CUSTOMER SUPPORT ELECTRIC PROFIBUS ANALYZER INFOLETTER 14/09 YOU PROBLEM FORECAST FOR TODAY An unplanned production stop and the loss of production is always an unpleasing situation. It is a major topic for the maintenance crew and also for Brückner to avoid such situations in advance and to detect problem origins quick and efficient, but there are parts in high-end stretching lines, which are very difficult to troubleshoot. One of these challenges is the so called bus communication fault. What exactly is this alarm? It indicates a fault somewhere in your PROFIBUS string. The cause, in most cases, is worn PROFIBUS cabling or a faulty PROFIBUS participant - and as soon as this error occurs it gets really tricky: You need to find the part which caused the fault, but this is difficult because if one PROFIBUS participant breaks down, the complete production will stop and a multiplicity of alarms occurs immediately. Statistics show that nearly every PROFIBUS installation will face such problems after a certain time. But why? The reason is that the PROFIBUS string is a wearing part. After a certain time period cables and plugs can outwear and cause errors which lead to a complete production stop. The important thing in this case is: A bus communication fault does not occur suddenly, there are certain indicators way before it really occurs! So it s most likely, that if we want to avoid such PROFIBUS errors, we need to take note of these indications on time. The question now is: How can we recognize that a problem will occur shortly? Infoletter 14/2009 1 / 6 Brückner
CUSTOMER SUPPORT ELECTRIC The answer is as simple and efficient: a small, permanent surveillance tool, which already recognizes first bus problem indications in advance, informs you about them and assist you in case a error really occurs: THE PROFIBUS ANALYZER MODULE! PROFIBUS Analyzer Module with integrated Webserver and TCP/IP port for remote access Infoletter 14/2009 2 / 6 Brückner
CUSTOMER SUPPORT ELECTRIC Who can use PROFIBUS Analyzer? - Every production plant or site, preferable with internet access for remote support Requirements: Minimum: - PROFIBUS Network Optimum: - PROFIBUS Network - RJ45 - TCP/IP Plant Network - (DSL) Internet Access Advantages: - Minimum hardware costs - Higher plant availability - Less unplanned production stops (preventive maintenance) - Less loss of production - Reduction of service costs - Integration possible during production Infoletter 14/2009 3 / 6 Brückner
CUSTOMER SUPPORT ELECTRIC How does it work: Nearly 80% of all PROFIBUS errors are of physical nature like bad cable contact inside plugs, damaged or oxidized wires, bad grounding and so on. Regarding this fact, it happens that a communication telegram, sent to a PROFIBUS participant can be destroyed. This is no problem as long as the telegram is repeated and the participant answers within the next cycle an error won t occur in this case. Exactly this repeat is the first announcement information which is needed for preventive PROFIBUS maintenance. Beside this, a state-of-the-art PROFIBUS analyzer also needs to provide you with debug information which helps you to detect the problem origin in case an error really occurred. The new PROFIBUS analyzer tool for the first time enables continuous, parallel monitoring of a higher number of PROFIBUS strings during operation. In combination with an web-browser, the intelligent diagnosis unit automatically identifies any malfunction, including physical problems. The clever thing and main highlight about this is no additional software and no configuration is required. It can be installed during production due to the fact, that it doesn`t influence the PROFIBUS communication. It`s nothing else than a silent listener, a spy which informs you about anything that happens inside your PROFIBUS string. The diagnosis unit monitors the data flow on the PROFIBUS, filtering and processing relevant diagnosis information. Detailed information for each network down to module level is displayed, showing network and/or device failures as well as diagnosis messages. In addition, all key quality parameters of the PROFIBUS status are recorded and evaluated. In a graphical bus and failure statistic, for example, critical network stations can be identified at a single glance based on failures and repeat telegrams. Infoletter 14/2009 4/6 Brückner
CUSTOMER SUPPORT ELECTRIC Furthermore, active infrastructure components such as diagnostic repeaters or DP/PA links are supported, which enable targeted evaluation of physical network parameters. An automatic email alert can notify users in case of first problem indication and links directly onto detailed information and specific recommendations to take actions for troubleshooting, before the bus fails and the production is down. Figure 1: PROFIBUS retry (yellow) and error (red) statistics including station and device information, timestamp, etc. Figure 2: PROFIBUS bandwidth statistic including reserve bandwidth buffer, package counter and master overview As a result, you are always able to monitor a PROFIBUS network of your plant and to set quick targeted actions in case the module informs you about any abnormal behavior inside your PROFIBUS string and all that even before en error leads to a production stop! Infoletter 14/2009 5/6 Brückner
CUSTOMER SUPPORT ELECTRIC Your benefit: The PROFIBUS analyzer has already proven its practical use in several HIGHLIGHTS field installations and the benefit is enormous. Even in plants which did components and cables in the preventive maintenance with minimum hardware and integration costs not have cyclic PROFIBUS errors, the module was able to detect worn True Permanent surveillance of your complete PROFIBUS string PROFIBUS string, which would have caused problems in the near future. Due to this information an exchange Immediate announcement of any unforeseen event on your PROFIBUS of the worn or faulty parts could be arranged within the next planned As a matter of fact, especially the integration in Internet Teleservice equipped plants makes PROFIBUS events, warnings and faults production stop and unforeseen plant breakdown was avoided. Remanent data storage of Full telegram analyze capability (with additional PROFIBUS scope software) sense. Brückner service specialists can access the device remote and assist you in PROFIBUS related service issues. They are even able to inform you in advance if your PROFIBUS string is worn or PROFIBUS devices get faulty, so plant breakdowns can be avoided. Take a look at this small and simple maintenance tool with it s enormous cost saving potential and contact our service department E-SERVICE@BRUECKNER.COM for more details. Ease your life with Brückner Servtec Best regards, Your Brückner Servtec Service Team Infoletter 14/2009 6/6 Brückner