to-point
connections for a wide variety of purposes, such as between a mouse or printer and a
computer. USB 3.0 allows communications at up to 5 Gibabytes per second (Gbps).
USB 4.0 supports 40 Gbps communications. USB has replaced the much older and
slower RS-232 interface, which was used on legacy computers.
RS-485: RS-485 is an interface standard for data communications that allows data
transmission speeds of up to 1 megabit per second (1 Mbps) on a 100 meter cable.
Data communications speed varies inversely with the total length of an RS-485 cable;
the shorter the total length, the faster the maximum speed and vice-versa. At RS-485
terminals and on conductors, a small negative voltage represents an off bit, and a small
positive voltage represents an on bit.
Most often RS-485 networks consist of point-to-point connections to nodes from a bus
cable. Twisted-pair wiring is used for the bus cable. It offers high immunity to electrical
noise when implemented properly. Terminating resistors are used on each end of the
network to minimize communications problems. In most RS-485 networks, one master
device communicates with slaves. It is a relative inexpensive network to supply and
install into controllers. This makes it an attractive option for relatively simple networks
and applications. RS-485 is widely-used.
Figure 3C shows how an RS-485 cable segments can be joined to a terminal strip near
an RS-485 node. In this arrangement, it’s possible to temporarily disconnect an RS-485
node without interrupting network communications.
RS-485 technology is so attractive that many communication and control devices come
with built-in RS-485 interfaces. A knowledgeable technician or engineer is needed to set
up an RS-485 network, but it is still fairly easy network to build.
RS-485 networks often are used in applications like building HVAC (Heating, Ventilation
and Air Conditioning) and power monitoring systems, where system parameters change
slowly and fast communication is not essential.
8P8C: 8P8C ports and cable connectors have 8 conductors, and 8P8C connectors are
attached to twisted-pair copper Ethernet cables, e.g., Category 6 cables. 8P8C ports
are built into Network Interface Cards (NICs) in computers, Ethernet switches, media
converters, and other devices. Various sizes and shapes of connectors, including RJ-11
and RJ-45 phone cable connectors, are part of the 8P8C group.
Data transmissions are usually done in consecutive clusters of many bytes. Each
cluster consists of parts that have either fixed or variable length, depending on the
protocol and particular situation. And protocols typically have specific ways to mark the
start and end of each transmission.
In TCP, or Transmission Control Protocol, which is used on the Internet and in most
Ethernet networks; these consecutive clusters are called frames. Frames, in turn, are
broken down into smaller units called packets that are handled by routers.
Individual data transmissions on a network also typically include the address of the
source node, and address(es) of the destination node(s).
Each protocol also has its own method (or user-selectable method) for error checking.
Error checking is used in protocols to make sure the data received at a destination
node is identical to the transmitted data. Electrical noise, connection problems, or a
failed part may interfere with effective data communications. If the sending node gets a
response from the receiving node that the data was received as intended, the task is
done. But if a mismatch was detected, or no acknowledgement that the data has been
received properly is returned, than either the data will be resent, an informative
message will be generated, or another appropriate action will be taken.
Protocols exist for communicating data. But different protocols are used for different
purposes. Yet, in plant control applications, much of the data falls into four categories:
Analog inputs
Analog outputs
Discrete inputs
Discrete outputs
Sometimes other types of data, like character data, are also transmitted. Log-on names,
passwords, text messages and product barcodes are examples of character data.
(ASCII, extended ASCII, and Unicode are widely-used standards used for representing
character data.)
Each protocol used in plant control applications has its own unique way of
characterizing different types of data.
Most people using communications and control protocols won’t have to be concerned
about these details – but one never knows. It might, for example, become necessary to
choose between two or more error-checking methods.
The first is Modicon. Modicon built the first PLC ever used. It was 1 of 3 functionally
similar controllers installed at a transmission plant of a General Motors subsidiary in
1969. Modicon was an independent company for about 8 years before it was purchased
by Gould in 1977, then by AEG in 1994. Modicon has been owned by Schneider Electric
since 1996. Modicon remains active in the PLC/ PAC market around the world. It has
maintained a significant market presence for over 50 years.
The last is the German multinational company Siemens. Siemens had a large market
position in Europe by 1990. It now has a world-wide presence. Siemens collaborated
with other German companies and a bureau of the German government to develop the
PROFIBUS protocols.
Note: Allen-Bradley has not supported the PLC-5 product group since 2012, so DH+ is
now a ”legacy” protocol.
In the 1970s, end users starting preferring transmitters with 4-20 milliampere (mA)
signal outputs over other options. Over 45 years later, 4-20 mA output transmitters
remain in widespread use. A typical transmitter is connected to a DC power supply, and
sends a 4 to 20 mA signal to a controller that's linear (or adjusted to be nearly linear) in
a range between the low and high limits of a transmitter's calibrated range. Rosemount,
Inc. was the most notable supplier of transmitters in the 20th century for a wide variety
of measurement devices. In the late-2010s, it still has a large market presence.
(Rosemount was bought by Emerson Electric in 1976.)
A simplified discussion of HART follows. HART transmitters place a wave of sorts atop
the 4-20 mA signal that isn't needed or sensed by a controller, and doesn't affect the
output of the transmitter. The wave’s frequency is continuously varied depending on
whether a bit is 0 or 1. The wave contains data about the circuit, measurement, and
transmitter. When a HART Handheld Terminal, or a PC loaded with HART software is
connected to the 4-20 mA circuit with a HART-compatible transmitter, the user can
monitor the circuit and adjust key transmitter aspects from the terminal. This simplifies
the tasks of checking for problems, and changing a transmitter's range without
removing the transmitter's cover. The superimposed wave is immune to electrical noise
and ground loop currents, which can affect a purely analog 4-20 mA signal.
HART communications can be used to represent two or more signals. For example, the
air flow measurement inferred from a differential pressure (D.P.) transmitter depends
on air temperature. If a HART-capable D.P. transmitter also measures temperature,
both measurements can be transmitted on the same cable.
These days, some HART devices have either IEEE 802.3 radio wireless compatible
receivers, or receivers that can be used with Bluetooth, a communications technology
that relies on short-range transmission of signals. These types of devices are used with
handheld HART interface devices. An IP version of HART (HART/IP) also has been
developed.
HART data can be shared with some other protocols like Modbus TCP/IP (p. 21)
provided the other protocol has drivers (p. 27) to translate the HART data. In this way,
it’s possible to use HART’s features to detect occurrences like a failed transmitter.
TCP/IP
TCP (Transmission Control Protocol) & IP (Internet Protocol) – known as TCP/IP - are
key protocols. They are used together on the Internet and in Ethernet networks
worldwide. "TCP/IP is a standard for transmitting data in packets from one computer to
another .... The two parts are TCP, which deals with construction of data packets, and
IP, which routes them from machine to machine." 3 IP uses 4 "octets" for a sum of 32
address bits. The decimal equivalents of each octet range from 0 to 255, and periods
separate octets in an IP address, e.g., 192.168.41.23. There are restrictions regarding
IP addresses. Some can't be used, and Internet Protocol version 4 (IPv4) is quickly
running out of available addresses for public access.
TCP/IP is mentioned here because some protocols used in control applications are
adaptations of TCP/IP. For example, in Modbus TCP/IP, TCP/IP is like an envelope for
data transmitted per the Modbus protocol. In these adaptations of TCP/IP, data is sent
from one node to another on a network using the same node addressing scheme that
IP uses.
In the 2020s, IPv6 (Internet Protocol version 6), with 8 octets and 128 address bits, is
gradually replacing IPv4.
Control protocols
Many control protocols are used with controllers. Some of the most widely-used ones
are explained in the remainder of this course.
Modbus and two of its variants: The original, proprietary Modbus protocol was
developed by Modicon in 1979 for use with Modicon PLCs. It is one of the earliest
control protocols ever developed. Data transmission in Modbus is serial – one bit
follows another. In 2004 Modbus became an open protocol managed by the Modbus
Foundation. Modbus is a relatively simple protocol that uses numbering schemes that
are familiar to those who have programmed Modicon PLCs. Some commercially
available instruments, meters, indicators, and actuators are Modbus-compatible.
It’s correct to refer to Modbus as a control protocol, but it also can be used for data
communications applications that don’t require control capability. Many commercially
available transmitters and indicators are Modbus compatible. The same is true for
FOUNDATION Fieldbus H1 and HSE, and PROFIBUS PA, which are examined later.
Modbus Characteristics
Master-slave network
Application layer protocol It isn’t hardware dependent.
Serial data communications The maximum obtainable speed varies with the
variant of Modbus used, and equipment on the
Modbus network.
Maximum nodes allowed 247 slaves possible with repeaters but 32 is
standard.
Modbus Variants
Modbus is used on different types of networks for different applications. Here are two of
its variants:
• Modbus RTU: This variation is very widely used. It’s typically used on RS-485
networks. Master-slave communications are used. It includes error checking. All
devices on a Modbus RTU network must be set to the same communications
speed.
• Modbus TCP/IP: This is Modbus adapted for use on an Ethernet network. It is
also known as Modbus IP. Process data in messages communicated using
Modbus TCP/IP are “embedded” in a TCP frame. Nodes in a network using
Modbus TCP/IP (and other protocols that use TCP/IP) use IP addresses.
Modbus RTU is rarely used in new control applications due to its slow communications
speed, however, it remains useful for applications like instrumentattion in which rapid
communcations is not essential.
b. ControlNet
ControlNet is an open protocol that’s notable for its use in Rockwell/ Allen-Bradley’s
ControlLogix group of controllers. Its functions are distributed in several layers in the
OSI model. Allen-Bradley participated in development of ControlNet (and EtherNet/IP &
DeviceNet). It’s an open protocol whose standards are managed by ODVA. Rated
communications speed is 500 kbps. Nodes in a ControlNet network are usually
connected by RG-6 coaxial cables and connectors. Each end of the network must have
a terminating resistor. It can support up to 99 nodes. The physical length of a
ControlNet network can be extended using repeaters and/or media converters which
interface copper and fiber optic cable.
Slave devices in a ControlNet (or EtherNet/IP) network are not limited to controller
remote racks or other controllers. The author once participated in a project where 10
Variable Frequency Drives (VFDs) were linked to a branch of a ControlNet network.
The use of many Input and Output (I/O) modules was avoided.
c. EtherNet/IP
According to John Rinaldi of Real Time Automation, EtherNet/IP will become an even
more important protocol in the 2020s. Rinaldi says EtherNet/IP’s high data transfer
speed and deterministic communications make it an ideal candidate for acting as a sort
of master protocol for use in large networks.
The FOUNDATION protocols are discussed below. Both are targeted mostly to the
Distributed Control System (DCS) market.
FOUNDATION Fieldbus H1
The Fieldbus Foundation participated in development of an international field bus
standard, IEC 61158. FOUNDATION Fieldbus H1 complies with IEC 61158-1. It is for
use for communications between a controller and field devices on a network - or
between field devices. All communications on Fieldbus H1 networks are only digital.
Fieldbus H1 networks can be connected using a variety of topologies, but the most
common one is the trunk (master cable) and spur (branch) one. The tree topology is
also used frequently. Also, redundant buses may be used for interfacing to the same
set of field devices for greater reliability, if the network hardware supports redundant
connections. Many DCSs are Fieldbus H1 compatible.
Anyone considering using Fieldbus H1 for the first time might contact FieldCommGroup
(www.fieldcommgroup.com), the organization which supplanted the Fieldbus
foundation on Jan. 1, 2015, or talk with controller OEMs.
The PROFIBUS protocols are not as widely-used in the United States as they are in
Europe and Asia. The PROFIBUS standards conform to IEC 61158. Both PROFIBUS
DP and PROFIBUS PA standards apply to controllers, field devices, cables and
connectors.
PROFIBUS DP
PROFIBUS DP (Decentralized Peripherals) is an important PROFIBUS standard which
is marketed for PLC applications. Some of its features include:
PROFIBUS PA
PROFIBUS PA (Process Automation) is another notable Profibus standard. It is
interoperable with PROFIBUS DP. PROFIBUS PA and FOUNDATION Fieldbus H1
are similar. PROFIBUS PA compatibility is offered by many instrumentation and
actuator OEMs. Its rated communication speed is 31.25 kbps. Some of its other
characteristics are listed below:
PROFINET
PROFINET is for use on high speed Ethernet networks. It has similarities to
EtherNet/IP and FOUNDATION Fieldbus HSE. PROFINET devices are designed to be
rugged enough to work in challenging factory and process control environments. Just
as EtherNet/IP is slowly replacing ControlNet, PROFINET is likewise gradually
supplanting PROFIBUS PA and DP.
Anyone considering using any variation(s) of PROFIBUS for the first time might talk
with controller OEMs first.
People use HMIs to monitor what controllers are doing, provide key information on
plant operations, and enable operators to operate equipment and systems from remote
locations. Operators must be able to start up and shutdown equipment and s ystems;
switch between automatic to manual modes; change set points of automatic control
loops; and intervene in other ways. Also, operators need to be able to view and
respond to alarms; monitor trends in processes; and access historical information.
Sometimes the protocol used for communications between HMIs and controllers differs
from the protocol the same controller uses to communicate between other controllers
and devices on a network like instruments and actuators.
An aspect of HMI software worth mentioning is that typically, it will request updated
data from the controllers to which it is connected at a periodic rate, and in a sequence,
even as each controller goes on executing its program. HMI data refreshes typically
occur at longer time intervals than PLC or DCS cycle times.
Some key Microsoft application programs use Object Linking and Embedding, or OLE.
OLE allows two applications to run simultaneously and share data. HMI developers and
controller OEMs alike sought to use OLE techniques so HMIs and controllers could
work together. This led to the development of OPC - Object Linking and Embedding for
Process Control. OPC is now known as Open Platform Communications.
OPC was developed for a key purpose: to provide a common set of standards, so any
OPC-compliant HMI software program would be able to interface with any controller.
OPC compliance is a very desirable feature and selling point for companies that offer
HMI software.
Around 2010, OPC UA, or OPC United Architecture was developed. OPC UA provides
OPC functionality, but also allows developers to write software for some other
« platforms » besides Windows, including Java and the C++ computer languages.
Sometimes the best choice for a driver is not obvious. For example: Emerson’s iFIX
HMI software can use the Modbus Ethernet (MBE) driver to interface with Rockwell/
Allen-Bradley ControlLogix processors.
Allen-Bradley has a somewhat different approach. It offers two HMI software programs
called RSLinx and FactoryTalk Linx. Both of them are OPC-compliant; both RSLinx and
FactoryTalk Linx act as network communications managers between HMIs and
controllers; and both have several different variations. And both have drivers that can
be selected to interface with programmable controllers provided by other OEMs
besides Rockwell/ Allen-Bradley PLCs and PACs.
Protocols interact with HMIs, and PLCs & DCSs on a network in part by reading from
and writing to specific addresses on each end. Usually these addresses will be the
same between the controller(s) and HMI, except the HMI addresses will different from
the controller addresses in some way that is consistent for all addresses. For example :
The topic of HMI software is quite complex. This course only provides an overview.
The main disadvantage is that using protocols and fieldbuses is that in some cases,
communications with multiple devices (instruments and/or actuators) can be lost if a
single device (like a power supply or interface module) fails, or, for some networks, if
electrical continuity is lost in a segment of a cable.
Using conventional transmitters with 4-20 mA signals and twisted-pair wiring has
advantages over using a protocol and a communications bus. So does using typical
wiring for interfacing with discrete sensors, and controlled devices like motors.
Technicians are more familiar with conventional devices than equipment operated over
a bus - and if a problem arises, it’s often easier to find the cause of a problem and fix it.
Sometimes there is a high turnover rate among techs, so if a few key people leave and
have to be replaced, then it’s easier to find replacement staff capable of using proven
technology.
Before choosing to use a new protocol, decision makers also need to judge the
capabilities of the installers, and in-house people who will be maintaining the system,
doing things like modifying programs, replacing failed modules, and expanding the
system. A new technology, with unfamiliar programming software and a new protocol,
shouldn’t be used unless it represents a good choice. In particular, the installers, OEMs
and software providers should have a good record of customer support.
Summary
This course discussed some widely-used industrial communications and control
protocols. It explained how use of protocols has improved reliability in plant
applications. It reviewed different types of networks, network cables, hardware devices
and network topologies. And it emphasized how reliable plant control depends on
reliable networks.
The reality is protocols often are very complex, many evolve over time, and some
cease to be used over time as technology changes and better alternatives emerge.
The Modbus RTU protocol is a simple protocol that’s widely used both for communications
only and control applications. There is one master device and multiple slaves. Slave devices
respond if a query issued by the master is directed to it.
Each slave on a Modbus RTU network must be set to the same communications speed, and
use the same parity setting: either Even, Odd, or None. A parity bit is added by the master
after each byte in the data component of each frame transmitted (unless “None” is selected).
Each Modbus RTU frame sent by a master consists of 7 components, as tabulated below.
Addresses can be either read-only (r) or read/write (r/w), that is, they can be both read from
and written to. The function code will determine the type of operation performed.
Function Codes
1 Read Coil (output bit) status
2 Read Input (input bit) status
3 Read Multiple Holding Registers
4 Read Input Registers
5 Write Single Coil
6 Write Single Holding Register
15 Write Multiple Coils (bits)
16 Write Multiple Holding Registers
Modbus RTU data is stored in registers (or consecutive registers) that hold either single bits,
16 bits, 32 bits, or 64 bits.
OEMs offering Modbus-compatible devices have considerable latitude regarding what the
address ranges may be for each class of register. However, there can be no more than
65,536 (216) registers of each type. This is far more registers than are needed by Modbus-
compatible field devices like transmitters and actuators.
Allen-Bradley offers its RSLogix5000 software for its enduring ControlLogix product line
(ControlLogix PLCs were introduced in 1997). However, the actual software picture is far
more complicated than that. Allen-Bradley’s 6200 software was initially used for programming
PLC-5 family PLCs; later on, RSLogix5 was used.
Currently, SIMATIC is probably the most commonly-used programmaing software used with
Siemens PLCs.
References :
1. Web resource : https://en.wikipedia.org/wiki/Hexadecimal (Wikipedia)
2. Web resource : https://en.wikipedia.org/wiki/Fieldbus (Wikipedia)
3. Web resource : http:www.fielbus.org
4. Web resource : www.profibus.com/
5. « Introduction to Computer Networking » (Course E175, Dale E. Callahan,
www.pdhcenter.com/ www.pdhonline.org)
6. « How to Develop High Reliability Ethernet Control Systems Using Media
Redundancy » (Acromag, Inc. White Paper)
7. « An Introduction to Modbus® Serial Communication » (Precision Digital Corp.)
Endnotes:
1
Dictionary of Computer and Internet Terms, Ninth Edition, Barron’s Educational Series, Inc.
2
Introduction to Modbus TCP/IP, Publication 8500-765-A05C000, Acromag, Inc., 2005
3
Dictionary of Computer and Internet Terms, Ninth Edition, Barron’s Educational Series, Inc.