The International Standards Organization (ISO) has determined a general architecture of

network specifications in their DIS 7498 model (applicable to most any digital network). These
network specifications were developed as part of the Open Systems Interconnection (OSI) initiative
to define the layering of communications in network protocol design. The OSI protocol stack is split
into seven layers for modularity. All of the software layers work together, building and distributing
the communications. Not all network protocols use every layer.

Digital fieldbus systems (FOUNDATION fieldbus and PROFIBUS PA) use three of the seven
layers: 1, 2, and 7. This is because physical and logical layers are the same and there is no direct
communication from one node to another across different segments.

The Layers in Detail

■ Level 1 – Physical Layer: Defines the electrical and physical specifications for devices. In
particular, the physical layer defines the relationship between a device and a physical medium. This
relationship includes the layout of pins, voltages, and cable specifications.

■ Level 2 – Data Link Layer: Is the protocol layer that transfers data between adjacent network
nodes in a wide area network or between nodes on the same segment. The Data Link Layer provides
the functional and procedural means to transfer data between network entities and provides the
means for error detection and correcting events that occur in the physical layer.

■ Level 3 – Network Layer: Establishes procedures for the encapsulation of data into packets for
transmission and reception.

■ Level 4 – Transport Layer: Defines how complete data files are handled over a network.
■ Level 5 – Session Layer: Organizes data transfer in terms of the start and end of a specific
transmission.

■ Level 6 – Presentation Layer: Defines the character sets, terminal control, and graphics commands
so that abstract data can be readily encoded and decoded between communicating devices.

■ Level 7 – Application Layer: Refers to

standards for generating and/or interpreting
c ommunicated data in its final form. In other
words, the actual software programs used to
communicate data.
Scenario: You work as an automation engineer in a manufacturing facility that utilizes Programmable
Logic Controllers (PLCs) for process control. Your task is to implement a new system that involves PLC
networking and communication protocols to improve production efficiency.

Experience:

1. Project Planning: You begin by defining the project's objectives and requirements. You need
to connect multiple PLCs across different production lines to a central control system to
monitor and control various processes. You choose Ethernet/IP as the communication protocol
due to its widespread use in the industry and compatibility with the PLCs in use.
2. PLC Selection: You select PLC models that support Ethernet/IP communication. These PLCs are
capable of sharing data in real-time, allowing you to gather information from various sensors,
motors, and control devices on the factory floor.
3. Network Design: You design the network layout, including switches, routers, and cabling
infrastructure. To ensure reliability and minimal downtime, you create a redundant network
structure and establish clear communication pathways between PLCs and the central control
system.
4. Protocol Configuration: You configure the Ethernet/IP protocol on each PLC, specifying
communication parameters, IP addresses, and data exchange rates. This involves setting up
Input and Output assemblies, which define the data that can be transmitted between devices.
5. Testing and Troubleshooting: Before implementing the system on the production floor, you
conduct rigorous testing. You use network analyzers and monitoring tools to check for any
communication issues, latency, or packet loss. If any problems arise, you troubleshoot and fine-
tune the configurations.
6. Data Exchange: Once the system is operational, PLCs exchange real-time data with the central
control system. This data includes information on machine status, production counts, sensor
readings, and more. With this information, you can monitor and control processes more
efficiently and respond quickly to any anomalies.
7. Security Measures: You implement security measures, such as firewalls and access control, to
safeguard the PLC network against unauthorized access or cyber threats. You also keep the
firmware and software of the PLCs up to date to address potential vulnerabilities.
8. Documentation: You maintain comprehensive documentation, including network diagrams,
configuration settings, and troubleshooting procedures, to ensure that the system can be easily
maintained and scaled in the future.
 9. Continuous Monitoring: After the system is in place, you continuously monitor the PLC
network to ensure its stability and performance. Regular maintenance and periodic updates to
the communication protocol or hardware may be necessary to keep the system up to date and
secure.

This experience demonstrates the complex and critical role that PLC networking and communication
protocols play in industrial automation, contributing to improved production efficiency and control in
manufacturing environments.