UNIT- 01

ANALOG AND DIGITAL COMMUNICATION AND INTERFACING

ANALOG AND DIGITAL COMMUNICATIONS ON PLANT FLOORS

1. Analog Communication: 
In analog communication the data is transferred with the help of analog signal in
between transmitter and receiver. Any type of data is transferred in analog signal.
Any data is converted into electric form first and after that it is passed through
communication channel. Analog communication uses a continuous signal which
varies in amplitude, phase, or some other property with time in proportion to that of
a variable. 
The below figure illustrates the Analog Communication System: 

2. Digital Communication: 
In digital communication digital signal is used rather than analog signal for
communication in between the source and destination. The digital signal consists of
discrete values rather than continuous values. In digital communication physical
transfer of data occurs in the form of digital bit stream i.e 0 or 1 over a point-to-
point or point-to-multipoint transmission medium. In digital communication the
digital transmission data can be broken into packets as discrete messages which is
not allowed in analog communication. 

Difference between Analog Communication and Digital Communication: 

          ANALOG
S .No.                         COMMUNICATION
In analog communication
01. analog signal is used for
information transmission.
Analog communication uses
analog signal whose
02.
amplitude varies continuously
with time from 0 to 100.
It gets affected by noise
highly during transmission
03.
through communication
channel.
In analog communication
only limited number of
04.
channels can be broadcasted
simultaneously.
In analog communication
05.
error Probability is high.
In analog communication
06.
noise immunity is poor.
In analog communication
07.
coding is not possible.
Analog communication
09. system is having complex
hardware and less flexible.
            DIGITAL
COMMUNICATION
In digital communication
digital signal is used for
information transmission.
Digital communication uses
digital signal whose amplitude
is of two levels either Low
i.e., 0 or either High i.e., 1.
It gets affected by noise less
during transmission through
communication channel.
It can broadcast large number
of channels simultaneously.
In digital communication error
Probability is low.
In digital communication
noise immunity is good.
In digital communication
coding is possible. Different
coding techniques can be used
to detect and correct errors.
Digital communication system
is having less complex
hardware and more flexible.
INTRODUCTION TO INDUSTRIAL NETWORKING
An industrial communication network is a backbone for any automation system
architecture as it has been providing a powerful means of data exchange, data
controllability, and flexibility to connect various devices. With the use of proprietary
digital communication networks in industries over the past decade led to improve end-
to-end digital signal accuracy and integrity.
Industrial communication network is a special type of network made to handle real-
time control and data integrity in harsh environments over large installations.
These networks, which can be either LAN (Local Area Network, which is used in a
limited area) or WAN (Wide Area Network which is used as global system) enabled to
communicate vast amounts of data using a limited number of channels. Industrial
networking also led to the implementation of various communication protocols
between digital controllers, field devices, various automation related software tools
and also to external systems.

The three significant control mechanisms used in industrial automation field

include Programmable Logic Controllers (PLCs), Supervisory Control and Data
Acquisition (SCADA) and Distributed Control System (DCS). All these elements
deals with field instruments, smart field devices, supervisory control PCs, distributed
I/O controllers and HMI suits.

In order to provide an interconnection between these devices and also to enable

communication in between them, a powerful and more effective communication
network or scheme is needed. They differ quite significantly from traditional
enterprise networks. These industrial networks form a communication path among
field devices, controllers and PCs.
Hierarchical Levels in Industrial Communication Networks
 Hence different levels may use different network based on the requirements such as
data volume, data transmission, data security, etc. Based on the functionality,
industrial communication networks are classified into three general levels which are
discussed below.

Device Level:
This lowest level consists of field devices such as sensors and actuators of processes
and machines. The task of this level is to transfer the information between these
devices and technical process elements such as PLCs. The information transfer can be
digital, analog or hybrid. The measured values may stay for longer periods or over a
short period.

Control Level:
This level consists of industrial controllers such as PLCs, distributed control units, and
computer systems. The tasks of this level include configuring automation devices,
loading of program data and process variables data, adjusting set variables,
supervising control, displaying variables data on HMIs, historical archiving, etc. So
this level requires characteristics like short response time, high speed transmission,
short data lengths, machine synchronization, constant use of critical data, etc.

Information Level:
This is the top level of the industrial automation system which gathers the information
from its lower level i.e., control level. It deals with large volumes of data that are
neither in constant use or time critical. Large scale networks are exists in this level. So
Ethernet WANs are commonly used as information level networks for factory
planning and management information exchange.  Sometimes these networks may
connect to other industrial networks via gateways.
RS 232-422-485 STANDARDS FOR DATA COMMUNICATION

RS in 232, 422, and 485 denotes Recommended Standard used for serial data
communication (data transfer) developed by Electronic Industry Association (EIA).

1. RS 232
 The RS-232 standard supports serial, asynchronous, and duplex communication
between two devices. RS232 is a byte-based communication rather than a bit-based
one.

 The RS232 serial port is present on most Windows PCs. RS232 allows only one
master and one slave to communicate on each line.

 RS232 operates in a full duplex mode, and its communication speed reaches up to
115Kbilts/s.

 In RS-232, the distance between the two devices does not generally exceed 15 meters
(50 ft). That means RS232 is limited to shorter run lengths. 

2. RS-422 Cabling

 The RS-422 standard is an evolution of the RS-232. RS422 is specified as a simplex

multidrop standard, which means that in addition to communicating between two
devices, the RS-422 allows a device to send messages to up to 10 receivers.

 The physical medium defined for RS-422 consists of two twisted pairs, one of which
is used for transmitter communication (usually the master) to the receivers (generally
the slaves), the other being used for the communication of the slaves with the master.

 RS-422 standard can handle data rates up to 100 kbps and distances up to 4000 ft.
3. RS-485
 RS-485 became the standard physical layer for automation protocols such
as Modbus RTU and PROFIBUS. This is because it supports longer runs, higher
speeds, and multiple devices.
 The standard RS-485 specifies only the transmitter’s and receiver’s electrical
characteristics. It does not recommend or specify any communication protocol. It
derives from RS-422 the maximum number of receivers is increased to 32.
 The RS-232 and RS-422 are called “Full-Duplex”, i.e. the system allows
communication in both directions simultaneously.

comparison between RS232, RS422, and RS485

S.
No Characteristics RS-232 RS-422 RS-485

1 Differential No Yes Yes

Max number of
2 transmitters 1 1 32

Maximum number of
3 receivers 1 10 32

Full-duplex, Full-duplex, Half- Full-duplex (4 wires), Half-duplex

4 Operating modes single-ended duplex Differential (2 wires), Differential

5 Network topology Point-to-point Multi-drop Multi-drop

Max distance (low capacitance cable is used 50 ft (The widely used

6 for long distances) thumb rule)  4000 ft  4000 ft

INDUSTRIAL ETHERNET
 Industrial Ethernet refers to the use of Ethernet-based communication
protocols and technologies in industrial applications and environments.
Ethernet, which is a widely adopted standard for local area networks
(LANs) in office and home settings, has also gained significant
popularity in industrial automation and control systems.

The key characteristics of Industrial Ethernet include:

1. Speed and Bandwidth: Industrial Ethernet networks provide high data

transfer rates, typically ranging from 10 Mbps to 10 Gbps, allowing for
fast and efficient communication between devices and systems.

2. Robustness and Reliability: Industrial Ethernet systems are designed to

withstand harsh industrial conditions, including extreme temperatures,
electrical noise, vibrations, and electromagnetic interference (EMI). The
use of industrial-grade components, ruggedized cabling, and redundant
network topologies ensures high reliability and availability.

3. Scalability and Flexibility: Industrial Ethernet allows for easy network

expansion and integration of new devices and systems. It supports a wide
range of network topologies, including star, ring, line, and tree structures,
providing flexibility in configuring the network layout.

4. Integration with IT Infrastructure: With the convergence of operational

technology (OT) and information technology (IT), Industrial Ethernet
facilitates seamless integration between the factory floor and enterprise
networks. It enables data exchange between industrial devices and
enterprise systems, supporting applications such as remote monitoring,
diagnostics, and data analytics.
CONCEPT OF FIELDBUS

Fieldbus is a fully digital communication protocol that transmits data

digitally using a multidrop network, where multiple devices are
connected to the same communication line.

Fieldbus supports a wider range of devices, including both simple and

complex devices, such as sensors, actuators, controllers, and more. It
enables seamless integration and communication between various
devices in a control system.

Fieldbus uses a peer-to-peer communication model, allowing devices to

communicate with each other on the network. It supports multicast and
broadcast messaging, enabling efficient data exchange between
multiple devices.

 Fieldbus reduces the amount of wiring required by allowing multiple

devices to share a common communication line, leading to cost savings
and easier installation and maintenance.

 Fieldbus systems provide deterministic and real-time communication,

enabling precise control and coordination of devices and processes.

 Fieldbus provides built-in diagnostics and monitoring features, enabling

proactive maintenance, troubleshooting, and fault detection.
MODBUS PROTOCOL

MODBUS is a communication protocol commonly used in industrial

automation systems to establish communication between devices such as
programmable logic controllers (PLCs), supervisory control and data
acquisition (SCADA) systems, and other industrial equipment. It was
developed in 1979 by Modicon, now a part of Schneider Electric.

The term “Modbus” typically refers to one of three related

protocols: Modbus ASCII, Modbus RTU, or Modbus TCP/IP:-

 Modbus ASCII was the first Modbus and is a serial

protocol, typically running on either the RS-232 or RS-
485 physical layer. All slaves are polled on demand by
the master, and there is only one master.

 Modbus RTU is really just a small variation on the

Modbus ASCII protocol. The only difference is in the
encoding of the data. ASCII encodes the message in
ASCII characters, while RTU uses bytes.

 Modbus TCP/IP is to picture it as simply encapsulating a

Modbus RTU packet within a TCP/IP packet.  Modbus
TCP/IP is also very simple to implement, because it uses
TCP/IP protocol for all messages, it is slow compared to
other Ethernet industrial protocols – but still fast enough
for monitoring applications.
How Modbus works

 Modbus is a simple master-slave protocol. The master has full

control of communication on the bus, whereas a slave will only
respond when spoken to. The master will record outputs and
read in inputs from each of its slaves, during every cycle, as
shown in Figure 2.
The slave devices do not “join” the network. They simply respond
whenever a master talks to them. If the master never talks to them,
then they are idle.  There is also no requirement for diagnostics
related to the slave’s health. If the master requests data that does
not make sense to the slave, then the slave can send an exception
response.

However, if the process variable is bad or if the device has problems

functioning, there is nothing in the protocol that requires the slave
to report this.
INTERFACING PLC WITH OTHER HARDWARE –

Programmable Logic Controllers (PLCs) are commonly used in industrial

automation systems to control and monitor various processes. To
interface a PLC with other hardware, you typically need to consider the
communication protocols and interfaces supported by both the PLC and
the hardware device you want to connect to. Here are some common
methods of interfacing a PLC with other hardware:

1. Digital I/O Modules: PLCs often come with built-in digital

input/output (I/O) modules. These modules allow you to connect the PLC
directly to devices such as sensors, switches, and actuators. You can wire
these devices to the PLC's I/O points, and the PLC can read the inputs
and control the outputs accordingly.

2. Analog I/O Modules: Similar to digital I/O, some PLCs also support
analog I/O modules. These modules enable you to interface with analog
devices such as temperature sensors, pressure transducers, and variable
frequency drives. Analog I/O modules convert the analog signals into
digital values that the PLC can process.

3. Serial Communication: Many PLCs support serial communication

protocols such as RS-232, RS-485, and Modbus. These protocols allow
you to connect the PLC to other devices like computers, HMI (Human-
Machine Interface) panels, and other PLCs. Serial communication can be
used for data exchange, programming, and monitoring purposes.

4. Ethernet Communication: PLCs increasingly support Ethernet-based

communication protocols such as Ethernet/IP, Modbus TCP/IP, and
Profinet. Ethernet communication provides a faster and more flexible
means of connecting the PLC to various devices, including other PLCs,
HMIs, supervisory control and data acquisition (SCADA) systems, and
enterprise networks.
5. Fieldbus Protocols: Fieldbus protocols like Profibus, DeviceNet, and
CANopen are widely used for industrial automation applications. These
protocols allow for the integration of PLCs with other devices in the field,
such as motor drives, remote I/O modules, and distributed control
systems (DCS). Fieldbus networks provide real-time control and
communication capabilities.

6. Wireless Communication: Some modern PLCs offer wireless

communication options, such as Wi-Fi and Bluetooth. These wireless
technologies can be used to connect the PLC with remote devices, mobile
devices, or access points, providing flexibility in system design and
monitoring.

When interfacing a PLC with other hardware, it's essential to ensure

compatibility between the communication protocols and interfaces
supported by both the PLC and the hardware device. Additionally, you
may need to configure the communication settings, such as baud rates, IP
addresses, and protocol-specific parameters, to establish a successful
connection and exchange data effectively.