07 - Checking The Electrical Bus Cable

Automation and Drives
Checking the electrical bus cable
PROFIBUS DP
SITRAIN
IK-PBSYS / BT200 + Diagnostic-Repeater Page 1 07/2007
Siemens AG 2007 - All reights reserved
Contents Page
BT200 test unit for bus cables to RS485 ........................................................................................... 2
Select special mode for extended functions ...................................................................................... 3
Log kit for BT200 .............................................................................................................................. 4
Exercise 1: Test your bus cable with the BT200 test unit .................................................................. 5
Exercise 1b: Test your bus cable with the simulator and BT200 test unit . 6
Exercise 2: Branch test for entering all slaves in a "live list" .............................................................. 7
Diagnostic repeater .......................................................................................................................... 8
Function of Diagnostic- Repeater ..................................................................................................... 9
Arrangement of the DP master in the topology .................................................................................. 10
Topology determination with STEP7 ................................................................................................. 11
Location of the fault is determined (1) ............................................................................................... 12
Location of the fault is determined (2) ............................................................................................... 13
Evaluation of the measurement results, GENERAL tab ..................................................................... 14
Evaluation of measurement results, DP SLAVE DIAGNOSTICS ...................................................... 15
Evaluation of the measurement results, DP1 tab and DP2 tab .......................................................... 16
Evaluation of the measurement results, DP3 tab and PG tab ............................................................ 17
Reading out the diagnostic buffer ..................................................................................................... 18
Diagnosis using the topology display in STEP 7, bus topology .......................................................... 19
Topology table and Statistics buffer .................................................................................................. 20
Exercise 3: Integrating the diagnostic repeater into the system ......................................................... 21
Exercise 4 : Configuring a diagnostic repeater in STEP7 .................................................................. 22
Exercise 5: Diagnosis of bus cable ................................................................................................... 23
SITRAIN Training for IK-PBSYS

Automation and Industrial Solutions Page 1 BT200 + Diagnostic-Repeater
BT200 test unit for bus cables to RS485
Testing the PROFIBUS cable:

Cable break/shield break
Short circuits between cables or cable and shield
Fault localization in the event of data cable
break/short-circuit
Detection of reflections which cause faults
Cable replacement
Lengths of the installed cables
Checking the accessibility of the slaves:

List of accessible slaves
Specific addressing of individual slaves
Checking the RS 485 interfaces of the masters and

slaves:
RS 485 driver
Supply voltage for cable termination
RTS signal
Display of the PROFIBUS DP address
SITRAIN
Function of the BT 200

The BT 200 offers diagnosis options for PROFIBUS systems by means of
the electrical bus cable to RS485.
The PROFIBUS cable can be tested with the BT200 test unit during the
installation phase.
The wiring can even be tested while the stations are connected. Installation errors
are detected quickly and easily. The person installing the system does not require
specialist PROFIBUS knowledge.
The RS 485 interfaces of the PROFIBUS DP stations can be tested even before
the system is commissioned.
The slaves which can be reached on the installed bus can be listed without a
master on the PROFIBUS DP.
In this way, the operating capability of individual bus segments can be tested
beforehand which reduces commissioning times.
With the help of the optional log kit the individual tests can be stored in the BT200
and transmitted to a PC. The test results can then be printed out in the form of a
report. In this way, the acceptance log can be drawn up simply and quickly.

Select special mode for extended functions
Menue for
standard and
special mode
Press the OK AND ESC keys

simultaneously
===> SPECIAL MODE activated
SITRAIN
Special mode Press the ESC and OK keys simultaneously to switch from normal mode to
special mode.
The following functions are available in special mode:

Wiring test (see normal mode).
Station test
Swapped cores
Short-circuit
Broken wire or shield
None or more than two terminating resistors
Station test (RS485 test)
Branch test
Distance measurement
Reflection test
Service menu
Menu items Menu items are selected with the cursor and activated with the OK key.
The ESC key can be used to cancel the current function or to return to the
higher-level menu item.
Operation The BT 200 is menu-driven using the input keys of the membrane keypad.
Cursor The current position of the cursor on the display is indicated by a flashing arrow
which also indicates the function being executed.

Log kit for BT200
SITRAIN
General In recording mode, implemented tests are logged in the BT200 and can then be
transferred via a serial (COM) interface to a PC with logging software.
The required logging kit comprises the software and connecting cable for the PC
and can be ordered using the order number 6ES7 193-8MA00-0AA0.

Exercise 1: Test your bus cable with the

BT200 test unit
Cabeling o.k.
(2R) OK
SITRAIN
Task description: Test the bus cable which you will be using for the next few exercises.
Procedure: The wiring test for a bus segment is performed between the BT 200 and
test plug.
No stations may be connected to the bus cable.
The test plug must be connected to one end of the bus cable which is to be
tested
The terminating resistor at the end of the test plug must be activated
The terminating resistor on the connection point of the BT200 must be
activated
1. Construct the test setup as described above.
2. Press the button to switch on the BT200.
2. Press the "TEST" button for a short time. The message

Please wait..." is displayed.
3. As a result of the test, a message is displayed which could

be as follows :
" Wiring OK
(1R) OK.

Exercise 1b: Test your bus cable with the

simulator and BT200 test unit
B -> Sh
A -> B
A -> Sh
A -> A
B -> B
Signal 0
3-5
Signal 0
8-6
SITRAIN
Task description: Test the bus cable with the simulator and the BT200.
Procedure: 1. Connect the simulator between the BT200 and the test plug.
2. Test the different switches on the simulator and check the result with the
BT200.

Exercise 2: Branch test for entering all slaves in

a "live list"
ON
Off
Master not connected

to bus
ON
"Live list" also over repeaters and opt. paths

Subsystems can be tested first for proper
functioning of the bus; no master is required
SITRAIN
Branch test In this way, the availability of all slaves connected to PROFIBUS can be tested or
an individual slave can be addressed.
The branch test can also be performed over repeaters or fiber-optic cables.
Procedure Remove all masters from the bus, e.g. PGs, OPs, CPs (see Figure above).
All slaves must be switched on and supplied with power.
Connect BT 200 to the bus as shown in the figure above, for example
Select special mode by simultaneously pressing the ESC and OK keys.
Now use the cursor key " to point to the menu item "Branch test,
with the flashing menu arrow next to this text.
Now select it with the " OK key". The text "Branch test" is displayed.
Then press the "TEST key"
To check which slaves are connected to the branch, use the cursor keys of
the BT200 to enter "000" as the slave address and confirm with the OK key.
"Please wait" is displayed
After the search is complete, the slave numbers found are output on the
display separated by commas.
Test results For the total branch test, each accessible slave is listed in a list of
accessible stations (LIVE LIST).

Diagnostic repeater
S7-CPU STEP7
COM
PROFIBUS
Segment 1
Start
determining
of topology
Diagnostic
distance to slave distance to disturbance
Segment 2 Segment 3
SITRAIN
Introduction Under normal operating conditions, the bus cables are also subjected to external
forces that can cause damage. In particular, in the case of exceptional stress, e.g.
trailing cables or strong vibrations, frequent inspection of the cables is
recommended to reduce failures to a minimum.
Diagnostic repeater The diagnostic repeater is available for line diagnostics during normal system
operation.
It is integrated as an RS 485 repeater in the PROFIBUS DP network and also
features powerful functions for line diagnostics.
The diagnostic repeater detects the following cable faults:

Wire break A or B
Short-circuit between signal lines and the shield
Missing bus terminating resistor
The diagnostic repeater is configured as a standard slave in STEP 7, with
COM PROFIBUS or using the GSD file.
Design Connection of 3 segments, of which diagnosis is possible for 2

Connection of up to 62 nodes (31 per diagnosable segment)
Connection of up to 9 diagnostic repeaters in series
Mounting on S7-300 rail or standard rail
LEDs for indication of 24 V DC, bus activity and line faults for each segment
Terminal block for external 24 V DC supply voltage
9-pin Sub D socket for PG connection, electrically isolated

Function of the Diagnostic- Repeater
PG interface
Start
Topology determination
CPU STEP 7 > V5.1 SP2
2
3
Segment 1
Slave distance
4 5 12 17 9
Segment 2 Segment 3
SITRAIN
Area of application The diagnostics repeater is a repeater that can monitor up to two segments of an
RS 485 PROFIBUS network (copper line) during operation and signal line faults
in a diagnostics message to the DP master.
The fault location and cause can then be displayed in plain text by means of an
HMI device. The line diagnostics during operation by the diagnostics repeater
permits early detection and locating of line faults.
Prerequisites Line diagnostics are possible for nodes that are connected to PROFIBUS
segments DP2 and DP3.
To implement a diagnostic repeater, you will need a PG/PC and STEP 7
V5.1 Service Pack 2 or higher or COM PROFIBUS V5.1 Service Pack 2.
To activate topology determination from the user program, an S7 CPU/CP
will be required that supports the integrated system function SFC 103
"DP_TOPOL" (e.g. integrated DP interfaces of S7-400 CPUs FW 3.1 and
higher).
Line diagnostics Line diagnostics are performed in two steps:

Step 1: Toplogy determination
The diagnostic repeater determines the PROFIBUS addresses and
distances to the nodes and creates a topology table.
Step 2: Fault localization

The diagnostic repeater checks the cables during normal operation of
the bus.
It determines the distance to the fault location, determines the cause
of the fault and issues a diagnostic alarm with a relative specification of
the fault location.

Arrangement of the DP master in the topology

Arrangement with
one segment ( DP2)
DP1: non
diagonostics-capable segment DP2: diagonostics-capable segment
Arrangement with
two segments ( DP2 and DP3)
SITRAIN
Prerequisities for determining the topology

A DP master is required for determining the topology that initiates the necessary
measurements and that is able to provide its diagnostic information over the
diagnostic repeater.
Arrangement of the DP master

It is usually recommended that the DP master is connected to the A1/B1
connection of segment DP1 of a diagnostic repeater.
Arrangement with one segment (DP2)

When only one segment with diagnostics capability is required, segment DP2 of
the diagnostic repeater must be used. If a bus cable is not connected to segment
DP3, the SEGMENT DP3 rotary selector switch must be set to OFF.
Arrangement with two segments (DP2 and DP3)

If a bus cable is connected to segment DP3, the SEGMENT DP3 rotary switch
must be set to ON.
If an outgoing bus cable is not connected to the A1/B1 connections of segment
DP1, the TERMINATOR DP1 rotary switch must be set to ON. The terminating
resistor for segment DP1 is therefore connected and the A1/B1 connections are
deactivated.
Determining the topology with STEP 7

In SIMATIC Manager, select the PROFIBUS network where the diagnostics
repeater with the connected PG/PC is located and select the menu command
Target system - PROFIBUS Prepare line diagnostics.
In the dialog box that is then displayed, select the button Start measurement.

Topology determination with STEP7
Example user programs
CALL "DP_TOPOL" SFC103 Calling topology determination

REQ :=M2.0 Starting topology determination (bool)
R :=M2.1 =1: Interrupt topology determination (bool)
DP_ID :=1 ID of the DP master system whose topology
has to be determined (int)
RET_VAL :=MW110 Return value for task status (int)
BUSY :=M112.0 =1 Topology determination is not yet completed.
DPR :=MB124 PROFIBUS address of the diagnostic
repeater reporting the fault (byte)
DPRI :=MB125 Measuring segment of the diagnostic repeater
reporting the fault (byte)
SITRAIN
Determining the topology with SFC 103 "DP_TOPOL"

The topology can also be determined using an S7 CPU that supports the integral
system function SFC 103 "DP_TOPOL".
You can use SFC 103 "DP_TOPOL" to start determining the topology for a
selected DP master system. The SFC 103 call addresses all the diagnostic
repeaters on a DP master system.
Duration of topology determination

The duration of the topology determination procedure is dependent on the
structure of your system and the transmission rate. Topology determination will
be interrupted if the duration exceeds the limits specified in the table.
Transmission rate Limit values
12 MB 5 min.
6 MB 5 min.
3 MB 5 min.
1.5 MB 8 min.
500 KB 12 min.

Location of the fault is determined (1)
Segment OK
Segment disturbed
Segment OFF
No information for the Segment
SITRAIN
Determining the fault location during operation

The diagnostic repeater signals the event "Fault location determined" during
normal operation as a diagnostic alarm to the CPU of the DP master.
You can display detailed information about the diagnostic event that has occurred
in the module information dialog box for the diagnostic repeater. The fault location
is shown pictorially in the dialog box with additional information, e.g. about the
cause of the fault (if it can be determined by the diagnostic repeater).

Location of the fault is determined (2)
SITRAIN
Example of a pictorial display in the "Module information" dialog box

If all the segments to which the diagnostic repeater is connected function
correctly, the corresponding tabs in the "Module information" dialog box are as
follows:
The "DP2" tab could show the disturbance in the following view: The Diagnostic
Repeater is assigned to PROFIBUS address 4, the error is located between the
partners assigned to the PROFIBUS addresses 16 and 21. In addition, the view
shows the distance to the neighboring DP Slaves.
In the figure below you can find an example of a simplified detailed presentation
of the arrangement illustrated above.

Evaluation of the measurement results,

GENERAL tab
SITRAIN
General This tab sheet contains general data concerning the module:
Description, system identification, rack, slot and module width
Address: The address displayed is the start address of the useful data area: For modules
without a useful data area, it corresponds to the diagnostic address.
System behavior: When the module is a CPU with multi-computing capability, this information is
shown here.
Version The order number and version of the selected module is indicated here. This
display comprises several components that vary in accordance with the module
type, for example, separate entries for the hardware and firmware of the module.
Status The existing status information is indicated here

Status of the module from the viewpoint of the CPU, e.g.:
Module found and OK.
Module faulty.
Module configured but not found.
Error LEDs
Differences detected between configured and inserted modules.
The Order numbers for the required type and actual type are displayed if
they can be determined.
For DP slaves, the status of lower-level modules can be displayed here.
The scope of information displayed varies in accordance with the selected
module and as to whether the function was called from the window "Accessible
nodes" or from a project window.
Identification Name of the PLC, name of the CPU, system identification

Evaluation of measurement results,

DP SLAVE DIAGNOSTICS
Diagnosis in
Hexadezimal Format
SITRAIN
"DP slave diagnostics"

This tab sheet contains slave diagnostic data that is presented in accordance with
EN 50170, Part 3, PROFIBUS.
Standard diagnosis of slave

General diagnostic information of the slave:
The information refers to correct startup or failure of the slave. Errors that are
displayed here are of the type "Slave cannot be addressed", configuration errors
or parameter assignment errors.
Device-specific diagnostic text of the slave:

The diagnostic texts displayed are obtained device-specifically using the GSD file
(device master file). If the diagnostic message is not stored in the GSD file, the
diagnosis cannot be displayed as plain text. The channel information is only
visible when you open the station online in the STEP 7 project. When you open
the station online without reference to a project (via accessible nodes), there is no
assignment to a GSD file and the channel information is not visible.
Channel-specific diagnosis
Display of channel-specific diagnostic texts for configured modules of the DP
slave: For each diagnostic message, the activating channel is specified.
A channel is uniquely identified by the slot location of the module and the channel
number. Device-specific diagnostic texts are obtained using the GSD file. If the
diagnostic message is not stored in the GSD file, the diagnosis cannot be
displayed as plain text.
"Hex. format" button

When you click this button, the complete diagnostic message frame is output in
hexadecimal format.


DP1 tab and DP2 tab
Segment DP1 is OK
Graphical display of
fault location:
Display of possible
cause of fault:
Further details about

the displayed fault
SITRAIN
DP1 tab A tab sheet is assigned for each connection of a diagnostic repeater to a segment
a fault in a segment is indicated by a fault symbol.
If a fault is detected or if the interface for this segment is switched off (segment is
deactivated), an appropriate message is displayed in the tab.
If a fault is detected, the following fields will be displayed:
Error location In the "Error location" field, the location of the fault is displayed graphically
provided that the diagnostic repeater can determine the location.
Error The fault is explained in plain text in the "Error" field.
Remedy In the "Remedy" field you will find measures for rectifying the fault.
If the "Details" button is activated, you can use it to display further details of the
fault.


DP3 tab and PG tab
SITRAIN

Reading out the diagnostic buffer
SITRAIN
Diagnostic buffer The diagnostic repeater contains one diagnostic buffer for each of segments DP1,
DP2, DP3 and the PG interface in which the last 10 events are saved. The buffer
contains the time, date and a brief description of the events.
Incoming error events are indicated with "I" and outgoing error events are
indicated with "O".
The diagnostic buffers can be printed out. They can be exported as CSV files and
then read into Microsoft Excel and evaluated.
The diagnostic buffers can also be read out from the user program, whereby the
function block SFC59RD_REC must be used (see online help).
Procedure 1. Mark the DP master system whose data you want to read.
2. Start the function using the menu item Options > Diagnostic buffer.

Diagnosis using the topology display in STEP 7,

bus topology
Diagnostic - Repeater
SITRAIN
Prerequisite To ensure that the distances specified in diagnostic messages are correct, the
topology must be determined again following every change in structure of the bus!
Requirements The diagnostics repeaters must support the function Display PROFIBUS network
topology. The PROFIBUS network must be set up according to the rules in the
diagnostics repeater manual so that the distance data can be determined
correctly. If diagnostics repeaters are cascaded, for example, they must only be
connected to a higher-level diagnostics repeater via the DP1 interface.
For the function Prepare line diagnostics, the programming device (PG) and the
diagnostics repeaters must be connected to the same PROFIBUS. Prepare line
diagnostics is also possible if no project is open.
For the function Display PROFIBUS network topology, the PROFIBUS network
with the diagnostics repeaters can also be connected to the programming device
via a Data record router (e.g. CP 443-5 Ext V3.2).
The programming device must be assigned in the STEP 7 project (menu
command Target system Assign PG/PC, in NETPRO use for the object
PG/PC). In order to be able to display the network topology via a routed
diagnostics repeater, the corresponding project must be opened and the
corresponding PROFIBUS subnetwork must be selected.
Procedure 1. In STEP 7, mark the DP master system whose data you want to read.
2. Start the function using the menu command View > Display >
All nodes/Only DR with nodes/Only DRs.

Topology table and Statistics buffer
There are too many line faults. Operation of

the segment is no longer possible
Line faults have been detected. Operation

of the segment is still possible. Nodes may,
however, fail as a result.
A few line faults have been detected.

Operation of the segment is optimal.
The severity of faults can also be assessed
on the basis of the color coding.
SITRAIN
Topology table The topology table contains the following information:

PROFIBUS address of the node.
Designation of the node, if it can be determined.
Address of the associated diagnostic repeater to whose measuring segment
the node is connected.
Distance with reference to the associated diagnostic repeater
Segment of the diagnostic repeater to which the node is connected.
Time when topology was last determined.
The topology table can be printed out. It can be exported as a CSV file and then
read into Microsoft Excel and evaluated.
It can also be read out from the user program, whereby the function block
SFC59RD_REC must be used.
Procedure 1. Mark the DP master system whose data you want to read.
2. Start the function using the menu item View > Topology table.
Statistics buffer The diagnostic repeater contains one statistics buffer each for segments DP2 and
DP3 in which information about the reflection error rate and message frame error
rate can be saved.
Reflection errors occur, for example when the signal is reflected through a faulty
or defective line.
Message frame errors are detected when message frames with, for example,
parity errors occur. Parity errors can be caused, for example, by a defective
node. The values are displayed for a period of 60 seconds starting from the time
when the dialog box was opened. Internally, further values are saved over the
displayed period. The statistics buffers can be printed out. They can be exported
as CSV files and then read into Microsoft Excel and evaluated. The statistics
buffers can also be read out from the user program.
Procedure 1. In the topology display, mark the diagnostic repeater whose data you want to
read out.
2. Start the function using the menu item Options > Statistics.

Exercise 3: Integrating the diagnostic repeater

into the system
SITRAIN
Task: The diagnostic repeater must be integrated into your existing system
line faults must be provoked and diagnosed using the diagnostic
repeater.
Procedure: 1. Modify your system as shown in the diagram above.

2. Code the diagnostics repeater as follows:
DP3 switch in the ON position
DP2 switch in the ON position
Set the DP address switch (DIP switch) to address 9
DP address switch, set the identifier with DR to OFF for no repeater
function

Exercise 4 : Configuring a diagnostic repeater in

STEP7
Diagnostic - Repeater
Properties
SITRAIN
Task The diagnostics repeater is to be configured for the master system with the
PROFIBUS address 9 as further DP slave.
Implementation
1. Open the hardware configuration on your training station
2. Drag the object Diagnostics Repeater from the hardware catalog under
PROFIBUS DP - Network Components to the master system
3. Assign the bus address 9 to this DP slave
4. Generate new system data blocks
5. Download the changed configuration onto the master CPU The master system
should ramp up without errors just like before
6. Connect the PG to the PG socket on the front of the diagnostics repeater using
the connecting cable of the diagnostics repeater
7. In SIMATIC Manager, select the subnetwork PROFIBUS(1) and select the
menu command Target system - PROFIBUS Prepare line diagnostics...
8. In the next window, start topology determination by clicking on the button
Restart

Exercise 5: Diagnosis of bus cable
SITRAIN
Implementation
1. Generate a bus fault, e.g. by removing a supply line in a bus connector.
2. Is the information about cable lengths consistent with the cable lengths in the
actual network?


07 - Checking The Electrical Bus Cable

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Automation and Drives

Checking the electrical bus cable

SITRAIN Training for IK-PBSYS

BT200 test unit for bus cables to RS485

Testing the PROFIBUS cable:

Checking the accessibility of the slaves:

Checking the RS 485 interfaces of the masters and

Function of the BT 200

SITRAIN Training for IK-PBSYS

Select special mode for extended functions

Press the OK AND ESC keys

===> SPECIAL MODE activated

The following functions are available in special mode:

SITRAIN Training for IK-PBSYS

Log kit for BT200

SITRAIN Training for IK-PBSYS

Exercise 1: Test your bus cable with the

1. Construct the test setup as described above.

2. Press the button to switch on the BT200.

2. Press the "TEST" button for a short time. The message

3. As a result of the test, a message is displayed which could

SITRAIN Training for IK-PBSYS

Exercise 1b: Test your bus cable with the

SITRAIN Training for IK-PBSYS

Exercise 2: Branch test for entering all slaves in

Master not connected

"Live list" also over repeaters and opt. paths

SITRAIN Training for IK-PBSYS

distance to slave distance to disturbance

The diagnostic repeater detects the following cable faults:

Design Connection of 3 segments, of which diagnosis is possible for 2

SITRAIN Training for IK-PBSYS

Function of the Diagnostic- Repeater

Line diagnostics Line diagnostics are performed in two steps:

Step 2: Fault localization

SITRAIN Training for IK-PBSYS

Arrangement of the DP master in the topology

Prerequisities for determining the topology

Arrangement of the DP master

Arrangement with one segment (DP2)

Arrangement with two segments (DP2 and DP3)

Determining the topology with STEP 7

SITRAIN Training for IK-PBSYS

Topology determination with STEP7

Example user programs

CALL "DP_TOPOL" SFC103 Calling topology determination

Determining the topology with SFC 103 "DP_TOPOL"

Duration of topology determination

SITRAIN Training for IK-PBSYS

Location of the fault is determined (1)

Determining the fault location during operation

SITRAIN Training for IK-PBSYS

Location of the fault is determined (2)

Example of a pictorial display in the "Module information" dialog box

SITRAIN Training for IK-PBSYS

Evaluation of the measurement results,

Status The existing status information is indicated here

Identification Name of the PLC, name of the CPU, system identification

SITRAIN Training for IK-PBSYS

Evaluation of measurement results,

"DP slave diagnostics"

Standard diagnosis of slave

Device-specific diagnostic text of the slave: