PROFIBUS Commissioning 8032 V123 Sep22

PROFIBUS
Commissioning Guideline
Guideline
for PROFIBUS
Version 1.23 – Date September 2022

Order No.: 8.032
File name: PROFIBUS_Commissioning_8032_V123_Sep22.docx
Prepared by PI Working Group PG3 “Installation Guides PROFIBUS and PROFINET” in Com-
mittee B.
The attention of adopters is directed to the possibility that compliance with or adoption of PI (PROFIBUS&PROFINET
International) specifications may require use of an invention covered by patent rights. PI shall not be responsib le
for identifying patents for which a license may be required by any PI specification, or for conducting legal inquiries
into the legal validity or scope of those patents that are brought to its attention. PI specifications are prospective
and advisory only. Prospective users are responsible for protecting themselves against liability for infringement
of patents.
NOTICE:
The information contained in this document is subject to change without notice. The material in this document details
a PI specification in accordance with the license and notices set forth on this page. This document does not
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ABILITY OR WARRANTY OF FITNESS FOR PARTICULAR PUR POSE OR USE.
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reliance or cover damages, including loss of profits, revenue, data or use, incurred by any user or any third
party. Compliance with this specification does not absolve manufacturers of PROFIBUS or PROFINET
equipment, from the requirements of safety and regulatory agencies (TÜV, BIA, UL, CSA, etc.).
PROFIBUS® and PROFINET® logos are registered trade marks. The use is restricted to
members of PROFIBUS&PROFINET International. More detailed terms for the use can be
found on the web page www.profibus.com/Downloads. Please select button "Presenta-
tions & logos".
In this specification the following key words (in bold text) will be used:
may: indicates flexibility of choice with no implied preference.
should: indicates flexibility of choice with a strongly preferred implementation.
shall: indicates a mandatory requirement. Designers shall implement such mandatory
requirements to ensure interoperability and to claim conformance with this spec-
ification.
Publisher:
PROFIBUS Nutzerorganisation e.V.
Haid-und-Neu-Str. 7
76131 Karlsruhe
Germany
Phone : +49 721 986197 0
Fax: +49 721 986197 11
E-mail: info@profibus.com
Web site: www.profibus.com
© No part of this publication may be reproduced or utilized in any form or by any means, electronic or
mechanical, including photocopying and microfilm, without permission in writing from the publisher.
Page 2 / 129
© Copyright by PI 2022 – all rights reserved
Revision log
Version Date Changes/History
0.2.2 24.06.04 3. Draft distribution for review
Changes according to the review of v.0.2.2 in Karlsruhe

0.2.3 20.07.04
01.07.04
Division into three documents (planning, assembly, commis-

0.2.4 09.08.04
sioning)
4. Draft distribution for review
0.2.5 26.11.04 Optical fibers chapter added
Diagnostic telegram chapter added
0.2.6 05.02.05 Change according to review contributions
0.2.7 07.06.05 Change according to review contributions
0.2.8 17.09.05 Modified by A. Verwer
Workgroup review
0.2.9 21.10.05
0.2.10 30.10.05 Changes according to review comments
1.0.0 18.11.05 Official version created
Renaming of the document from Installation recommendation

1.0.1 07.02.06
to Installation Guideline
Changes according to the phone conference on July 13th

1.0.2 03.08.11
2011
1.0.3 Internal version
1.0.4 Review version for working group
1.0.5 Internal version, not published
1.0.6 Review version
1.0.7 21.11.14 Reviewed by head of working group
1.0.8 26.02.15 Translation of changed sections
1.0.9 13.05.15 Release Version
Page 3 / 129
Internal Version, not published, layout renewed, chapter “Pro-
1.10 to fibus design guideline” from network documentation added,
26.03.2019
1.20 symbols renewed, cover page (template) renewed, section
referenced standards updated
1.21 18.09.2019 Final Review prior to release
Bugfix in Table 3.2: 1.5 kBit/s changed to 1.5 Mbit/s. Copy-

1.22 31.07.2022
right updated to 2022. Phone numbers of PNO updated.
1.23 22.09.2022 Final review prior to release
Page 4 / 129
Table of contents
1 INTRODUCTION........................................................................................................................... 10
1.1 PREFACE ................................................................................................................................ 11
1.2 SAFETY INFORMATION ............................................................................................................. 12
1.3 DISCLAIMER OF LIABILITY ......................................................................................................... 13
1.4 REFERENCE STANDARDS ......................................................................................................... 14
1.5 REFERENCED PROFIBUS DOCUMENTS................................................................................... 14
1.6 EXPLANATION OF SYMBOLS ...................................................................................................... 16
2 SIMPLE PROFIBUS DIAGNOSTICS ........................................................................................... 18
2.1 INTRODUCTION ........................................................................................................................ 19
2.2 HANDHELD DEVICES ................................................................................................................ 20
2.3 OPTICAL FIBER MEASUREMENTS ............................................................................................... 21
2.3.1 Attenuation measurement for optical fibers .................................................................. 21
2.3.2 OTDR measurement ..................................................................................................... 23
2.3.3 Using optical fiber measurement processes ................................................................. 23
2.4 COMMUNICATION STATISTICS ................................................................................................... 24
3 ASSEMBLY ACCEPTANCE ........................................................................................................ 26
3.1 VISUAL INSPECTION - PROFIBUS COPPER AND OPTICAL FIBER CABLE ...................................... 28
3.2 ACCEPTANCE MEASUREMENTS PROFIBUS RS-485 ................................................................ 31
3.3 ACCEPTANCE MEASUREMENTS - PROFIBUS MBP (PA) .......................................................... 36
3.4 ACCEPTANCE MEASUREMENTS OPTICAL FIBER .......................................................................... 37
3.4.1 General .......................................................................................................................... 37
3.4.2 Measurement Results Damping Measurement ............................................................. 38
4 COMMISSIONING / ACCEPTANCE ............................................................................................ 39
4.1 BUS TEST ................................................................................................................................ 40
Page 5 / 129
4.2 COMMISSIONING THE BUS ........................................................................................................ 41
4.2.1 System configuration (step 3) ....................................................................................... 41
4.2.2 Verifying PROFIBUS station addresses (step 4) .......................................................... 45
4.2.3 Commissioning PROFIBUS stations (step 5) ............................................................... 45
4.2.4 Testing the Signal Inputs (step 6) ................................................................................. 47
4.2.5 Testing the Signal Outputs (step 7)............................................................................... 48
4.2.6 Create acceptance checklist (step 8) ............................................................................ 49
5 TROUBLESHOOTING.................................................................................................................. 50
5.1 INTRODUCTION TO TROUBLESHOOTING ..................................................................................... 51
5.2 CHECKING THE CABLING INFRASTRUCTURE .............................................................................. 52
5.3 MEASUREMENTS WITH A BUS MONITOR .................................................................................... 54
5.4 THE DIAGNOSTIC TELEGRAM..................................................................................................... 56
5.5 OSCILLOSCOPE MEASUREMENTS ............................................................................................. 58
5.5.1 Technical Prerequisites ................................................................................................. 58
5.5.2 Measurement Aids ........................................................................................................ 59
5.5.3 Measurement PROFIBUS RS485 ................................................................................. 60
5.5.4 Typical Signal Waveforms ............................................................................................. 65
5.5.5 Measurements PROFIBUS MBP (PA) .......................................................................... 70
5.6 OPTICAL FIBER MEASUREMENTS ............................................................................................... 74
6 ANNEX .......................................................................................................................................... 75
6.1 COMMISSIONING/ACCEPTANCE CHECKLISTS ............................................................................. 76
6.2 MULTIMETER (INSTRUMENT FOR MEASURING VOLTAGE, RESISTANCE, AND CURRENT) .................. 81
6.2.1 PROFIBUS RS485 with 9-Pin Sub-D Plug Connector .................................................. 82
6.2.2 PROFIBUS RS485 with 5-Pin M 12 Plug Connectors .................................................. 90
6.2.3 PROFIBUS MBP (PA) with 4-pin M12 Plug connectors ............................................... 90
6.3 PROFIBUS DOCUMENTATION ................................................................................................. 97
Page 6 / 129
6.3.1 PROFIBUS relevant information for documentation ..................................................... 97
6.3.2 Proposal for a PROFIBUS forwards documentation ................................................... 100
6.3.3 Example of a PROFIBUS forwards documentation .................................................... 103
6.3.4 Problems of forwards documentation in the production lifecycle ................................ 116
7 TERMS / DEFINITIONS / ABBREVIATIONS ............................................................................. 117
8 INDEX ......................................................................................................................................... 127
Page 7 / 129
List of figures
Figure 2-1: Attenuation measurement principle ............................................................ 21
Figure 2-2: OTDR measurement principle ...................................................................... 23
Figure 5-1: Measurement plug oscilloscope measurement .......................................... 60
Figure 5-2: Potential shift at signals ............................................................................... 63
Figure 5-3: Ideal signal form PROFIBUS RS485 ............................................................ 64
Figure 5-4: Measurement PROFIBUS RS-485................................................................. 65
Figure 5-5: Signal waveform for PROFIBUS cables that are too long .......................... 66
Figure 5-6: Signal waveform for non-connected PROFIBUS stations .......................... 66
Figure 5-7: Too much terminator resistance .................................................................. 68
Figure 5-8: Missing terminator ........................................................................................ 69
Figure 5-9: Ideal signal form PROFIBUS MBP (PA) ....................................................... 71
Figure 5-10: PROFIBUS MBP (PA) with defective bus terminator ................................ 72
Figure 5-11: Measurement PROFIBUS MBP (PA) (1 telegram)...................................... 73
Figure 5-12: OTDR measurement principle .................................................................... 74
Figure 6-1: PROFIBUS RS485 cable schematic with end terminations switched in .... 84
Figure 6-2: Measurement aid sockets (PROFIBUS RS485) ........................................... 89
Figure 6-3: Fields of interest in a plant lifecycle .......................................................... 100
Figure 6-4: Cover page example for PROFIBUS forwards documentation ................ 104
Figure 6-5: Example of forwards documentation for the automation of three plant
sections .......................................................................................................................... 107
Figure 6-6: Example of PROFIBUS forwards documentation, physical topology plan

........................................................................................................................................ 108
Figure 6-7: Example of PROFIBUS forwards documentation, information in cases

of faults ........................................................................................................................... 115
Figure 6-8: Example of PROFIBUS forwards documentation, diagnostic port

example .......................................................................................................................... 115
Page 8 / 129
List of Tables
Table 1-1: Symbols for structuring the text.................................................................... 16
Table 2-1: Maximum fiber attenuation - optical fiber ..................................................... 22
Table 3-1: Checklist for visual inspection of PROFIBUS copper cable ........................ 29
Table 3-2: Checklist for Acceptance measurements for PROFIBUS RS485 cabling ... 32
Table 3-3: Maximum fiber attenuation - optical fiber ..................................................... 38
Table 6-1: Resistance measurements for step 2 (PROFIBUS RS485) .......................... 86
Table 6-4: Loop Resistance PROFIBUS MBP (PA) cable............................................... 91
Table 6-5: Resistance measurements for step 2 (PROFIBUS MBP (PA)) ..................... 94
Table 6-8: Further information on the devices in the topology................................... 102
Table 6-9: Example of PROFIBUS forwards documentation, preliminary

considerations ............................................................................................................... 103
Table 6-10: Information in the title box in accordance with [ISO 7200] ..................... 105
Table 6-11: Proposal for title box in accordance with [ISO 7200] ............................... 106
Table 6-12: Example of title box in accordance with [ISO 7200] ................................. 106
Table 6-13: Example for PROFIBUS forwards documentation, additional device

information ..................................................................................................................... 109
Table 6-14: Example of PROFIBUS forwards documentation, enhanced device

information ..................................................................................................................... 111
Table 6-15: Example of PROFIBUS forwards documentation, cable list .................... 113
Table 6-16: Example of PROFIBUS forwards documentation, enhancement of cable

list ................................................................................................................................... 114
Page 9 / 129
Introduction
1 Introduction
Page 10 / 129
Introduction
1.1 Preface
There are already a large number of documents available for PROFIBUS. So why is the In-
stallation Guideline for Commissioning being added now? The answer is very simple. The
existing documents have been created at different times and, therefore, feature a different
structure. In addition, they contain extensive specifications directed at PROFIBUS component
developers. The user does not require this information, and it can be more a source of confu-
sion than an aid.
The Installation Guideline for Commissioning, as the name implies, is designed to support the
commissioning of PROFIBUS systems. It helps you to verify proper installation and assembly
of your PROFIBUS network. Moreover, the Installation Guideline helps you to locate possible
errors. Consequently, the Installation Guideline for Commissioning is designed not only for
commissioning personnel, but also for service personnel.
The presentation of information has been kept as simple as possible to ensure understanda-
bility. However, commissioning and troubleshooting do require previous PROFIBUS experi-
ence. Thus you should be familiar with the fundamentals involved in planning and assembling
PROFIBUS systems. In addition you should have experience in implementing PROFBUS sys-
tems.
The operating principle of PROFIBUS is not discussed in the Installation Guideline for Com-
missioning. If you require this information, please use the respective documents provided by
the PI or corresponding technical literature.
Information on PROFIBUS assembly is available in the Installation Guideline (Order no.

8.022).
This document does not replace any existing document. The previous documents of the PI
remain in effect.
Page 11 / 129
Introduction
1.2 Safety Information
The use of the PROFIBUS Installation Guideline for Commissioning may involve handling
hazardous materials or tools, or involve dangerous work. Due to the many and diverse appli-
cations of PROFIBUS, it is not possible to take all options or safety requirements into consid-
eration. Each system makes different demands. In order for you to competently judge possible
dangers, you must inform yourself about the safety requirements of the respective system
before starting your work. Special attention must be paid to adhering to the laws and regula-
tions of the respective country in which the system will be operated. You should also observe
general health and safety requirements, as well as the requirements of the company for whom
the system is being built.
Also consider the documentation for the PROFIBUS components supplied by the manufac-
turer.
Page 12 / 129
Introduction
1.3 Disclaimer of Liability
PROFIBUS Nutzerorganisation e.V. (PROFIBUS user organization, hereinafter in this dis-

claimer referred to as “PNO”) has taken utmost care in the preparation of this document and
compiled all information to the best of its knowledge. This document is nevertheless based on
present knowledge, is of an informative character and is provided on the basis of liability ex-
clusion. This document may be subject to change, enhancement or correction in the future
without any expressive reference.
This document has no normative character. It may be useful in certain operating environments,
in certain technical constellations or when used in certain countries to deviate from the given
recommendations for action. In this case, the installer and operator of the installation should
weigh up the advantages and disadvantages of the recommendations made in the specific
application and, if deemed appropriate, decide on the implementation of a different solution if
necessary.
The user may not distribute, rent or make available the Information in any other way to any
third party at any time.
Any liability for defects as to quality or title of the information, especially in relation to the
correctness or absence of defects or the absence of claims or third-party rights or in relation
to completeness and/or fitness for purpose are excluded, except for cases involving gross
negligence, willful misconduct or fraudulent concealment of a defect. Any further liability is
excluded unless required by law, e.g. in cases of personal injury or death, willful misconduct,
gross negligence, or in case of breach of fundamental contractual obligations.
Page 13 / 129
Introduction
1.4 Reference Standards
DIN EN 61158-1 (2017-09)
Industrial communication networks – Fieldbus specifications
IEC 61508-4 (2010)
Functional safety of electrical / electronic / programmable electronic safety-related systems:

Part 4: Definitions and abbreviations
IEC 61784-1 (2019)
Digital data communications for measurement and control – Part 1 Profile sets for continuous
and discrete manufacturing relative to fieldbus use in industrial control systems.
1.5 Referenced PROFIBUS Documents
PROFIBUS Assembling Guideline (2019-09)
Order No.: 8.022, Version 1.45 – Guideline for PROFIBUS
PROFIBUS Design Guideline (2019-09)
Order No.: 8.012, Version 1.27 – Guideline for PROFIBUS
Diagnosis, Alarms and Time Stamping (2004-07)
Order No.: 3.522, Version 1.0 - PROFIBUS Profile Guidelines
Page 14 / 129
Introduction
PROFIBUS System Description (2016-10)
Order No.: 4.331, PROFIBUS Technology and Application
Functional Equipotential Bonding and Shielding of PROFIBUS and PROFINET
Order No.: 8.102, Version 3.1, September 2022
Page 15 / 129
Introduction
1.6 Explanation of symbols
This document contains various images intended to help the reader understand the text. Ad-
ditionally, symbols are used for structuring the text. These symbols mark especially important
passages in the text or combine text to form text sections.
Table 1-1: Symbols for structuring the text
Symbol Name Meaning
Tip Used to mark a recommendation and / or sum-

mary of the current topic.
Important Used for information which, if not observed,

may result in malfunctions during operation.
Instruction Used for direct instructions.
Danger! Used to mark a danger to life and health. The

observance of an instruction marked in this
way is extremely important!
Page 16 / 129
Introduction
The color violet is used only for emphasizing important details. The following field shows the
color used.
The following line shape is used to display equipotential bonding and grounding cable.
In addition, the following symbol is used to display the grounding connection.
Page 17 / 129
Simple PROFIBUS Diagnostics
2 Simple PROFIBUS Diagnostics
Page 18 / 129
2.1 Introduction
This chapter describes some simple diagnostic tools with which you can test the PROFIBUS
cable installation. These tests are particularly important for cabling acceptance. The tools also
help you locate errors that occur during installation. The following tools are introduced here.
• Multimeter (Multiple measuring instrument)
The multimeter can help you to check the PROFIBUS installation after installation. How-
ever, the use of a multimeter is very time-consuming. You can get the results much faster
and easier by using a handheld device.
• Handheld devices
Handheld devices are devices that have been especially developed for testing PROFIBUS
cabling with RS485 interfaces. In addition to testing the installation, they offer additional
functions, e.g. determining the reachable PROFIBUS stations. In order to use a handheld
device it must be possible to connect the device to the PROFIBUS cable via a 9-pin Sub-
D plug connector.
• Attenuation measurement
Measuring attenuation is the most simple test process for optical fibers. You can use it to
determine the magnitude of brightness losses from one end of the optical fiber to the other.
• Diagnostics buffer/Master statistics
The diagnostic buffer and the master statistics provide the first clues for troubleshooting.
They are integrated in the PROFIBUS stations and do not require any additional devices,
except the programming device and corresponding software.
Page 19 / 129
2.2 Handheld Devices
Handheld devices have been developed in order to simplify and speed up test procedures
PROFIBUS installations. Measurements with a handheld device offer you faster checking than
with a multimeter, clearer results and more diagnostic possibilities. In addition to examining
the PROFIBUS cable, it is also possible to perform other measurements and checking of
PROFIBUS stations.
The devices that are available on the market are similar in their functions and scope. However,
they do differ in operation. This is why these devices are not described here in more detail.
If you want more precise information, ask the manufacturer. You must read
the manufacturer's operating instructions.
When using hand-held devices to test cables and connectors, the test is usually performed
from both ends of a segment. This kind of measurement ensures that typical cable faults such
as short circuits, wire breaks, different impedances and cross-connections are detected. If
there should be a cross-connection of wires in two connectors, this fault can be found by
testing every connector on each segment. A common example of this type of fault is when an
intermediate plug is wired with the cores swapped on both the incoming and outgoing PRO-
FIBUS cable.
If no hand-held device should be available to you for testing, some basic measurements can
also be performed by using a standard multimeter. Please refer to the Annex for a description
of how to proceed.
Page 20 / 129
2.3 Optical fiber measurements
2.3.1 Attenuation measurement for optical fibers
Attenuation or insertion-loss measurement (to IEC 60793-1-40B) is useful for optical fibers.
The measurement can highlight losses in the optical fiber and/or connections. Light is emitted
into one end of the fiber by the transmitter. A calibrated receiver measures the received light
and thus indicates the losses. Attenuation or insertion-loss is normally specified in dB. In some
countries, the term damping is also used to describe the same measurement.
Transmitter Receiver
Test sig. Optical fiber Test sig.
Figure 2-1: Attenuation measurement principle
The following table provides information on the maximum attenuation for various PROFIBUS
fiber types.
Page 21 / 129
Table 2-1: Maximum fiber attenuation - optical fiber
Singlemode fi- Multimode fiber PCF-/HCS1- Synthetic fiber

ber optic optic fiber
Standard In-
creased
Typical wave-
1 320 nm 850 nm 660 nm 660 nm 660 nm
length
Max. fiber atten-

5 dB 6 dB 4 dB 6 dB 11.5 dB
uation
*1 PCF and HCS are trademarks
The measurement is performed in two steps. First the receiver must be calibrated. For this the
measurement transmitter's transmission power is measured using a reference fiber. The ref-
erence fiber must be in very good condition and in particular, the connections must be polished
to a very high quality. The reference fiber should only be used for a maximum of 500 reference
measurements. Then the connections must be re-polished. After 2 000 reference measure-
ments the reference fiber must be replaced. Once the receiver has been calibrated, the meas-
urement can be performed in a second step. The wavelength of the transmitted light must be
tuned to the fiber type. Consequently, you will require a measurement system that matched
the fiber being used.
Only special reference fibers should be used to calibrate the receiver.
The measurement must be performed with the transmitter that belongs to

the test receiver. These subassemblies are matched. The PROFIBUS signal
must be disabled during testing; otherwise the measurement will be cor-
rupted.
Because the reference fiber connections are polished to a very high quality, they must be
handled with the utmost care.
Page 22 / 129
2.3.2 OTDR measurement
In addition to attenuation measurement, Optical Time Domain Reflectometers (OTDR) are

also available. An OTDR can locate defective points in the optical fiber. To do this, the device
transmits a signal into the optical fiber. Portions of the signal are reflected at connection points
or interference points. The device measures the strength of the reflected part of the signal,
and the delay after which the reflection is received. The measurement provides an indication
on severity and location of a fault.
OTDR
Transm.
Optical fiber
Receiver
Reflection point (Reflektion)
Figure 2-2: OTDR measurement principle
This process is particularly demanding, as the results are not displayed in plain text. Normally
there is a graphic display. The operator evaluates the measurement results and evaluation
requires considerable experience.
2.3.3 Using optical fiber measurement processes
If you only process optical fibers on rare occasions, you should not purchase the measurement
devices, due to the high costs and the required skill. Instead have a specialist firm perform
this task.
However, if you do purchase an appropriate measurement system, then take

a training course offered by the device manufacturer.
Please read the appropriate industry literature for more information.
Page 23 / 129
2.4 Communication statistics
PROFIBUS telegrams may be corrupted by one of the following:
• Signal reflections resulting from cable faults (e.g. cable break, bad contacts, faulty ter-
minating resistors, stubs)
• Especially high electromagnetic interference in the environment of the devices or ca-

bles
• Faulty devices
PROFIBUS has many mechanisms to ensure reliable communications even in the presence
of such corruption. For example, any corrupted requests or missing or corrupted responses
will cause the controlling master to repeat the request. The number of permissible retries can
be configured by setting the “Retry-Limit”. Note that increasing the number of permissible re-
tries will also increase the cycle time.
PROFIBUS systems can operate for long periods without visible error, even though a number
of telegrams are being corrupted. Ideally, the commissioning engineer would like to know the
extent of telegram corruption occurring on a network so that corrective measures can be taken.
Some PROFIBUS master stations have integrated counters that provide statistics on the qual-
ity or reliability of communications. These master components provide information on how
many telegrams have been transmitted and how many had to be repeated. The counters count
the number of valid and invalid telegrams received.
Examination of these counters provides a valuable indication of the condition of your PROFI-
BUS system. Any repeated or defective telegrams indicate problems within the PROFIBUS
system. This information may be useful for commissioning.
It is often possible to gain access to the counters by using the corresponding planning software
in the programming tool. For details please refer to the manufacturer’s documentation.
Page 24 / 129
If your PROFIBUS master station should not have these counters, it is also possible to use
external devices for determining telegram corruptions.
Please check the description provided by the manufacturer to learn which of

the above-listed functions are available on your PROFIBUS master station.
Page 25 / 129
Assembly Acceptance
3 Assembly Acceptance
Page 26 / 129
Assembly Acceptance
The assembly acceptance procedure takes place after completing the installation. The in-
staller can document that the assembly has been executed according to the planning and the
regulations, through the assembly acceptance procedure.
Consequently, record the assembly acceptance results. The log can then be submitted to
commissioning personnel.
At this point we discuss what should be done for the assembly acceptance procedure, and
how to document the results. Each PROFIBUS segment should be individually tested and
documented. Templates for the assembly acceptance documentation are provided in the Ap-
pendix.
Page 27 / 129
Assembly Acceptance
3.1 Visual Inspection - PROFIBUS Copper and optical fiber Cable
Visual inspection of the PROFIBUS cabling should always be carried out before other tests
are started. Visual inspection enables you to verify the installation had been carried out ac-
cording to cabling guidelines. Errors like
• damaged PROFIBUS cable

• insufficient bend radius
• non-compliance with minimum spacing
and other possible errors can be detected during this stage.
Table 3-1 provides a checklist of items that should be checked during visual inspection. The
table applies to:
• PROFIBUS RS-485,
• PROFIBUS MBP (PROFIBUS PA) and
• PROFIBUS optical fiber cables
However, step 13 is not required for PROFIBUS MBP (PA) segments. Similarly, steps 3, 5, 8,
9, 10, 16 and 17 can be skipped for optical fiber segments.
Steps 23 to 26 need only be carried out for systems used in potentially explosive atmospheres.
And steps 27 and 28 must be performed in systems with PROFIsafe requirements.
The Appendix provides checklists for visual inspection of PROFIBUS RS-485, PROFIBUS
MBP (PA) and PROFIBUS optical fiber segments.
Page 28 / 129
Assembly Acceptance
Table 3-1: Checklist for visual inspection of PROFIBUS copper cable
1. Cable laid according to plan?
2. Cable type according to plan?
3. Max. length of branch lines not exceeded?
4. Connectors available according to plan (M12, Sub-D9, etc)?
5. Minimum spacing between cabling has been complied with, or metal partitions
have been inserted?
6. PROFIBUS cable in order (no damage)?
7. Bend radii specification observed?
8. Cable crossings executed at right angles?
9. Every segment provided with two powered terminating resistors?
10. Guaranteed power supply for terminating resistors (even in case of emergency
stop)?
11. Sharp edges have been covered or removed?
12. Safeguards against mechanical damage present at hazard points?
13. At least one plug is present with programming device connection?
14. Strain relief fixtures attached?
15. Equipotential bonding established according to the regulations?
16. Shielding is applied to the PROFIBUS stations, and connected to the equipo-
tential bonding?
17. Shielding on the cabinet entrance is connected with the equipotential bonding?
18. Cable trays grounded?
19. Subassemblies used in accordance with the structure plan (24 V / 230 V subas-
semblies not reversed)?
Page 29 / 129
Assembly Acceptance
20. Transmission speed and PROFIBUS address are set according to structure
plan?
21. Channels not required are switched according to manufacturer's description?
22. Proper measurement range selected on the analog subassembly (current/volt-

age)?
Additionally in case of RS485-IS segments (Ex environment)
23. Fieldbus-isolating repeaters used only?
24. Transmission rate limited to 1.5Mbit/s?
25. No connectors with discrete inductors (e.g. 110 nH such as required for high
transmission rates) in use?
26. Devices in use are Ex certified?
Additionally in case of PROFIsafe installations
27. No stubs are used?
28. PROFIsafe certified devices only (safety and standard)?
Page 30 / 129
Assembly Acceptance
3.2 Acceptance Measurements PROFIBUS RS-485
The second part of the assembly acceptance procedure is verification of the electrical function
of the PROFIBUS cable. Please use a handheld device for this measurement.
Whichever method is used, the measurement results should be properly documented. The
assembly acceptance checklist in the appendix is available as a template. The log can then
be submitted to commissioning personnel.
Many handheld test tools have associated PC software which can be used to automatically
document the measurement results.
Table 3-2 provides a checklist of measurements that should be made for acceptance.
In general, handheld devices are not suitable for use in plants where there
is an explosion hazard.
Page 31 / 129
Assembly Acceptance
Table 3-2: Checklist for Acceptance measurements for PROFIBUS RS485 cabling
1. Wiring test
No short circuit between data core A and B?
No short circuit between data core A and shielding?
No short circuit between data core B and shielding?
Data core A intact?
Data core B intact?
Shielding is intact?
Data cores not reversed (swapped)?
Terminators on only at the segment ends (max 2 terminations per segment)?
2. Interface test?
Voltage present for terminators on all interfaces?
RS485 signal strength sufficient on all stations?
CNTR signal present on the master?
3. Live list?
All PROFIBUS stations are reachable at their address?
4. Segment length measurement (cable type A)?
Maximum segment length at 9.6 kBit/s to 93.75 kBit/s: 1,200 m?
Maximum segment length at 187.5 kBit/s: 1 000 m?
Maximum segment length at 500 kBit/s: 400 m?
Maximum segment length at 1.5 MBit/s: 200 m?
Maximum segment length at 3 MBit/s to 12 MBit/s: 100 m?
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Assembly Acceptance
5. Minimum required cable length between PROFIBUS devices observed? (See

the PROFIBUS Installation Guideline for Planning)
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Assembly Acceptance
Description of the acceptance process steps

• Step 1: Wiring test
Using the measurement processes described in chapter 2, verify whether the wiring has
been executed correctly.
• Step 2: Interface test
A handheld device can be used to check the PROFIBUS cable, and slave device inter-
faces. The following interface characteristics are verified:
o PROFIBUS signal
o Supply voltage for terminator
o CNTR signal (not all handheld devices)
For this, connect the handheld device to the respective PROFIBUS station.
See the manufacturer's description of the handheld device for the precise
procedure.
The supply voltage can also be checked with a multimeter. The measurement is performed
between pin 5 (+5 V) and pin 6 (Earth) of the 9-pin sub-D connector.
• Step 3: Generate a live list
Check whether all PROFIBUS stations can be reached. Many handheld devices support
this feature. Some programming devices with appropriate software also offer this possibil-
ity.
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Assembly Acceptance
• Step 4
Using the measurement processes described in chapter 2, verify that the specifications for
maximum permissible cable runs have been complied with.
• Step 5: Reflection test
Check whether there are reflections on the PROFIBUS with a handheld device. These can
occur at defective connection points, or they can be caused by stubs or damaged PROFI-
BUS cable. If you are experienced in handling an oscilloscope, then you can also use this
device as described in chapter 5.5.
If you do not have a handheld device available, you can also use a multimeter for a few basic
tests. A description can be found in chapter 6.2 of the appendix.
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Assembly Acceptance
3.3 Acceptance Measurements - PROFIBUS MBP (PA)
The PROFIBUS MBP (PA) wiring can be checked with a multimeter or installation tester.
Chapter 6.2.3 describes how to do this. A checklist for the acceptance measurements for
PROFIBUS MBP (PA) can be found in the Appendix. When using a multimeter for the ac-
ceptance measurement, the DC voltage on the PROFIBUS MBP (PA) cable must be meas-
ured. This should be at least 9 V and not more than 32 V at each station. A typical value for
non-hazardous installations is 19 V. For intrinsically safe installations where there is an explo-
sion hazard, the value should not be more than 13.5 V.
PROFIBUS MBP (PA) is often used in areas where there is an explosion

hazard. Note that special regulations apply for plants where there is an ex-
plosion hazard. Speak with the plant operator before the acceptance meas-
urement, to determine whether an acceptance measurement is possible,
and which safety measures you must comply with in this case.
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Assembly Acceptance
3.4 Acceptance measurements optical fiber
3.4.1 General
In planning you cannot precisely calculate the quality of a signal transmission via an optical
fiber. For example, signal transmission is weakened or attenuated through the optical fiber
and the connections. Attenuation measurement performed after the installation has been com-
pleted is the only way to determine the extent of the losses (see section 2.3.1). The test can
also determine whether the optical fiber was damaged when it was laid.
Because attenuation measurement requires expensive equipment and evaluation of the

measurement results require specialized skills you should consider hiring a specialized com-
pany to perform the measurements. For this reason we do not discuss the measurement pro-
cesses for optical fibers in more detail here. If you intend to purchase the appropriate meas-
urement devices, then obtain advice on the necessary equipment and training from the man-
ufacturer.
Please note that modern devices monitor the signal strength on the incoming FO cable and
provide the corresponding diagnostic data. However, this is intended for operational monitor-
ing only and is no substitute for the acceptance measurement.
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Assembly Acceptance
3.4.2 Measurement Results Damping Measurement
If a specialized firm performs the measurements for you, then you will get a measurement log
from that firm. In the measurement log, you will find a measured value that shows you the
extent of signal attenuation of the transmission path. The loss is normally shown in db. The
measured attenuation value should be less than the maximum fiber attenuation shown in Ta-
ble 3-3.
Table 3-3: Maximum fiber attenuation - optical fiber
Synthetic fiber
Single mode fi- Multimode fi- PCF-/HCS1-
ber optic ber optic fiber Standard In-
creased
Typical wave-
1 320 nm 850 nm 660 nm 660 nm 660 nm
length
Max. fiber atten-

5 dB 6 dB 4 dB 6 dB 11.5 dB
uation
*1 PCF and HCS are trademarks
Please refer to the manufacturer’s information for the attenuation of the fiber
used.
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Commissioning / Acceptance
4 Commissioning / Acceptance
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4.1 Bus test
After installation, the PROFIBUS network must be commissioned. The installation acceptance
documentation should be submitted to you for commissioning. If this documentation has been
submitted, then additional testing of the PROFIBUS assembly is not required. If this documen-
tation is not present, then you should perform the assembly acceptance, as described in chap-
ter 3, together with the installer.
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4.2 Commissioning the bus
The commissioning process is divided into eight steps:
Step 1: Visual inspection
Step 2: Acceptance measurements
Step 3: System configuration
Step 4: Verify the address setting of PROFIBUS stations.
Step 5: Commission masters and slaves
Step 6: Test signal inputs
Step 7: Test signal outputs
Step 8: Create acceptance checklist
Steps 1 and 2 are part of the assembly acceptance and should already be completed. Steps 3
to 8 are now explained in more detail.
4.2.1 System configuration (step 3)
Configuration of the PROFIBUS devices generally involves using a software configuration tool
to describe your PROFIBUS system. Because the programming device and software varies
from manufacturer to manufacturer, we cannot give detailed instructions on how this stage is
carried out. Before you start with system configuration you should be familiar with the opera-
tion of the programming device and the associated software. Here we list a few points that
you should be aware of.
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Data rate
The PROFIBUS data rate is an important consideration. Higher bit rates yield faster cycle
times, however high bit rates require strict adherence to wiring guidelines, as the requirements
on the cabling quality considerably increase with higher data rates. In practice it is recom-
mended that you use the lowest bit rate that can achieve the required cycle time. The bit rate
is set on the PROFIBUS master devices; most modern PROFIBUS slaves do automatically
adapt to the master bit rate. Only occasionally do you need to set the bit rate on a slave device.
Ensure that you set the correct bit rate for all PROFIBUS stations requiring this. If the trans-
mission speed is set incorrectly then communication will not be established.
Device description files
PROFIBUS stations are integrated in a project via device description files. This involves a
standardized file type in which PROFIBUS station characteristics are described. The device
description file is generally abbreviated as "GSD file". GSD stands for "General Station De-
scription". The GSD file for a device contains standardized information on the characteristics
and options available for that device. GSD files often incorporate text which appears on the
PC screen in the configuration tool. The language used for the text in GSD files is not specified
(normally English or German are used). Specific language versions of GSD files are often
available and are designated by a language specific filename extension. If possible, you
should use the appropriate device description file for your chosen language. The following file
types are possible:
• *.gse for English
• *.gsf for French
• *.gsg for German
• *.gsi for Italian
• *.gsp for Portuguese
• *.gss for Spanish
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In addition the general file type "*.gsd" is also possible; this file type is created in English. It is
essential that the correct GSD files are used for the devices on your PROFIBUS system. Each
type of PROFIBUS device has a unique identification (ID) number. The ID number is assigned
by the PROFIBUS User Organization and is unique worldwide for each type of PROFIBUS
device. The GSD file must correspond to the ID number of the configured device. The process
of selecting the GSD file is made simple because the GSD file name contains the ID number.
A GSD file name comprises of up to 8 characters. The first four characters indicate the name
of the manufacturer of the PROFIBUS device; the last four characters are its ID number ex-
pressed in hexadecimal.
For example:
“SIEM8027.GSD” – A generic file for Siemens device ID 8027
“WAGOB760.GSE” – An English language file, for WAGO device ID B760
Often when using devices from different manufacturers, the GSD files from the various man-
ufacturers’ devices must be imported into the configuration tool. Quite often this simply means
copying the GSD file into the correct directory on the PC or notebook being used for configu-
ration.
Please see the configuration program manual or help file to learn how to
import a GSD file.
The current GSD files of the PROFIBUS stations used are available from the manufacturers.
When using the GSD files, ensure that the GSD file version matches the
version of the PROFIBUS station. Otherwise it is possible that some func-
tionality will not be available.
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Addressing
It is essential that the address of every PROFIBUS station is correctly set in the configuration
tool. If an incorrect address is set, then the master will not be able to communicate with the
station. You should ensure that the addresses used in the configuration tool agree with the
planned addresses of the PROFIBUS stations. In addition, you should check that the ad-
dresses set on the physical PROFIBUS stations matches with the addresses in the project
plan.
Bus parameters
Bus parameters are used to set the details of the timing within a PROFIBUS cycle. There are
many parameters involved, however normally the system standard settings can be used.
If you need to change the bus parameters, please read the manufacturer's
instructions relative to projecting software, and to the PROFIBUS stations
used.
Save the project
Once completed, the system configuration should be saved on suitable data media (USB stick,
CD) and submit it to the customer as part of the acceptance process. In addition a back-up
copy should also be stored safely. Thus the information will also be available to you in the
future, i.e. in the event of malfunction, or for service.
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4.2.2 Verifying PROFIBUS station addresses (step 4)
The address of a PROFIBUS station can be set in one of three ways:
• A local switch on the device (binary dip switch or rotary switch).
• Software setting of device address over the PROFIBUS network using a configuration tool
(called a Class-II master).
• Some devices may use special software and a serial link or hand-held tool to set the device
address (e.g. some masters, drives or HMI devices).
PROFIBUS stations which incorporate setting of the address over PROFIBUS are often deliv-
ered with a pre-set address of 126. It is important that no two devices have the same address
on the network otherwise communication is impossible. Consequently, either the addresses
of such stations must be correctly set before the station is connected to the bus, or only one
station must be connected to the bus at a time and its address must be changed before con-
necting the next station.
Accordingly many PROFIBUS stations would have the same address if you do not change the
pre-installed address. Consequently, check the addresses of the PROFIBUS stations prior to
commissioning.
Only one PROFIBUS station with the address 126 can be connected at a
time. The address must be changed before another station can be added.
Incorrect address setting can be difficult to diagnose, particularly when duplicate addresses
are set. Consequently, checking of addresses should be carried out prior to commissioning.
Hand held tools can be used for this (see chapter 2.2).
4.2.3 Commissioning PROFIBUS stations (step 5)
After you have configured the master system, you can commission the PROFIBUS.
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It is good practice to use separate power supplies for the PROFIBUS sta-
tions and for their outputs. This allows the PROFIBUS network to operate
without danger of actuating plant equipment such as drives, heating ele-
ments etc. For safety reasons, the powersupplies for the PROFIBUS station
outputs should be switched off when commissioning a PROFIBUS network.
First verify that all PROFIBUS stations are supplied with voltage. See the manufacturer's de-
scription for the supply voltage required by each PROFIBUS station. The configuration can be
downloaded to the master station(s).
Master stations have four different modes of operation:
• Off-line – No interaction with the bus.
• Stop mode – No interaction with the configured slaves but master will take part in the bus
communication.
• Clear mode – The master goes into data exchange with the configured slaves but all out-
puts will be in their fail-safe state (normally off).
• Operate mode – Full communication with all configured slaves using output data derived
from the plant control program.
Placing the master(s) into clear or operate mode will establish communication between the
master(s) and slave stations. After a short time, all PROFIBUS stations should signal that they
are ready for operation. The operating status of the master can normally be read via the con-
figuration software using the programming device. Many PROFIBUS slave stations are pro-
vided with an LED indicating “bus fault” (BF). Sometimes a status display is provided. When
the master is in clear or operate mode the slave stations should not be indicating a bus fault.
Any stations that do show a bus fault are not communicating properly and will need further
investigation.
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Please refer to the manufacturer's description for the meaning of the slave
device status displays
4.2.4 Testing the Signal Inputs (step 6)
The next step is to test the signal inputs of the slaves. To do this, first check the voltage supply
for the sensors. The sensor supply voltage will be specified in the sensor manufacturer’s in-
formation.
Next you should activate the sensor. This can sometimes be done manually or sometimes by
simulation of the process input on the sensor. Trace the signal all the way back to the master.
The LEDs on the PROFIBUS station where the transducer is connected, and the I/O map in
the master, are available to help you do this. The I/O map can often be read on the program-
ming device using the configuration or programming software. Some sensors also have their
own display.
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4.2.5 Testing the Signal Outputs (step 7)
The signal outputs can next be tested in a similar way to the inputs. However you must first
check that it is safe to activate the outputs and that appropriate safety precautions have been
taken.
Danger – activation of signal outputs may cause motors to start and actua-
tors to move. You must take appropriate safety precautions before activating
outputs.
After checking that it is safe to apply the output control voltage, the output supply should be
switched on. A check should be made on the value of the control voltage. The output supply
voltage will be specified in the manufacturer’s information. Each signal output can now be
activated or forced manually via the configuration or programming software. Trace the signal
from the master all the way to the signal output. Check the IO map in the master, the LEDs on
the slave, and the output itself. Analog signal outputs can also be forced to a particular value
and checked using a multimeter to measure output voltage or current.
It is not unusual to find that the output supply voltage fails when switching
on many outputs simultaneously. This can be caused by poorly specified
power supply which cannot supply the required current when all outputs are
activated. A check should be made on the control voltage with all outputs
switched on so that the maximum current is drawn. If the voltage dips when
the outputs are switched then a power supply with a higher current limit
should be used.
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4.2.6 Create acceptance checklist (step 8)
The last step is to create an acceptance checklist. With this checklist you can document that
the acceptance was successful. In the Appendix you will find commissioning checklist and
acceptance checklist templates.
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Troubleshooting
5 Troubleshooting
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Troubleshooting
5.1 Introduction to troubleshooting
This chapter is designed to help you locate errors in PROFIBUS cabling. The first steps have
already been discussed in chapter 2. Here we discuss other possibilities that require some-
what more experience than is required for simple PROFIBUS diagnostics. The following pos-
sibilities are available to you:
• Checking the cabling infrastructure
• Measurements with a bus monitor
• Diagnostic telegram interpretation
• Oscilloscope measurements
• Optical fiber measurements
Additional troubleshooting information is included in the “PROFIBUS Profile Guideline – Part

3: Diagnosis, Alarms and Time Stamping from the PI”.
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Troubleshooting
5.2 Checking the Cabling Infrastructure
Checking the cabling infrastructure should be one of your first troubleshooting steps. Errors
can creep in here, for example, if the routing of the PROFIBUS cable has been changed. The
potential for errors when extending or modifying a network is particularly high. For example,
exceeding the maximum segment cable length or exceeding the maximum permissible num-
ber of PROFIBUS stations in a segment.
Stub lines, particularly at high transmission speeds (above 1.5 MBit/s) also represent a prob-
lem for PROFIBUS RS485 transmission technology and should be avoided. Spurs are per-
missible for PROFIBUS MBP (PA), however, only within a limited length.
Check the cabling structure for the following points:
• Do the cabling structures adhere to the planning?
• Do the maximum permissible segment lengths comply with the planning?
• RS-485 transmission technology: It is highly recommended to avoid any stub lines.
• MBP (PA) transmission technology: Were the maximum number of spurs and the associ-
ated spur lengths within specification according to the planning?
• Was the PROFIBUS network installed according to the planning?
• Were any changes made during the installation and have these changes been incorpo-
rated into the documentation?
• Were changes made to an existing system?
• Was the cabling structure maintained after the changes?
• Does the maximum permissible segment length still comply with the specification after the
changes?
• Were the changes documented?
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Troubleshooting
In addition to testing the actual cabling, you should also test the cabling of the equipotential
bonding. An error in the equipotential bonding can result in communication malfunctions. Since
errors in the equipotential bonding are very difficult to locate, you should check all equipotential
bonding connections.
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Troubleshooting
5.3 Measurements with a Bus Monitor
A bus monitor is a device that can record and display the data traffic on the PROFIBUS net-
work. Bus monitors provide an effective way of observing the communications of the PROFI-
BUS stations. However, analysis of the recorded information requires experience. Many mod-
ern bus monitors provide some telegram decoding which makes them easier to use. However,
detailed analysis of the communication will require a specialist. Modern bus monitors also
incorporate communication statistics which can help to diagnose and locate intermittent faults
which are very difficult to find in any other way.
Read the description provided by the manufacturer for information on oper-

ating the bus monitor.
A PROFIBUS monitor should have the following features:
• Message capture and display with the ability to “trigger” on particular telegrams or condi-
tions.
• Real-time operation at the required bit-rate without “missed telegrams”.
• Message filtering to allow display of selected telegrams.
Other useful features include:
• “Live list” overview showing all devices that are taking part in communications.
• Decoding of the telegrams.
• Oscilloscope triggering facility allowing the capture of the transmitted waveform from a
particular slave.
• Communication statistics showing numbers of corrupted and/or repeated telegrams.
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Troubleshooting
A good bus monitor can help to diagnose and locate a wide variety of faults, however training
is essential. Certified PROFIBUS Engineer Courses, which cover the use of a bus monitor,
interpretation of telegrams and fault finding procedures are available in many countries. These
are publicized on the PROFIBUS International web site, www.profibus.com.
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Troubleshooting
5.4 The diagnostic telegram
Potential faults are not limited to the PROFIBUS network. For example, power supply, I/O
wiring and sensor/actuator faults can also occur. PROFIBUS provides extensive diagnostics
that can help to diagnose and locate many faults. When diagnostic information is available in
a PROFIBUS device, the device sets an error bit during cyclic data exchange to prompt the
master to request this diagnostic information. The PROFIBUS master then reads the diagnos-
tic data and saves them separately for each device. When and how the diagnostic information
is indicated to the user depends on the control unit to which the PROFIBUS master is allo-
cated.
The diagnostic buffer of a slave may contain several parts:
• 6-bytes of standardized diagnostics provided by every PROFIBUS slave.
• An optional device-dependent diagnostics, which are manufacturer dependent, but

may be defined in the device manual or GSD file.
• An optional module-related diagnostics, that indicate which, if any, modules have a

problem. The structure of the module related diagnostic block, if provided, is described
in the PROFIBUS standard.
• One or more optional channel-related diagnostic blocks, which indicate which channels
on particular modules, have a problem. The channel-related diagnostic block also pro-
vides a code which describes the details of the fault. Channel-related diagnostics are
described in the PROFIBUS standard.
The standard PROFIBUS diagnostics are always present as the first 6-bytes of the diagnostic
telegram or buffer. The other blocks are optional, and may appear in any order and can even
be repeated for different faults on different modules. For example, a particular diagnostic tel-
egram may contain 6-bytes of standard diagnostics followed by a module-related diagnostic
block, followed by several channel-related blocks, one for each channel fault.
Many PROFIBUS tools are available that can show the diagnostic buffer. These tools can
include the following functionalities:
• Master configuration software which has on-line functionality.
• Class-II masters.
• PROFIBUS bus monitors.
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Troubleshooting
Some of these tools will also interpret the diagnostics for you, according to the PROFIBUS
standard, or as described in the device GSD file. You can also interpret the diagnostics man-
ually. However, this requires considerable experience and skill. Certified PROFIBUS Engineer
Courses, which cover the use of an analyzer, interpretation of diagnostics are available in
many countries. These are publicized on the PROFIBUS International web site, www.profi-
bus.com.
Additional information on the diagnostic telegram is provided by the following document from
the PROFIBUS User Organization:
PROFIBUS Profile Guideline – Part 3: Diagnosis, Alarms and Time Stamping, Version 1.0
(July 2004).
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Troubleshooting
5.5 Oscilloscope Measurements
Usually, sufficient results can be obtained by measurements with a bus mon-

itor. It is recommended to verify the signal waveform with an oscilloscope
only if troubleshooting with a bus monitor should be ineffective. Oscilloscope
measurements on PROFIBUS require a certain level of experience. Conse-
quently, the measurements should only be performed by experts.
Oscilloscope measurements are a very effective means of troubleshooting PROFIBUS. With

a little practice different statements about errors and signal quality can be derived from the
signals displayed. This chapter shows which characteristics the oscilloscope must have, which
auxiliary aids are practical, and what you can measure with the oscilloscope. In addition typical
signal waveforms are shown in some figures in this document.
5.5.1 Technical Prerequisites
The following characteristics require an oscilloscope for measurements on the PROFIBUS.
Design: Digital storage oscilloscope
Bandwidth 100 MHz
Channels: 2, potential separated to each other and against the device ground
(network connection)
Trigger: Internal + external
Coupling type: DC
Battery-powered oscilloscopes are well suited. Due to the handy format and independent
power supply they offer a high level of mobility in the system.
The potential separation between the two input channels and against the device ground is
particularly important. Separation of the two channels ensures that they do not affect each
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Troubleshooting
other. It is just as important that both channels are also potential separated from the device
ground. If this is not the case, then an unintentional or intentional connection of a channel
ground to a live core can result in a short circuit. For measurements on the PROFIBUS, often
the channel reference potential is connected to one of the two data lines. Measurement would
not be possible without a potential separated oscilloscope, since the signal is tapped on
ground on the data line. This is particularly undesirable for measurements during system op-
eration and must be avoided. Connecting the reference potential to the data line would result
in a communication breakdown. However, you can avoid this by measuring both signals sep-
arately, and then indicate the signal difference. In this case potential separation of the two
channels is not required. However, proceed very carefully in this case. There is a risk of short
circuit if you connect the measurement cable incorrectly. Alternatively, you can use a differen-
tial probe.
Another useful function is a multimeter integrated in the oscilloscope. In this case you can
save one device.
Modern digital oscilloscopes offer an integrated RS-232 interface or a USB interface for con-
necting to the PC. Thus measurements performed can be saved and documented with the
PC.
5.5.2 Measurement Aids
Use a 9-pin Sub-D plug or an appropriate M12 junction, on which you can tap the signals, as
measurement aid. The following drawing shows which signals can be measured on which
pins.
Programming de-
vice connection
Pin 8: Data core A

Pin 3 Data core B
Pin 4: CNTR-P signal (standard)
Pin 9: CNTR-N signal (PG/OP)
Pin 5: Data source potential
PROFIBUS station connection
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Troubleshooting
Figure 5-1: Measurement plug oscilloscope measurement
A PROFIBUS plug with a programming device connection is best suited for this measurement
aid. This is primarily helpful if the PROFIBUS structure does not have a programming device
connection. In this case you can then insert the measurement plug between the PROFIBUS
station and the PROFIBUS cable.
For some PROFIBUS stations, such as programming devices or operation panels, the CNTR
signal is not routed out of standard pin 4. In this case pin 9 is used on these PROFIBUS sta-
tions. For some operation panels the CNTR signal must also be activated, for example through
DIP switches. Read the operating manual in this case or ask the manufacturer.
5.5.3 Measurement PROFIBUS RS485
The important thing is that the measurement must be performed on the interface of the re-
spective PROFIBUS station. If only individual PROFIBUS stations show errors, then it is best
to start with the measurement on these stations.
You should perform the following measurements:
• Data core B against data line A
Measurement of the data signals of data line B against data line A shows you the actual
signal waveform on the PROFIBUS. Both cores are used for PROFIBUS data transmis-
sion. The signals are transmitted concurrently on both cores. However, the signal on data
line B is transmitted reversed to data line A. The actual signal is a result of the voltage
differential between B and A. This type of signal transmission has the advantage that noise
affecting both data lines uniformly does not have an effect on the transmitted data tele-
gram. Through differential transmission, noise on one core is subtracted from the noise on
the other core. Thus no there is no noise voltage remaining in the actual data telegram.
There are two ways to perform the measurement. You need an oscilloscope that can sub-
tract two channels from each other as the first possibility. This should be possible with
most digital oscilloscopes: Adjust the oscilloscope as follows:
Displayed signal: Voltage B - voltage A
If you have an oscilloscope with isolated channels, you can also measure the differential
voltage B - A directly. Connect the ground terminal of one channel to data line A, and the
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Troubleshooting
signal terminal of the same channel to data line B. This measurement is more precise than
the subtraction of the voltage B-A, however, it has two disadvantages:
1. You must have an oscilloscope with potential separation.
2. Due to its structure, the ground cable acts like a spur that is only connected to one
data line. This can cause signal distortion at high transmission speeds. Usually this
does not cause problems. However, you should bear this in mind.
The voltage differential between high level and low level measured between B and A
should be between 4 V and 7 V. The positive and negative voltage value should be ap-
proximately the same size. The difference between the two values in practice is approxi-
mately 0.5 V. The quiescent level should be 1 V.
Many PROFIBUS stations supply the so-called CNTR-P signal. The CNTR-P signal has a
logical high level (approximately 3 V to 5 V) while the PROFIBUS station is transmitting.
This is helpful if you want to examine a certain PROFIBUS station. Use the rising edge of
the CNTR signal as trigger signal for the oscilloscope. Use either the external trigger input
(advantage: second channel remains free for use) or the second channel (advantage:
CNTR signal itself is visible) of the oscilloscope with this signal. Thus you can observe the
transmission of the respective PROFIBUS station.
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Troubleshooting
Through the CNTR signal you can also detect the associated telegrams of masters and
slaves (passive). The master's telegram is namely the last telegram that was on the PRO-
FIBUS prior to the slave's telegram. If you measure directly on the master, the CNTR signal
will be transmitted concurrently with the telegram.
For the measurements on data line A, on data line B, and between data line B and data
line A, you should set the input voltage level to at least 1 V/division. Less resolution is not
effective, details would get lost. For the time division you should first select a low time
resolution. You should be able to see several telegram packets. Thus you can better detect
asymmetries in the signal or EMC interference. Take a second measurement with finer
time resolution so that you can see only one bit or just a few bits. This makes it possible
to see details in the edges.
• Measure data line A against data ground
• Measure data line B against data ground
With the measurements, data line A against ground, and data line B against ground, you
can check the signals on the individual lines and uncover errors like defective bus drivers.
However, you must perform the measurements directly on each PROFIBUS station. Due
to the needed effort, you should only perform this measurement if you have detected errors
when measuring B against A.
Ensure that the data grounds of the individual PROFIBUS stations are not connected to
each other via the PROFIBUS cable. Since you must perform the individual measurements
of the data lines against the data ground, only the signal sent from the PROFIBUS station
is correctly displayed. You can detect this by the simultaneous transmission of the CNTR
signal through the PROFIBUS station.
The important thing for these measurements is that you execute them against the data
ground of the interface. A measurement against the device ground usually will not be suc-
cessful, because usually potential separation is present in PROFIBUS stations. You
should be able to measure the following voltages on the interface:
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Troubleshooting
• Quiescent voltage: Data core A: app. +2 V
• Quiescent voltage: Data core B: app. +3 V
• Transmission state Minimal voltage data line A: app. +1 V
• Transmission state Maximum voltage data line A: app. +4 V
• Transmission state Minimum voltage data line B: app. +1 V
• Transmission state Maximum voltage data line B: app. +4 V
For newer devices the maximum voltage on the data lines can be somewhat higher due
to more powerful bus drivers. The minimum values and maximum values however, should
be similar on both data lines. If this is not the case, then one of the two bus drivers could
be defective.
Due to potential shifts it may be the case that the signals are shifted on the
data lines by a positive or negative offset voltage. This can cause interfer-
ences in telegram traffic. The offset voltage on the data lines can be a max-
imum of +12 V or -7 V. Higher offset voltages may destroy the bus drivers.
+ 12 V
Telegramm
Telegramm Potential diff.
Telegramm
-7V
Figure 5-2: Potential shift at signals
Due to potential shifts it may be the case that the signals are shifted on the data cores by a
positive or negative offset voltage. This can cause interferences in telegram traffic. The volt-
age on the data cores can be up to +12 V or -7 V. At higher values the receiver subassemblies
of the PROFIBUS stations can be destroyed.
Page 63 / 129
Troubleshooting
Figure 5-3 shows the ideal form for a PROFIBUS signal.
1
CNTR
0 t
U (V)
5
Data 4
3
core A 2
1
0 t
U (V)
5
Data 4
3
core B 2
1
0 t
U (V)
Diff. 4
3
2
signal 1 „0“ „1“ „0“ „1“
0 t
B-A -1
-2
-3
Figure 5-3: Ideal signal form PROFIBUS RS485
The Figure 5-3 shows you the ideal form of the PROFIBUS signal, in practice the signal wave-
form will never look this ideal. The Figure 5-4 shows you an example of what the signal wave-
form of PROFIBUS signals can really look like.
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Troubleshooting
Data core B
Data core A
Diff. signal
B-A
Figure 5-4: Measurement PROFIBUS RS-485
5.5.4 Typical Signal Waveforms
In this chapter typical signal waveforms are shown based on some figures. The figures shown
always represent the signal resulting from the measurement "B-A".
PROFIBUS cable too long

Cable that is too long generally functions like a condenser. It changes the signal form. The
result is that for a square wave signal the rising edge is rounded (e-function). This effect is
more pronounced the longer the PROFIBUS cable.
If the signal is changed too drastically then it may be the case that the receiver cannot correctly
recognize the signal. This is why the signal should have reached the full voltage level after
50% of the bit period, at the latest. This ensures good noise immunity even in the presence of
other interferences.
Adjust the oscilloscope for this measurement in such a manner that you can only observe one
to two bits and their edges.
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Troubleshooting
Figure 5-5: Signal waveform for PROFIBUS cables that are too long
Non-Connected PROFIBUS Plugs

Another error source are PROFIBUS plugs that are inserted in the PROFIBUS cable, but are
not connected to any PROFIBUS station.
To reduce signal reflections caused by spurs at high transmission rates ( 3 MBit/s), inductors
have been integrated in the PROFIBUS plugs. If a PROFIBUS station is not connected to a
PROFIBUS plug, then the open connector in conjunction with the inductor generate signal
interference. The interference should not be greater than 0.5 V.
The following figure shows what this kind of interference looks like.
Voltage
Max. 0.5 V
Time
Figure 5-6: Signal waveform for non-connected PROFIBUS stations
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Troubleshooting
Adjust the oscilloscope for this measurement in such a manner that you can only see one to
two bits and their edges.
Defective Bus Terminator

For the bus connection two types of errors can occur, both of which cause a signal reflection.
The reflection strength depends on the error.
For the one error, too many terminators are switched on. Thus approximately 1/3 of the signal
is reflected and is turned by 180° relative to the original signal. It then runs back on the PRO-
FIBUS cable and can encounter the next sent telegram. The two signals are overlaid at the
crossing point. If the signal waveform of the two signals is juxtaposed, the level is reduced. If
the signal waveform is in the same direction then the levels are added.
The other error is a missing terminator. In this case there is also a reflection. However, the
reflection is not turned 180° relative to the original signal. The signal returns in full height. If
the reflected signal encounters a new data signal, then it may be the case that both signals
cancel each other out, or a double high signal will occur. A break of the two data lines produces
the same effect. In Figure 5-7 and in Figure 5-8 the possible signal waveforms are shown.
The signals show a step-like waveform when the telegram is overlaid with the reflection. The
waveform can be different depending on measurement location, and cable run. Cable tele-
grams and reflection meet at different points, due to different signal start times on the PRO-
FIBUS.
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Troubleshooting
Too much terminator resistance
Original signal
Reflection for too much switched-on terminator resistance
Overlaid signal (original signal + reflection) for too much switched-on terminator resistance
Figure 5-7: Too much terminator resistance
Page 68 / 129
Troubleshooting
Missing terminator
Original signal
Reflection with missing terminator
Overlaid signal (original signal + reflection) for too little terminating resistance
Figure 5-8: Missing terminator
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Troubleshooting
5.5.5 Measurements PROFIBUS MBP (PA)
The data signal on the PROFIBUS MBP (PA) is generated via current modulation. This makes
it possible to supply PROFIBUS stations with energy and data via the same two cores.
Measuring the signal is not always easy with PROFIBUS MBP (PA). Some PROFIBUS
MBP (PA) stations are encapsulated or drip molded for security reasons. Moreover, PROFI-
BUS MBP (PA) stations are often directly connected or connected via an M 12 plug connector;
consequently, measurement is primarily possible only on the terminals of the signal coupler,
or on the PROFIBUS MBP (PA) devices. You should perform two measurements to verify the
signal on the PROFIBUS MBP (PA). With the first measurement you detect the direct current
portion of the signal voltage with which the PROFIBUS MBP (PA) device is supplied. For this
you set the oscilloscope on measurement type "DC", Adjust the vertical division (voltage) so
that you can easily identify the signal on your screen. Select a very low resolution for the
horizontal division (time). At this measurement the waveform over a certain period is more
interesting than the details.
In plants where there is no explosion hazard voltage should be a maximum of 32 VDC. A

typical value is 19 VDC. For plants were there is an explosion hazard the maximum direct
current is 13.5 VDC. The voltage that the feed device must supply is provided is specified by
the device description. Perform the measurement directly on the feed device, and if possible
on the most remote PROFIBUSMBP (PA) station.
You should measure the above-mentioned voltages on the bus power supply, which is often
integrated in the DP/PA Linking device. If the voltage is lower, then this indicates a defective
voltage supply, or too many stations on the PROFIBUSMBP (PA) cable. You must measure
at least 9 VDC at the PROFIBUSMBP (PA) station. A lower voltage is not sufficient to supply
the PROFIBUSMBP (PA) stations. If the direct current is too low only on the most remote
PROFIBUSMBP (PA) station, then the PROFIBUSMBP (PA) cable could be too long.
Check the alternating voltage in the second measurement. This is the actual data signal. The-
oretically the difference between the maximum positive and the maximum negative alternating
voltage is 900 mV. In practice the value is between 800 mV and 1 000 mV. A higher value
indicates a missing bus terminator. On the other hand a lower value indicates too many bus
terminators. Set the oscilloscope to measurement type AC for the measurement. Select ap-
proximately 200 mV/division for the vertical division (voltage). For the horizontal division (time)
you should set approximately 20 µs/division.
The figures below show the signal in the ideal case, as well as with too few and too much
terminating resistors.
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Troubleshooting
Ideal signal
500 mV
Signal OK
400 mV
800 mV-1000 mV
-400 mV
Signal OK
-500 mV
Figure 5-9: Ideal signal form PROFIBUS MBP (PA)
Page 71 / 129
Troubleshooting
Missing bus terminator
Too many bus terminators
500 mV
400 mV
-400 mV
-500 mV
Figure 5-10: PROFIBUS MBP (PA) with defective bus terminator
Page 72 / 129
Troubleshooting
In practice you will never encounter an ideal signal form as shown in Figure 5-9. In Figure 5-11
is shown of what a data telegram can really look like on the PROFIBUS MBP (PA).
Figure 5-11: Measurement PROFIBUS MBP (PA) (1 telegram)
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Troubleshooting
5.6 Optical fiber measurements
The OTDR measurement process (OTDR = Optical Time Domain Reflectometer) is particu-
larly interesting for troubleshooting. Based on the measurement results a specialist can not
only determine the presence of an error, but also determine the location of the error.
To do this, the OTDR-device transmits a signal into the optical fiber. Portions of the signal are
reflected at connectors or at defective points (see Figure 5-12).
The device measures the strength of the reflected part of the signal, and how much time
elapses from signal transmission until the reflection is received. The measurement results
allow you to identify the location of the damage.
OTD
Transmitter
Receiver Optical fiber
Interference point (Reflection)
Figure 5-12: OTDR measurement principle
This process is particularly demanding, as the results are usually displayed in graphical format.
The operator needs to interpret the results. You should use this process only, if you have
experience with it. Otherwise let a specialist perform the measurements. If, however, you still
need to use an OTDR measurement device, then it is recommended to sign-up for a training
course.
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6 Annex
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6.1 Commissioning/Acceptance Checklists
Checklist for visual inspection PROFIBUS cabling RS485 / MBP (PA) / Fiber optics
System Segment name
Transmission speed
Assembly acceptance performed by
Comments
Visual inspection
OK Not OK
1. Cable laid according to plan?
2. Cable type according to plan?
3. Max. length of stubs not exceeded? (Only relevant for PROFIBUS MBP (PA), DP does not allow for
stubs.)
4. Connectors available according to plan (M12, Sub-D9, etc)?
5. Minimum spacing between cabling has been complied with, or metal partitions have been inserted?
6. Recommended minimum cable length of 1 m between PROFIBUS devices observed? (See the
PROFIBUS Installation Guideline for Planning)
7. PROFIBUS cable in order (no damage)?
8. Bend radii specification observed?
9. Cable crossings executed at right angles?
10. Only two terminating resistors inserted (on both cable ends)?
11. Guaranteed power supply for terminating resistors (even in case of emergency stop)?
12. Sharp edges have been covered or removed?
13. Safeguards against mechanical damage present at hazard points?
14. At least one plug is present with programming device connection?
15. Strain relief fixtures attached?
16. All Equipotential bonding points available according to plan?
17. Shielding is applied to the PROFIBUS stations, and connected to the equipotential bonding?
18. Shielding on the cabinet entrance is connected with the equipotential bonding?
19. Cable trays grounded?
20. Subassemblies used in accordance with the structure plan (24 V/230 V subassemblies not re-
versed)?
21. Transmission speed and PROFIBUS address are set according to structure plan?
22. Channels not required are switched according to manufacturer's description?
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23. Proper measurement range selected on the analog subassembly (current/voltage)?
Additionally in case of RS485-IS segments (Ex environment)
24. Only isolating repeaters used?
25. Transmission rate limited to 1.5MBIt/s?
26. No connectors with discrete inductors (e.g. 110nH such as required for high transmission rates) in
use?
27. Devices in use are Ex certified?
Additionally in case of PROFIsafe installations
28. No stubs are used?
29. Certified devices only (safety and standard)?
Date Installer signature Commissioning personnel signature
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Log for the assembly acceptance measurement inspection PROFIBUS cabling RS485
System Segment name
Transmission speed
Comments
Assembly acceptance measurement

OK Not OK
1. Wiring test
No short circuit between data line A and B?
No short circuit between data line A and shielding?
No short circuit between data line B and shielding?
Data core A intact?
Data core B intact?
Shielding intact?
Data cores not reversed?
Terminators only inserted on the cable ends?
2. Interface test
Voltage present for terminators on all interfaces?
RS485 signal strength sufficient on all stations?
CNTR signal present on the master?
3. Live List
All PROFIBUS stations are reachable at their address?
4. Segment length measurement (cable type A)
Maximum segment length at 9.6 kBit/s to 93.75 kBit/s: 1,200 m?
Maximum segment length at 187.5 kBit/s: 1000 m?
Maximum segment length at 500 kBit/s: 400 m?
Maximum segment length at 1.5 kBit/s: 200 m?
Maximum segment length at 3 MBit/s to 12 MBit/s: 100 m?
5. Reflection test
No reflection present?
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Checklist for the assembly approval measurement PROFIBUS cabling MBP (PA)
System Segment name
Transmission speed
Comments
Assembly acceptance measurement

OK Not OK
1. Wiring test
Short circuit between data line PA + and PA -?
Short circuit between data line PA + and shielding?
No short circuit between data line PA + and shielding?
Data core PA+ intact?
Data core PA- intact?
Shielding intact?
Data cores not reversed?
Terminators only inserted on the cable ends?
2. Supply voltage
Supply voltage sufficient on all stations (at least 9 VDC)?
Maximum supply voltage not exceeded (Ex plants: 13.5 VDC, non-Ex plants: 32 VDC)?
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Log for commissioning/acceptance PB
System Segment name
Transmission speed
Comments
OK Not OK
1. Visual inspection (according to the visual inspection protocol)?

2. Acceptance measurement (according to the acceptance measurement protocol)?
3. Project planning
Project planning created?
Project planning stored on data media?
4. Address of the PROFIBUS station correctly set?
5. Commission masters and slaves
Control voltage 24 V present?

Project planning transferred into the master?
All PROFIBUS stations signal operation readiness?
6. Testing the signal inputs
24 V control voltage present?
Signal inputs activate?
IO map coincides with the signal inputs?
7. Testing the signal outputs
Control voltage of the signal outputs present?
Signal outputs are activated?
IO map does not coincide with the outputs?
Date Commissioning personnel signature Customer signature
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6.2 Multimeter (instrument for measuring voltage, resistance, and current)
A multimeter is probably the simplest tool to use for troubleshooting in a PROFIBUS installa-
tion. With the multimeter it is possible to detect and locate errors like
• Simple "inversion" in the data lines
• Interruption of one of the two data lines
• Cable shielding interruption
• Short circuit between the data lines
• Short circuit between the data lines and the cable shield
The descriptions below list the auxiliary material you require and outline the measurement
procedures.
With the measurements you can check whether the installation was executed correctly. In
addition to the errors cited, the measurements also supply clues about the lengths of the PRO-
FIBUS cable segments. They are not just helpful for simple diagnostics; they are also helpful
for the assembly acceptance. You can document the measurements using the checklists in
the Appendix.
The measurements do not supply values that are 100% precise, but they do provide a rough
indication. However, the prerequisite for the measurements is that uniform components (PRO-
FIBUS cable and plugs) must be used in the entire segment.
The PROFIBUS components should not be connected for the measurements.
The PROFIBUS cable must be de-energized. You can determine if the cable is de-energized
by measuring the voltage between the shielding and the two data lines.
In addition, all terminators must be disconnected.
If you have permanently connected PROFIBUS components in the system, such as repeaters,
then these must be disconnected. Each segment must be measured separately.
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6.2.1 PROFIBUS RS485 with 9-Pin Sub-D Plug Connector
Determining loop resistance

Loop resistance is determined by measuring the resistance of the two cores of the PROFIBUS
cable. The resistance of the cores depends on the cable construction and also is temperature
dependent.
Specific Cable resistance is normally specified in ohms per km at a given temperature. It is

equivalent to the measured loop resistance of a 1 km long PROFIBUS cable.
A typical value for PROFIBUS RS-485 cable type A has a loop resistance of
110 ohm/km at 20C. However, this value can deviate for special cable, e.g.
highly flexible cable. Cable resistance typically increases with temperature
by 0.4% per degree Celsius.
You should use the cable resistance values from the cable manufacturer’s
data sheets.
The measurement of cable loop resistance is relatively simple:
• At one end of the PROFIBUS cable, you must short-circuit or bridge the two cores,
data core A and data core B.
• At the other end of the cable, measure the loop resistance between the two cores.
• See the PROFIBUS cable manufacturer’s datasheets for the specific loop resistance
(ohm/km) for the cable used.
• Using the specific loop resistance, you can estimate the length of the cable segment.
Thus you can verify compliance with the permissible cable run specifications.
Measured loop resistance in ohms

Length in km =
Specific cable resistance in ohm/km
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The cable loop resistance can also be estimated from knowledge of the cable length:
Loop resistance, Rloop, in ohms = Cable length in km  Specific cable resistance in ohm/km
Example:
The loop resistance of a segment of PROFIBUS RS485 type A cable is found to be 20  at

20C. The estimated cable length is thus:
20
= 0,182km = 182m
110 / km
Note that the cable length estimated from resistance measurement is generally not very ac-
curate because of the variation of specific resistance with temperature and the possible addi-
tional resistance of connectors. Cable length measurement based on signal reflection provides
a more accurate estimate on installed cable length (see section 6).Executing the measure-
ment is quite simple.
Testing the PROFIBUS cable and the bus connectors

Figure 6-1 shows a schematic of a typical PROFIBUS RS485 cable with 9-pin sub-D plug
connectors and termination resistors at each end. Typically the end termination resistors are
mounted in the connector plugs and can be switched in or out as required. Sometimes termi-
nation resistors are built in to the PROFIBUS devices that are connected. Termination may
also be provided by a separate “active terminator”, which only provides the termination resis-
tors and a power supply.
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First connector Last connector
VP VP
Pin 6 Pin 6
390 390
B line (data plus)
Pin 3 Pin 3
220 220
A line (data minus)
Pin 8 Pin 8
390 390
Shield
Pin 5 Pin 5
DGND DGND
Note that other inter-
Shield Shield
mediate connectors
are not shown
Figure 6-1: PROFIBUS RS485 cable schematic with end terminations switched in
Measurements are made with a multimeter at each connector on the segment. All stations
must be disconnected from the cable and all terminations switched off or disconnected before
the testing is started. The required steps are described below. Please make this steps in every
PROFIBUS segment. Step 1 checks that the cable is free of voltage from powered terminators.
Step 2 checks for shorts between wires. The checks in step 1 and 2 should be performed at
each connector before starting step 3. For steps 3 and 4 short circuits are introduced between
selected pins in the first connector and the measurements are made on each of the remaining
connectors. Failure to detect the introduced short circuit at a connector indicates a broken wire
or wrongly connected cable.
A systematic method must be used in testing your cables. Steps 1 to 4 must be completed in
the correct sequence in order to fully check that the cable has no wiring faults.
Step 5 is used to check the cable length by introducing a short between the A and B lines on
the first connector and measuring the loop resistance at the last connector.
Finally, all shorts are removed and the termination resistors switched in and checked in step 6.
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• Step 1
Using a low DC voltage range on your multimeter check that the voltage between the
shield and the A and B pins of the connector is zero. Should any voltage be detected
then the cable is either not disconnected from all devices or a powered termination is
still switched in. Ensure the cable is voltage-free before proceeding to step 2.
• Step 2
The resistance is measured between the connector pins at each connector. Failure to
measure infinite resistance indicates a short circuit, or termination resistors switched
in. In order to make the measurements, you will need to estimate the cable loop re-
sistance, Rloop. This can be found by multiplying the segment cable length by the spe-
cific cable resistance as shown above. The specific loop resistance of a PROFIBUS
RS485 standard cable is 110 Ω/km. The specific loop resistance of the used PROFI-
BUS cable you can find in the data sheet of the manufacturer.
The loop resistance may be taken as zero for short cables (less than 50 m). Table 6-1
shows the measurements that must be performed, the expected results and indicated
fault. Short circuits on PROFIBUS cables can be difficult to locate since the whole
cable will appear shorted by a fault in just one connector. A solution is to isolate sec-
tions of the cable until the short disappears. Special isolating connectors, which dis-
connect the outgoing cable when the termination resistor is switched in, can be useful
for this; however you must remember that the termination resistor that is switched in
will introduce a resistance of 220  between the A and B lines. You may proceed to
step 3 only if there are no short circuits detected and all terminations are off.
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Table 6-1: Resistance measurements for step 2 (PROFIBUS RS485)
Measure the re- Measured

sistance between resistance Measured re- Measured re- Measured re-
connector pins infinite sistance Rloop sistance 110 sistance 220
Pin 8 (A Pin 3 (B Short between 2 termination 1 termination

Cable ok
line) line) A and B resistors on resistor on
Pin 8 Short between

Shield Cable ok ---- ----
(A line) A and shield
Pin 3 Short between

Shield Cable ok ---- ----
(B line) B and shield
• Step 3
For step 3 you must introduce a short circuit between pin 8 (A line) and shield at the
first connector of the tested segment. This can be done by introducing a link from pin 8
to the shield in the first connector. Measurements are then made at each of the other
connectors. Table 6-2 shows the measurements that must be performed, the expected
results and indicated fault.
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Measure the resistance be- Measured resistance is in- Measured resistance

tween connector pins finite Rloop
Pin 8 (A line) Pin 3 (B line) Cable ok Crossed wires A-B
Pin 8 (A line) Shield Open circuit in A or shield Cable ok
• Step 4
For step 4 you must now introduce a short circuit between pin 3 (B line) and shield at
the first connector of the tested segment. This can be done by introducing a link from
pin 3 to the shield in the first connector. Measurements are then made at each of the
other connectors. Table 6-3 shows the measurements that must be performed, the
expected results and fault symptoms.
Measure the resistance be- Measured resistance is in- Measured resistance

tween connector pins finite Rloop
Pin 3 (B line) Shield Open circuit in B or shield Cable ok
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• Step 5
We measure the cable loop resistance in step 5 by introducing a short between pin 3
(B line) and pin 8 (A line). This can be done by introducing a link between pins 3 and
8 in the first connector. Loop resistance is then measured at the last connector be-
tween pin 3 (B line) and pin 8 (A line). The cable length can then be checked using the
cable specific resistance.
Measured loop resistance in ohm

Length in km =
Example
The loop resistance of a segment of PROFIBUS RS485 type-A cable is found to be 20  at

20 
= 0,182 km = 182 m
110  / km
Note:
If your installation does not have a 9-pin Sub-D plug connector at the beginning or end of the
segment, then you can also perform the measurements directly on the cable cores.
Measurement aid for 9-pin Sub-D plugs

For measurements on a PROFIBUS copper cable with 9-pin Sub-D plug connectors, you can
make a simple aid by using two 9-pin Sub-D sockets, a single pole toggle switch and a three-
position changeover toggle switch with center off position. These components are available
from specialized electronics shops.
Figure 6-2 shows how to make up the two sockets; one for connecting the multimeter and the
other for introducing the short-circuits described in steps 3 and 4 above.
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Shield 1 To PROFI-
3
To multi- BUS plug
Core B
8
meter connector 6 1
Core A 7 2
9-pin sub-D 8 3
9 4
5
female sock-
1 ets View from rear of
3
To PROFI- sockets
8
BUS plug
connector
Figure 6-2: Measurement aid sockets (PROFIBUS RS485)
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6.2.2 PROFIBUS RS485 with 5-Pin M 12 Plug Connectors
The multimeter measurement for 5-pin M 12 plug connectors is similar to the measurement
for 9-pin Sub-D plug connectors. You must ensure that data core A is connected to pin 2, and
that data core B is connected to pin 4. A pair of measurement aid sockets can also be made
for connection to M12 plugs in a similar way to the sockets shown in Figure 6-2.
6.2.3 PROFIBUS MBP (PA) with 4-pin M12 Plug connectors
Determining loop resistance

The loop resistance if MBP (PA) wiring is measured in exactly the same way as described for
RS485 wiring (chapter 6.2.1). You must measure the resistance of a loop of two cores. For
this introduce a short circuit between the both cores of the PROFIBUS cable. After this meas-
ure the resistance at the other end of the cable.
In the data sheet of the manufacturer you can find the specific loop resistance. The specific
loop resistance describes the loop resistance of a 1 km long PROFIBUS cable. So to compare
the specific loop resistance with the measured loop resistance you must convert the measured
loop resistance on cable length of 1 km. However, there are four different cable types for
PROFIBUS MBP (PA). For new systems, i.e. replacement or extensions of PROFIBUS MPB
only use cable types A or B. In old systems it is still quite possible to encounter cable types C
or D. Typical specific loop resistance values are shown in Table 6-4.
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Table 6-4: Loop Resistance PROFIBUS MBP (PA) cable
Cable type A B C D
One or multi-
ple twisted Multiple twisted Multiple non-
Twisted pair,
Cable structure pairs, com- pairs, non- twisted pairs,
shielded
pletely shielded non-shielded
shielded
Core cross section 0.8 mm² 0.32 mm² 0.13 mm² 1.25 mm²
Specific Loop resistance

44 ohm 112 ohm 264 ohm 40 ohm
in ohm / km
You should use the cable resistance values from the cable manufacturer’s
data sheets.
Cable resistance typically increases with temperature by 0.39% per degree

Celsius.
Testing the PROFIBUS MBP (PA) cable and the bus connectors
The testing of MBP (PA) cabling can be dome in a similar way to that described for RS485
cabling (chapter 6.2.1). However, the termination networks for MBP (PA) segments is quite
different to that for RS485, consisting of a resistor in series with a capacitor. These termina-
tions are normally wired into junction boxes or sometimes into devices. Because MBP (PA)
terminations incorporate an isolating capacitor, they do not introduce any resistance into the
circuit and thus will not affect the resistance readings.
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Measurements are made with a multimeter at each connector on the segment. All stations
must be disconnected from the cable before the testing is started. The required steps are
described below. Step 1 checks that the cable is free of any voltage. Step 2 checks for shorts
between wires. The checks in step 1 and 2 should be performed at each connector before
starting step 3. For steps 3 and 4 short circuits are introduced between selected pins in the
first connector and the measurements are made on each of the remaining connectors. Failure
to detect the introduced short circuit at a connector indicates a broken wire or wrongly con-
nected cable.
A systematic method must be used in testing your cables. Steps 1 to 4 must be completed in
the correct sequence in order to fully check that the cable has no wiring faults.
Step 5 is used to check the cable length by introducing a short between the data lines on the
first connector and measuring the loop resistance at the last connector.
Finally, the short-circuit plugs are removed and the terminating resistors are switched on and
checked as described in step 6.
• Step 1
Using a low DC voltage range on your multimeter, check that the voltage between the
shield and the PA+ and PA- pins of the connector is zero. Should any voltage be de-
tected then the cable is not disconnected from all devices. Ensure the cable is volt-
free before proceeding to step 2.
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• Step 2
The resistance is measured between the connector pins at each connector. Failure to
measure infinite resistance indicates a short circuit. In order to make the measure-
ments, you will need to estimate the cable loop resistance, Rloop. This can be found by
multiplying the segment cable length by the specific cable resistance as shown above.
There are following specific loop resistances for PROFIBUS MBP (PA):
Cable Type A B C D
Specific loop 44 Ohm 112 Ohm 264 Ohm 40 Ohm

resistance
The loop resistance may be taken as zero for short cables (less than 50 m). Table 6-5 shows
the measurements that must be performed, the expected results and indicated fault. Short
circuits on PROFIBUS cables can be difficult to locate since the whole cable will appear
shorted by a fault in just one connector. A solution is to isolate sections of the cable until the
short disappears. You may proceed to step 3 only if there are no short circuits detected.
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Table 6-5: Resistance measurements for step 2 (PROFIBUS MBP (PA))
Measure the resistance be- Measured resistance in- Measured resistance

tween connector pins finite Rloop
Short between
Pin 1 (PA+) Pin 3 (PA-) Cable ok
PA+ and PA-
Short between
Pin 1 (PA+) Shield Cable ok
PA+ and shield
Short between
Pin 3 (PA-) Shield Cable ok
PA- and shield
• Step 3
For step 3 you must introduce a short circuit between pin 1 (PA+ line) and shield at
the first connector of the tested segment. This can be done by introducing a link from
pin 1 to the shield in the first connector.
Note: Usually the cable shield is connected to the screwed gland of the connector.
Measurements are then made at each of the other connectors. Table 6-6 shows the
measurements that must be performed, the expected results and indicated fault.
Note that many PA devices are not polarity sensitive, thus they will still work without
error if the PA+ and PA- lines are crossed or swapped.
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Measure the resistance be- Measured resistance is Measured resistance

tween connector pins infinite Rloop
Crossed wires
Pin 1 (PA+) Pin 3 (PA-) Cable ok
PA+ to PA-
Open circuit in
Pin 1 (PA+) Shield Cable ok
PA+ or shield
• Step 4
For step 4 you must now introduce a short circuit between pin 3 (PA- line) and shield
at the first connector of the tested segment. This can be done by introducing a link
from pin 3 to the shield in the first connector. Measurements are then made at each of
the other connectors. Table 6-7 shows the measurements that must be performed, the
expected results and fault symptoms.
Measure the resistance be- Measured resistance is Measured resistance

tween connector pins infinite Rloop
Open circuit in
Pin 3 (PA-) Shield Cable ok
PA- or shield
• Step 5
We measure the cable loop resistance in step 5 by introducing a short between pin 1
(PA+) and pin 3 (PA-). This can be done by introducing a link between pins 1 and 3 in
the first connector. Loop resistance is then measured at the last connector between
pin 1 (PA+) and pin 3 (PA-). The cable length can then be checked using the cable
specific resistance.
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Measured loop resistance in ohms

Length in km =
The typical loop resistances for PROFIBUS-MBP (PA) cables are listed inTable 6-4. However,
the values of the existing PROFIBUS-MBP (PA) cable may differ.
The exact values for the typical loop resistance can be found in the data sheet of the cable
manufacturer.
Example:
The loop resistance of a segment of PROFIBUS MBP (PA) type-A cable is found to be 5  at
5
= 0,114 km = 114 m
44  / km
Note:
If your installation does not have a 5-pin M12 plug connector at the beginning or end of the
segments, then you can also perform the measurements directly on the cable cores.
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6.3 PROFIBUS Documentation
This chapter makes a proposal for the documentation of PROFIBUS networks. The notes are
to be regarded as recommendations. Depending on the conditions in the system or in the
company, it is possible to deviate from the specifications.
6.3.1 PROFIBUS relevant information for documentation
Prior to starting the documentation, the following aspects should be clarified:

• Responsibilities
- For the creation of the network documentation
- For the management of the network documentation
- Are there any persons responsible for the plant? Are there any responsibilities
for individual plant sections?
• How and where will the documentation be distributed?
The cover page should contain all relevant information needed for identifying the document:
• ID of the documentation
- Document type (here: Network documentation)
- ID number / name
- Date of issue
- Revision index or version
- Revision date
- Document status (is it a draft or final version?)
- Specific data (customer name, plant name)
• Information on the creator
- Company name
- Company address
- Responsible author
The network documentation should range from a network overview for the entire plant over
detailed views of the networks of plant section up to device-specific information. A topology
overview is a visual representation and, hence, provides a good introduction.
• For example an R&I diagram or the architecture.

• Draw the bus nodes.
- Automation devices
- Bus infrastructure
▪ Cabling
▪ The cabling order must be represented correctly.
- The persons responsible of the plant must be noted.
• The identifiers/names of the devices must be included.
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- Device type (e.g. PLC, repeater, etc.)

- Make a clear allocation to the locality.
▪ Specify the building (part).
▪ Specify the room.
▪ Make a note of the spot height to allow for easy device localization (e.g.
in a high-bay storage).
▪ Note the cabinet.
• The connection terminals (ports) of the devices must be designated.
• Segmentation plan
• Information on the cable
- Cable length between two nodes
- Used cable type (included in cable list?)
- The medium must be noted.
For reasons of simplicity, further information should be documented in a separate Annex about
topology.
• Information on the products

- Manufacturer
- Serial numbers of the devices
- Model name / type designation
- Spare parts
▪ Serial number
▪ Order number
▪ Version number
▪ Supplier (or alternative supplier)
▪ Reference picture
- Store data sheets.
- Describe the device functionality.
- Certificates
- Used software or firmware revision levels
• Document the reference measurements of the network.
- Measure and document the network load in normal operation.
- Mark any points where EMC disturbances have to be expected.
- Validation report of the physical layer (what are the physical variables during
commissioning?)
- Validation report of the communication layer (what does data modulation look
like?)
- Validation report of the hazardous area (which devices are used in the hazard-
ous area?) Are these devices certified?
- Are there any delays? How long is the delay?
• Information for cases of faults
- List for fault localization
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- Description of integrated diagnostic systems

- Drawings and diagrams
- Contact information for further help (hotline/support)
- Who is responsible of the plant (parts)?
The following information is required for PROFIBUS networks
• Where are terminating resistors?

• Where are diagnostic connectors?
• The device addresses must be noted at the nodes in the plan.
• Note the data transmission rate (Mbit/s) of the segments.
• Which protocol is used?
• Are the GSD files saved? Which GSD files are used?
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6.3.2 Proposal for a PROFIBUS forwards documentation
This section is intended to further explain the information in section 6.3.1. The individual steps
of forwards documentation are discussed and the difficulties are described.
A network documentation often addresses more than one target group (persons in charge of
the installation, revision, operation, troubleshooting or audit). In a simplified approach, how-
ever, it is possible to identify two fields of interest (see Figure 6-3).
Figure 6-3: Fields of interest in a plant lifecycle
As the installation and revision departments normally use electrical wiring diagrams, the plant
operators are the main target group of the network documentation.
The next step defines the format in which the network documentation is to be created. It must
be clarified whether printed plans are to be published or digital documentation is to be used
instead. Mind the fact that sensitive data must be access-protected. Digital plans must be
saved in a file format which ensures (read and write) access and data readability and integrity.
Also pay attention to the retention obligation. The documentation must be available for the
retention period.
The persons responsible for the document creation and management during the operation
phase must be defined. For large companies or plants the persons responsible for the corre-
sponding plant or plant sections must be contacted.
Every forwards documentation begins with a cover page. The cover page should provide the
information relevant for identification (plant, creator, responsibility). The document revision
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information (index, date) provides the revision level and allows you to clearly determine
whether the document is up to date. It is also useful to indicate the status on the cover page.
Moreover, it must be possible to clearly identify the creator for possible questions.
A table of contents must be included after the cover page. The more details the table of con-
tents contains, the better, as you can directly access the information needed.
Begin with the topology plan. A template of the architecture of an R&I diagram is helpful. All
necessary network nodes must be integrated and numbered consecutively. Assign a unique
device name. The name contains the type or function of a node and should also be enhanced
with its location (building or building part, room). Indicating the spot height is useful in high
halls (e.g. a high-bay storage) For each device, write down the device name, the device ad-
dress and the status of the terminating resistor (on or off). Document the transmission rate
(kbit/s or Mbit/s) for every segment.
Then add the connections of all network nodes. Be sure to draw the connections in the correct
order. The port of each node must be noted in the plan to allow for unique identification of the
device connectors. Is it useful to assign a unique name to each connection (does a cable list
exist?) and to note down the length of the laid cables (actual length.
Any further information and details should be moved to the Annex in order to keep the actual
overview short and clear. It is recommended to list all further information in the Annex in a
table and group the individual items by categories (products, cables).
Every network node should be specified in details by the information listed in Table 6-8. Addi-
tionally, the used GSD files must be saved. All data sheets and certificates must also be
stored. Saving a functional description of the device is helpful. Defective devices can be re-
placed quickly by means of an exact list of information. It is recommended to record in the
documentation not only the information shown in Table 6-8, but also the serial number, (alter-
native) suppliers and a picture of the node.
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Add a network load calculation and measurement results of the network load in the individual
segments to the network documentation. Also record the data communication delays in the
commissioning phase. Areas where EMC disturbances are likely to occur must also be
marked. It is helpful to add a validation report for the physical layer and the communication
layer. The reports should indicate whether and to which extent the physical (current, voltage)
and communication-related (edge rise and fall times) PROFIBUS requirements were initially
met by the plant. If required, provide a validation report about the hazardous area or the cor-
responding certificates.
Document the integrated diagnostic systems (diagnostic connectors) and note the data of
contact persons who may provide support (e.g. line manager, consultant engineer, hotline and
support).
Table 6-8: Further information on the devices in the topology
No. Device Manufac- Model/type HW re- Firmware Serial number

name turer vision revision
level level
1 HMI+HA1_1 Manufac- HMI 17 1.3 1.3.1 ABC-12345

turer 1
2 PLC+HA1_1 Manufac- PLC 5 2.0 2.2 1920-1812-8212-0

turer 2
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6.3.3 Example of a PROFIBUS forwards documentation
Table 6-9 shows the preliminary considerations.
Table 6-9: Example of PROFIBUS forwards documentation, preliminary considerations
Target group Operator, special knowledge yes, special language yes
Target country/language Germany/German
Type of publication Printed documents, centrally managed plans, access only by

counter-signature
Number of copies 3 (1 design dpt, 1 operator, 1 external backup copy)
Retention period 12 years, ensured by storage of printed plans in different loca-

tions
Creation Company A, Mr. Sample
Management Company B, Ms. Example
Responsibilities
Ms. Meyer (administration
Plant Mr. Smith (hall 1)
Ms. Schulz (hall 2)
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Figure 6-4 shows a cover page example.
Figure 6-4: Cover page example for PROFIBUS forwards documentation
The information provided on the cover page should be repeated on all other pages. A title
block on each page is a suitable means of achieving this. The title block must be placed in the
bottom right corner of each page and contains all relevant information on the document. Table
6-10 lists the 15 most important items. Table 6-11 shows the structure of the title box in ac-
cordance with [ISO 7200] and Table 6-12, it also contains an example of the title box which
will be represented on the following pages by a gray box for the purpose of simplification.
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Table 6-10: Information in the title box in accordance with [ISO 7200]
Number Data field
1 Legal owner of the document
2 Title
3 Supplementary title
4 Reference number
5 Change index
6 Date of issue of the initial version of the document
7 Language
8 Number of pages/sheets
9 Document type
10 Document status
11 Responsible department
12 Technical reference (contact person with required knowledge)
13 Name of the person who created the document
14 Name of the person who approved the document
15 Classification/key words
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Table 6-11: Proposal for title box in accordance with [ISO 7200]
Responsible dept. Technical reference Created by Approved by

(11) (12) (13) (14) (15)
Document type Document status

(9) (10)
Title, Supplementary title
(1) (3) (4)
Rev. Date of Issue Lang. Sheet

(5) (6) (7) (8)
Table 6-12: Example of title box in accordance with [ISO 7200]
Responsible dept. Technical reference Created by Approved by

Design 2 Ms. N. Meyer Mr. S. Sample Mr. K. Smith
Document type Document status

Network Documentation Released
Title, Supplementary title
Company Inc. PROFIBUS 2508
Plant sections in hall 1
Rev. Date of Issue Lang. Sheet
A 25.08.2016 En 1/5
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Figure 6-5 shows the plant to be automated. It consists of three plant sections in hall 1 (re-
sponsible: Mr. Smith) of a company. A cabinet is already planned to be installed in the hall;
therefore, it is represented by a dotted line.
Figure 6-5: Example of forwards documentation for the automation of three plant sections
Figure 6-6 shows the configured automation devices and the required network infrastructure.
In addition to a PLC and three remote IOs, there is a switch for connecting the network nodes
and an HMI (Human Machine Interface) for visualizing the process.
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Figure 6-6: Example of PROFIBUS forwards documentation, physical topology plan
Table 6-13 contains further information on the automation devices and additional network
nodes. Table 6-14 provides additional information for the replenishment. Table 6-15 summa-
rizes the most important information about the cables. An enhancement of the cable list is
shown in Table 6-16.
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Table 6-13: Example for PROFIBUS forwards documentation, additional device information
Firmware re- GSD

No. Device name Address Segment Port Cable Device
vision level saved?
IN T -
1 PLC+HA1+S01_1 10 1 2.2 10.5 Server on 31.08.2016
OUT -W102 HMI+HA1+S01_1
IN -W102 PLC+HA1+S01_1
2 HMI+HA1+S01_1 15 1 2.1 8.4 Server on 02.09.2016
OUT -W101 Repeat+HA1+S01_1
1 IN -W101 HMI+HA1+S01_1
1R OUT -W103 IO+HA1-PS2_1

3 Repeat+HA1+S01_1 1 1.3.1 1.1 Server on 02.09.2016
2 IN - -
2R OUT - -
IN -W105 IO+HA1-PS3_1
4 IO+HA1-PS1_1 21 1 2.5 1.3 Server on 02.09.2016
OUT T -
IN -W103 Repeat+HA1+S01_1
5 IO+HA1-PS2_1 22 1 2.5 1.3 Server on 02.09.2016
OUT -W104 IO+HA1-PS3_1
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1.3 Server on IN -W104 IO+HA1-PS2_1

6 IO+HA1-PS3_1 23 1 2.5
02.09.2016 OUT -W105 IO+HA1-PS1_1
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Table 6-14: Example of PROFIBUS forwards documentation, enhanced device information
(Alternative)
HW/
No. Device name Manufacturer Model Serial number supplier
FW revision level
Order number
Vendor X
1 PLC+HA1+S01_1 Manufacturer 1 PLC 5 2.0 / 2.1 1920-1812-8212-0
1855215
Vendor X
2 HMI+HA1+S01_1 Manufacturer 1 HMI 17 2.5 / 2.5.1 1231-3017-0111-5
6532978
Vendor X
3 Repeat+HA1+S01_1 Manufacturer 2 Repeater 2 1.3 / 1.3 ABC-12345
1582649
Vendor X
4 IO+HA1-PS1_1 Manufacturer 3 IO S2 2.0 / 2.2 14-93-15
4561286
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Vendor X
4561286
Vendor X
4561286
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Table 6-15: Example of PROFIBUS forwards documentation, cable list
Connector 1 Connector 2 Type /

Name Connection Actual length/m Medium
Device Port Device Port Nature
-W101 Sub-D HMI+HA1+S01_1 OUT Repeat+HA1+S01_1 1 IN 10.50 Cu A
-W102 Sub-D PLC+HA1+S01_1 OUT HMI+HA1+S01_1 IN 5.00 Cu A
-W103 Sub-D Repeat+HA1+S01_1 1R OUT IO HA1-PS2 IN 85.00 Cu A
-W104 M12 IO+HA1-PS2_1 OUT IO HA1-PS3 IN 32.00 Cu A
-W105 M12 IO+HA1-PS3_1 OUT IO HA1-PS1 IN 25.00 Cu A
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Table 6-16: Example of PROFIBUS forwards documentation, enhancement of cable list
Line Connector
Name
Manufacturer Order number Manufacturer Order number
-W101 Manufacturer A PBK1050A Manufacturer A PBS3
-W104 Manufacturer A PBK1050A Manufacturer B M12PB5
-W105 Manufacturer A PBK1050A Manufacturer B M12PB5
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Describe normal plant operation in a clear manner (see Figure 6-7). For detailed checklists for
visual inspection, installation dimensions and commissioning refer to the Annex of the PRO-
FIBUS Commissioning Guideline [PBI2019].
Figure 6-8 shows how the diagnostic port could be marked.
Figure 6-7: Example of PROFIBUS forwards documentation, information in cases of faults
Figure 6-8: Example of PROFIBUS forwards documentation, diagnostic port example
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Keep all data sheets and the manuals of the used devices. Also provide a functional descrip-
tion of the plant to allow for easy familiarization.
6.3.4 Problems of forwards documentation in the production lifecycle
Deviations frequently occur in the installation or commissioning phase already. They should
be eliminated in a revision. However, the large number of manual user interactions by different
employees results in a high risk of faults. Once the system has been delivered to the plant
operator, the designers are no longer responsible, and the knowledge recorded in a good
network documentation is no longer available. In cases of faults, the employees of the plant
operator normally attempt to eliminate the faults themselves. Minor changes of the plant are
often not recorded as they have to be made under some time pressure.
A forwards documentation often contains many items throughout the entire lifecycle of the
plant. These reduce the quality of the network documentation. The network documentation
becomes unclear, difficult to understand or faulty. Often the network documentation is not up-
to-date, the access is denied or the documents are missing.
Due to these detriments it is not recommended to used the forwards documentation in the
operational phase of the lifecycle. Writing an up-to-date network documentation on site is more
suitable for troubleshooting. A standardized backwards documentation helps reduce the time
required for documentation.
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Terms / Definitions / Abbreviations
7 Terms / Definitions / Abbreviations
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Address (station address)
For PROFIBUS the address of a communication station (master or slave). The permissible
address range is 0 to 127, with
- 126 reserved for the use of the preset addressing of a new slave
- 127 reserved for sending broadcast messages to all PROFIBUS stations.
The highest value bit of the address is used to transmit a data telegram without DSAP
(Destination Service Access Point = NIL) or SSAP (Source Service Access Point) in the
address field.
Bus cycle
The following times are defined for calculating the bus cycle and system reaction times:
Asynchronous communication
- Token Transfer Period (TTP)
- Message Transfer Period (TMP)
- System reaction time (TSR)
- Isochronous cycle time (TCT)
See IEC 61158-4 for further details and calculation formulas
Commissioning
The systematic process used to place a fieldbus network, the connected devices, and the
associated parts of a machine or system in operation. The steps include configuration, set-
ting parameters, programming, troubleshooting on different system levels, such as PROFI-
BUS diagnostics, system diagnostics, program observation etc. The project planning sys-
tems lead to these steps. Commissioning is concluded when the system works according
to the planning and the customer requirements and when the system documentation has
been concluded.
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Communication
For PROFIBUS this means the electronic transfer of digital data from one network station
to another.
Data
IEC vocabularies: Reinterpretable depiction of information in a formal manner, suitable for

communication, interpretation or automated processes.
Data Link Service Access Point (DLSAP)
IEC 61158-3: A Data Link Service Access Point is a communication access point for data
connection.
Decentral peripherals (DP)
The term "Decentral peripheral" and the abbreviation "DP" stand for a simple, fast, cyclic,
and deterministic exchange of input/output data between a bus master and its associated
slaves.
Diagnosis
Detection and determination of the cause of a defective reaction or unexpected reaction on

the part of a PROFIBUSDP device. PROFIBUS provides auxiliary material to convert digital
information into information that people can use with helpful instruction texts or graphics.
DIN
Deutsches Institut für Normung (German industry standards) (www.din.de)
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DP master
IEC 61158-5: A fieldbus device within PROFIBUSDP that can be a master class 1 or master
class 2.
A master class 1 is a controlling device that controls multiple DP slaves.
Note: Normally this is housed in a programmable controller or in a process controller
A master class 2 is a controlling device that manages configuration data and diagnostic
data (e.g. programming devices).
DP slave
61158-5: A field device that is allocated to a DP master class 1, and which supplies/receives
input/output data exchange. In addition acyclic functions and alarms can be transmitted.
Drive
A drive is an electronic output subassembly that is used to control the speed, torque, and
position etc. of a DC or AC motor.
The PI supports two application profiles for drives.
EN (European norm)
European standard/norm recognized and used by all European countries. Many of the IEC
standards have been adopted as EN standard.
Fiber optic / optic fiber
In industrial environments it may be the case that standard bus physics in copper technol-
ogy can cause problems through interference. This problem can be solved by using fiber
optic technology (see also "Optical transmission technology").
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IEC
International Electronics Commission (headquartered in Geneva, Switzerland)
Interface
General term for each connection and interaction between hardware, software, and the
user.
Intrinsic safety (IS)
A degree of protection in which a part of the electrical system contains only intrinsically safe
components (equipment, electric circuits and wiring) that are not capable of creating an
ignition in an ambient atmosphere. No individual device or no wiring is intrinsically safe on
its own (with the exception of battery powered devices like pagers, transmitters-receivers,
gas detectors, etc. that have been especially designed as intrinsically safe devices). It is
only intrinsically safe if it has been dimensioned for operation in intrinsically safe systems.
This degree of protection is identified by the letter “i”.
Manufacturer code
The PI offers a reference list on the Internet that contains the manufacturer code, the as-
sociated company name, and additional useful information. This list is partially coordinated
with the reference list provided by the Hart association.
Optical transmission
IEC 61158-2: Transmission physics with the following characteristics:
- Optical fiber made out of quartz (glass) or plastic
- Great distances, independent of the transfer rate
- Immune to electromagnetic interferences
- Galvanic isolation between connected stations
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- Star, ring, line and mixed wiring structures
- Connection to electrical network segments possible
- Transfer rates: 9.6 / 19.2 / 45.45 / 93.75 / 187.5 / 500 kBit/s, 1.5 / 3 / 12 Mbit
Possible optical fibers
- Multimode optical fiber
- Singlemode optical fiber
- Plastic fiber
- HCS optical fiber
PROFIBUS
IEC 61784-1: Communication network according to the communication profile family 3

(CPF 3), unifying application profiles and system integration aspects, such as interfaces,
languages for project planning tools, and HMI.
PROFIBUS is an open, digital communication system with a broad field of applications,

specifically in the area of factory and process automation. PROFIBUS is suitable for fast,
time-critical applications and complex communication processes.
PROFIBUS components
Designates all components, that comprise a PROFIBUS network (e.g. cable, plug connect-
ors, master/slave interfaces, repeaters, etc.)
PROFIBUS-MBP (PA)
Refers to the transmission technology PROFIBUS Manchester-coded & bus-powered.

PROFIBUS MBP (PA) is used for synchronous data transmission.
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PROFIBUS PA
Refers to “PROFIBUS for Process Automation”. This is an application profile based on

PROFIBUS DP and independent of the physical layout (RS485, optical, MBP (PA)). The
requirements for continuous manufacturing are covered within the "PA devices" application
profile.
PROFIBUS station
Device that communicates with other devices via the PROFIBUS cable (master, slave)
PROFIsafe
Communication technology that is especially adapted to the requirements of safety-ori-

ented, distributed, discrete, and continuous manufacturing.
In the PROFIBUS implementation area "PROFIsafe is used for PROFIBUS applications in

the factory and process automation together with the corresponding PROFIsafe technology
for all transmission technologies (e.g. RS485, MBP (PA), optic).
Note: A PROFIsafe slave must be realized in such a manner that it agrees with the stand-
ards derived from IEC 65108. The implementation of safe communication is not sufficient
for functional safety.
The PI maintains the following "PROFIsafe" specifications
- PROFIsafe – Profile for safety technology, Order Nr. 3.092
- PROFIsafe Policy, Order Nr. 2.282
- PROFIsafe – Requirements for Installation, Immunity and electrical safety, Order

Nr. 2.232
- PROFIsafe – Test Specification for safety related PROFIBUS DP-Slaves, Order

Nr. 2.242
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PROFIBUS User Organization (PI)
PROFIBUS & PROFINET International authorized PROFIBUS Nutzerorganisation e.V. (PI

Germany) to set up Committees (C), Working Groups (WG) and Project Groups (PG) to
define and maintain the open, and manufacturer-independent PROFIBUS standard. The
PI was founded in 1989. The PI is a non-profit organization headquartered in Karlsruhe
Germany. Members of PROFIBUS International are entitled to participate in the Technical
Committees and the Working Groups of the PI. A member can take an active role in the
maintenance and further development of PROFIBUS. This ensures openness and manu-
facturer independence of PROFIBUS technology. Additional information can be found un-
der http://www.profibus.com/pi-organization.
Programming device
There are many types of programming devices and/or software that match the size of the
respective programmable logic controller (PLC) and are sold by the manufacturer.
- Single command programming devices: This programming device is useful for small
changes in an existing program
- Specific computer hardware and software that is always assigned by the manufacturer
for special programming languages, such as "ladder logic", contain special functions
for automation applications or for industrial environments. These programming devices
are extended into project planning tools and, therefore, enable all commissioning
steps.
- PC-compatible software to allow use of a standard PC or a notebook as programming

device. Special hardware is required to complete this system as a project-planning
tool, e.g. a PROFIBUS DP interface.
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Risk
IEC 61508-4: Potential hazard source. The term includes hazards for personnel which oc-
cur within a short time (e.g. fire and explosion) and moreover, such hazards that have a
long-term effect on a person's health (e.g. toxic waste).
RS485
Refers to the standard transfer technology for PROFIBUS that operates with a data transfer
technology according to the RS485 standard. PROFIBUS RS485 is used for asynchronous
data transmission.
RS485-IS
Refers to a PROFIBUS transfer technology that operates according to the RS485 standard.
IS refers to Intrinsic Safety. Thus technology can be used in hazardous areas.
Terminator
IEC 61158-2: A resistor that connects the core pairs on the end of the cable, to avoid re-
flections that occur at the cable ends. Ideally it should be as great as the wave resistance
of the cable.
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8 Index
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Assembly acceptace Counters and Diagnostics Buffer 24
acceptance meaurements optical fibers 38 Handheld devices 20
Assembly Acceptace Introduction 19
Acceptance Measurements PROFIBUS MBP 36 Loop Resistance PROFIBUS MBP 90
Acceptance Measurements PROFIBUS RS-485 Loop Resistance PROFIBUS RS-485 82

31
Multimeter 81
Assembly Acceptance 26
Optical fibers 21
Visual Inspection 28
PROFIBUS MBP cable 91
Commissioning / Acceptance 39
Testing PROFIBUS cable RS-485 83
Commissioning PROFIBUS stations 45
Troubleshooting 50
Commissioning the Bus 41
Bus Monitor 54
Create Acceptance Checklist 49
Checking the Cabling Infrastructure 52
Create Project Planning 41
Defective Bus Terminator 67
Testing the Signal Inputs 47
Introduction 51
Testing the Signal Outputs 48
Non-Connected PROFIBUS Plugs 66
Optical fiber 21
Oscilloscope – Measurement Aids 59
Insertion Measurement Process 21
Oscilloscope - Technical Prerequisites 58
Optical Fiber
Oscilloscope Measurements 58
Acceptance Measurements 37
Oscilloscope Measurements PROFIBUS MBP
Damping Measurement 21 70
Maximum fiber attenuation 22 Oscilloscope Measurements PROFIBUS RS-485

60
Measurement Results Damping Measurement
38 PROFIBUS cable too long PROFIBUS RS-485
65
Necessity of the Acceptance Measurements 37
Signal form PROFIBUS RS-485 65
Simple PROFIBUS Diagnostics 18
Signal Form PROFIBUS-MBP 71
4-pin M12 plug connector PROFIBUS MBP 90
Typical Signal Waveforms PROFIBUS RS-485
5-pin M12 plug connector PROFIBUS RS-485
65
90
9-pin Sub-D plug connector 82

Page 128 / 129
Addresses
PROFIBUS Competence Center
PI Competence Centers (PICC) are points of contact if there are problems with PROFIBUS.
PI Competence Centers have specialists that can assist you if you are experiencing problems
with PROFIBUS. In addition PI Competence Centers conduct training and develop new com-
ponents for PROFIBUS. PI Competence Centers can be found in many countries throughout
the world. Current addresses are listed on the Internet at www.profibus.com in the support
area.
© Copyright by:
PROFIBUS Nutzerorganisation e. V. (PNO)

PROFIBUS & PROFINET International (PI)
Haid-und-Neu-Str. 7 ● 76131 Karlsruhe ● Germany
Phone +49 721 986197 0● Fax +49 721 986197 0
E-mail info@profibus.com
www.profibus.com ● www.profinet.com
KHN
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PROFIBUS Commissioning 8032 V123 Sep22

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PROFIBUS

Version 1.23 – Date September 2022

Version Date Changes/History

0.2.2 24.06.04 3. Draft distribution for review

Changes according to the review of v.0.2.2 in Karlsruhe

Division into three documents (planning, assembly, commis-

4. Draft distribution for review

0.2.5 26.11.04 Optical fibers chapter added

Diagnostic telegram chapter added

0.2.6 05.02.05 Change according to review contributions

0.2.7 07.06.05 Change according to review contributions

0.2.8 17.09.05 Modified by A. Verwer

0.2.10 30.10.05 Changes according to review comments

1.0.0 18.11.05 Official version created

Renaming of the document from Installation recommendation

Changes according to the phone conference on July 13th

1.0.3 Internal version

1.0.4 Review version for working group

1.0.5 Internal version, not published

1.0.6 Review version

1.0.7 21.11.14 Reviewed by head of working group

1.0.8 26.02.15 Translation of changed sections

1.0.9 13.05.15 Release Version

1.21 18.09.2019 Final Review prior to release

Bugfix in Table 3.2: 1.5 kBit/s changed to 1.5 Mbit/s. Copy-

1.23 22.09.2022 Final review prior to release

1.1 PREFACE ................................................................................................................................ 11

1.2 SAFETY INFORMATION ............................................................................................................. 12

1.3 DISCLAIMER OF LIABILITY ......................................................................................................... 13

1.4 REFERENCE STANDARDS ......................................................................................................... 14

1.5 REFERENCED PROFIBUS DOCUMENTS................................................................................... 14

1.6 EXPLANATION OF SYMBOLS ...................................................................................................... 16

2 SIMPLE PROFIBUS DIAGNOSTICS ........................................................................................... 18

2.1 INTRODUCTION ........................................................................................................................ 19

2.2 HANDHELD DEVICES ................................................................................................................ 20

2.3 OPTICAL FIBER MEASUREMENTS ............................................................................................... 21

2.3.1 Attenuation measurement for optical fibers .................................................................. 21

2.3.2 OTDR measurement ..................................................................................................... 23

2.3.3 Using optical fiber measurement processes ................................................................. 23

2.4 COMMUNICATION STATISTICS ................................................................................................... 24

3 ASSEMBLY ACCEPTANCE ........................................................................................................ 26

3.2 ACCEPTANCE MEASUREMENTS PROFIBUS RS-485 ................................................................ 31

3.3 ACCEPTANCE MEASUREMENTS - PROFIBUS MBP (PA) .......................................................... 36

3.4 ACCEPTANCE MEASUREMENTS OPTICAL FIBER .......................................................................... 37

3.4.1 General .......................................................................................................................... 37

3.4.2 Measurement Results Damping Measurement ............................................................. 38

4 COMMISSIONING / ACCEPTANCE ............................................................................................ 39

4.1 BUS TEST ................................................................................................................................ 40

4.2.1 System configuration (step 3) ....................................................................................... 41

4.2.2 Verifying PROFIBUS station addresses (step 4) .......................................................... 45

4.2.3 Commissioning PROFIBUS stations (step 5) ............................................................... 45

4.2.4 Testing the Signal Inputs (step 6) ................................................................................. 47

4.2.5 Testing the Signal Outputs (step 7)............................................................................... 48

4.2.6 Create acceptance checklist (step 8) ............................................................................ 49

5.1 INTRODUCTION TO TROUBLESHOOTING ..................................................................................... 51

5.2 CHECKING THE CABLING INFRASTRUCTURE .............................................................................. 52

5.3 MEASUREMENTS WITH A BUS MONITOR .................................................................................... 54

5.4 THE DIAGNOSTIC TELEGRAM..................................................................................................... 56

5.5 OSCILLOSCOPE MEASUREMENTS ............................................................................................. 58

5.5.1 Technical Prerequisites ................................................................................................. 58