I have been pondering a pressing issue lately and am seeking advice on best practices and insights. I am currently dealing with a plant that has a large DH+ network which is causing numerous problems. Initially designed for a small packaging line, the network has since expanded to encompass approximately 30 nodes. This extensive network layout seems inefficient to me, lacking smaller sub-networks for specific equipment communication needs. Covering 3 production lines and various support equipment, I have also observed circular connections such as both a & b channels connected on a DHRIO bridge. Before devising a plan for moving forward, I believe it is crucial to map the physical layout of the network to gain a comprehensive understanding. I intend to utilize a software called NetDecoder to identify machines communicating with each other and compile a list of message instructions in use. However, I am facing a challenge in tracing the actual cables. My current plan involves unplugging all connections when the system is down and using a cable tracer on each connection, but the thought of potentially missing a controller and damaging the communication port makes me apprehensive. Given the size of the facility, this method seems impractical and time-consuming. Has anyone encountered a similar situation or can offer any suggestions for tackling this issue effectively?
I once had a customer with around 20 nodes connected, which I initially thought was too many. The number of nodes depends on the amount of data being passed through. DH+ works by transmitting data in a single puck from node to node. To optimize performance, I recommend splitting the data into 3 pucks - one for each production line. If budget allows, consider adding a bridge to divert some traffic to Ethernet. DH+ is known for its industrial strength and reliability. If you encounter issues, ensure that terminal resistors are in place at the end nodes. If problems persist, it may be due to an excessive number of nodes or data overload. For additional information, refer to this document: [link to document]. My customer had a significant amount of data, with new recipes being loaded every few hours. These recipes included various temperature, pressure, and vacuum ramps, which could potentially cause performance issues.
In order to troubleshoot the connections at a large facility, one suggestion is to disconnect all cables while the systems are offline and use a cable tracer on each connection. However, this method can be daunting as there is a fear of missing a controller and damaging the communication port. It may seem like a time-consuming task, but it is important for ensuring proper functionality. To simplify the process, consider using RSLinx to access the network and identify all active nodes. From there, create a map of the network by determining which devices are communicating with each other. This task may prove to be challenging, but it is crucial for maintaining a smooth operation.
According to geniusintraining, DH+ served as a reliable industrial network that can withstand wiring mistakes to some extent. However, optimal performance is achieved with proper wiring. The network is designed to be a daisy chain without any tees or branches, and should have a terminating resistor at each end. While it may function in unconventional setups with branches and stars, this is not recommended. To troubleshoot network issues, it is advisable to follow geniusintraining's suggestion and use RSLinx to explore the network while it is operational. This will help identify connected devices and channels. However, assessing the cabling arrangement requires physically tracing the cables. Start visually and use a tracer if cables disappear into complex wiring setups or conduits. Note the position of each conductor when disconnecting cables to ensure correct reconnection, as inconsistent connections can lead to functionality issues and unnecessary troubleshooting.
Have you ever wondered if there is a large interconnected network designed for a centralized SCADA system or data collection?
I recently encountered a similar situation and ended up having to trace the wires to resolve it. While Net Decoders is highly regarded as top Industrial communication software, it lacks the capability to map network cabling. I'm curious if the DH+ network experienced deterioration after the addition of DHRIOs. In my experience, the PLC 5 / SLC built-in DH+ ports were more reliable and powerful compared to DHRIO. I recall reading a white paper recommending the use of only one channel for DH+ communications and keeping the other channel off, as well as limiting the attachment of devices to a single 1756-DHRIO card to 16. If I come across the paper, I'll make sure to provide the link here. Good luck with your situation.
Your approach of mapping out the physical network is a solid strategy. The use of NetDecoder should be extremely useful in identifying the machines in communication. For the cable tracing, your caution is well-founded. Unplugging all connections could indeed lead to problems. In my experience, I found that using a proper cable management system incredibly helpful. Labelling and color-coding the cables could assist in easy identification of each connection later. Depending on the network complexity, sophisticated cable management software can also be considered. These software solutions often come with graphical interfaces that can help you manage even fairly complex networks without needing to physically trace every cable. Finally, I suggest considering a network upgrade or segmentation into several smaller, efficient sub-networks for specific equipment zones to minimize future issues. This diverts the traffic to respective segments and could lead to less communication overhead.
From my experience, your approach to use NetDecoder is definitely on track for identifying machines communicating with each other. Tracing cables, on the other hand, can indeed be a daunting task considering the scale of your plant. Instead of unplugging everything during a system downtime, I would suggest trying wireless cable tracers which can accurately trace the cables without unplugging them. This will not only save downtime but also eliminate the risk of missing a controller and damaging a communication port. Another approach you might consider is segmenting your network further to manage subsections independently, which can simplify maintenance and troubleshooting in the future.
Your prevailing concerns are very valid. Mapping the network is indeed a smart first step. Your choice of using NetDecoder is commendable as it is an excellent tool for mapping out the network with in-use instructions. In regards to your apprehensions about cable tracing, perhaps consider using an Inline Network Tester (INT). It allows for in-situ cable tracing without disconnecting anything, minimizing the risk of missing a controller or damaging a communication port. It could save you loads of time and essentially eliminate the potential for mishaps. Changing from a flat network to a hierarchical model could improve your overall system efficiency, too. You might consider utilizing a switch with IGMP snooping enabled if multicast is causing an issue.
It sounds like you're facing quite a daunting challenge with that extensive network! I've been in a similar situation, and I found that creating a detailed network map using a combination of digital tools and manual tracing was incredibly beneficial. If you're worried about unplugging connections, consider using an Ethernet switch with a port mirroring feature to capture data without interrupting the network. Additionally, if possible, involve your IT department for support, as they may have insights or tools for network analysis that can save you some headaches. Taking your time to properly map the network will definitely pay off in the long run, leading to more efficient configurations and fewer headaches down the line. Good luck!
It sounds like you’re tackling a complex situation! One strategy that might help before diving into unplugging connections is to create a preliminary network diagram based on existing documentation or device labels, if available. This could give you a clearer picture of how things are currently set up without having to physically disconnect everything. Additionally, you might consider using network monitoring tools that can give you visibility into active connections without the need for extensive physical tracing—some tools can even help you identify where traffic is flowing within the network. Lastly, it might be worth consulting with the equipment manufacturers or a network specialist who could provide insights tailored to your specific DH+ setup. Good luck with your mapping!
It sounds like you're dealing with a complex network, and mapping it out is definitely a smart first step. Instead of unplugging everything, which can be risky, consider using a combination of network monitoring tools alongside your NetDecoder software to monitor the traffic. This way, you can identify active nodes without the need to physically disconnect them. Additionally, if you have access to network diagrams or prior documentation, it might be helpful to cross-reference those with your findings. Lastly, involving someone with experience in network troubleshooting could provide some valuable insights and help streamline the process. Good luck!
✅ Work Order Management
✅ Asset Tracking
✅ Preventive Maintenance
✅ Inspection Report
We have received your information. We will share Schedule Demo details on your Mail Id.
Answer: Answer: The discussion thread is focusing on the challenges faced with mapping and optimizing a large DH+ network with an extensive layout.
Answer: Answer: The DH+ network currently encompasses approximately 30 nodes, covering 3 production lines and various support equipment.
Answer: Answer: The software being considered for mapping the network layout is NetDecoder to identify machines communicating with each other and compile a list of message instructions in use.
Answer: Answer: The individual is facing a challenge in tracing the actual cables of the network, considering the size of the facility, and is concerned about potentially missing a controller and damaging the communication port.
Answer: Answer: The current plan involves unplugging all connections when the system is down and using a cable tracer on each connection. The individual is apprehensive about potentially missing a controller and damaging the communication port, as this method seems impractical and time-consuming given the size of the facility.
Join hundreds of satisfied customers who have transformed their maintenance processes.
Sign up today and start optimizing your workflow.