PROTOCOL:

It is a set of rules and regulations which determines the data transfer in communication between the
devices.

TYPES OF PROTOCOLS:

1.ETHERNET

The cable which connects devices together with in a local area network like PCs and routers. The cable
possess 8 wires and a larger plug(RJ 45).

Fig1: Ethernet communication Fig2: CAT6 Ethernet with RJ45 plug

We use LEGRAND CAT6 100OHMS U/UTP 24AWG ETHERNET CABLE

CAT6: Category6 stands for standardized twisted pair cable. CAT6 can go up to around 700 feet.

100 OHMS: Ethernet cable resistance

24AWG: American Wire Gauge

FEATURES

1. Speed-100gb/s.
2. Reduced crosstalk
3. Reduced noise
4. Length up to 700ft.

HART:

The HART Communication Protocol (Highway Addressable Remote Transducer) is a

hybrid analog+digital industrial automation protocol. Its most notable advantage is that it
can communicate over legacy 4–20 mA analog instrumentation current loops, sharing the
pair of wires used by the analog only host systems.
According to the huge installed base of 4–20 mA systems throughout the world, the HART
Protocol is one of the most popular industrial protocols today. HART protocol has made a
good transition protocol for users who wished to use the legacy 4–20 mA signals, but
wanted to implement a "smart" protocol.
The protocol was developed by Rosemount Inc., built off the Bell 202 early communications
standard in the mid-1980s as a proprietary digital communication protocol for their smart
field instruments.
Use of 250 ohm resistor:
The 250 ohm resistor in HART is a shunt resistor just like the terminator for FOUNDATION fieldbus.
The HART communication signal works this way:
The talking device transmits a current
The listening device picks up on voltage
The purpose of the 250 ohm shunt resistor is to convert the transmitted
current to a voltage the received can pick up
250 ohm resistor converts the 4-20 mA analog signal from the HART transmitter to a 1-5 volt drop to allow
the Analog Input card of the DCS or PLC to read the analog signal. The HART digital FSK (Frequency Shift
Keying) signal is also present on this line and supplies the HART digital data to the HART modem chip usually
present on the same Analog Input card for all new DCSs and PLCs.
Actually you can use a number of possible resistance values that will allow communication between HART
devices. This value depends on the transmitter minimum operating voltage requirement. Simple OHM's LAW.
For example, if the voltage requirement for a certain transmitter is 12-24 volts use a resistor that will not give
you a drop of below 12 volts or else you will not deliver power to your transmitter. Most transmitters are supplied
with 24 volts and as per computation 250 ohms to 500 ohms gives a drop of almost 18 v which is somewhat in
between the operating voltage.
The HART signal is a high frequency superimposed on the analog signal. In order to receive the signal you
need a means of creating a some impedance in the loop, a resistor does this.
If you were to connect the transmitter directly across a 24 VDC power supply, the analog signal would be just
fine but the HART signal would be damped right out. If you add some resistance in the loop you will get some
DC voltage drop but also across the resistor you will get the HART signal.
V=IR =
1v=4ma
2v=8ma
3v=12ma
4v=16ma
5v=20ma
1v=4ma*r
then r=1/4=0.25#250ohms
For 4mA Analog Signal,
4mA*250âŠ=1000mV=+-1VDC
For 20mA Analog Signal,
20mA*250âŠ=5000mV=+-5VDC
So in this Ways 4-20mA Analog Signal converting into +-1-5VDC Digital Signal by using 250⊠resistor in
HART System.
MODES:

There are two main operational modes of HART instruments: point to point (analog/digital)
mode, and multi-drop mode.
Point to point
In point-to-point mode the digital signals are overlaid on the 4–20 mA loop current. Both the
4–20 mA current and the digital signal are valid signaling protocols between the controller and
measuring instrument or final control element.
The polling address of the instrument is set to "0". Only one instrument can be put on each
instrument cable signal pair. One signal, generally specified by the user, is specified to be the 4–
20 mA signal. Other signals are sent digitally on top of the 4–20 mA signal. For example,
pressure can be sent as 4–20 mA, representing a range of pressures, and temperature can be sent
digitally over the same wires. In point-to-point mode, the digital part of the HART protocol can
be seen as a kind of digital current loop interface.
Multi-drop
In Multi-drop mode the analOg loop current is fixed at 4 mA and it is possible to have more than
one instrument on a signal loop.
HART revisions 3 through 5 allowed polling addresses of the instruments to be in the range 1–
15. HART revision 6 and later allowed address up to 63. Each instrument needs to have a unique
address.
Advantages:
HART can help reduce set-up time by facilitating the easy transfer of configuration settings and
calibration information. It can also reduce maintenance costs by providing the ability to capture
performance data and to diagnose errors remotely, eliminating the need for field checks. Regulatory
compliance is simplified by automated record keeping and the ability to take advantage of intelligent
multivariable devices for more thorough, accurate reporting.
2.PROFIBUS

Profibus is a standard for fieldbus communication in automation. It is also known as process field bus.

It works in master slave configuration.

Fig3: Profibus cable

Fig4: Profibus pin configuration

 Fig5: Profibus serial data transmission pin configuration
PROFIBUS DP has, itself, three separate versions. Each version, from DP-V0 to DP-V1 and DP-V2,
provides newer, more complicated features.
Profibus is further divided in to 3 categories:
1.Profibus FMS
FMS stands for Field Message Specification. It is used to provide communication of data between
profibus masters like between computers 0r between computer and HMI. It requires event message
communication.

2.Profibus DP
DP stands for Decentralized Peripheral. It is a protocol used to communicate between profibus
masters and remote I/O slaves. Profibus DP is used to operate sensors and actuators via a
centralised controller in production (factory) automation applications. Profibus-DP is recognized as a
high-performance bus network capable of transmitting thousands of I/O points information in less
than a few milliseconds. For that reason, it has been used extensively for fast response control
applications such as turbine servos and variable speed drives.
Data transfer speed is about 9.6kbps to 12mbps. RS485 balanced transmission used in profibus
 DP. It allows 126 devices to connect at once.

• High speed data access capable of handling time critical functions.

• Networks up to 32 devices (up to 126 with repeaters) on a 4-wire network; (2 wires for signal and 2
wires for power).
• Trunk network may extend up to 4,000 feet (1220 meters) per segment.
• Dramatically cuts wiring costs and commissioning over conventional applications.
• Interfaces readily into newer control systems.

3.Profibus PA
Profibus-PA – Designed especially for process automation. It permits sensors and actuators
to be connected on one common bus line even in intrinsically safe areas. Permits data
communication and power over the bus using 2-wire technology according to the
international standard IEC 1158-2. Will not be implemented in this spec because only I/O will
be controlled.

PA stands for Process Automation. Profibus PA is slower than profibus DP and runs at a speed of
31.2kbps. PROFIBUS PA uses a special transmission technology known as MBP (Manchester bus
powered) that also allows field devices to be supplied via the bus. Profibus-PA was designed as a
substitute for HART and 4 to 20mA signal transmission in the process industries. Profibus-PA
links to the control architecture via Profibus-DP with a segment coupler or link as shown. Segment
couplers are signal converters that adapt the RS-485 signals to the 61158-2 signal level. They are
transparent from the bus protocol point of view. If segment couplers are used, the baud rate on the
DP (RS-485) segment must be restricted to 45 Kbits/sec. The segment coupler also injects power
into the PA network for the segment instrumentation. Links are independent slaves on the DP
network which represent all devices connected to the 61158-2 segment. When PA segments are
connected using links there is no limit to the baud rate on the DP segment which enables faster
overall bus network performance.

POWER AND DATA ARE TRANSMITTED THROUGH SAME LINE.

ADVANTAGES
1. It can be easily used with greater flexibility
2. Large number of connection possibilities for a single controller
3. HART technology integration is easy
 • More than 100 devices can be commissioned per day
• One person can complete commissioning; no need for a second person in the field to find
and “activate” an instrument for the loop check
• Communication faults can be located from the control room
• No 4-20mA calibration is required since the digital device measures the full range of
process values
• Instrument settings can be downloaded from the control room; no need to connect a
handheld to each transmitter individually

DISADVANTAGES
1. High cost compared to ethernet
2. Speed is limited to Mbps.
3. Distance extension is complicated
4. If master fails entire communication will fails.

3.PROFINET
It is also known as profibus on ethernet. Profinet cables are industrial ethernet cables. It is also
known as industrial cat5 or two pair cat5 with TCP/IP protocol. These cables are mostly used in
drive technology such as transport, conveyors and machine tool manufacturing
TD+ YELLOW

TD- ORANGE

RD+ WHITE

RD- BLUE

Table1: color coding

Fig6: Profinet cable

Fig7: Connection diagram to RJ45

PROFINET facilitates integrated communication from the management to the field level. PROFINET
offers many functions in a single cable such as Machine and standard IT data are merging.

Profinet obeys 3protocols:

1. TCP/IP for non-time critical data and commissioning of plant with reaction time in the range of
100ms.
2. RT (Real Time) protocol for profinet IO applications up to 10ms range.
3. IRT (Isynchronous Real-Time) protocol for profinet IO applications in drive systems in the range
of 1ms.
Profinet I/O consists of 3 devices:
1. IO Controller, which controls the automation task.
2. The IO Device, which is a field device, monitored and controlled by an IO Controller.
3. The IO Supervisor, is a software typically based on a PC for setting parameters and
diagnosing individual IO Devices.
FEATURES:

1. I/O link integration, open standard and High data rate

2. Flexible installation
3. Best diagnostics
4. Secure IT integration
5. Safety integrated
6. Expandability

MODBUS:
Modbus is a serial communications protocol. Modbus enables communication among many devices
connected to the same network. It read/write the memory addresses directly.

Each device which wants to communicate using Modbus is given a unique address. In serial
networks, only the node assigned as the Master may give a command. A Modbus command
contains the Modbus address of the device it is intended for (1 to 247). The device will only act on
that command even other devices might receive it.

Introduction to Modbus

Modbus is the “granddaddy” of industrial communication protocols. It was originally designed in the
mid-1970s by Modicon as a way to link intelligent devices with PLCs using a simple master/slave
concept. “Simple” is a key descriptor for Modbus – and also its biggest strength. It is easy to
implement and easy to use. When it was first introduced, it was a proprietary protocol that only
Modicon could use. However, it was later published royalty-free so that anyone could use it.
Finally, Modicon made it an open protocol. When it was published, a number of companies started
using it, creating different interpretations and modifications of the original specification. As a result,
there are now quite a few variations in the field.

The specification document is fewer than 100 pages in length, which is a good indication of the
protocol’s low level of complexity. In comparison, Profibus’ specification document is thousands of
pages long. The term “Modbus” typically refers to one of three related protocols: Modbus ASCII,
Modbus RTU, or Modbus TCP/IP
Modbus ASCII was the first Modbus and is a serial protocol, typically running on either the RS-232
or RS-485 physical layer. All slaves are polled on demand by the master, and there is only one
master. The message frame can be up to 252 bytes in length, and up to 247 addresses are possible.
The message frame and function codes, shown in Figures 1 and 1.1, are very simple.
Modbus RTU is really just a small variation on the Modbus ASCII protocol. The only difference is in
the encoding of the data. ASCII encodes the message in ASCII characters, while RTU uses bytes,
thus increasing the protocol’s throughput. In general, RTU is more popular, particularly in new
installations.
Modbus TCP/IP was added much later. One simple way of thinking about Modbus TCP/IP is to
picture it as simply encapsulating a Modbus RTU packet within a TCP/IP packet. There is a bit more
to it than that, but this is essentially what Modbus did. As a result, Modbus TCP/IP is also very
simple to implement. The tradeoff is that, because it uses TCP/IP protocol for all messages, it is slow
compared to other Ethernet industrial protocols – but still fast enough for monitoring applications.

How Modbus works

As already noted, Modbus is a simple master-slave protocol. The master has full control of
communication on the bus, whereas a slave will only respond when spoken to. The master will
record outputs and read in inputs from each of its slaves, during every cycle, as shown in Figure 2.
The slave devices do not “join” the network. They simply respond whenever a master talks to them.
If the master never talks to them, then they are idle. There is also no requirement for diagnostics
related to the slave’s health. If the master requests data that does not make sense to the slave, then
the slave can send an exception response.
However, if the process variable is bad or if the device has problems functioning, there is nothing in
the protocol that requires the slave to report this.
How does it work, and why use it for IIoT?

The method is used for transmitting information over serial lines between electronic devices. The
device requesting information is called “master” and “slaves” are the devices supplying information.
In a standard Modbus network, there is one master and up to 247 slaves, each with a unique slave
address from 1 to 247.

According to Intel, communication between a master and a slave occurs in a frame that indicates a
function code. The function code identifies the action to perform, such as read a discrete input; read
a first-in, first-out queue; or perform a diagnostic function. The slave then responds, based on the
function code received, with a response indicated by a set of bytes. Slaves can therefore be
intelligent devices or simple devices that represent a single sensor.
Because of this operation, systems based on the protocol are critical parts of the industrial “internet
of things” for automation and control, housing valuable information that can be unlocked and used by
analytics and enterprise systems.

The protocol is commonly used in IIoT as a local interface to manage devices. It is an open protocol
that is free for manufacturers to build their equipment into, and is now the most commonly available
means of connecting industrial electronic devices, according to Simply Modbus.

Benefits of using Modbus

These are some advantages of using Modbus, as outlined by the Modbus Organization:
▪ If a Modbus driver is already installed and the user is familiar with Ethernet and TCP/IP
sockets, a driver can be up and running and talking to a PC in a few hours. Development
costs are said to be low; minimum hardware is required; and development is said to be
easy under any operating system.
▪ There are no “exotic” chipsets required and the system can use standard PC Ethernet
cards to talk to newly implemented device; as the cost of Ethernet falls, there should be a
cost reduction in hardware; and users are not tied to one vendor for support, but can
benefit from current developers.
▪ The specification is available free of charge for download, and there are no subsequent
licensing fees required for using Modbus protocols.
 ▪ Interoperability among different vendors’ devices and compatibility with an installed
base of compatible devices.

Fig8: MODBUS

ADVANTAGES
1. Simple, robust and easy to maintain.
2. moves raw bits or words without placing many restrictions on vendors
3. Contains checksum to determine the transmission of errors.
DISADVANTAGES

1. Large binary objects are not supported.

2. Consumes more bandwidth and network time.
3. Modbus is restricted to addressing 254 devices on one data link.
4. Modbus protocol itself provides no security against unauthorized commands.
RS232:

A modem cable has pin-to-pin connections, and is designed to connect a DTE device to a DCE
device. RS-232 is widely used for connections between data acquisition devices and computer
systems. RS-232 devices are defined as either DTE (usually a computer) or DCE (usually an
interface device).
The term RS232 stands for "Recommended Standard 232" and it is a type of serial
communication used for transmission of data normally in medium distances. It was introduced
back in the 1960s and has found its way into many applications like computer printers, factory
automation devices etc.
How RS232 Works?
RS232 works on the two-way communication that exchanges data to one another. There are
two devices connected to each other, (DTE) Data Transmission Equipment& (DCE) Data
Communication Equipment which has the pins like TXD, RXD, and RTS& CTS. Now,
from DTE source, the RTS generates the request to send the data. Then from the other
side DCE, the CTS, clears the path for receiving the data. After clearing a path, it will give
a signal to RTS of the DTE source to send the signal. Then the bits are transmitted
from DTE to DCE. Now again from DCE source, the request can be generated
by RTS and CTS of DTE sources clears the path for receiving the data and gives a signal to
send the data. This is the whole process through which data transmission takes place.

TXD TRANSMITTER

RXD RECEIVER

RTS REQUEST TO SEND

CTS CLEAR TO SEND

GND GROUND
Pin Description DB-9 Connector:

PIN No. Pin Name Pin Description

1 CD (Carrier Detect) Incoming signal from DCE

Receives incoming data from

2 RD (Receive Data)
DTE

3 TD (Transmit Data) Send outgoing data to DCE

4 DTR (Data Terminal Ready) Outgoing handshaking signal

5 GND (Signal ground) Common reference voltage

6 DSR (Data Set Ready) Incoming handshaking signal

Outgoing signal for controlling

7 RTS (Request to Send)
flow

Incoming signal for controlling

8 CTS (Clear to Send)
flow

9 RI (Ring Indicator) Incoming signal from DCE