16

INTERBUS Means
Speed, Connectivity,
Safety

16.1 Introduction to Field Communication ...........................16-1

Jürgen Jasperneite
Phoenix Contact GmbH & Co. KG
16.2 INTERBUS Overview........................................................16-2
16.3 INTERBUS Protocol .........................................................16-4
16.4 Diagnostics.........................................................................16-7
16.5 Functional Safety...............................................................16-8
16.6 Interoperability, Certification ...........................................16-9
16.7 Connectivity ....................................................................16-10
16.8 IP over INTERBUS .........................................................16-12
16.9 Performance Evaluation..................................................16-13
16.10 Conclusions .....................................................................16-14
References ...................................................................................16-14

16.1 Introduction to Field Communication

The growing degree of automation in machines and systems increases the amount of cabling required
for parallel wiring due to the large number of input/output (I/O) points. This brings with it increased
configuration, installation, start-up, and maintenance effort. The cable requirements are often high
because, for example, special cables are required for the transmission of analog values. Parallel field wiring
thus entails serious cost and time factors. In comparison, the serial networking of components in the
field using fieldbus systems is much more cost-effective. The fieldbus replaces the bundle of parallel cables
with a single bus cable and connects all levels, from the field to the control level. Regardless of the type
of automation device used, e.g., programmable logic controllers (PLCs) from various manufacturers or
PC-based control systems, the fieldbus transmission medium networks all components. They can be
distributed anywhere in the field and are all connected locally. This provides a powerful communication
network for today’s rationalization concepts. There are numerous advantages to a fieldbus system in
comparison with parallel wiring: The reduced amount of cabling saves time during planning and instal-
lation, while the cabling, terminal blocks, and control cabinet dimensions are also reduced (Figure 16.1).
Self-diagnostics minimize downtimes and maintenance times. Open fieldbus systems standardize data
transmission and device connection regardless of the manufacturer. The user is therefore independent
of any manufacturer-specific standards. The system can be easily extended or modified, offering flexibility
as well as investment protection.
Fieldbus systems, which are suitable for networking sensors and actuators with control systems, have
represented state-of-the-art technology for some time. The main fieldbus systems are combined under

16-1

© 2005 by CRC Press

16-2 The Industrial Communication Technology Handbook

FIGURE 16.1 Serial instead of parallel wiring.

TABLE 16.1 The Four Basic Types of Arithmetic Operations for Field Communication
Signal acquisition Quick and easy acquisition of signals from I/O devices
Functional safety Transmission of safety-related information (e.g., emergency stop)
Drive synchronization Quick and precise synchronization of drive functions for
distributed closed-loop controllers
Connectivity Creation of seamless communication between business processes
and production

the umbrella of IEC 61158 [1]. This also includes INTERBUS as type 8 of IEC 61158 with an installed
basis of 6.7 million nodes and more than 1000 device manufacturers.
The requirements of these systems can be grouped according to the four basic types of arithmetic
operations for field communication shown in Table 16.1.

16.2 INTERBUS Overview

INTERBUS has been designed as a fast sensor–actuator bus for transmitting process data in industrial
environments. Due to its transmission procedure and ring topology, INTERBUS offers features such as
fast, cyclic, and time-equidistant process data transmission, diagnostics to minimize downtime, and easy
operation and installation, as well as meets the optimum requirements for fiber-optic technology.
In terms of topology, INTERBUS is a ring system; i.e., all devices are actively integrated in a closed
transmission path (Figure 16.2). Each device amplifies the incoming signal and forwards it, enabling
higher transmission speeds over longer distances.
Unlike other ring systems, the data forward and return lines in the INTERBUS system are led to all
devices via a single cable. This means that the general physical appearance of the system is an open tree
structure. A main line exits the bus master and can be used to form seamless subnetworks up to 16 levels
deep. This means that the bus system can be quickly adapted to changing applications.
The INTERBUS master–slave system enables the connection of up to 512 devices, across 16 network
levels. The ring is automatically closed by the last device. The point-to-point connection eliminates the
need for termination resistors. The system can be adapted flexibly to meet the user’s requirements by
adding or removing devices. Countless topologies can be created. Branch terminals create branches,

© 2005 by CRC Press

INTERBUS Means Speed, Connectivity, Safety 16-3

FIGURE 16.2 Topology flexibility.

which enable the connection and disconnection of devices. The coupling elements between the bus
segments enable the connection and disconnection of a subsystem and thus make it possible to work on
the subsystem without problems, e.g., in the event of an error or when extending the system.
Unlike in other systems where data are assigned by entering a bus address using dual in-line package
(DIP) or rotary switches on each individual device, in the INTERBUS system data are automatically
assigned to devices using their physical location in the system. This plug-and-play function is a great
advantage with regard to the installation effort and service friendliness of the system. The problems and
errors, which may occur when manually setting device addresses during installation and servicing, are
often underestimated. The ability to assign easy-to-understand software names to the physical addresses
enables devices to be added or removed without readdressing.
In order to meet the individual requirements of a system, various basic elements must be used
(Figure 16.2):
1. Controller board: The controller board is the master that controls bus operation. It transfers output
data to the corresponding modules, receives input data, and monitors data transfer. In addition,
diagnostic messages are displayed and error messages are transmitted to the host system.
2. Remote bus: The controller board is connected to the remote bus devices via the remote bus. A
branch from this connection is referred to as a remote bus branch. Data can be physically transmitted
via copper cables (RS-485 standard), fiber optics, optical data links, slip rings, or other media (e.g.,
wireless). Special bus terminal modules and certain I/O modules or devices such as robots, drives,
or operating devices can be used as remote bus devices. Each has a local voltage supply and an
electrically isolated outgoing segment. In addition to the data transmission lines, the installation
remote bus can also carry the voltage supply for the connected I/O modules and sensors.
3. Bus terminal module: The bus terminal modules, or devices with embedded bus terminal module
functions, are connected to the remote bus. The distributed local buses branch out of the bus
terminal module with I/O modules, which establish the connection between INTERBUS and the
sensors and actuators. The bus terminal module divides the system into individual segments, thus
enabling one to switch individual branches on/off during operation. The bus terminal module
amplifies the data signal (repeater function) and electrically isolates the bus segments.
4. Local bus: The local bus branches from the remote bus via a bus coupler and connects the local
bus devices. Branches are not allowed at this level. The communications power is supplied by the
bus terminal module, while the switching voltage for the outputs is applied separately at the output
modules. Local bus devices are typically I/O modules.

© 2005 by CRC Press

16-4 The Industrial Communication Technology Handbook

FIGURE 16.3 The layer 2 summation frame structure of INTERBUS.

16.3 INTERBUS Protocol

INTERBUS recognizes two cycle types: the identification cycle for system configuration and error man-
agement, and a data transfer cycle for the transmission of user data. Both cycle types are based on a
summation frame structure (Figure 16.3).
The layer 2 summation frame consists of a special 16-bit loopback word (preamble), the user data of
all devices, and a terminating 32-bit frame check sequence (FCS). As data can be simultaneously sent
and received by the ring structure of the INTERBUS system (full-duplex mode), this results in very high
protocol efficiency.
The logical method of operation of an INTERBUS slave can be configured between its incoming and
outgoing interfaces by the register set shown in Figure 16.4. Each INTERBUS slave is part of a large,
distributed shift register ring, whose start and end point is the INTERBUS master.
In the input data register, input data, i.e., data that is to be transmitted to the master, is loaded during
data transfer. The output data registers and the cyclic redundancy check (CRC) register are switched to
the input data register in parallel [8]. The polynomial g(x) = x16 + x12 + x5 + 1 is used for the CRC. After
finishing a valid data transfer cycle, output data from the output data register are written to a memory
and then accepted by the local application. The CRC registers are used during the frame check sequence
to check whether the data have been transmitted correctly. The length of the I/O data registers depends
on the number of I/Os of the individual node.
The master needs to know which devices are connected to the bus so that it can assign the right I/O
data to the right device.

FIGURE 16.4 Basic model of an INTERBUS slave node.

© 2005 by CRC Press

INTERBUS Means Speed, Connectivity, Safety 16-5

Once the bus system has been switched on, the master starts a series of identification cycles, which
enable it to detect how many and which devices are connected. Each slave has an identification data
register, which has a 16-bit ID code. The master can use this ID code to assign a slave node to a defined
device class (e.g., digital I/O node, analog I/O node) and detect the length of the I/O data registers in a
data cycle. The control data registers are switched in parallel to the identification data registers, whereby
the individual devices can be managed by the master. Commands are transmitted, e.g., for local resets
or outgoing interface shutdown. The identification cycle is also used to find the cause of a transmission
error and to check the integrity of the shift register ring.
The individual registers are switched in the different phases of the INTERBUS protocol via the selector
in the ring.
On layer 1, INTERBUS uses two telegram formats with start and stop bits similar to those of Universal
Asynchronous Receiver/Transmitter (UART):
• The 5-bit status telegram
• The 13-bit data telegram
The status telegram is used to generate defined activity on the medium during pauses in data trans-
mission. The slave nodes use the status telegram to reset their internal watchdogs, which are used to
control a fail-safe state. The data telegram is used to transmit a byte of the layer 2 payload. The remaining
bits of both telegrams are used to distinguish between data and ID cycles, as well as the phase data transfer
and FCS within a cycle. This information is used by the selector shown in Figure 16.4 to switch the
relevant register in the ring. INTERBUS uses a physical transmission speed of 500 kbps or 2 Mbps.
The cycle time, i.e., the time required for I/O data to be exchanged once with all the connected modules,
depends on the amount of user data in an INTERBUS system. Depending on the configuration, INTER-
BUS can achieve cycle times of just a few milliseconds. The cycle time increases linearly with the number
of I/O points, as it depends on the amount of information to be transmitted. For more detailed infor-
mation, refer to the performance evaluation.
The architecture of the INTERBUS protocol is based on the OSI reference model according to ISO
7498. The protocol architecture of INTERBUS provides the cyclic process data and an acyclic parameter
data channel, using the services of the peripheral message specification (PMS) as well as a peripheral
network management (PNM) channel (see Figure 16.5). As is typical for fieldbus systems, for reasons of
efficiency, ISO layers 3 to 6 are not explicitly used, but are combined in the lower-layer interface (LLI)
in layer 7. The process data channel enables direct access to the cyclically transmitted process data. It is
characterized by its ability to transmit process-relevant data quickly and efficiently. From the application
point of view, it acts as a memory interface. The parameter channel enables data to be accessed via a
service interface. The data transmitted in the parameter channel have a low dynamic response and occur
relatively infrequently (e.g., updating text in a display).
Network management is used for manufacturer-independent configuration, maintenance, and start-
up of the INTERBUS system. Network management is used, for example, to start or stop INTERBUS
cycles, to execute a system reset, and for fault management. Furthermore, logical connections between
devices can be established and aborted via the parameter channel in the form of context management.
To transmit parameter data and time-critical process data simultaneously, the data format of the
summation frame must be extended by a specific time slot. In several consecutive bus cycles, a different
part of the data is inserted in the time slot provided for the addressed devices. The Peripherals Commu-
nication Protocol (PCP) performs this task [5]. It inserts a part of the telegram in each summation frame
and recombines it at its destination (see Figure 16.6). The parameter channels are activated, if necessary,
and do not affect the transfer of I/O data. The longer transmission time for parameter data that are
segmented into several bus cycles is sufficient for the low time requirements that are placed on the
transmission of parameter information.
INTERBUS uses a master–slave procedure for data transmission. The parameter channel follows the
client–server paradigm. It is possible to transmit parameter data between two slaves (peer-to-peer com-
munication). This means that both slaves can adopt both the client and server functions. With this

© 2005 by CRC Press

16-6 The Industrial Communication Technology Handbook

FIGURE 16.5 Protocol architecture of an INTERBUS node.

FIGURE 16.6 Transmission of parameter data with a segmentation and recombination mechanism.

function, layer 2 data are not exchanged directly between the two slaves, but are implemented by the
physical master–slave structure; i.e., the data are first transmitted from the client to the master and then
forwarded to the server from the master. The server response data are also transmitted via the master.
However, this diversion is invisible for slave applications.
The task of a server is described using the model of a virtual field device (VFD).
The virtual field device model unambiguously represents that part of a real application process that
is visible and accessible through the communication. A real device contains process objects. Process
objects include the entire data of an application process (e.g., measured values, programs, or events).
The process objects are entered in the object dictionary (OD) as communication objects. The object
dictionary is a standardized public list in which communication objects are entered with their properties.
To ensure that data are exchanged smoothly in the network, additional items must be standardized, in
addition to the OD, which can be accessed by each device. This includes device features such as the
manufacturer name or defined device functions that are manufacturer independent. These settings are

© 2005 by CRC Press

INTERBUS Means Speed, Connectivity, Safety 16-7

used to achieve a closed and manufacturer-independent representation of a real device from the point
of view of the communication system. This kind of modeling is known as a virtual field device.

16.4 Diagnostics
The system diagnostics play an important role in practical applications. In increasingly complex systems,
errors must be located quickly using system diagnostics and clearly indicated to the user. In addition to
detecting errors, good error diagnostics include reliable error localization. For message-oriented fieldbus
systems with a bus structure, only one telegram is ever transmitted to a device at any one time. An error,
which affects the system via a specific device or a device nearby, can even destroy telegrams, which are
not themselves directed at the faulty device, but may be directed at remote devices. It is therefore virtually
impossible to determine the exact error location.
INTERBUS uses the CRC procedure in each device to monitor the transmission paths between two
devices and, in the event of CRC errors, can therefore determine in which segment the error occurred.
An important criterion for maintaining data communication is the response of the master in the event
of the following errors:
• Cable break
• Failure of a device
• Short circuit on the line
• Diagnostics of temporary electromagnetic interference (EMI)
In all fieldbus systems, in the event of a line interrupt, the devices after the interrupt are no longer
reached. The error localization capability depends on the transmission system used. In linear systems,
telegrams are still sent to all devices. However, these telegrams are lost because the devices are no longer
able to respond. After a certain period, the master detects the data loss. However, it cannot precisely
determine the error location because the physical position of the devices is not known. The system
diagrams must be consulted so that the service or maintenance personnel can determine the probable
error location (Figure 16.7).
Unlike linear systems, the individual devices in the INTERBUS system are networked so that each one
behaves as a separate bus segment. Following a fatal error, the outgoing interfaces of all devices are fed

FIGURE 16.7 The behavior of bus systems and ring systems in the event of a cable break.

© 2005 by CRC Press

16-8 The Industrial Communication Technology Handbook

back internally via a bypass switch. In the event of a line interrupt between the devices, the master
activates each separate device in turn. To do this, the master opens the outgoing interface, starting from
the first device up until the error location, thus clearly identifying the inaccessible device. The controller
board can then clearly assign the error location as well as the station or station name and display it in
plain text. This is a huge advantage, particularly in large bus structures with numerous devices, where
bus systems are typically used.
If a device fails, the fieldbus behaves in the same way as for a line interrupt. However, the functional
capability of the remaining stations differs in linear and ring systems. In a linear system, bus operation
cannot be maintained because the condition of physical bus termination using a termination resistor is
no longer met. This can lead to reflections within the bus configuration. The resulting interference level
means that correct operation is not possible. In an INTERBUS ring system, the termination resistor is
opened and closed together with a bypass switch, which ensures that the condition of the closed ring is
always met. In the event of a line interrupt or device failure, the master can either place the devices in a
safe state or start up the remaining bus configuration autonomously.
Short circuits on the line are a major challenge in a bus system. In the event of a direct or indirect
(e.g., via ground) short circuit on the line, the transmission path is blocked for the entire section. In
linear systems, the transmission line is used equally for all devices, which means that the master cannot
reach segment parts either. This considerably reduces further error localization. In the INTERBUS system,
the user is aided by the physical separation of the system into different bus segments. As described for
the line interrupt, the devices are activated by the master in turn and the ring is closed prior to the short
circuit, which means that subsystems can be started up again. The error location is reported in clear text
on the controller board. Linear systems also support a division into different segments. Repeaters, which
are placed at specific points, can then perform diagnostic functions. However, a repeater cannot monitor
the entire system; it can only cover a defined number of devices per segment. Furthermore, the use of
repeaters incurs additional costs, which should not be underestimated, and increased configuration effort.
In summary, the INTERBUS diagnostic features are essentially based on the physical segmentation of
the network into numerous point-to-point connections. This feature makes INTERBUS particularly
suitable for use with fiber optics, which are used increasingly for data transmission in applications with
large drives, welding robots, etc. In linear systems, the use of fiber optics — like bus segmentation —
requires expensive repeaters, which simulate a ring structure. Fiber-optic path check in the INTERBUS
system is another feature, which is not offered by other buses. In this system, a test pattern for the fiber-
optic cable is transmitted between the interfaces to determine the quality of the connection. If the cable
deteriorates due to dirt, loose connections, bending, etc., the transmission power is increased automat-
ically. If a critical value is reached, the system generates a warning message so that the service personnel
can intervene before the deterioration leads to expensive downtimes.
Studies by the German Association of Electrical and Electronic Manufacturers (ZVEI) and the German
Engineering Federation (VDMA) indicate that many bus errors are caused by direct or hidden installation
faults. For this reason alone, bus diagnostics simplify start-up and ensure the smooth operation of the
system, even in the event of extensions, servicing, and maintenance work. Every bus system should
automatically carry out comprehensive diagnostics of all connected bus devices without the need to install
and configure additional tools. Additional software tools for system diagnostics often cost several thou-
sand Euro.
In the INTERBUS system, all diagnosed states can be displayed directly on the controller board. If the
master has a diagnostic display, various display colors can be used so that serious errors are clearly visible
even from a distance. In addition, each master has a diagnostic interface, which can be used to transfer
all functions to visualization systems or other software tools.

16.5 Functional Safety

In recent years, safety technology has become increasingly important in machine and system production.
This is because complex automation solutions require flexible and cost-effective safety concepts, which

© 2005 by CRC Press

INTERBUS Means Speed, Connectivity, Safety 16-9

FIGURE 16.8 The safety extension of INTERBUS.

offer the same advantages that users have come to appreciate in nonsafe areas. This means that consid-
erable savings can be made, e.g., in terms of both cost and time, by changing from parallel to serial wiring.
From the user’s point of view, however, various requirements must be taken into consideration. First,
safe and nonsafe signals must be separated in order to simplify the programming, operation, and
acceptance of safety applications. Second, all components used should be operated on a fieldbus, because
a standardized installation concept and standard operation make planning operation, start-up, and
maintenance easier. These requirements have led to the safety extension of INTERBUS.
As the INTERBUS master, the controller board uses an integrated safe control system. The INTERBUS
controller board with integrated safe controller is the basic unit in the system (Figure 16.8). It processes
all safety-related inputs and confirms them to the standard control system by setting an output or resetting
the output. This method of operation is similar to existing contact-based safety technology. The enabling
of output data is programmed with preapproved blocks such as emergency stop, two-hand control, or
electrosensitive protective equipment in SafetyProg Windows software, which is compatible with IEC
61131. The amount of programming required is reduced considerably through the use of blocks and the
enable principle.
The safe input and output components form the interface to the connected I/Os. They control, for
example, contactors or valves and read the input status of the connected safety sensors, including
intelligent sensors. The user uses the parameterization function of INTERBUS to select the settings for
the I/O components, such as clock selection, sensor type, and signal type. The INTERBUS Safety system
meets safety functions up to category 4 according to EN 954 [6] and safety integrity level 3 (SIL 3)
according to IEC 61508 [7]. Depending on the application, the user can choose to use either a one-cable
solution with integrated safety technology or a two-cable solution, where one bus cable is used for
standard signals and the other for safety signals.
A safety protocol is used between the safe controller and the connected I/O safety devices. This protocol
provides the desired security of data transmission and can only be interpreted by the connected safety
devices. The safety data are integrated transparently into the INTERBUS summation frame (Figure 16.9).
This feature ensures the simultaneous operation of standard and safety devices in the bus system.

16.6 Interoperability, Certification

The basic aim of open systems is to enable the exchange of information between application functions
implemented on devices made by different manufacturers. This includes fixed application functions, a
uniform user interface for communication, and a uniform transmission medium. For the user, this profile
definition is a useful supplement to standardized communication and provides a generally valid model
for data content and device behavior. These function definitions standardize some essential device

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FIGURE 16.9 Safety protocol on top of the INTERBUS summation frame.

parameters. As a result, devices from different manufacturers exhibit the same behavior on the commu-
nication medium and can be exchanged without altering the application software when these standard
parameters are used.
INTERBUS takes a rigorous approach to the area of interoperability using the Extensible Markup
Language (XML)-based device description FDCML (Fieldbus Description Configuration Markup Lan-
guage) [9]. FDCML enables the different views of a field device to be described due to the generic device
model used. Some examples include identification, connectivity, device functions, diagnostic informa-
tion, and mechanical description of a device. This electronic device description is used in the configu-
ration software for configuration, start-up, and other engineering aspects. Different applications can use
FDCML to evaluate various aspects of a component. For example, Figure 16.9 shows the use of the
FDCML file as an electronic data sheet in a Web browser.
To simplify interoperability and interchangeability, the members of the INTERBUS Club compile a set
of standard device profiles in several user groups for common devices such as drives (DRIVECOM Profile
22), human machine interfaces (MMI-COM D1), welding controllers (WELD-COM C0), and I/O devices
(Sensor/Actuator Profile 12). These profiles can also be described neutrally with regard to the manufac-
turer and bus system in FDCML.
The INTERBUS Club and various partner institutes have offered certification for several years to ensure
maximum safety when selecting components. Independent test laboratories carry out comprehensive
tests on devices as part of this process. The device only receives the “INTERBUS Certified” quality mark,
which is increasingly important among users, if the test object passes all the INTERBUS conformance
tests. The conformance test is composed of examinations that are carried out by test laboratories using
various tools.
The conformance test is divided into the following sections:
• Basic function test (mandatory)
• General section (valid for all interface types)
• Fiber optics (for devices with fiber-optic interfaces)
• Burst noise immunity test (mandatory)
• PCP software conformance test (for devices with PCP communication) (dependent)

16.7 Connectivity
As shown in Table 16.1, connectivity is one of the four basic arithmetic operations of field communication.
Connectivity is the integration of fieldbus technology in company networks.

© 2005 by CRC Press

INTERBUS Means Speed, Connectivity, Safety 16-11

FIGURE 16.10 Example of an FDCML device description visualized in a Web browser.

However, there are still no standard concepts for connectivity solutions. This makes it more difficult
to integrate the field level in the company-wide distributed information system and is only possible
through increased programming and parameterization.
The Internet Protocol (IP) can be used here as an integration tool [2, 3]. IP is increasingly used in
automation technology in conjunction with Ethernet and is then frequently referred to as Industrial
Ethernet, for example, [4]. In many cases, IP is already well suited to the field.
This section deals with transparent IP communication at the field level, taking into consideration
the real-time requirements. This means that the advantages of fieldbus technology are maintained, and
at the same time, the user is provided with a new quality of connectivity. For example, well-known
office applications such as browsers can be used to load device descriptions, e-mails can be used to
send maintenance messages, or File Transfer Protocol (FTP) can be used to upload and download files
(Figure 16.10).
Ethernet’s role in the future of automation is an important current issue. On the one hand, its
specification suggests it could solve all of the communication problems in automation applications and
supersede fieldbuses. On the other hand, fieldbuses, with their special characteristics, have arisen because
the real world does not consist simply of bits and bytes. However, Ethernet and INTERBUS can only be
fully integrated if transparent communication beyond the boundaries of the system is possible without
complex conventional gateway processes. This is achieved by using Transmission Control Protocol
(TCP)/IP as the standard communication protocol on both systems. While TCP/IP is now standard on
Ethernet, this is by no means the case in the factory environment. Virtually all fieldbus organizations
and promoters map their fieldbus protocol to Ethernet TCP/IP in order to protect their existing invest-
ments. INTERBUS took a different direction early on and integrated TCP/IP into the hybrid INTERBUS

© 2005 by CRC Press

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protocol. TCP/IP standard tools and Internet technologies based on TCP/IP can therefore be readily
transferred to the factory environment without additional expense.
For example, on INTERBUS, the FTP service can be used to download control programs and other
data to a process controller. The use of FTP to upload and download files such as robot programs is just
one advantage, since TCP/IP opens up automation to the world of the Internet. Internet browsers will
also be the standard user interface of the factory of the future, when all devices have their own integrated
Web page. Special configuration tools, now supplied for devices by virtually every manufacturer, will no
longer be needed, as in the future these devices will be configured through ActiveX controls or Java
applets that are loaded through the network, and therefore do not have to be present on the control
computer beforehand.

16.8 IP over INTERBUS

Figure 16.11 shows the system architecture for IP tunneling. The known Ethernet TCP/IP structure can
be seen on the left, and the extended protocol structure of an INTERBUS device can be seen on the right.
An IP router, with the same mechanisms as in the office environment, is used for coupling. This function
is best performed in the PLC. IP tunneling is performed by introducing a new data-send-acknowledged
(DAS) service in the INTERBUS parameter channel (Figure 16.12 and Figure 16.13).

FIGURE 16.11 Connectivity creates new options such as Web-based management.

Server
H H S
Client T P T
N
T PD M T MIB
M
P S P
P
TCP/ TCP/
IP IP- Forw . IP
ETH ETH IB IB
Internet/
Intranet

IP PD/PMS/Safety
Ethernet INTERBUS

FIGURE 16.12 Basic architecture for IP tunneling.

© 2005 by CRC Press

INTERBUS Means Speed, Connectivity, Safety 16-13

…..
Real-Time
LLI-User services Internet Protocol
Application
• Data-Transfer- (IP)
Confirmed (DTC)
API (z.B.C, DDI)
• Data-Transfer-
Acknowledged (DTA) PMS
• Data-Send- DAS-Service
Acknowledge (DSA) Layer 7
• Associate (ASS)
Lower Layer Interface (LLI)
• Abort (ABT)

Peripherals Data Link (PDL)

Layer 2
…

FIGURE 16.13 Protocol architecture of an IP-enabled INTERBUS node.

This DAS service enables LLI user protocol data units (PDUs) to be transmitted for unconfirmed,
connectionless LLI user services and is used for transparent IP data transmission. These data are trans-
mitted in the same way as the parameter channel (PMS) at the same time as the time-critical process
data (PD) exchange.

16.9 Performance Evaluation

This section considers the performance of the concept in relation to the relevant fieldbus parameters,
such as the number of I/O modules and the amount of cyclic I/O data. The achievable data throughput
for IP tunneling is a key performance indicator. Due to the determinism of the INTERBUS system, the
throughput can be easily calculated.
The following applies to the INTERBUS medium access control (MAC) cycle time TIB (ms):

1
TIB = 13 ◊(6 + N ) ◊ ◊1000 + TSW
Baud rate

where

i =k

N= Â PL
i =1
i

The IP throughput (IP_Th) of a device is calculated as follows:

M -1
IP _ Th = ◊8
TIB

where:

N = total payload size: sum of all user data (bytes) of all devices k where
N £ 512 bytes and k £ 512
Baud rate = physical transmission speed of INTERBUS Mbps (0.5, 2) Mbps
TSW = software runtime (ms) of the master (0.7 ms, typical, depending on implementation)
PLi = Layer 2 payload of the ith device (bytes) where 1 £ i £ k, where k £ 512
M = reserved MAC payload (bytes) for the IP channel of a device (M = 8, typical)
IP_Th = throughput (kbps) for IP data telegrams

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16-14 The Industrial Communication Technology Handbook

14 80
12 70
IP throughput
10 60

IP_Th (kbps)
50

TIB (ms)
8
TIB@2 Mbps 40
6
30
4 20
2 10
0 0
0 100 200 300 400 500
typical N (bytes)

FIGURE 16.14 Performance data.

In Figure 16.14, the curve for the INTERBUS cycle time at the MAC level and the IP throughput for
a baud rate of 2 Mbps is illustrated as the function of payload size N.
For a medium-size configuration of N = 125 bytes, an IP throughput of 36 kbps at an INTERBUS
cycle time of approximately 1.6 ms is achieved. This roughly corresponds to the quality of an analog
modem for Internet access. For smaller configurations, even Integrated Services Digital Network (ISDN)
quality can be achieved. The calculated values could be confirmed in a practical application. In this
configuration it should be noted that, in addition to the dedicated process data devices, several IP-
compatible devices can be operated at the same time with this throughput.

16.10 Conclusions
The open INTERBUS fieldbus system for modern automation seamlessly connects all the I/O and field
devices commonly used in control systems. The serial bus cable can be used to network sensors and
actuators, to control machine and system parts, to network production cells, and to connect higher-level
systems such as control rooms.
After a comprehensive introduction to INTERBUS, IP tunneling for fieldbuses was described for
improved connectivity at the field level. An essential requirement is that time-critical process data
transport is not affected.
The integration of the Internet Protocol in INTERBUS creates a seamless communication platform to
enable the use of new IP-based applications, which can make it considerably easier to engineer distributed
automation solutions. Analysis has shown that the IP throughput can be as high as ISDN quality.

References
[1] IEC 61158: Digital Data Communication for Measurement and Control: Fieldbus for Use in
Industrial Control Systems, IEC 2001.
[2] Postel, J., RFC-793: Transmission Control Protocol (TCP), USC/Information Science Institute, CA,
1981.
[3] Postel, J., RFC-791: Internet Protocol (IP), USC/Information Science Institute, CA, 1981.
[4] Feld, J., Realtime communication in PROFINET V2 and V3 designed for industrial purposes, in
5th IFAC International Conference on Fieldbus Systems and Their Applications (FeT 2003), Aveiro,
Portugal, July 2003.
[5] Phoenix Contact INTERBUS Slave Implementation Guide: Communication Software PCP, 1997,
www.interbusclub.com/itc/sc_down/5193a.pdf.
[6] DIN EN 954-1: Safety of Machinery: Safety-Related Parts of Control Systems: Part 1: General
Principles for Design, 1997; German version, 1996.

© 2005 by CRC Press

INTERBUS Means Speed, Connectivity, Safety 16-15

[7] IEC 61508, Functional safety of electrical/electronic/programmable electronic safety-related sys-

tems - General requirements, 1999.
[8] INTERBUS Protocol Chip SUPI 3, http://www.interbusclub.com/itc/sc_down/supi3_op_e.pdf,
2004.
[9] Field Device Configuration Markup Language (FDCML), www.fdcml.org, 2004.

© 2005 by CRC Press