How to Commission Industrial Ethernet Installations: A Step-by-Step Guide

Industrial Ethernet is the use of Ethernet in an industrial environment with protocols that provide determinism and real-time control1 It is used to connect devices such as PLCs, local and distributed I/O, servo controllers and drives on the plant floor and in industrial facilities12 Industrial Ethernet can also refer to the use of standard Ethernet protocols with rugged connectors and extended temperature switches in an industrial environment, for automation or process control1

Commissioning industrial Ethernet installations is a process of ensuring that the network is properly designed, installed, configured, tested and documented. Commissioning is essential for achieving optimal performance, reliability and security of the industrial Ethernet network. In this guide, we will cover the following steps for commissioning industrial Ethernet installations:

Step 1: Design the network topology and select the components

The first step is to design the network topology and select the components that meet the requirements of the application. The network topology defines how the devices are connected and how the data flows between them. The components include the cables, connectors, switches, routers, firewalls and other devices that make up the network.

There are different types of network topologies, such as star, ring, bus, tree and mesh. Each topology has its own advantages and disadvantages in terms of performance, scalability, redundancy and cost. For most industrial Ethernet installations, star topology is preferred, as it connects devices to a central access point, such as a switch, and provides high bandwidth and easy troubleshooting2 However, some applications may require ring topology, which reduces cable run distances and provides fault tolerance2

The components should be selected based on the network speed, distance, environment, protocol and other factors. For example, the cables should be rated for the expected data rate, such as Cat5e or Cat6, and should be shielded to reduce electrical noise and interference2 The connectors should be rugged and watertight, such as M12 or M8, to withstand harsh industrial conditions1 The switches should be managed or unmanaged, depending on the level of control and configuration needed. Managed switches can offer features such as VLANs, QoS, IGMP snooping and redundancy, which can improve the performance and reliability of the network2

Step 2: Install the cables and components

The second step is to install the cables and components according to the network design and the manufacturer’s instructions. The installation should follow the best practices for industrial Ethernet cabling, such as:

• Avoiding sharp bends, kinks, twists and knots in the cables3
• Using cable ties, clips, trays and conduits to secure and protect the cables3
• Maintaining a minimum distance of 6 inches (15 cm) between the Ethernet cables and the power cables or other sources of electromagnetic interference3
• Using patch cables for connecting end devices to switches, and crossover cables for connecting end devices directly without a switch2
• Terminating the cables with the correct connectors and pins, and verifying the polarity and continuity3
• Grounding the shielded cables and the components properly to avoid potential differences and ground loops2

Step 3: Configure the network settings and parameters

The third step is to configure the network settings and parameters for the devices and the switches. The configuration should be based on the communication protocol and the application requirements. The configuration may include:

• Assigning IP addresses, subnet masks, gateways and DNS servers for the devices2
• Setting up VLANs, QoS, IGMP snooping and other features on the switches to segment the network, prioritize the traffic and optimize the multicast performance2
• Enabling security features, such as encryption, authentication and firewall, to protect the network from unauthorized access and attacks4
• Configuring the industrial Ethernet protocol, such as EtherCAT, EtherNet/IP, PROFINET, POWERLINK, SERCOS III, CC-Link IE or Modbus TCP, to establish the communication between the devices and the controllers12
• Adjusting the network parameters, such as cycle time, jitter, latency and bandwidth, to achieve the desired determinism and real-time control1

Step 4: Test the network performance and functionality

The fourth step is to test the network performance and functionality to ensure that the network meets the specifications and expectations. The testing should include:

• Measuring the network parameters, such as data rate, throughput, latency, jitter, packet loss and error rate, using network analyzers, testers and software tools2
• Checking the network functionality, such as data transmission, device discovery, protocol communication and control logic, using simulation, emulation and debugging tools2
• Performing stress tests, such as increasing the network load, disconnecting and reconnecting devices, and inducing faults and errors, to evaluate the network robustness and resilience2
• Comparing the test results with the design criteria and the application requirements, and identifying and resolving any issues or discrepancies2

Step 5: Document the network configuration and results

The fifth and final step is to document the network configuration and results to provide a reference for future maintenance, troubleshooting and expansion. The documentation should include:

• A network diagram, showing the network topology, the devices, the connections and the IP addresses2
• A network inventory, listing the network components, their models, serial numbers, firmware versions and locations2
• A network configuration, detailing the network settings and parameters, such as IP addresses, VLANs, QoS, IGMP snooping, security and protocol2
• A network performance report, summarizing the network parameters, such as data rate, throughput, latency, jitter, packet loss and error rate, and the network functionality, such as data transmission, device discovery, protocol communication and control logic2
• A network test report, describing the test methods, procedures, scenarios, results and conclusions2

By following these steps, you can commission industrial Ethernet installations in a systematic and effective way, and achieve optimal network performance, reliability and security for your industrial applications.