Commissioning cabling
infrastructure for OT networks- including Single Pair Ethernet and Ethernet-APL™
March 9, 2022
Theo Brillhart
Technology Director
Fluke Electronics

Storyline
Outline•••••Standards for specification of OT
network wiring systems including
power delivery
Network topologies and wiring
practices
Specific commissioning tests for pointto-point links to identify non-compliant
cabling and bad connections, as wellas routine workmanship issues
Measurement properties andassociated industry standards forphysical infrastructure
Re-purposing legacy cabling forindustrial Ethernet

Technical Track© 2022 ODVA, Inc.

Storyline• With the widespread
implementation of Ethernet, it’s
now possible to apply routine
best-practices from IT
networking to save time andadd value in the industrial
space.
• One such practice, cable
testing, leads to more reliable
operations and less troubleshooting.

2022 Industry Conference & 21st Annual Meeting
All rights reserved.

www.odva.org

2

Industrial Protocol Market Shares - 2020
– Fieldbuses are in decline,
wireless is stable, Industrial
Ethernet share at 64%, up
from 59% in the previous
year– EtherNet/IP and Profinet
are the dominant Industrial
Ethernet variants with 17%
market share eachhttps://hms-networks.com/news-and-insights/news-from-hms/2020/05/29/industrial-network-market-shares-2020-according-to-hms-networks

Technical Track© 2022 ODVA, Inc.

2022 Industry Conference & 21st Annual Meeting
All rights reserved.

www.odva.org

3

Why worry about the Network Physical Layer?
•••

More than half of failures in the network are in thedata link and physical layer*
Switch hardware will turn over 4X or more over thelife of the plant’s cabling infrastructure
60% of plant floor nodes are on a variant of Ethernet

Today’s topic: Effective network planning and testing forfaster commissioning, increased uptime and improved OEE*source: ISA
Technical Track© 2022 ODVA, Inc.

2022 Industry Conference & 21st Annual Meeting
All rights reserved.

www.odva.org

4

50% of OT Network Problems
Common defects▪ Wrong cable for the application▪ Re-terminated on-site (too long)▪ Damaged during installation or operation▪ Wired incorrectly▪ Pair separation causing noise ingress▪ Poorly connected shields

Problems Reported
Connectors
20%

Length
10%

Cable
20%

Noise incables 20%

Other
10%

Configurations
and Devices
20%

Environment makes matters worse▪ Vibration, Flex, Moisture, Oxidation, Temperature, EMI

High number of intermittent problems (not repeatable)▪ A few lost or damaged frames can stop a machine▪ Time consuming to diagnoseTechnical Track© 2022 ODVA, Inc.

2022 Industry Conference & 21st Annual Meeting
All rights reserved.

www.odva.org

5

Standards applied to OT networks

Technical Track© 2022 ODVA, Inc.

2022 Industry Conference & 21st Annual Meeting
All rights reserved.

www.odva.org

Applicable Standards
•
•

•
•
•
•

Information and Communications Technology (ICT)TIA/EIA-568 Defines cabling types, distances,connectors, cable system architectures, cabletermination, installation requirements and methodsof testing installed cable
Defines the overall premises infrastructure forcopper and fiber cabling
Addresses components of the copper cabling
systemAddresses components of fiber optic cable systems
The ANSI/TIA-1005 industrial standard is explicitly
supported by the 568-cabling standard series

Common Standards

Premises Standards

ComponentStandards

ANSI/TIA-568.0-D(Generic)

ANSI/TIA-568.1-D(Commercial)

ANSI/TIA-568.2-D(Balanced
twisted-pair)

TIA-569-D-1(Pathways andspaces)ANSI/TIA-570-C(Residential)

ANSI/TIA-568.3-D(Optical fiber)

ANSI/TIA-606-C(Administrative)

ANSI/TIA-942-B(Data centers)

ANSI/TIA-568.4-D(Coaxial)

ANSI/TIA-607-C(Bonding andgrounding / earthing)

ANSI/TIA-1005-A(Industrial)

ANSI/TIA-758-B(Outside plant)

ANSI/TIA-1179(Healthcare)

ANSI/TIA-862-B(Intelligent Building
Systems)

The Telecommunications Industry
Association (TIA)
Technical Track© 2022 ODVA, Inc.

2022 Industry Conference & 21st Annual Meeting
All rights reserved.

ANSI/TIA-5017(Security)

www.odva.org

ANSI/TIA-4966(Education)
ANSI/TIA-5018(DAS)

ANSI/TIA-1152-A(Twisted pair fieldtesting)
ANSI/TIA-1183-A(Lab test equipment)

7

TIA-1005-A adds to the TIA-568 Series• M12 D-code connector type
• M12 X-code (published in TIA-1005-A-1
in 2015)• > 4 connector channel (6 connector)• Introduction of Coupler/Adaptor• M.I.C.E ratings
Office (Clean) to Industrial (Dirty)
Mechanical

M1

M2

M3

Ingress

I1

I2

I3

Climatic

C1

C2

C3

Electromagnetic

E1

E2

E3

Technical Track© 2022 ODVA, Inc.

2022 Industry Conference & 21st Annual Meeting
All rights reserved.

www.odva.org

8

TIA Developments for SPE• TIA-568.5 cabling and component standard– minimum requirements for balanced single twisted-pair cabling
channels and components (cable, connectors, connecting
hardware, and cords) used in commercial buildings– also specifies measurements for all transmission parameters.
• TIA-1005 rev.B premises standard for industrial environments– drafted this past year and deferred pending SPE additions– includes the new End-to-End link type

• TIA-568.7 new! Industrial Single-Pair Ethernet (SPE) project•– 1st Committee Ballot circulating soon
– Includes M.I.C.E. requirements for SPE

TIA-5071 new! Requirements for SPE Field Test Instruments

Technical Track© 2022 ODVA, Inc.

2022 Industry Conference & 21st Annual Meeting
All rights reserved.

www.odva.org

9

Applicable International Standards• Information and Communications Technology(ICT)• ISO/IEC 11081 governs all premises types• ISO/IEC 11081-3 covers the specifics ofIndustrial premises cabling• ISO/IEC TR11801-9902 specifies End-to-End
link configurations• ISO/IEC 14763-2 defines planning,
installation, and acceptance testing• ISO/IEC 14763-3 defines Testing of opticalfiber cabling• IEC 61918 Installation of communication
networks in industrial premises

Technical Track© 2022 ODVA, Inc.

2022 Industry Conference & 21st Annual Meeting
All rights reserved.

Premises Specific
Design Standards
ISO/IEC 11801 -1(Generic Cabling)

ISO/IEC 11801-2
ISO/IEC 11801-3
ISO/IEC 11801-4
Etc.

Cabling Design
Technical Reports

Installation
Operation &Administration
ISO/IEC 14763-2
ISO/IEC 18598
ISO/IEC 30129

IEC 61918

ISO/IEC 11801-9901
ISO/IEC 11801-9902
Etc.

www.odva.org

Testing
ISO/IEC 14763-3

10

Global Developments for SPE•

ISO/IEC• ISO/IEC 11081-3 Amd1:2021 Industrial premises cabling– Amended to include performance of single-pair Ethernet links•

IEC 61918/AMD1 Installation of communication networks in industrial
premises– amendment to support all current IEEE BASE-T1 (1000/100/10)– forecast publication next year•

IEEE P802.3de Time Synchronization for Point-to-Point Single Pair Ethernet
Task Force• Of particular interest is IEC/IEEE 60802 TSN Profiles for Industrial Automation– new project approved Nov-2020, targeting 2023 publication
Technical Track© 2022 ODVA, Inc.

2022 Industry Conference & 21st Annual Meeting
All rights reserved.

www.odva.org

11

Network Infrastructure & Topology

Technical Track© 2022 ODVA, Inc.

2022 Industry Conference & 21st Annual Meeting
All rights reserved.

www.odva.org

TIA-1005 Model
Structured cabling for industrial premise
Physical infrastructure model for cablingand connectivity design
Flexible and scalable
Defines interconnects (to switch) andtestable links/channels
D = Distributor (MDF, IDF, Access layer)
EO = Equipment Outlet

Technical Track© 2022 ODVA, Inc.

2022 Industry Conference & 21st Annual Meeting
All rights reserved.

www.odva.org

13

Industrial Networks and TIA-1005

Technical Track© 2022 ODVA, Inc.

2022 Industry Conference & 21st Annual Meeting
All rights reserved.

www.odva.org

14

Why Structured Cabling Is a Best Practice•Same cabling concept is used with I/O andterminal strips•

Manage the backbone separate
from the patch to the controller –through a terminal strip or IFM•

Predictable and eases MACs

Terminal Strips

1492-IFM
15

Structured and Point-to-Point Cabling
Point-to-Point Cabling• Stranded cable field-terminated with plugs• Infrequently tested• No standard exists to define the measurement
method• If the lights blink, it’s assumed it will work!
Structured Cabling•

Solid horizontal cable terminated with jacks•

Typically installed and left in place; measured andwarranted performance
Connection to equipment with flexible patch cords

•

16

16

End-to-End link configurations
Plug terminated channels
Plug

Jack

Plug

Plug

• Specific industrial use• 2 to 6 connections• Total cabling channel• Added with TIA 1005-B
and ISO/IEC 11081-3
Amd1; both in 2021ータル・システム（チャンネル全体）

Standardized point-to-point cabling channel for use where outlet jacks are impractical

Technical Track© 2022 ODVA, Inc.

2022 Industry Conference & 21st Annual Meeting
All rights reserved.

www.odva.org

17

Structured Cabling within Zone Enclosures
Test points(downlink)

Test points(uplink)18

Benefits of Choosing M.I.C.E Rated Components•

Certified to withstand the severity of theassociated M.I.C.E element•

When choosing network cabling systems
always consider components rated towithstand the worst-case environment for
exposure•

Commercial grade network components(M1I1C1E1) can also be considered inapplicable areas

TIA-1005-A
ISO/IEC 11801
IEC 60603-7
19

Shielded Cable for Industrial Environments•

The better the “electricalbalance” of a cable the more
protection from EMI•

Shielded cabling provides
added layer(s) of protection•

Managing interference isstrongly tied to proper design
and installation (especiallygrounding & bonding)Areas addressed in TIA-1005-A:• Equipotential/Mesh grounding system (conductor sizing)• Star Grounding System (with ground isolation)• RC Device Termination (resistor-capacitor)
20

Examples of Shielding Solutions for Ethernet Cabling
Shielded RJ-45 Field
Terminable Plug

Shielded RJ-45 Jack

Shielded Wiring Duct

M12 X-code Field
Terminable Plug

Shielded DIN Rail Copper Patching
Solution

Braided Screen & Foil Screen
Around Unshielded Twisted
Pairs
600 V rated patch
cords, rated forcontrol panel use

SF/UTP

600 V rated 2 pair and4 pair copper cable21Section Take-Aways• Review your internal standards for the
network physical layer– Specify the latest norms for Industrial Ethernet– Structure for flexibility, testability and longevity• Use the M.I.C.E. concept to improve designs
and mitigate environmental factors in advance• Learn and follow controls vendors Industrial
Ethernet physical recommendations

22

Acceptance Tests for Cabling Infrastructure

Technical Track© 2022 ODVA, Inc.

2022 Industry Conference & 21st Annual Meeting
All rights reserved.

www.odva.org

Why test cabling as part of commissioning?
•

To be sure that the installed cabling meets the performance you arepaying for. An untested cable is a source of uncertainty.
– Cat 6A Jack + Cat 6A Cable + Cat 6A Installer ≠ Cat 6A performance•

To run faster now and support future applications. Experience has shownthat tested networks:
–
–
–
–

•

Reduce CRC/FCS errors that lead to re-transmissions
Reduce New Machine Start-up Time
Reduce intermittent Production Down Time
Have a longer service life

To get paid for the job (if you are the installer or machine builder)
Beware of anyone offering to save $$ on installation by not testing24

Commissioning & Performance Validation
Channel Testing with the TIA model••••

Channel testing should be done ateach cabling subsystem level
This includes Subsystem 1, and fieldlevel 1-0 connections
Testing is typically be done just prior
to commissioning stage in a project
ANSI/TIA/EIA 568 & 1152-A define
testing & field test equipment

TIA 1005 Model shown with industrial enclosures25

Acceptance tests
Engineering Guideline Ethernet-APL™ v1.0•

During the acceptance test the integrity of the cabling should be measured anddocumented for later use and troubleshooting during the operation of the plant.

EtherNet/IP Network Infrastructure Guide – ODVA Pub 35••

Testing is easily done with commercially available hand-held network
testers. Special adapters may be necessary for sealed connectors. Testing
output includes conformance to all electrical requirements including, but
not limited to, attenuation, impedance, return loss, cross-talk, and cablesegment length measurements.
Each cabling segment (consisting of cable and connectors) must be tested
to confirm that, after installation, the segments all conform to The
EtherNet/IP™ Specification* for performance. (*The CIP Networks Library, Vol. 1 and 2)

Technical Track© 2022 ODVA, Inc.

2022 Industry Conference & 21st Annual Meeting
All rights reserved.

www.odva.org

26

Acceptance test results
•
•

•
•

Technical Track© 2022 ODVA, Inc.

Simple pass/failplus wire-map
Or complete
frequency sweep
and guaranteed
standards
complianceSimple operation
Wireless cloudstorage for resultsand .pdf reports

2022 Industry Conference & 21st Annual Meeting
All rights reserved.

www.odva.org

27

Measurement Properties

Technical Track© 2022 ODVA, Inc.

2022 Industry Conference & 21st Annual Meeting
All rights reserved.

www.odva.org

What parameters are measured?
•
•
•
•
•
•

The capacity of a cable to support high speed data is based on
measurements of signal and noiseContinuity testing, or Wire-Map, is not sufficient assurance for even theslowest Ethernet
Signal Strength, or loss, is measured as attenuation a.k.a. Insertion Loss
Noise is measured with two parameters, NEXT and Return Loss
Putting together these measurements we get a Signal to Noise Ratio
The greater the frequency where we can maintain a positive SNR, thefaster and farther we can communicate

29

Continuity - RJ45 or M12 D or X (or soon SPE)
SPE

RJ45

M12

SPE

30

Most Common Problem: Bad Wire Map

Open Pairs

Flipped Pair

Short

Crossed Pairs

Split Pair

Signal Strength – Insertion Loss
Insertion Loss:• In dB, the signal loss down the cable

Signal Loss increased with:• Length• Frequency• Temperature–

Cables in hot locations may not perform to 100 meters

32

Noise – Return Loss
Return Loss:• In dB, the reflected signal on the same pair

Return Loss increases with:• Defective / damaged cable• Pairs being separated• Water in the cable– Sometimes the cable isn’t bad, it’s just the wrong
cable for the application
33

Noise – NEXT (Near-end Crosstalk)NEXT:• In dB, the disturbed signal on an adjacent pairNEXT is increased by:• Connector geometries and pin configurations• Defective / damaged cable or connectors• Untwisting wire-pairs in the connector• Wrong category of cable or connectors
34

SNR = ACR (Attenuation Crosstalk Ratio)
Combining I/L and NEXT parameters– In dB, signal to noise ratio of a given pair

ACR is a derived parameter– NEXT minus Insertion Loss across frequency

Better ACR, faster communications– Category 5e to 100 MHz - Supports up to
5GBASE-T– Category 6 to 250 MHz - Can support
10GBASE-T to 55 meters– Category 6a to 500 MHz - Supports
10GBASE-T to 100 meters

35Reminder: ISO & TIA M.I.C.E. Classifications

These can be tested!

36

Electromagnetic interference:
Lost packets – CRC/FCS errors•••

May cause excess network latency
May cause retry/loss of connection
A few frame errors can cause
machines to stop

E2

E3

E2

E1

E3

37

Shield Integrity –•••Modern test tools can determine if
the shield continuously follows thepath of the cable
If the shield does not follow the pathof the cable an open shield will bereported (shown on the right)
Even when both ends are grounded(shown here)

38

Reject EMI with Well Balanced Links
Balanced Cable• Motor or VFD noise is equal across pairs• Noise is rejected, devices get proper
logic levels– Packets get through the 1st time

Unbalanced Cable• VFD noise NOT equal across pairs• Devices WILL NOT get proper logic
levels••

FCS and CRC errors. Re-tries and latency
Usually intermittent

39

TCL – Balance measurement for cabling•

Transverse Conversion Loss is the ratio (in dB) of a common-mode voltage
measured on a wire pair relative to a differential-mode voltage applied to thesame end of the pair. The TCL value shows you how well the impedances of thepair’s conductors are balanced.

40

Re-purposing legacy control cabling•

Technical Track© 2022 ODVA, Inc.

Extend the cabling assets you already have2022 Industry Conference & 21st Annual Meeting
All rights reserved.

www.odva.org

Cable Reuse?
• Potential for high quality, recent vintage,
control cabling to perform well for SPE
traffic• Quickest and most certain way to tell is
to test it• Certification tests – high accuracy, total
parametric coverage, highest level ofassurance• Verification tests – less parameters,slightly reduced accuracy, reasonableassurance• Doesn’t mean you have to test every link
• Statistical sampling is recommended forreuse of large populations* Given the supplier and age is fairly uniform
Technical Track

2022 Industry Conference & 21st Annual Meeting© 2022 ODVA, Inc.

All rights reserved.

www.odva.org

42

Statistical sampling methods•

ISO/IEC 14763-2 Cabling planningand installation standard•

Test to an equivalent acceptancequality level (AQL) of 0.4% as defined
for link populations up to 500,000, perISO 2859-1

43

Topology reuse•

SPE doesn’t change the way you install– Homerun wiring– Fieldbus wiring

•

•
•
•

SPE will improve on the fieldbus trend of
replacing control boxes with switches andaddressing the end-nodes (IP)
Small field switches can connect directly toedge devices (sensors, actuators, counters)
Design your wiring on CAD, not in the field
Faster and easier commissioning - therefore
faster project completion
44

Recap•Technical Track© 2022 ODVA, Inc.

Summary of key take-aways

2022 Industry Conference & 21st Annual Meeting
All rights reserved.

www.odva.org

Quick Recap
•
•
•
•
•

Fieldbuses are in decline; Industrial Ethernet is now
more than 60% and SPE/APL are here to wire theremainder
Review your internal standards for the network
physical layer and specify the latest norms for
Industrial Ethernet
Use the MICE concept to improve designs andmitigate environmental factors in advanceGreater than 50% of problems operating industrial
ethernet can be traced to cabling problems
Assessment tests are a recommended best-practicethat can catch most common defects and provide thegreatest assurance over the lifetime of the network
46

THANK YOU
It has been a great pleasure
theo.brillhart@flukenetworks.com

The presenter would like to recognize
and thank Mike Berg, Sr. Business
Development Manager, Panduit Corp.
and Jim Davis, Regional Marketing
Engineer, Fluke Networks for theircontributions to much of the source
material for this presentation.