1、INDUSTRIAL ETHERNETON THE PLANT FLOORA PLANNING AND INSTALLATION GUIDELounsbury.book Page i Thursday, March 20, 2008 4:29 PMLounsbury.book Page ii Thursday, March 20, 2008 4:29 PMINDUSTRIAL ETHERNET ON THE PLANT FLOORA PLANNING AND INSTALLATION GUIDEByRobert LounsburyLounsbury.book Page iii Thursday
2、, March 20, 2008 4:29 PMIndustrial Ethernet on the Plant Floor: A Planning and Installation GuideCopyright 2008 ISAThe Instrumentation, Systems, and Automation SocietyISA67 Alexander DriveP.O. Box 12277Research Triangle Park, NC 27709All rights reserved. Printed in the United States of America. 10 9
3、 8 7 6 5 4 3 2 ISBN 978-1-934394-26-7No part of this work may be reproduced, stored in a retrieval system, or transmitted in anyform or by any means, electronic, mechanical, photocopying, recording or otherwise, withoutthe prior written permission of the publisher. NoticeThe information presented in
4、 this publication is for the general education of the reader.Because neither the author nor the publisher have any control over the use of theinformation by the reader, both the author and the publisher disclaim any and all liabilityof any kind arising out of such use. The reader is expected to exer
5、cise sound professionaljudgment in using any of the information presented in a particular application.Additionally, neither the author nor the publisher have investigated or considered theaffect of any patents on the ability of the reader to use any of the information in aparticular application. The
6、 reader is responsible for reviewing any possible patents thatmay affect any particular use of the information presented. Any references to commercial products in the work are cited as examples only. Neitherthe author nor the publisher endorses any referenced commercial product. Anytrademarks or tra
7、de names referenced belong to the respective owner of the mark orname. Neither the author nor the publisher makes any representation regarding theavailability of any referenced commercial product at any time. The manufacturersinstructions on use of any commercial product must be followed at all time
8、s, even if inconflict with the information in this publication. Library of Congress Cataloging-in-Publication DataLounsbury, Robert.Industrial ethernet on the plant floor : a planning and installation guide / By Robert Lounsbury.p. cm.Includes bibliographical references and index.ISBN 978-1-934394-2
9、6-7 (alk. paper)1. Ethernet (Local area network system) I. Title. TK5105.8.E83L68 2008670.285468dc222008009004Lounsbury.book Page iv Thursday, March 20, 2008 4:29 PMThis book is dedicated to my wife, Fran Lounsbury, and my two sons, Craig and Brian. It is also dedicated to those who set their goals
10、and strive to meet them.Robert LounsburyLounsbury.book Page v Thursday, March 20, 2008 4:29 PMLounsbury.book Page vi Thursday, March 20, 2008 4:29 PMviiContentsList of Figures ixList of Tables xiiiAcknowledgments xvAbout the Author xvi1. Introduction . . . . . . . . . . . . . . . . . . . . . . . . .
11、 . . . . . . . . . . . . . . . 11.1 Industrial Ethernet Networks 21.2 Differences between IT Networks and Industrial Control Networks 31.3 Deciding Which Network to Install 52. Quick Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132.1 Understand Your Applicati
12、on Needs 132.2 Understanding the Environment (MICE) 172.3 Evaluate the Buildings Grounding System 182.4 Design Your System 192.5 Ordering the Correct Components 202.6 Plan Your Routing 212.7 Install Your System 222.8 Verify the Channel After Installation 232.9 Validate Your System 233. Designing You
13、r Network . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253.1 Basic Physical Topologies 253.2 Generic Cabling 293.3 Channel Lengths for Generic Cabling 343.4 On Machine Cabling 34Lounsbury.book Page vii Thursday, March 20, 2008 4:29 PMviii Contents3.5 Rules for Mixing Two-Pair and Four-P
14、air Cables in a Channel 423.6 Grounding and Bonding 423.7 Building Wiring Methods 443.8 Sources of Protective Earth Currents 473.9 Grounding Shielded Cabling 504. Environmental Considerations . . . . . . . . . . . . . . . . . . . . . . . . 714.1 MICE Tutorial 714.2 Understanding the Environment 765.
15、 Selecting Cabling Components . . . . . . . . . . . . . . . . . . . . . . . . 835.1 Copper Cabling 835.2 Copper Connectors 995.3 Fiber Connectors 1056. Installation Guidance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1096.1 Documentation 1096.2 Routing of Cables 1096.3 Pulling Cab
16、les 1116.4 Connector Installation 1126.5 Grounding and Bonding 1247. Network Verification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1297.1 Initial Verification Process 1297.2 Life Cycle of Your Network 1297.3 Verification Tools 1317.4 What to Verify 1327.5 Verification of Groundi
17、ng and Bonding 1347.6 Documentation 1378. Network Certification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1398.1 Life Cycle of Your Network 1408.2 Why Certify Your Network 1408.3 Certification Tools 1408.4 What to Certify 1428.5 Documentation 1429. Troubleshooting the Network . .
18、 . . . . . . . . . . . . . . . . . . . . . . 1479.1 Ground Problems 148Index 157Lounsbury.book Page viii Thursday, March 20, 2008 4:29 PMixList of FiguresFigure 11 Cost and Performance Optimization . . . . . . . . . . . . . . . 1Figure 12 Generic Telecommunications Infrastructure with Optional Redun
19、dancy. . . . . . . . . . . . . . . . . . . . . . . . . . . 6Figure 13 Industrial Connectivity to the Generic Telecommunications Infrastructure . . . . . . . . . . . . . . . . 6Figure 14 Expansion of Generic Telecommunications Infrastructure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20、 . . . 7Figure 15 Connectivity Inside an Automation Island . . . . . . . . . . 7Figure 16 Example of an Ethernet Control System Using Generic Cabling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Figure 17 Example of a Control System Using Reduced Cabling . . 9Figure 18 Example of
21、 a Control System Using Minimum Cabling . . 9Figure 21 Example of Mixing Telecommunications Wiring with Industrial Wiring . . . . . . . . . . . . . . . . . . . . . . . . . 14Figure 22 Redundant Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16Figure 23 Redundant Line . . . . . . .
22、. . . . . . . . . . . . . . . . . . . . . . . 16Figure 24 MICE Classification System . . . . . . . . . . . . . . . . . . . . . 18Figure 31 Example of Star Topology. . . . . . . . . . . . . . . . . . . . . . . 26Figure 32 Example of Bus Topology . . . . . . . . . . . . . . . . . . . . . . . 26Figure
23、33 Example of a Ring Topology. . . . . . . . . . . . . . . . . . . . . 27Figure 34 Example of Hierarchal Stars . . . . . . . . . . . . . . . . . . . . . 28Figure 35 Channel Boundaries . . . . . . . . . . . . . . . . . . . . . . . . . . . 29Figure 36 Permanent Link Boundaries . . . . . . . . . . . .
24、. . . . . . . . . 30Figure 37 Bulkhead Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32Figure 38 Connections in a Channel . . . . . . . . . . . . . . . . . . . . . . 32Figure 39 Example of Six Connections within a Channel. . . . . . 33Figure 310 Maximum Cordage Length . . . . . . .
25、 . . . . . . . . . . . . . . 34Figure 311 Length De-Rating for Cordage (m). . . . . . . . . . . . . . . . 35Lounsbury.book Page ix Thursday, March 20, 2008 4:29 PMx List of FiguresFigure 312 Length De-Rating for Cordage (ft) . . . . . . . . . . . . . . . . 36Figure 313 Substituting Long Cords for Ho
26、rizontal C Cable. . . . 37Figure 314 Temperature De-Rating for Cables . . . . . . . . . . . . . . . . 41Figure 315 T568A and T568B Wiring . . . . . . . . . . . . . . . . . . . . . . . 43Figure 316 Terminating Four Pairs into Two Pairs. . . . . . . . . . . . . 43Figure 317 Non-isolated Groundbus . .
27、. . . . . . . . . . . . . . . . . . . . . 45Figure 318 Isolated Groundbus . . . . . . . . . . . . . . . . . . . . . . . . . . . 45Figure 319 Symbol Legend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45Figure 320 TN-C Wiring Scheme . . . . . . . . . . . . . . . . . . . . . . . . . .
28、 46Figure 321 TN-S Wiring Scheme. . . . . . . . . . . . . . . . . . . . . . . . . . . 47Figure 322 TN-C with Communications . . . . . . . . . . . . . . . . . . . . 48Figure 323 TN-S with Communications. . . . . . . . . . . . . . . . . . . . . 48Figure 324 Drive-Induced Noise . . . . . . . . . . . .
29、. . . . . . . . . . . . . . . 49Figure 325 Ground Loop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51Figure 326 Parallel RC Network . . . . . . . . . . . . . . . . . . . . . . . . . . . 51Figure 327 Shield Grounding Schemes . . . . . . . . . . . . . . . . . . . . . 52Figure 328 S
30、chematic of Single Point Hybrid Ground. . . . . . . . . . 53Figure 329 Single Point Ground Patch Cords. . . . . . . . . . . . . . . . . 53Figure 330 Ground Loop in a Shielded Cable . . . . . . . . . . . . . . . . 55Figure 331 Noise Transient in a Data Bit . . . . . . . . . . . . . . . . . . . . 55Fi
31、gure 332 Frequency Range of EMI. . . . . . . . . . . . . . . . . . . . . . . . 57Figure 333 Example of Induced Noise Coupling . . . . . . . . . . . . . . 57Figure 334 Conversion of 5 V Common Mode Noise to Differential Noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59Figure 335 Exam
32、ple of Common Mode to Differential Voltage Conversion STP Cables for 5 V Noise. . . . . . . . . . . . . . 61Figure 336 Isolated Functional Groundbus Bar . . . . . . . . . . . . . . . 61Figure 337 Isolator for Mounting DIN Rails. . . . . . . . . . . . . . . . . . 61Figure 338 Isolated DIN Rail Mounti
33、ng . . . . . . . . . . . . . . . . . . . . . 62Figure 339 Star Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63Figure 340 Equipotential Grounding System. . . . . . . . . . . . . . . . . 65Figure 341 Building View Equipotential Grounding System . . . . . 65Figure 342 Machine
34、 Level Equipotential Grounding System . . . . 66Figure 343 Equipotential and MESH Grounding within TN-S Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67Figure 344 Conductor Size Versus Conductor Length . . . . . . . . . . 69Figure 345 Bonding Metal Structures Toge
35、ther . . . . . . . . . . . . . . . 69Figure 346 Bonding and Grounding Connections. . . . . . . . . . . . . 70Figure 347 Bonding Ground Wires to Metallic Conduit . . . . . . . . 70Figure 41 MICE Areas within a Typical Factory Floor . . . . . . . . . 72Figure 42 Isolation, Separation, and Enhancement
36、. . . . . . . . . . . 73Figure 43 MICE Levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73Figure 44 Frequency Range of Noise-Generating Devices . . . . . . 74Lounsbury.book Page x Thursday, March 20, 2008 4:29 PMList of Figures xiFigure 45 Separation from Other Circuits . . .
37、 . . . . . . . . . . . . . . . 77Figure 51 Simple AO/TO Model . . . . . . . . . . . . . . . . . . . . . . . . . . 87Figure 52 Example AO/TO with CP Model . . . . . . . . . . . . . . . . . 88Figure 53 Cross Connect AO/TO with CP Model. . . . . . . . . . . . . 88Figure 54 Example Cable SpecificationSt
38、ep 1. . . . . . . . . . . . . . 88Figure 55 Example Cable SpecificationStep 2. . . . . . . . . . . . . . 90Figure 56 Example Cable SpecificationStep 3. . . . . . . . . . . . . . 94Figure 57 Example Cable SpecificationStep 4. . . . . . . . . . . . . . 96Figure 58 Example Cable SpecificationStep 5. .
39、. . . . . . . . . . . . 97Figure 59 Example Cable SpecificationStep 6. . . . . . . . . . . . . . 99Figure 510 Cat 5e and Cat 6 RJ-45 Plug . . . . . . . . . . . . . . . . . . . . 101Figure 511 Panel-Mount M12 “D”-Coded . . . . . . . . . . . . . . . . . . 102Figure 512 M12 “D”-Coded Field Installable
40、. . . . . . . . . . . . . . . . 102Figure 513 Encapsulated RJ-45 IEC 61076-3-106 Variant 1 . . . . . 102Figure 514 M12-4 “D”-Coded to Eight-Way Modular Jack Bulkhead Connector. . . . . . . . . . . . . . . . . . . . . . . . . . 103Figure 516 MicroFX with 24V . . . . . . . . . . . . . . . . . . . . .
41、. . . . . . 106Figure 515 Sealed Fiber LC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106Figure 517 Fiber LC Bulkhead. . . . . . . . . . . . . . . . . . . . . . . . . . . . 107Figure 61 Example of Running Cables in Protected Areas . . . . . 111Figure 62 Example of a Cable Management
42、System . . . . . . . . . 112Figure 63 Connector Installation Crimp Tool . . . . . . . . . . . . . . 113Figure 64 T568A/T568B Wiring Examples . . . . . . . . . . . . . . . . . 114Figure 65 Cable Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115Figure 66 Arrangement of Conductors
43、. . . . . . . . . . . . . . . . . . . . 115Figure 67 Wire Orientation T568B . . . . . . . . . . . . . . . . . . . . . . . 116Figure 68 Example of Aligning the Conductors (T568B) . . . . . . 117Figure 69 Inserting the Conductors into the Connector Body T568A and T568B . . . . . . . . . . . . . . . .
44、. . . . . . . 117Figure 610 Inserting the Cable into the Connector. . . . . . . . . . . 117Figure 611 Crimping the Connector . . . . . . . . . . . . . . . . . . . . . . 118Figure 612 Four-Pair Crossover Cable. . . . . . . . . . . . . . . . . . . . . . 118Figure 613 Straight Through Two-Pair Cable .
45、. . . . . . . . . . . . . . . 118Figure 614 Exploded View of M12-4 D-Coded Connector Using Cage Clamp Termination. . . . . . . . . . . . . . . . . 120Figure 615 Exploded View of M12-4 D-Coded Connector Using IDC Termination . . . . . . . . . . . . . . . . . . . . . . . 120Figure 616 Two-Pair Wire Le
46、ngth. . . . . . . . . . . . . . . . . . . . . . . . . 121Figure 617 Two-Pair Wire Preparation . . . . . . . . . . . . . . . . . . . . . 121Figure 618 M12-4 D-Coding Pin Identification . . . . . . . . . . . . . . 121Figure 619 Installing M12-4 D-Coding Wire Ferrule . . . . . . . . . . 122Figure 620 C
47、onnector Body Installation . . . . . . . . . . . . . . . . . . . 122Figure 621 Wire Gland Installation . . . . . . . . . . . . . . . . . . . . . . . 122Lounsbury.book Page xi Thursday, March 20, 2008 4:29 PMxii List of FiguresFigure 622 M12-4 D-Coded Straight-Through Cable . . . . . . . . . . 123Fig
48、ure 623 M12-4 D-Coded Crossover Cable . . . . . . . . . . . . . . . . 123Figure 624 Single-Ground Shield Termination . . . . . . . . . . . . . . 125Figure 625 Bonding Shields to Ground . . . . . . . . . . . . . . . . . . . . 125Figure 626 Making Connections for Bonding and Grounding . . 126Figure 71
49、 Verification Process. . . . . . . . . . . . . . . . . . . . . . . . . . . 130Figure 72 Network Life Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . 131Figure 73 Voice, Video, Data Tester, and Tracer . . . . . . . . . . . . 133Figure 74 Ideal Voice, Video, and Data Tester . . . . . . . . . . . . . . 133Figure 75 Cable Tester with Length Measurement Capability. . 133Figure 76 Fiber Visual Fault Finder. . . . . . . . . . . . . . . . . . . . . . . 133Figure
