Comprehensive Insights: Exploring Modbus

Protocols, with Emphasis on Modbus TCP-IP,

In-Depth Modbus RTU Understanding, and
Comprehensive Comparison of Industrial
Protocols Modbus RTU vs TCP

Fahmi FERJANI
R&D Mechatronics Engineer
I- Modbus protocol overview :
The Modbus protocol serves as a communication protocol facilitating interaction among
devices through various media like serial lines and Ethernet. Originally developed in 1979 by
Modicon, a company specializing in Programmable Logic Controllers (PLCs), the protocol
was created to enable communication between these devices. Modbus establishes a messaging
structure to facilitate master-slave communication between intelligent devices. When Device
A (master) sends a Modbus message, it prompts a response from Device B (slave). The
protocol's role encompasses defining communication content, packaging information, and
managing the order of message transmission. Known for its simplicity and robustness, the
Modbus protocol is widely adopted in industrial control systems. As an open standard, it is
freely available for use and modification, contributing to its widespread acceptance across the
industry.

History and Origin of Modbus Protocol:

Developed in 1979 by Modicon, now under Schneider Electric ownership, the Modbus
protocol was designed for use with PLCs in the manufacturing industry. The Modbus
Organization, formed in 2002, advocates for the protocol's use, providing public access to its
specifications and related information, ensuring its availability, enhancement, and application
in industrial automation markets.

Components of Modbus Protocol:

-Modbus Devices/Machines:
These are physical devices communicating via the Modbus protocol, ranging from
temperature sensors to motor controllers, located anywhere from factory floors to remote oil
fields.
-Modbus Master:
Initiating Modbus transactions, the master sends requests to slave devices and awaits
responses. It can communicate with multiple slaves, requesting various data types from each.
-Modbus Slave:
A slave device waits for requests from the master, processing and responding accordingly.
Slaves do not initiate communication but respond to master requests.

Data Model and Registers:

The Modbus data model relies on registers, representing memory locations that store data in
devices. Two register types exist:
1. Holding registers: Read and written to by a Modbus master.

2. Input registers: Can only be read by a master.

Types of Inputs:
Two main types of inputs in a Modbus system are:
1. Coils: Represent binary states (e.g., ON/OFF) and are readable and writable by a Modbus
master.
2. Discrete inputs: Similar to coils but only readable, not writable.

Modbus Message Frame

A Modbus frame is the structure of a Modbus message. It consists of a start frame, function code, data, and an end
frame. The following table shows the structure of the frame in more detail:

Start Address Function Data LRC End

: 2 Chars 2 Chars N Chars 2 Chars CR LF

Modbus Communication Modes

There are three main communication modes in the Modbus protocol:

 RTU (Remote Terminal Unit)

 ASCII (American Standard Code for Information Interchange)
 TCP/IP (Transmission Control Protocol/Internet Protocol)

II- Modbus RTU :

1- Introduction to Modbus RTU :

Modbus RTU (Remote Terminal Unit) is a Modbus serial communication protocol designed
for industrial automation systems. It facilitates data exchange between various devices, such
as sensors, actuators, and controllers, connected to a shared communication channel. Here, we
will delve into the key features of Modbus RTU that highlight its simplicity, reliability, and
broad adoption across different industries.

Modbus RTU, as a reliable and widely adopted serial communication protocol in industrial
automation, facilitates seamless connectivity between diverse devices such as PLCs, HMIs,
and SCADA systems. With its efficient data exchange capabilities, Modbus RTU empowers
real-time monitoring, control, and coordination across the network. In this comprehensive
guide, we will delve into the essential aspects of Modbus RTU, including its robust error-
handling mechanisms, implementation best practices, and troubleshooting techniques. By
harnessing the power of Modbus RTU, you can optimize the performance and reliability of
your industrial automation systems.

2- Modbus RTU Frame Structure

The RTU frame structure forms the backbone of the Modbus RTU communication protocol,
defining the organization and transmission of Modbus data between devices. This
transmission is enabled through the transport layer which encompasses protocols and
techniques utilized to ensure reliable and efficient data transfer. A Modbus RTU frame
consists of several components that enable efficient and accurate data transmission. The frame
structure includes the following elements:

Figure1 : Modbus data frame ( credits : development.libelium.com)

 Slave Address (1-byte): This field is a unique identifier assigned to each slave device
in the network, allowing the master device to communicate with specific slave
devices. Since it’s an 8-bit value, it accepts the range 0-247.
 Function Code (1-byte): It is a numerical code that specifies the type of action or
request being made by the master device, such as reading or writing data.
 Data: The data field is the actual modbus message being transmitted, which can be the
values being written/read from the slave registers. The size can vary in length
depending on the function code and the specific operation to be performed.
 Error Check (2-byte): Modbus RTU uses a cyclic redundancy check (CRC) for
checking errors. It is used to verify the integrity of the transmitted data and detect
potential communication errors.
 Silent Period: The silent period is the idle time between consecutive frames, during
which the communication line remains quiet. It serves as a minimum gap period that
separates two frames, indicating the start and end of the message. The silent period
plays a crucial role in frame synchronization and helps ensure the reliable transmission
of Modbus RTU frames over the communication line.

The combination of these components allows for efficient and reliable data exchange between
devices in a Modbus RTU network.

3- Modbus RTU Addressing

Addressing Modbus RTU is essential for ensuring that data is sent to and received from the
correct devices. There are different types of addresses used in Modbus RTU:
  Slave Addresses: Each slave device in the network is assigned a unique address,
ranging from 1 to 247. The master device uses these addresses to communicate with
specific slave devices. The values 248 to 255 are reserved for other purposes.
 Data Addresses: Modbus RTU uses a hierarchical addressing scheme for data, which
includes four primary types of data objects: coils, discrete inputs, input registers, and
holding registers. Each data object has a specific address range, allowing the master
device to access the desired data within a slave device.

In Modbus RTU, single-bit data is commonly exchanged between devices using coils or
discrete inputs. Coils represent outputs, allowing control signals to be sent from the master to
the slave, while discrete inputs represent inputs monitored by the slave and provide status
information to the master. The single-bit nature of Modbus RTU enables efficient and precise
control and monitoring of individual digital signals in industrial applications.

Let’s discuss how data addressing works in Modbus RTU, along with an example.

Modbus RTU communication involves the exchange of data through Modbus registers, which
are predefined memory locations in the slave devices. Modbus registers can hold various
types of data, such as holding registers for numerical values or coils for single-bit states. The
master device can read or write to these Modbus registers, allowing for efficient and
standardized access to critical data within the Modbus RTU network.

Below is a table showing the address range of each register type referenced in the modbus
devices.

Table1: modbus data tables and their address ( credits: https://www.se.com)

Consider a scenario where you would like to read the data from the Holding Register of a
slave device, addressed 17. The starting address of the 3 registers is from #40108 to 40110.
This translates to the hexadecimal value of 6B (Subtracting 40108 from the offset value
40001, results in 107, which equals to 6Bh).
Since the function to be performed is reading from the Analog Output Holding Register, the
function code will be 03.

The appropriate command for performing this operation will be 11 03 006B 0003 xxxx.

11: This is the hexadecimal equivalent of 17, the slave id.

03: Function code for reading the data from the holding register.

6B: Hexadecimal equivalent of the first registered address.

0003: Number of required registers.

xxxx: CRC checksum.

The above command will result in a response from the slave device with the stored register
values that were addressed by the master device.

By using a well-defined addressing scheme, Modbus RTU ensures accurate and efficient data
exchange between devices in an industrial automation system.

4- Modbus RTU Communication Modes

Modbus RTU supports two main communication modes: master/slave and client/server. Each
mode has its advantages and disadvantages, depending on the specific requirements of the
industrial automation system.

Master/Slave Mode

In the master/slave mode, one device, known as the master, initiates communication with
other devices, called slaves. The master device sends requests to the slave devices, which then
respond with the requested data or perform the specified action. This mode is characterized by
the following features:

 Unidirectional communication: The master device initiates all communication, and

slave devices only respond to requests from the master.
 Polling mechanism: The master device continuously polls each slave device for data
or status updates, ensuring up-to-date information is available.
 Deterministic response times: Since the master device controls the communication,
response times can be predictable and consistent.

The master/slave mode is suitable for applications where a central controller needs to manage
multiple devices and deterministic response times are crucial.
Client/Server Mode

In the client/server mode, devices can act as both clients and servers, allowing for more
flexible communication between devices. This mode is characterized by the following
features:

 Bidirectional communication: Devices can initiate communication with each other,

enabling more dynamic data exchange.
 Event-driven communication: Devices can send data or request information from
other devices based on specific events or conditions, reducing unnecessary
communication overhead.
 Scalability: The client/server mode can accommodate a larger number of devices and
support more complex communication patterns.

The client/server mode is suitable for applications where devices need to communicate with
each other directly and more complex communication patterns are required. However, it
should be noted that Modbus RTU primarily operates in the master/slave mode, and the
client/server mode is more commonly associated with Modbus TCP/IP, another variant of the
Modbus protocol.
5- Modbus RTU Function Codes

Function codes play a crucial role in Modbus RTU communication, as they define the type of
action or request made by the master device. Each function code corresponds to a specific
operation, such as reading or writing data, and helps ensure accurate and efficient
communication between devices.

Read Function Codes

Read function codes allow the master device to request data from slave devices. Some
common read function codes include:

 Read Coils (0x01): This function code is used to read the status of multiple coils
(digital outputs) in a slave device.
 Read Discrete Inputs (0x02): This function code is used to read the status of multiple
discrete inputs (digital inputs) in a slave device.
 Read Holding Registers (0x03): This function code is used to read the values of
multiple holding registers (analog outputs) in a slave device.
 Read Input Registers (0x04): This function code is used to read the values of
multiple input registers (analog inputs) in a slave device.
Write Function Codes

Write function codes that enable the master device to send data to slave devices, modifying
their internal states or settings. Some common write function codes include:

 Write Single Coil (0x05): This function code is used to write the status of a single
coil (digital output) in a slave device.
 Write Single Register (0x06): This function code is used to write the value of a single
holding register (analog output) in a slave device.
 Write Multiple Coils (0x0F): This function code is used to write the status of
multiple coils (digital outputs) in a slave device.
 Write Multiple Registers (0x10): This function code is used to write the values of
multiple holding registers (analog outputs) in a slave device.

By using function codes, Modbus RTU ensures that the master device can accurately request
data from or send data to slave devices, facilitating efficient and reliable communication in
industrial automation systems.

6- Modbus RTU Error Handling

Effective error handling is vital in Modbus RTU to promptly identify and resolve any
communication errors between the master and slave devices. It also ensures reliable and
accurate data exchange between the devices. Modbus RTU employs various mechanisms to
detect and handle errors that may occur during communication.

Error Detection

Modbus RTU uses a cyclic redundancy check (CRC) to detect errors in the transmitted data.
The CRC is a mathematical algorithm that calculates a checksum value based on the frame's
content. The sender appends this checksum to the frame, and the receiver recalculates the
CRC upon receiving the frame. If the calculated CRC matches the received CRC, the frame is
considered error-free. Otherwise, an error is detected, and the receiver can request a
retransmission. Modbus RTU uses a 16-bit CRC algorithm, specifically CRC-16.

Implementations of CRC calculation for Modbus RTU are available in various programming
languages and libraries, simplifying the process for developers. By using the CRC
mechanism, Modbus RTU ensures data integrity and facilitates error-free communication in
industrial automation systems.
Error Codes

When a slave device encounters an error while processing a request from the master device, it
responds with an exception message containing an error code. These error codes provide
information about the nature of the error, allowing the master device to take appropriate
action. Some common Modbus RTU error codes include:

 Illegal Function (0x01): The error code indicates that the requested function code is
not supported by the slave device.
 Illegal Data Address (0x02): The error code indicates that the requested data address
is not valid or out of the allowable range for the slave device.
 Illegal Data Value (0x03): The error code indicates that the data value provided in the
request is not valid or allowed by the slave device.
 Slave Device Failure (0x04): The error code indicates that the slave device
encountered an internal error while processing the request.
 Acknowledge (0x05): The error is sent by the slave device to indicate that it has
received the request but needs additional time to process it.
 Slave device busy (0x06): Th error is sent by the slave device to indicate that it is
busy executing some other command. The master should send the request once the
slave device is available.

By using error codes, Modbus RTU enables efficient error handling and provides feedback to
the user about potential issues in the communication process.

Timeout and Retransmission

In Modbus RTU communication, the master device expects a response from the slave device
within a specified time frame, known as the timeout period. If the master device does not
receive a response within this period, it assumes that an error has occurred, such as a lost
frame or a non-responsive slave device. In such cases, the master device can attempt to
retransmit the request or take other appropriate actions, such as reporting the error to the user
or initiating a fault recovery process.

By employing error detection, error codes, and timeout mechanisms, Modbus RTU ensures
reliable and accurate communication between devices in an industrial automation system.

7- Modbus RTU Implementation

Implementing Modbus RTU in an industrial automation system involves several steps,

including selecting appropriate hardware and software components, configuring devices, and
establishing communication between devices. Understanding the requirements and best
practices for Modbus RTU implementation is crucial for ensuring reliable and efficient
communication in your system.

Hardware Considerations

Selecting the right hardware components for Modbus RTU communication is essential for
successful implementation. Key hardware components include:

 Master and slave devices: These devices, such as programmable logic controllers
(PLCs), sensors, and actuators, must support Modbus RTU communication. Ensure
compatibility with the Modbus RTU protocol when selecting devices for your system.
 Serial communication interface: Modbus RTU typically uses serial line for RS-232
or RS-485 serial communication. RS-485 is a commonly used physical layer interface
and is recommended for industrial applications due to its robustness, longer
communication distances, and support for multi-drop networks.
 Signal converters and isolators: In some cases, you may need signal converters to
adapt between different communication interfaces or isolators to protect devices from
electrical noise and ground loops.

When selecting hardware components, consider factors such as communication distance,

network topology, and environmental conditions to ensure optimal performance and
reliability.

Software Considerations

Software components play a crucial role in Modbus RTU communication, enabling devices to
interpret and process data according to the protocol. Key software considerations include:

 Modbus RTU libraries and drivers: Choose software libraries and drivers that
support Modbus RTU communication for your specific devices and programming
languages. Ensure compatibility with your hardware components and operating
systems.
 Configuration and diagnostic tools: Utilize software tools that facilitate device
configuration, network setup, and diagnostics to streamline the implementation
process and simplify troubleshooting.
 Custom application development: Depending on your system requirements, you may
need to develop custom software applications to manage Modbus RTU
communication, process data, and implement control logic.
Selecting the appropriate software components and tools is essential for efficient and reliable
Modbus RTU communication, enabling seamless integration with your industrial automation
system.

8- Modbus RTU Troubleshooting

Troubleshooting is an essential aspect of maintaining and optimizing Modbus RTU

communication in industrial automation systems. Identifying and resolving common issues
can help ensure reliable and efficient data exchange between devices. Here are some typical
problems and their solutions:

Communication failure between master and slave devices:

 Check the wiring and connections between devices, ensuring proper termination and
shielding.
 Verify the configuration of master and slave devices, including baud rate, parity, and
stop bits.
 Ensure that the slave device address in the master's request matches the actual address
of the slave device.

Incorrect or inconsistent data values:

 Inspect the data addressing scheme, ensuring that the master device is requesting data
from the correct registers or coils in the slave device.
 Verify the data types and scaling factors used in the communication, ensuring
consistency between master and slave devices.
 Check for potential sources of electrical noise or interference that may corrupt the
transmitted data.

Timeouts or slow response times:

 Adjust the timeout settings in the master device to account for communication delays
or slow-responding slave devices.
 Inspect the network topology and communication distances, ensuring that they are
within the limits specified by the Modbus RTU protocol and the chosen serial
communication interface.
 Optimize the polling mechanism used by the master device, reducing the number of
requests or prioritizing critical devices to minimize response times.

Error codes or exception messages:

  Analyze the error codes returned by the slave devices to identify the nature of the
problem, such as illegal function codes, invalid data addresses, or device failures.
 Review the master device's requests to ensure they are valid and supported by the
slave devices.
 Inspect the slave devices for potential hardware or software issues that may cause
errors or failures.
 By following these troubleshooting tips, referring to the protocol specifications, and
maintaining a proactive approach to identifying and resolving issues, you can ensure
the reliability and efficiency of Modbus RTU communication in your industrial
automation system.

9- Modbus RTU vs. Modbus ASCII

When exploring the realms of industrial communication, Modbus RTU and Modbus ASCII
emerge as distinctive variants of the Modbus protocol, with Modbus RTU known for its
binary efficiency and Modbus ASCII celebrated for its human-readable ASCII representation.
Understanding the distinctions between Modbus RTU and Modbus ASCII is crucial in
selecting the appropriate variant for specific industrial applications.

Data Representation

Modbus RTU uses binary encoding, representing data in a compact and efficient manner
using binary values (0s and 1s). This allows for faster transmission speeds and smaller
message sizes. On the other hand, Modbus ASCII uses ASCII encoding, representing data
using ASCII characters. While this offers human readability and ease of troubleshooting, it
results in larger message sizes and slower transmission speeds.

Transmission Efficiency

Due to its binary format, Modbus RTU achieves higher transmission speeds and better
efficiency in terms of bandwidth usage. It can transmit more data in a shorter amount of time.
Modbus ASCII has slower transmission speeds and larger message sizes due to the additional
overhead of ASCII encoding and decoding. This makes it less efficient in terms of bandwidth
utilization.

Character Set

Modbus RTU does not rely on any specific character set since it uses binary encoding.
Modbus ASCII uses a specific subset of the ASCII character set for data representation, with
each character representing a binary value.
Error Detection

Modbus RTU utilizes CRC (Cyclic Redundancy Check) as an error-checking mechanism,

ensuring data integrity during transmission. Modbus ASCII uses LRC (Longitudinal
Redundancy Check) for error detection, but it is considered less robust than CRC.

The choice between Modbus RTU and Modbus ASCII depends on factors such as the specific
application requirements, transmission speed needs, compatibility with existing systems, and
the importance of human readability and troubleshooting capabilities.
Conclusion

In conclusion, Modbus RTU remains a reliable and widely adopted Modbus communication
protocol in industrial automation systems. With its binary data representation, compact frame
structure, and efficient transmission, Modbus RTU offers fast and reliable communication
over serial interfaces. By leveraging the strengths of Modbus RTU, businesses can achieve
seamless integration, real-time monitoring, and efficient control of devices in their automation
networks.

III- Modbus TCP/IP:

1- Introduction

The Modbus TCP/IP protocol is a cornerstone in the realm of industrial communication

systems. It is an application layer messaging protocol that works in conjunction with ethernet,
to enable client/server communication between devices connected on different types of
networks. Originating as a Modbus serial protocol (Modbus RTU), Modbus has evolved to
embrace modern technologies such as TCP/IP, playing a crucial role in areas ranging from
building automation and energy management systems to complex industrial automation
processes. With a focus on simplicity and robustness, this protocol has widespread adoption
due to its ease of use, openness, and ability to integrate diverse devices into a network,
making it the protocol of choice for many applications.
2- Modbus TCP/IP: Basic Concepts and Principles

Let’s begin to understand the basic functioning of Modbus TCP/IP, as to how it leverages
modern technology to ensure seamless communication between electronic devices in
industrial automation.

What is Modbus TCP/IP

Modbus TCP/IP is an adaptation of the well-established Modbus protocol for use over TCP/IP
networks. It provides a standardized TCP interface that allows Modbus devices to
communicate seamlessly over an Ethernet network, enabling efficient and reliable data
exchange. Hence, its primary function is to establish a bridge for Modbus communication
over Ethernet-based systems, which are ubiquitous in today's interconnected world.

The Modbus TCP/IP messaging protocol inherits the simplicity and robustness (by retaining
the message structure, register-based communication, etc.) of the original Modbus protocol,
adding TCP/IP's reliability and interoperability. It encapsulates the traditional Modbus data in
a TCP/IP packet, enabling the data to be transported over standard network infrastructures.

Modbus TCP/IP utilizes TCP (Transmission Control Protocol) as the underlying transport
protocol. TCP ensures reliable and ordered delivery of Modbus messages over the network by
providing features such as data segmentation, acknowledgment, and retransmission.

The protocol relies on the IP layer (Internet layer) for addressing, routing, and packet
delivery. It uses IP addresses to identify the source and destination devices in a network. IP
ensures that Modbus TCP/IP messages are appropriately routed between devices connected to
the Ethernet network.

The encapsulation of Modbus messages within TCP/IP packets takes place in the client-server
model. This model designates one device as a client that initiates requests, while other devices
act as servers that process these requests and send responses.

Modbus TCP/IP thus offers an elegant solution for facilitating Modbus communication over
modern network infrastructures, enhancing the protocol's relevance in today's digitized
industrial landscape. A few of its highlight features have been discussed further.

Basic principles of Modbus TCP/IP

The Modbus protocol family, including Modbus TCP/IP, centers around a few fundamental
concepts and principles that serve as the foundation for its operation. These are stated below:

1. Client/Server Architecture: The Modbus messaging structure is a command/response

protocol and requires a client (also TCP client) that requests data and a server that
processes requests and returns a response.
2. Register-based Communication: In the realm of Modbus, data is stored in four basic
data entities, namely, Discrete Inputs, Coils, Input Registers, and Holding Registers.
These entities are essential for the organization and interpretation of data within a
Modbus system. Discrete Inputs and Coils deal with binary information, while Input
and Holding Registers handle numerical data.
 3. Addressing: Modbus employs a simple addressing scheme to identify the registers
being accessed. The addressing typically uses numerical values to specify the starting
register address and the number of registers to read or write.
4. Function Codes based Read/Write operations: Data access in Modbus is defined by the
function code field in the Modbus data frame. These function codes are critical as they
specify the type of action to be performed on a data entity. Actions can range from
reading and writing to data manipulation functions.
5. Transaction-oriented: An essential principle of Modbus is its transaction-oriented
nature. Each request made by a Modbus client is independent of all others. This
transactional property allows Modbus to be employed in a broad spectrum of
applications and use cases.

TCP/IP vs Modbus TCP/IP

Figure 2: TCP/IP Model and Modbus ( application layer)

Whether TCP/IP and Modbus TCP/IP are synonymous, or distinct technologies, would be an
evident curiosity for a beginner. The following section offers you the right clarity on these
terminologies.

The TCP/IP protocol stack is the backbone of the internet and most modern networks. It is a
suite of communication protocols used to interconnect network devices on the internet. Since
this protocol is widely used over an ethernet network, it is also called Ethernet TCP/IP. On the
other hand, Modbus TCP/IP is a protocol specifically designed for communication in
industrial automation and control systems over TCP/IP networks.

While TCP/IP communication serves as a general-purpose protocol designed for transmitting

data packets on the internet, Modbus TCP/IP is specialized, utilizing the TCP/IP stack for
industrial applications. Modbus TCP/IP utilizes the transport and network capabilities of
TCP/IP at the lower layers while operating at the application layer to carry Modbus
messaging structure data over the internet or local network infrastructures.

Data Handling: A fundamental difference lies in their data handling approach. TCP/IP
functions as a carrier of bytes, forming a comprehensive suite of protocols that establishes the
basis for network communication. It operates at the lower layers of the protocol stack,
concentrating on tasks like addressing, routing, sequencing, error detection, and
retransmission.

TCP/IP breaks down messages or files into packets for transmission over the internet, which
are subsequently reconstructed at their intended destination. However, it is important to note
that TCP/IP does not possess an inherent understanding of the content it carries; it treats the
data as raw bytes.

However, Modbus TCP/IP encompasses data structure definitions. It not only carries data but
also understands the nature of the data it carries, such as whether the data represents a
command or response, or which data type (coil, discrete input, input register, or holding
register) the data belongs to.

In TCP/IP, data is transferred without any specific action related to the data. In contrast,
Modbus TCP/IP involves specific actions performed on the data, such as reading or writing to
a register or coil.

Versatility: Furthermore, TCP/IP operates independently of any specific application, making

it highly versatile for many different types of data communication. Modbus TCP/IP, however,
is application-specific, designed to work within the parameters of industrial automation
systems and to communicate specific types of information related to these systems.

Thus, while both are integral to modern network communications, TCP/IP serves as the
underpinning transport protocol, and Modbus TCP/IP offers a tailored solution for specific
industrial communication needs.

3- Modbus TCP/IP Architecture

Modbus TCP/IP Architecture represents a layered approach to network communications. This

architecture comprises two main components: the TCP/IP stack and the Modbus Application
Protocol (MBAP). The integration of the Modbus protocol with TCP/IP is achieved by the
inclusion of the MBAP header before the usual Modbus message structure.

The TCP/IP stack constitutes the lower layers, including the physical layer (Ethernet),
network layer (IP), and transport layer (TCP). This structure takes care of the physical and
logical transmission of data across the network.

The MBAP, positioned above the TCP/IP stack (as part of the application layer), is
responsible for encapsulating the Modbus message inside a TCP/IP packet. This architecture
allows for seamless communication of Modbus data over standard network infrastructure.

At the heart of the architecture is the Modbus message. Modbus TCP/IP messages contain a
Modbus Application Protocol header, a Function code indicating the message operation, and
the Data field, which varies depending on the Function code. The messages are constructed in
a format that allows them to be easily processed and understood by devices in the network.

This layered structure is crucial for achieving seamless interoperability across different
devices in a Modbus network. It also aids in maintaining the simplicity and robustness of the
Modbus protocol, even as it adapts to work over modern network technologies.

Modbus Application Protocol (MBAP)

Figure3: a diagram showing modbus frames including MBAP header

(credits: https://www.ipc2u.com/)

The Modbus Application Protocol (MBAP) is a key component of the Modbus TCP/IP
protocol. It's an application layer protocol that defines the data encoding for communication
between devices in a Modbus TCP/IP network. The MBAP header plays a vital role in the
successful delivery of Modbus messages over TCP/IP networks.

The MBAP header is a 7-byte structure prefixed to the standard Modbus message. This header
includes three primary fields:
 1. Transaction Identifier (2 bytes): The Transaction Identifier is a unique identification
number for each transaction.
2. Protocol Identifier (2 bytes): The Protocol Identifier is set to 0 for Modbus services.
3. Length (2 bytes): The Length (or byte count) field indicates the number of remaining
bytes in the message. It is used to determine the size of the message payload, allowing
the recipient to properly handle and process the data.
4. Unit Identifier (1-byte): It identifies the target device or unit within a Modbus
network.

The use of MBAP encapsulation enables the Modbus TCP/IP protocol to utilize the robust,
reliable transport mechanism of TCP/IP while maintaining the simplicity and
straightforwardness of the Modbus messaging structure. It serves as the bridge that integrates
the Modbus protocol with modern network technologies.

TCP/IP Protocol

The TCP/IP protocol is the foundation for data communication over the Internet and within
private networks. It's the underlying protocol that Modbus TCP/IP builds upon to enable
industrial communication. The TCP/IP protocol stack is a four-layer model consisting of the
Application, Transport, Internet, and Network Interface layers (as visible in Fig. 1). Let’s
briefly discuss them below:

1. Application Layer: At the top, the Application layer provides protocols for specific
data communication services. These protocols work directly with software
applications such as web browsers or email clients. Examples include HTTP for web
browsing and SMTP for email transmission.
2. Transport Layer: The Transport layer is responsible for end-to-end communication
control, ensuring complete data transfer. Two principal protocols operate at this level:
Transmission Control Protocol (TCP) and User Datagram Protocol (UDP). TCP
provides reliable, ordered, and error-checked data delivery. It manages packet
sequencing, acknowledgment of packet receipt, and retransmission of lost data.
3. Internet Layer: The Internet layer, also known as the Network layer, is responsible
for data routing across multiple networks. The key protocol at this level is the Internet
Protocol (IP), which handles the addressing and routing of packets to their final
destination. Each data packet carries both the sender's and recipient's IP addresses.
4. Network Interface Layer: Finally, the Network Interface layer, also referred to as the
link layer or the physical layer, manages the physical transmission of data. It includes
 protocols like Ethernet and Wi-Fi, which define the electrical and physical
specifications of devices.

In the context of Modbus TCP/IP, the MBAP (Modbus Application Protocol) sits at the
Application layer of the TCP/IP stack. The MBAP encapsulates the Modbus protocol data
units into TCP/IP packets. The TCP protocol, at the Transport layer, then ensures the reliable
delivery of these packets across the network. Meanwhile, the IP protocol routes these packets
to their destination based on the IP addresses, and the Network Interface layer handles the
physical transmission over the network medium.

The TCP/IP protocol's versatility, robustness, and widespread adoption make it an ideal
choice for Modbus to extend its reach to modern network technologies.

Device and Register Addressing

Understanding device and register addressing is crucial to working with Modbus TCP/IP, as it
provides the mechanism to reference specific data points within a networked device. This
section breaks down the core concepts related to the device and registers addressing in a
Modbus TCP/IP network.

Device addressing in Modbus TCP/IP is handled at the IP level of the network. Unlike
Modbus RTU or Modbus ASCII, where each device is assigned a unique slave ID in the range
of 1-247, devices in a Modbus TCP/IP network are addressed using their IP addresses. The
use of IP addressing allows for a vast number of devices to be connected and networked, each
with its unique identifier, facilitating complex and large-scale industrial systems.

Meanwhile, register to address in Modbus TCP/IP pertains to the way data is accessed within
a device. In Modbus, data is organized into four fundamental tables, each associated with a
specific type of data:

 Coils (Read/Write, Boolean)

 Discrete Inputs (Read-Only, Boolean)
 Input Registers (Read-Only, 16-bit)
 Holding Registers (Read/Write, 16-bit)

Each table has a unique function code for accessing its data, and each data point within a table
has a unique address, typically in the range of 0-65535. For example, a request to read the
Holding Register at address 40001 would be sent with a function code of 3 (Read Holding
Registers) and an address of 0 (since Modbus addressing is zero-based, meaning that the
registers are numbered starting from 0, not 1).
One unique aspect of Modbus TCP/IP is that the protocol supports both unicast and multicast
requests. Unicast requests are directed at a single device, using the device's unique IP address.
In contrast, multicast requests are sent to a group of devices, using a multicast IP address.
This feature allows for efficient and concurrent data access when dealing with multiple
devices in a network.

Thus, the device and register to address in Modbus TCP/IP form a two-level hierarchical
structure. The IP address identifies a specific device in the network, while the function code
and data address identifies a specific data point within that device. This structure allows for
precise control and data access in industrial automation systems.

4- How Modbus TCP/IP Works

Modbus TCP/IP follows a simple yet robust model for data communication and control. It is
designed with an understanding that reliability, efficiency, and simplicity are paramount for
industrial automation and process control applications. The framework of Modbus TCP/IP
comprises different facets, from its inherent client-server model to specific methods of data
transmission and querying.

Client-Server Communication

One of the defining aspects of Modbus TCP/IP is its client-server model. This model forms
the backbone of data communication in a Modbus TCP/IP network.

In this model, a client sends a request to a server (or multiple servers), which then processes
the request and sends back a response. The client is typically a human-machine interface
(HMI), programmable logic controller (PLC), or any device requiring data or control over
devices. The server, on the other hand, is typically a sensor, actuator, or other such device
providing data or carrying out actions.

Each client request contains an MBAP header, a function code, and data fields. The MBAP
header is unique to Modbus TCP/IP and includes details such as the transaction identifier and
protocol identifier. The function code denotes the operation the client wants the server to
perform. This could be reading data, writing data, or diagnosing the server. The data fields
contain the details of the request, such as the registered address to read from or the value to
write to a register.

The server processes the request as per the function code. If the request is to read data, the
server retrieves the requested data from its registers. If the request is to write data, the server
writes the provided value to the specified register. The server then sends a response back to
the client, confirming the successful completion of the operation or indicating an error if the
operation could not be completed.

This simple client-server model is at the heart of Modbus TCP/IP's operations. Its simplicity
and robustness make it an excellent protocol for industrial automation and process control,
where reliability and efficiency are crucial.

Modbus Functions

Modbus functions are integral to the operation of the Modbus TCP/IP protocol, providing the
methods for a client to request various types of operations from a server. They are embedded
within the client's request message, denoted by a unique function code.

Modbus functions are generally classified into two categories:

i) Public functions: Public functions are pre-defined and universally accepted across all
Modbus devices, while user-defined functions are custom-defined by individual
manufacturers and may not be universally recognized.

Public Modbus functions cover a wide range of operations. A common one is the 'Read
Holding Registers' function, denoted by function code 03. When a client sends a request with
this function code, it is asking the server to provide the contents of certain holding registers.
This function can read up to 125 registers in a single request.

Another significant function is 'Write Single Register', denoted by function code 06. It is used
when a client wants to write a specific value to a particular holding register on the server. The
data field of the request would contain the address of the register and the value to be written.

Function code 16, or 'Write Multiple Registers', is used when a client wishes to write values to
multiple contiguous registers in a single request. The data field, in this case, would include the
start address, the number of registers, and the set of values to be written.

ii) User-Defined functions: In contrast, user-defined functions provide manufacturers the

flexibility to implement unique operations beyond the scope of the public functions. In other
words, manufacturers and developers can define their own set of function codes and
corresponding operations that suit their specific requirements. These user-defined functions
allow for customization and flexibility in Modbus-based systems. They are represented by
function codes in the range of 65-72 and 100-110. The exact functionality associated with
these codes is proprietary to the manufacturer.

When implementing user-defined function codes, it is crucial to ensure compatibility and

interoperability with other Modbus devices or systems. Clear documentation and adherence to
the Modbus communication standards help to ensure proper communication and avoid
conflicts or misunderstandings when using user-defined functions in Modbus networks.

The use of function codes allows for a standardized yet versatile method of requesting
operations, contributing to the effectiveness of the Modbus TCP/IP protocol in industrial
automation and process control systems.

5- Modbus TCP/IP: Real-World Applications

Modbus TCP/IP in Industrial Automation

Modbus TCP/IP plays a pivotal role in industrial automation systems due to its openness,
simplicity, and wide acceptance. It functions as a common communication protocol linking
diverse industrial devices, including programmable logic controllers (PLCs), remote terminal
units (RTUs), and sensors.

Its application in PLCs is widespread. A PLC with Modbus TCP/IP capabilities can connect
with other PLCs and devices over Ethernet to create an integrated, multi-node control system.
This can include a centralized PLC, issuing commands to peripheral PLCs, or a complex
setup with PLCs sharing control responsibilities in a distributed network. This enhances the
degree of automation, reduces human involvement, and significantly improves the efficiency
and accuracy of industrial processes.

Modbus TCP/IP is also extensively used in connecting RTUs in industrial settings. RTUs are
typically applied in large-scale systems like oil and gas pipelines or water treatment plants,
which span vast areas. Using Modbus TCP/IP, RTUs transmit data from field instruments
back to a central control room, making it a critical component of supervisory control and data
acquisition (SCADA) systems.

Modbus TCP/IP in Building Automation

In the domain of building automation, Modbus TCP/IP holds a significant place due to its
versatility and ease of integration. Building automation systems (BAS) often incorporate a
variety of subsystems, including HVAC, lighting control, access control, and fire safety
systems, each potentially using different communication protocols.

In such scenarios, Modbus TCP/IP enables seamless communication between these

subsystems. For example, HVAC systems often use Modbus TCP/IP to interface with
controllers and sensors for monitoring parameters such as temperature, humidity, and air
quality. This data can then be used to control HVAC operations automatically, optimizing for
factors such as energy efficiency and occupant comfort.
Similarly, Modbus TCP/IP facilitates interaction between lighting control systems and
associated devices such as light sensors and dimmers. This interaction allows for the
automated adjustment of lighting levels based on natural light availability or predefined
schedules, enhancing energy efficiency.

Furthermore, Modbus TCP/IP serves as a vital link in integrating access control systems with
other building systems. For instance, an access control system could signal the HVAC and
lighting systems when a room is occupied, allowing these systems to adjust conditions
according to occupancy.

Modbus TCP/IP in Energy Management

Modbus TCP/IP's role extends to energy management systems, a critical area for businesses
seeking to optimize energy use and minimize costs. Modbus TCP/IP is a communication
medium between various components of energy management systems, such as power meters,
submeters, and energy management software.

Power meters are integral in monitoring energy usage across various equipment and circuits.
Many modern power meters support Modbus TCP/IP and provide real-time data on electrical
parameters such as voltage, current, power factor, and energy consumption. This real-time
data is valuable for identifying areas of excessive energy use and implementing corrective
measures.

Submeters are often used in larger facilities to track energy usage at a more granular level,
such as by department, floor, or specific equipment. Like power meters, submeters frequently
use Modbus TCP/IP to communicate with central energy management systems. By
monitoring energy consumption at these smaller scales, businesses can further refine their
energy-saving strategies, addressing specific areas of high usage that may not be apparent
when looking at overall energy consumption.

Finally, Modbus TCP/IP facilitates the integration of power meters and submeters with energy
management software. This software can collect and analyze the data provided by the meters
to generate actionable insights, such as identifying peak demand periods, recognizing
inefficiencies, and predicting future energy needs. These insights can inform a comprehensive
energy management strategy, helping businesses to reduce energy waste, lower costs, and
minimize their environmental impact.
6- Advantages and limitations of Modbus TCP/IP
Advantages:
Modbus TCP/IP offers several advantages that have made it a preferred protocol for industrial
automation and other applications.

1. Seamless Integration: Firstly, the use of TCP/IP as the underlying transport protocol
ensures wide compatibility and easy integration with existing network infrastructure. The
ubiquitous nature of TCP/IP means that devices using Modbus TCP/IP can communicate
across local area networks, wide area networks, and even the internet, providing significant
flexibility in network design and scalability.

2. Simplicity & Efficiency: The simplicity of the Modbus protocol is another advantage.
With its small, well-defined set of function codes and straightforward data model, Modbus is
easy to implement in devices and software. This simplicity also results in less processing
overhead, making the protocol efficient even on low-power devices.

3. Reliability & Robustness: Modbus TCP/IP benefits from the robustness of the TCP
protocol, which offers reliable, ordered, and error-checked delivery of a stream of bytes. This
reliability is critical in many industrial automation scenarios where the accurate delivery of
control commands and status updates can directly impact the safety and productivity of the
operation.

4. Scalability: Modbus TCP/IP supports a large address space, with up to 247 individual
devices addressable in a single network. This makes it suitable for large-scale applications
where many devices need to communicate. In addition, Modbus TCP/IP supports
broadcasting, where a message from one device can be sent to all others on the network,
enhancing the efficiency of network communications.

5. Open & Versatile: Lastly, the openness of the Modbus protocol is a significant advantage.
The protocol specifications are freely available, and there is no licensing required to
implement the protocol. This has led to a large ecosystem of Modbus-compatible devices and
software, providing users with a wide range of options when designing their systems.

Limitations and Challenges of Modbus TCP/IP

While Modbus TCP/IP is widely used and brings numerous benefits, it is not without its
challenges and limitations. Understanding these can help when deciding on whether to use
this protocol or when troubleshooting a network that uses it.

1. Security: One key issue is security. Modbus was designed in an era before cybersecurity
became a critical concern, and it lacks built-in security features. The protocol does not support
encryption or authentication, meaning that data transmitted via Modbus TCP/IP can be easily
intercepted and altered. It's also easy for unauthorized devices to join a Modbus network and
start sending commands. This makes the protocol a poor fit for scenarios where sensitive data
is being transmitted, or where unauthorized access could have serious consequences.

2. Device Configuration: Another challenge is that Modbus TCP/IP lacks support for some
modern networking features. For instance, it does not support automatic device discovery,
meaning that when a new device is added to a network, its address and other details must be
manually configured. This can make setting up and maintaining a Modbus network more
time-consuming than protocols that support automatic configuration.

3. Lacks Advanced Features: Modbus TCP/IP's simplicity, while an advantage in many

ways, also means it lacks the flexibility and features of some more modern industrial
protocols. For instance, it supports only a simple request/response communication model,
with no support for event-driven or publish/subscribe communication. This means it may not
be the best choice for scenarios that require complex communication patterns or real-time
performance.

4. Dependency on TCP’s Congestion Control: The protocol also relies on TCP's congestion
control mechanisms, which can lead to inefficiencies and delays in busy networks or long-
distance connections. The congestion control mechanisms in TCP are designed for general-
purpose networks, not the specific requirements of industrial automation. In some scenarios,
this can lead to latency or jitter that exceeds what is acceptable for the control of real-time
industrial processes.

5. Scalability: Modbus supports a large number of devices in theory, in practice the

performance of the network can degrade as more devices are added, especially if many of
them are broadcasting messages. This limitation is not unique to Modbus, but it's important to
be aware of it when designing a large-scale system.

Conclusion

Modbus TCP/IP is an adaptation of the well-established Modbus RTU protocol, designed for
use over TCP/IP networks. It carries the simplicity and reliability of the original protocol into
the realm of Ethernet and Internet communication. With its open standard, it has gained wide
acceptance in industrial automation and building management systems. Yet, there are
concerns over the protocol's lack of security measures and other modern networking features
that can affect its suitability for certain applications.

Despite these challenges, Modbus TCP/IP continues to be a relevant choice due to its
widespread use, familiarity within the industry, and extensive library of supported devices.
Profinet, as a robust fieldbus protocol, addresses the limitations of Modbus by offering real-
time communication, advanced diagnostics, and precise control, making it a suitable choice
for industrial automation applications.

As with all technical choices, the key is to understand the strengths, weaknesses, and
suitability of the Modbus TCP/IP for the specific needs of the intended application.

IV- Modbus RTU vs Modbus TCP

1- Modbus RTU vs Modbus TCP: Communication Media and Speed

When comparing Modbus RTU and Modbus TCP, it is important to consider the
communication media and speed, as they play a significant role in determining the overall
performance and suitability of each protocol for different applications.

Modbus RTU Communication Media

Modbus RTU primarily utilizes serial ports such as RS-232 and RS-485. RS-232 is suitable
for short-distance communication (up to 50 feet or 15 meters), while RS-485 supports long-
distance communication (up to 4000 feet or 1200 meters), with multi-drop configurations, and
enables multiple devices to share a single communication line. It transmits data in binary
format i.e. 0 & 1.

Serial communication in Modbus RTU is typically slower compared to Ethernet-based

communication used by Modbus TCP. RS-232 and RS-485 speeds range from 1.2 kbps to a
max of 115 kbps, but the actual communication speed is influenced by factors such as cable
length, noise, and the number of devices on the network.

Modbus TCP Communication Media

Modbus TCP utilizes Ethernet-based communication media, which offers several advantages
over serial communication, including higher data rates, increased reliability, and widespread
adoption across various industries. Ethernet communication supports data rates of 10 Mbps,
100 Mbps, 1 Gbps, and even higher, significantly surpassing the speeds achievable
with Modbus RTU. It converts the binary data into a hexadecimal string for easy transmission
of data.

Ethernet networks can span longer distances using switches and routers, providing greater
flexibility in network design and implementation. Additionally, Ethernet communication
supports advanced features such as Quality of Service (QoS) and network diagnostics, further
enhancing the performance and reliability of Modbus TCP networks.
When comparing Modbus RTU vs Modbus TCP for communication speed, we find Modbus
TCP leading ahead, with the leverage of Ethernet TCP/IP which is widely popular in the
market. Not only does Modbus TCP has a compact data frame relatively, but its reliance on
Ethernet TCP/IP protocol for error correction leaves it the best choice for efficient utilization
of available bandwidth. Interestingly, RTU remains the most commonly used choice
considering the application requirements in the industry that do not require very high
communication speed, while the TCP interface is catching up.

2- Modbus RTU vs Modbus TCP: Network Topology and Scalability

When evaluating Modbus RTU and Modbus TCP, it's essential to consider the network
topology and scalability aspects. Both protocols support different topologies and have varying
degrees of scalability, which can influence the choice of protocol based on the specific
requirements of a given industrial automation system.

Network Topology and Scalability in Modbus RTU

Modbus RTU networks can be configured in various topologies, such as point-to-point, multi-
drop, and multi-point. The most common topology is the multi-drop configuration, where
multiple slave devices are connected to a single master device on a single communication
line. This can also be called daisy chain topology. This is made possible using RS-485
communication, which supports multi-drop configurations. In this master-slave configuration,
up to 32 slave devices (which can be extended to 247 devices) can be connected in a single
communication line, generally. However, only one slave can communicate at a time.

Modbus RTU networks also encounter limitations when it comes to network expansion and
complexity. For example, as the number of devices increases, the complexity of managing
and troubleshooting the network can become cumbersome. Besides the total number of
devices, the overall network distance also impacts communication speed and reliability.

Network Topology and Scalability in Modbus TCP

Modbus TCP, being based on Ethernet and IP, supports various network topologies, such
as star, tree, ring, and mesh. This allows for greater flexibility in network design, which
makes it easier to expand and modify the network as needed. Ethernet switches and routers
are of great help in achieving network expansion while spanning long distances.

Also, Modbus TCP can accommodate a higher number of devices (247) on the same line
network, with each device having a unique IP address for easy identification and
management. The use of IP addressing simplifies device identification and management,
making it more straightforward to configure, monitor, and troubleshoot the network. This
enhances the scalability and performance of Modbus TCP networks.

Scalability is a critical factor to consider, especially in large industrial automation systems

that require the interconnection of numerous devices. Modbus TCP offers superior scalability
compared to Modbus RTU due to its reliability on Ethernet which supports various network
topologies. If it’s monitoring a few devices, RTU serves this best. However, for a growing
business that will involve a myriad of devices requiring advanced monitoring facilities, TCP
is the way to go.
3- Modbus RTU vs Modbus TCP: Network Security

Network security is the most critical factor in industrial automation systems, to protect the
integrity and confidentiality of data, as well as to ensure the availability of the system. In this
section, we will analyze and compare the network security aspects of Modbus
RTU and Modbus TCP, providing insights into their respective strengths and weaknesses.

Modbus RTU Network Security

Modbus RTU relies on serial communication, typically using RS-485 or RS-232 physical
layers. Due to its nature, Modbus RTU can be considered more secure than Modbus
TCP when it comes to external cyber threats. Serial communication is less prone to remote
cyber-attacks, as an attacker would need physical access to the communication line to
intercept or manipulate data.

However, Modbus RTU does not inherently include any encryption or authentication
mechanisms. This means that if an unauthorized person gains physical access to the
communication line, they could potentially eavesdrop on the data being transmitted or even
inject malicious messages. To mitigate these risks, additional security measures, such as
secure communication channels or physical access control, should be implemented.

Modbus TCP Network Security

Modbus TCP, being based on Ethernet and IP, is more susceptible to cyber threats
than Modbus RTU, as it operates on a more widely-used and accessible communication
medium. This means that Modbus TCP networks can be targeted remotely by attackers,
potentially exposing them to a broader range of threats.

Like Modbus RTU, the Modbus TCP protocol does not natively incorporate any encryption or
authentication mechanisms. As a result, the data transmitted over the network is vulnerable to
interception, manipulation, or denial of service attacks.
To enhance the security of Modbus TCP networks, various techniques can be employed. One
approach is to use Virtual Private Networks (VPNs) to create secure communication tunnels
between devices, encrypting the data transmitted over the network. Another option is to
implement network segmentation, isolating critical devices or systems from the rest of the
network to limit potential attack surfaces.

Firewalls and intrusion detection systems can also be used to monitor and filter network
traffic, detecting and blocking potential threats. Additionally, proper access control, secure
password management, and regular security updates for network devices and software should
be established as part of a comprehensive security strategy.

Comparing the network security aspects of Modbus RTU and Modbus TCP, it becomes
apparent that each protocol has its own set of challenges and advantages. Modbus
RTU benefits from the inherent security provided by serial communication, making it less
prone to remote cyber-attacks. However, it lacks native encryption and authentication
mechanisms, which can expose the network to physical security breaches.

On the other hand, Modbus TCP networks are more susceptible to remote cyber threats due to
their reliance on Ethernet and IP. While the protocol itself does not include built-in encryption
or authentication features, a variety of security techniques can be employed to enhance the
overall security of the network.

Ultimately, the choice between Modbus RTU and Modbus TCP will depend on the specific
security requirements of the system, as well as the ability to implement additional security
measures to address the inherent vulnerabilities of each protocol.

Modbus Security

In August 2018, Modbus Security was published, considering the lack of proper security
implementation that leaves the messages vulnerable to hackers. It is also called Modbus TCP
TLS (Transport Layer Security) as it’s used over the existing TCP/IP layer, to add security
over the ongoing communications. Using the cryptographic code keys, Modbus TLS verifies
the message between the client and server. Besides, the devices on the server also exchange
the codes and keys for further verification.

This prevents the hackers from sending false messages from clients or devices or overloading
the system with messages to hack it.

Though Modbus TLS adds strong security to the existing scenario, it nonetheless isn’t
considered a perfect system.
For this reason, companies using Modbus are always recommended to implement the best
network security practices to ensure safety from security hacks.
4- Modbus RTU vs Modbus TCP: Ease of Integration

The ease of integration of Modbus RTU and Modbus TCP protocols into existing systems and
infrastructure plays a crucial role in the selection process. This section will delve into the
factors that influence the integration process and provide a comparison of both protocols in
terms of their ease of integration.

Modbus RTU Integration

Modbus RTU, as a serial communication protocol, can be easily integrated into systems that
already use RS-485 or RS-232 interfaces. Devices with serial communication capabilities
(like Modbus RTU devices) are often found in legacy systems, making Modbus RTU an
attractive choice for retrofitting or upgrading existing installations.

One advantage of Modbus RTU is its simplicity, which results in lower implementation costs
and reduced complexity. It requires fewer resources and less processing power than Modbus
TCP, making it suitable for devices with limited computational capabilities.

However, there are some challenges when integrating Modbus RTU into larger systems. The
protocol requires a dedicated communication channel for each connection, which can limit the
scalability of the network. Additionally, Modbus RTU networks may suffer from signal
degradation and noise issues when transmitting data over long distances or in electrically
noisy environments.

Modbus TCP Integration

Modbus TCP is designed for Ethernet-based communication, which is the prevalent

communication medium in modern industrial automation systems. Due to the widespread
availability of Ethernet-compatible devices and infrastructure, the integration of Modbus
TCP into new installations becomes more straightforward.

Another advantage of Modbus TCP is its compatibility with the standard TCP/IP stack, which
allows for seamless integration with existing IP networks. This compatibility enables Modbus
TCP devices to communicate over local networks, as well as remotely over the Internet,
providing greater flexibility in network architecture.

However, the integration of Modbus TCP into systems with limited resources or legacy
devices can be more challenging. Modbus TCP requires more processing power and memory
than Modbus RTU, which may necessitate the use of more powerful or specialized hardware.
Comparing the ease of integration of Modbus RTU and Modbus TCP reveals that RTU is a
good choice where implementation is simple, and cost is a concern. Besides, many industries
with legacy systems will find RTU as the best retrofit. On the other hand, TCP could be the
standard Modbus choice considering the widespread usage of modern Ethernet-based systems.
However, its higher resource requirements may not be integrable with various limited devices.

5- Modbus Gateways

Just like language a translator helps people speaking different languages understand each
other. Similarly, Modbus gateways help in exchanging data between different devices that use
different protocols for communication.

Consider a device that uses serial communication using Modbus RTU/ASCII. However, you
would like to integrate this into a network that uses Modbus TCP/IP over ethernet. Modbus
Gateways makes this possible.

Not just for Modbus devices, but it can also be used to connect non-Modbus devices to the
Modbus network, or vice versa. Besides protocol conversion, Modbus Gateways also perform
data mapping, interface conversion, filtering, etc.

6- Modbus RTU vs Modbus TCP: Cost Considerations

When choosing between Modbus RTU and Modbus TCP, cost considerations play a
significant role in the decision-making process. In this section, we will examine the various
factors that contribute to the overall costs of implementing and maintaining both protocols.

Modbus RTU Cost Factors

Modbus RTU, as a serial communication protocol, is generally considered to be more cost-

effective than Modbus TCP in certain scenarios. The hardware required for Modbus
RTU communication, such as RS-485 or RS-232 transceivers, is typically less expensive than
the hardware necessary for Ethernet-based communication.

Additionally, Modbus RTU's simplicity and lower resource requirements can lead to savings
in terms of computational resources and memory. This means that less expensive and less
powerful devices can be used in a Modbus RTU network, reducing overall hardware costs.

However, there are some cost-related drawbacks to Modbus RTU. The need for dedicated
communication channels for each connection can increase wiring and installation costs in
larger systems. Moreover, the potential for signal degradation and noise interference in long-
distance or electrically noisy environments may necessitate the use of repeaters or additional
shielding, further increasing the overall cost.
Modbus TCP Cost Factors

Modbus TCP, being an Ethernet-based protocol, generally requires more expensive hardware
than Modbus RTU, such as Ethernet switches, routers, and network interface cards.
Furthermore, the higher processing power and memory requirements of Modbus TCP may
necessitate the use of more powerful devices, which can increase hardware costs.

However, Modbus TCP benefits from the ubiquity of Ethernet-based infrastructure, which can
result in lower installation costs due to the widespread availability of Ethernet cables and
devices. The use of standard TCP/IP communication also allows for the sharing of
communication channels, reducing the need for dedicated wiring and lowering installation
costs.

In addition, Modbus TCP's compatibility with existing IP networks enables remote access and
monitoring, potentially reducing maintenance and troubleshooting costs by allowing remote
diagnostics and updates.

When comparing the cost considerations of Modbus RTU and Modbus TCP, it is essential to
take into account factors such as hardware, installation, and maintenance expenses.
Evaluating based on these factors with the help of system designers, the best choice can be
estimated between the two.
7- Modbus RTU vs Modbus TCP: Real-World Applications

When it comes to real-world applications, the choice between Modbus RTU and Modbus
TCP often depends on the specific requirements of the system, the environment, and other
factors. In this section, we will explore typical use cases for both Modbus RTU and Modbus
TCP, highlighting their strengths and weaknesses in different scenarios.

Modbus RTU in Industrial Automation

Modbus RTU is widely used in industrial automation applications due to its simplicity,
reliability, and cost-effectiveness. It is particularly well-suited for small-scale systems or for
connecting devices within a localized area, such as a factory floor or a single building.

For instance, Modbus RTU can be employed to connect Programmable Logic Controllers
(PLCs) to various sensors, actuators, and other devices in a production line. This allows for
the monitoring and control of processes such as temperature regulation, motor speed control,
or fluid level monitoring. Its deterministic nature, which ensures a fixed response time, is
essential in time-sensitive applications where quick decision-making and control are crucial.

Modbus TCP in Building Automation and Smart Grids

Modbus TCP is an ideal choice for applications that require extensive networking, remote
access, or integration with other IP-based systems. In building automation, for
example, Modbus TCP can facilitate communication between various building systems, such
as heating, ventilation, air conditioning (HVAC), lighting, and security systems. This allows
for centralized monitoring and control, improving energy efficiency and optimizing building
operations.

Similarly, in smart grid applications, Modbus TCP can enable communication between
different components of the electrical grid, including power generation, transmission, and
distribution systems. This facilitates real-time monitoring, control, and data analysis, helping
to optimize grid performance, enhance reliability, and improve energy efficiency.

Hybrid Applications

In some cases, a hybrid approach that combines both Modbus RTU and Modbus TCP may be
the most suitable solution. For example, in a large industrial facility, Modbus RTU can be
used for local communication between devices within individual production lines or sections,
while Modbus TCP can be utilized for higher-level communication between different sections
or for remote access and monitoring.

This hybrid approach allows organizations to leverage the strengths of both protocols: the
simplicity, cost-effectiveness, and deterministic nature of Modbus RTU for local device
communication, and the networking capabilities, remote access, and integration potential
of Modbus TCP for more extensive communication requirements.

Conclusion

In conclusion, Modbus RTU and Modbus TCP are both widely used communication protocols
in industrial automation and control systems. While RTU is the most popular so far, the
recognized benefits of TCP are narrowing this gap. Ultimately, the choice between these two
protocols depends on various factors which we discussed above and has been summarized for
you in the table below. By thoroughly evaluating these factors, system designers can
determine the best protocol for their specific application and optimize system performance.

Table 2: Comparison of Modbus RTU vs TCP:

Factors Modbus RTU Modbus Ethernet TCP/IP

Cable Type RS 232, RS-422, RS-485; Ethernet TCP/IP;

 Designed for Serial Designed for communication over ethernet
Communication with TCP/IP protocols

115 Kbps; 100 Mbps;

Max Speed Often sufficient for small-scale Suitable for applications requiring large
industry usages where master- data handling, faster data transmission, and
slave devices are nearby. real-time performance.

Length Upto 1200 meters Upto 100 Meters

Daisy Chain
Star, Tree, Daisy Chain, etc.
(supports upto 32 slaves without
Topology (up to 247 servers)
repeaters and 247 with repeaters)

Master-Slave
Single Master Multiple Clients
Communication

Difficult as compared to TCP.

More vulnerable as compared to RTU.
Security Can be hacked after gaining
Can be hacked remotely by hackers.
physical access.

Integrable with existing RTU

systems and legal systems. Widely integrable due to the widespread
Ethernet technology. Ideal for devices
Integration Suitable with low-level hardware spread at far distances and at multiple
requirements application, also with locations, requiring remote monitoring and
master-slave having close control.
proximity between them.

Low hardware and infrastructure Cheaper cabling costs as easier to install,

Cost costs. and with existing ethernet infrastructure
setup.
However, wiring cost increases
 with the number of devices and However, requires advanced equipment and
maintenance factors. troubleshooting, which are high on cost

Distributed systems at multiple locations,

Devices in close proximity, legacy
modern industrial automation requiring
Application systems, a wide range of field
ethernet communication, SCADA systems
devices, oil and gas industries, etc.
for real-time monitoring, etc.