Preventing Network Problems on the Plant Floor with VLANs WP-29-REV0-4008-1/7

© 2008 by B&B Electronics.

Preventing Network Problems on the Plant

Floor with VLANs

The success of Ethernet technology came about because of its

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cost, effectiveness and simplicity compared with other network

schemes. The lure of linking large numbers of systems was
powerful.
 
All this connectivity came at a price. As networks grew, data
collisions and delays increased. These delays slowed Ethernet’s
progress with industrial control networks, where guaranteed
response times are so important.

Then switch technology entered the scene. With unique

pathways to each port, switches reduce collisions. Switch costs
Reliability, speed and came down and they became widespread in non-industrial
security are just a few of
Ethernet networks. Then the development of industrial-
the benefits of industrial
VLANs.
hardened switches allowed these to be used more widely in
industry.

Switches by themselves don’t limit traffic, but facilitate it. This

traffic, if left uncontrolled, could lead to congested bandwidth
and “clogged arteries.”  

Virtual Local Area Networks or VLANs use managed

switches to balance this expanded connectivity with useful
boundaries on data traffic. VLANs make networks more reliable,
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and this reliability is what makes VLANs so useful in industrial

settings.

Industrial VLANs

A VLAN is a single broadcast domain, not limited by physical

location. VLANs create logical separation of control networks
within a physical network, dividing physical interfaces into useful
groups.
 
VLANs are created using parts of a switch, full switches or
multiple switches linked together. An administrator assigns ports
to each VLAN. Each VLAN then functions as an independent
switch, broadcast domain and network. Each device on a VLAN
has its own Media Access Control (MAC) address. MAC

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addresses are assigned by the manufacturer, and the VLAN

uses these to tell where data goes.

Each VLAN is in effect a separate network. The only way to get

data to a device on another VLAN is to send it outside the VLAN
through a router – even if the receiving device is on a port on
the same switch but on another VLAN.
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“Tag VLAN” is the

technology that makes
even the largest VLANs
secure, flexible and
powerful.
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Figure 1. Examples, Industrial VLAN Components

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Benefits of industrial VLANs

Isolation – VLANs isolate network traffic to accommodate

differences in operational needs.

Simplicity – As networks grow, they can turn into difficult to

manage monsters. By segmenting networks, VLANs make them
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easy to understand, change, and troubleshoot.

Speed and Performance – VLANs reduce delays, also called

latency, by reducing the size of the collision domain. Broadcast
traffic is reduced, since it doesn’t go past its own VLAN.

Scalability – A VLAN may be as small as a single port on one

switch, or span any size organization.

Flexibility – Additions and changes are simple. Moving a user

to a different VLAN is just a matter of reconfiguring the port. And
different operating systems can coexist on a single network, as
long as each is on its own VLAN.

Cost – Subdividing networks using VLANs saves money over

buying separate physical networks.

Security – Securing data is a great reason for using VLANs.

Also, as priorities change, they can be adapted to the situation.
For example, an IT department’s security protocols may differ
from the manufacturing department, where reliability is often
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more important than security. While they don’t guarantee

security, data from one VLAN can’t accidentally leak to another,
regardless of shared cables, networks, routers or switches.

Special Applications – VLANs may be required wherever

bandwidth or operational concerns create conflicts with other
areas.

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Port Or Tag VLAN?

Port based VLANs are suitable for smaller settings. As the

name implies, ports are assigned to VLANs, and all users on a
single port are members of the same VLAN. This allows the
separation of office computers from industrial electronic devices.

IEEE 802.1Q Tag VLANs are so called because a “tag” or

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header is added to data packets to identify which VLAN they

belong to. The 802.1Q standard specifies how VLANs manage
data flow across multiple switches.
WAN technology, when
used as part of an
industrial VLAN, makes is
possible for an individual
VLAN to be built on a
scale that covers the entire
planet.

Figure 2. IEEE 802.1Q Tag VLAN Header

 
VLAN Trunking – When more than one switch is involved, one
port on each switch (a trunk port) communicates VLAN
information to the other switches involved. The links between
switches (trunk links) not only communicate where each link of a
VLAN is located, they also transmit the actual data between
switches, which is then delivered to the appropriate port and
device.
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Trunking, when used regarding VLANs, refers to the combined

connections and software that make switches and VLANs
interconnect smoothly. GARP VLAN Registration Protocol
(GVRP) is the standards based system used by many
manufacturers. VLAN Trunking Protocol (VTP) is a proprietary
system used when only Cisco switches are involved. Both
accomplish the same thing.

Applications

User types, departments or operations may all be reasons to

segment the network into VLANs. For example, a factory
automation network has greatly differing needs from the building
automation, office, IT or human resource network. Even within
the industrial side of things, there may be no need for the

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operator interface, vision, motion or other systems to be on the

same VLAN.

Here are some other advantages of segregation:

• A VLAN can isolate office and other network traffic from

the factory automation network, eliminating the chance
that outside traffic can flood and interfere with time critical
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control communications.
• Inventory control with Radio Frequency Identification
(RFI) creates huge data streams. A VLAN limits this data
to where it is needed. Video surveillance and other
systems may also use lots of bandwidth and require a
Industrial VLANs need separate VLAN.
more reliable designs, • Security is often the top priority for the IT department,
equipment and software while reliability is for manufacturing. Since these
than is typical of concerns may conflict, it just makes sense to be on
commercial settings. separate VLANs.
• Functional differences may warrant separate VLANs,
such as network management and monitoring.
• Groups of users in three separate buildings can all be
part of the same VLAN, and at the same time, be
completely isolated from all unnecessary traffic. Taken
further, VLANs can be securely scaled beyond a single
location, over a Wide Area Network (WAN) link if
necessary.
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Figure 3. Extended VLAN, Connected Over WAN

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Network Topology, Configuration and Hardware: Industrial

VLAN Best Practices

Industrial VLANs use a wide variety of configurations and

equipment. Part of the attraction of Ethernet VLANs is that
legacy devices, wiring and topology can be used as part of a
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full system of VLANs.

Managed switches make it possible to create and manage

VLANs, and the right industrial switch can save a lot of trouble.
An industrial managed switch should have the right number and
kind of ports, strength, dependability and ultra fast recovery for
the real needs of the industrial settings*. The need for reliable
ruggedness typically exceeds that of commercial installations.
Data flow rates can be controlled to avoid problems. The fastest
ports available on each switch should be used for network trunk
links, as these carry the most traffic.

Switch and router placement makes a difference.

Inefficiencies may arise if they aren’t located the shortest
physical distance to the maximum number of nodes on the
VLAN. Longer paths increase the likelihood of failures and
complicate problem diagnosis.

Unshielded twisted pair (UTP) cable is the most commonly

used wiring. At many plants is this is already in place, often
making a VLAN possible without running new cable. Fiber optic
cable carries more data over greater distances, and is useful for
network trunk links.
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Management Software for industrial VLANs should be graphic

oriented. In non-industrial settings it’s presumed that everyone
dealing with the network went to IT school. But industrial
automation is very visual, and plant personnel are often the first
responders to VLAN issues. They’re much more used to dealing
with colors and check boxes than a command line interface.

Packet Filtering – Tag VLAN headers may cause trouble on

industrial networks. It’s OK to leave the tag data on packets
going to tag-aware devices. But if all devices aren’t tag-aware,
the switch must strip tags from packets before they go out to the
VLAN. This is very important in dealing with the legacy
equipment found in many industrial settings.

International Headquarters: Ottawa, IL USA 815-433-5100 www.bb-elec.com

European Headquarters: Oranmore Co. Galway Ireland, +353 91 792444 www.bb-europe.com
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Redundancy is a key to reliable operation. Though industrial

equipment typically withstands far more abuse than commercial,
the nature of many industrial networks makes back-up systems
necessary. A degree of redundancy is often the best way to 
ensure network stability. And in some situations full 
redundancy is both needed and available.  

*Equipment capability - The best equipment is “tuned” to the

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The best industrial needs of the specific industrial situation. An outstanding

networking equipment is example of how to do this is B&B Electronics’ robust line of Elinx
“tuned” to the 500/600 Managed Industrial Switches.
requirements of the
specific VLAN.

Finding and configuring

the right switches used to
be hard.

Figure 4. Elinx Industrial Fully Managed Switches, with alarm outputs, dual
power inputs, IP30 cases, DIN or panel mounts and gigabit options.

These switches are industrial hardened and have a graphic

interface. Often it takes two switches to get the right
combination of copper and fiber. This doesn’t need to happen.
B&B Electronics’ Vlinx 500/600 switches feature virtually every
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fiber optic combination available. Additionally, Vlinx 600 series

switches are equipped with Gigabit ports.
 
B&B Electronics offers a comprehensive line of industrial
network, data communications and automation equipment. See
our full offering today at www.bb-elec.com.

B&B Electronics started in 1981 manufacturing a single product, an RS-232

tester. Since then B&B Electronics has had continuous growth in industrial
communications and automation. For a library of technical information and
one of industry’s most popular industrial electronics and communications
catalogs, find us at www.bb-elec.com

International Headquarters: Ottawa, IL USA 815-433-5100 www.bb-elec.com

European Headquarters: Oranmore Co. Galway Ireland, +353 91 792444 www.bb-europe.com