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Wiring 9
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Wiring 9 — RS-485 Modbus RTU Daisy Chain with Termination

What you'll learn

Modbus RTU communicates over RS-485 — a differential signalling standard designed for long cable runs in electrically noisy industrial environments. Instead of sending a signal relative to a common ground, RS-485 uses two wires called **A** and **B** that carry the same data with **opposite polarity** at all times. The receiver measures the voltage difference between A and B. Any noise picked up equally on both conductors (common-mode noise — inductive and capacitive interference from nearby motor drives, relay coils, and power cables) cancels out in the subtraction. RS-485 cables routinely run 1 200 metres in switchgear cabinets that would destroy an RS-232 link.

Lab time: ~18 minutes.

Lesson briefing

RS-485 Modbus RTU Daisy Chain with Termination

Why RS-485?

Modbus RTU communicates over RS-485 — a differential signalling standard designed for long cable runs in electrically noisy industrial environments. Instead of sending a signal relative to a common ground, RS-485 uses two wires called A and B that carry the same data with opposite polarity at all times. The receiver measures the voltage difference between A and B. Any noise picked up equally on both conductors (common-mode noise — inductive and capacitive interference from nearby motor drives, relay coils, and power cables) cancels out in the subtraction. RS-485 cables routinely run 1 200 metres in switchgear cabinets that would destroy an RS-232 link.

The Four Critical Wires per Node

Every Modbus node on the segment needs four connections:

  1. A — non-inverting differential line.
  2. B — inverting differential line.
  3. COM / 0V — a common reference wire that runs alongside A and B. Without it the differential signal can drift outside the receiver's common-mode input range (typically ±7 V), and communication becomes intermittent or fails entirely. This is the most-skipped wire in field installations and the most common cause of "works in the lab, fails in the cabinet" Modbus problems.
  4. Cable shield — bonded to PE at one end only (typically the master end). Bonding both ends creates a ground loop: any potential difference between the two earth points drives a circulating current down the shield, inducing noise on the very conductors you are trying to protect.

Daisy-Chain Topology — No Stars, No Spurs

RS-485 must be wired as a single linear chain: master → slave 1 → slave 2 → ... → last slave. The cable passes through each device in turn. Star wiring (one cable out from a central hub to each device) and spurs (short branches off the main cable) cause signal reflections that corrupt data, especially at higher baud rates (19 200 bps and above). Short spurs under approximately 30 cm are tolerated in practice because their reflection returns before the driver has finished the bit transition; longer spurs are not.

Termination at the Extremes Only

When a voltage step travels down a cable and reaches the far end, it reflects back unless the cable's characteristic impedance is matched at that end. Belden 9841 and similar twisted-pair cable have a characteristic impedance of approximately 120 Ω. Place a 120 Ω resistor across A-B at each extreme end of the chain (master end and last-slave end) — not at any intermediate node. Termination in the middle halves the load impedance seen by the drivers and reduces the signal amplitude. Termination at one end only leaves the other end unterminated, and that reflection arrives back exactly when the driver is trying to resolve the next bit.

Biasing

When no node is transmitting, the A and B lines float to an undefined voltage. Some receivers interpret a floating line as a mark (logic 1) because a mark is the idle state; others interpret it as a space (logic 0), causing a framing error the moment the first byte arrives. Most modern Modbus master ports include built-in bias resistors — a pull-up on B and a pull-down on A that force the lines to a known idle state (typically 4-5 V differential) between transmissions. In this lesson the master node is assumed to have biasing built in; no separate bias resistor pair is modelled.

Common Modbus Wiring Mistakes

  • Missing COM wire. All three conductors (A, B, COM) must run between every adjacent pair of nodes. Omitting COM causes intermittent failures that worsen over cable length.
  • Terminating in the middle. A terminator across the A-B of a middle node loads the bus permanently. Symptoms: weak signal, high error rate, or complete failure at higher baud rates.
  • Spurs longer than ~30 cm. A device tapped off the main cable with a spur longer than 30 cm acts as a stub antenna. Remove the spur; splice the device into the main cable run.
  • Ground loop on the shield. Bonding the cable shield to PE at more than one point creates a low-resistance loop. The circulating current induced by earth-potential differences is a significant noise source on the signal conductors.

Hints

Hint 1

Three signal wires connect each adjacent pair of nodes — A, B, and a shared 0V common reference (COM). The cable shield bonds to PE at the master end only. A-B carry the differential signal; 0V prevents the common-mode voltage from drifting outside the receiver's input range.

Hint 2

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Hint 3

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Hint 4

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Hint 5

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This lesson uses 11 placed components on the lab canvas. Components are vendor-neutral (no proprietary trademarks); the wiring rules apply to any equivalent industrial part.

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Competency and practice field guide

RS-485 Modbus wiring lesson: implementation, evidence and troubleshooting

Direct answer

RS-485 Modbus wiring lesson becomes useful when it connects two-wire or four-wire interface, trunk and stubs, conductor impedance, polarity convention, reference conductor, shield grounding, termination endpoints, bias, isolation, baud, parity and node identity with transceiver through differential pair and topology to remote transceiver, uart settings, rtu frame, addressed server, response, register interpretation and process value, then proves one known request and response repeat reliably across the intended bus while raw and engineering values match a controlled state under normal, boundary, fault and recovery conditions. The objective is a repeatable engineering or learning result, not merely activity inside a page or tool.

This guide is written for pLC and instrumentation learners wiring a serial trunk with correct topology, polarity, common reference, shield, bias and termination before configuring Modbus RTU. The intended result is specific: the learner can separate an electrical-layer failure from serial framing, device identity, request and data-interpretation errors.

an industrial network diagnostics lab connecting generic controllers, distributed I/O, serial and Ethernet paths to protocol traces and process values while studying RS-485 bus wiring and Modbus communication evidence
The scene keeps RS-485 bus wiring and Modbus communication evidence connected to a declared operating condition, observable evidence, safe boundaries and a result another person can reproduce.

System map / 02

Six concepts that control the result

Treat these as connected checkpoints. Each checkpoint has an expected state, an observable state and a boundary to the next part of the system. That structure prevents a software indication from being mistaken for physical proof.

NODE 01observable

Define the operating contract

two-wire or four-wire interface, trunk and stubs, conductor impedance, polarity convention, reference conductor, shield grounding, termination endpoints, bias, isolation, baud, parity and node identity. For RS-485 bus wiring and Modbus communication evidence, record the initial condition, actor, requested change, observable result and stopping condition before selecting a tool or implementation.

NODE 02observable

Map the evidence path

transceiver through differential pair and topology to remote transceiver, UART settings, RTU frame, addressed server, response, register interpretation and process value. Separate request, internal state, output or service, physical or user-visible result and independent feedback so each boundary can be inspected.

NODE 03observable

Prove normal operation

one known request and response repeat reliably across the intended bus while raw and engineering values match a controlled state. Run more than one cycle from a known state and retain the values, timings or artifacts that demonstrate repeatability.

NODE 04observable

Exercise a boundary case

reversed pair, star wiring, long stub, missing common, excess termination, shield path, duplicate address, parity mismatch, noise, timeout and reconnect. Choose minimum, maximum, simultaneous, delayed or restart conditions that reveal assumptions hidden by the happy path.

NODE 05observable

Diagnose a controlled fault

a transceiver, conductor, topology, termination, bias, reference, EMC, serial, identity, protocol or data mismatch. Preserve the first symptom, divide the system at a measurable boundary and change one condition only after predicting the result.

NODE 06observable

Transfer and hand over

the installed link inspected and tested on target cable and devices using current manuals, captures and controlled communication-loss cases. Restore normal state, remove temporary changes, repeat affected checks and document which claims remain limited to the learning environment.

Procedure / 03

A six-step practice and commissioning workflow

Run the steps in order the first time. Later, the same structure becomes a diagnostic loop: define the expected condition, observe the boundary, interpret the difference and choose one proving action.

  1. 01

    Write the acceptance case

    Convert two-wire or four-wire interface, trunk and stubs, conductor impedance, polarity convention, reference conductor, shield grounding, termination endpoints, bias, isolation, baud, parity and node identity into initial conditions, one stimulus and observable pass criteria.

    Evidence: Another person can repeat the case without guessing the intended result.

    Avoid: Using page completion or an animation as the acceptance criterion.

  2. 02

    Build the map

    Document transceiver through differential pair and topology to remote transceiver, uart settings, rtu frame, addressed server, response, register interpretation and process value and name who owns each state or decision.

    Evidence: Every request and result has a source, destination and useful inspection point.

    Avoid: Using the same value as command, status and independent feedback.

  3. 03

    Run the baseline

    Apply one known request and response repeat reliably across the intended bus while raw and engineering values match a controlled state from a clean start and record the expected evidence.

    Evidence: Repeated runs produce the same bounded result.

    Avoid: Changing several parameters before a baseline exists.

  4. 04

    Challenge assumptions

    Test reversed pair, star wiring, long stub, missing common, excess termination, shield path, duplicate address, parity mismatch, noise, timeout and reconnect without changing the acceptance contract.

    Evidence: Limits, timing and restart behavior reach defined states.

    Avoid: Testing only one ideal sequence.

  5. 05

    Isolate one failure

    Introduce or analyse a transceiver, conductor, topology, termination, bias, reference, emc, serial, identity, protocol or data mismatch and locate the first disagreement.

    Evidence: The proving action distinguishes the leading hypotheses.

    Avoid: Resetting, forcing or replacing before evidence is retained.

  6. 06

    Close the evidence loop

    Complete the installed link inspected and tested on target cable and devices using current manuals, captures and controlled communication-loss cases and repeat the affected regression cases.

    Evidence: A learner completes the surface by explaining the result, passing a changed case and identifying what still requires supervised target-equipment practice.

    Avoid: Treating an acknowledged message or one successful rerun as handover.

Diagnostic matrix / 04

Symptoms, proving points and next actions

The table is a reasoning aid, not a parts-replacement chart. Preserve the initial symptom, inspect the named boundary and use the interpretation to choose the next controlled test. Site safety procedures and equipment manuals remain authoritative.

Diagnostic symptoms, inspection points, interpretations and next actions for RS-485 Modbus wiring lesson: implementation, evidence and troubleshooting
Observed symptomInspectInterpretationNext proving action
The expected result is unclearRequirement, initial state, actor, stimulus, units and pass conditionThe learner, instructor and assessor may be solving different versions of the task.Rewrite one observable acceptance case before continuing.
Internal state changes but the outcome does notRequest, final owner, output or service boundary and independent feedbackA software or interface indication proves intent at one layer, not the complete outcome.Trace the first boundary after the changing state.
Normal case passes but an edge case failsLimits, timing, simultaneous events, reset and restart assumptionsThe implementation contains a hidden assumption exposed by the changed condition.Add the failed boundary as a permanent regression case.
The failure disappears after resetOriginal symptom, histories, diagnostics, timestamps and active causeReset changed evidence or state without proving the initiating cause.Reproduce under a controlled condition and preserve pre/post-event data.
Simulator and target disagreeModel boundary, software version, task timing, I/O behavior, data types and configurationA learning model and the intended target do not share one of the recorded assumptions.Reduce the case and verify against current target documentation.
The result cannot be explainedPrediction, observation, proving action, alternative hypotheses and limitationsActivity occurred but the evidence is not yet transferable or reviewable.Have the learner defend the signal path and repeat a changed case.

Product evidence / 05

What the browser practice can actually demonstrate

The browser platform can retain programs, scenario results, attempts and observable machine state so practice is attached to evidence rather than seat time alone.

Where simulation stops

The lesson cannot certify installed cable, EMC performance, hazardous-area suitability, device conformance or network cybersecurity.

Commissioning notebook / 06

Six cases that turn the concepts into evidence

Use these as written briefs rather than click-through instructions. For every case, state the expected condition before acting, retain the first useful observation and explain why the final result proves the requirement. A different program or component choice can still be correct when it produces the same bounded behavior and evidence.

Case 01

predict → observe → prove

Prove define the operating contract

Engineering context. two-wire or four-wire interface, trunk and stubs, conductor impedance, polarity convention, reference conductor, shield grounding, termination endpoints, bias, isolation, baud, parity and node identity. For RS-485 bus wiring and Modbus communication evidence, record the initial condition, actor, requested change, observable result and stopping condition before selecting a tool or implementation. Begin with a written normal condition and identify which request, state, physical result or communication value will provide independent confirmation. Do not begin by changing the configuration; the initial state is part of the evidence and should remain reproducible.

Controlled setup. Use the “Write the acceptance case” stage of the workflow: convert two-wire or four-wire interface, trunk and stubs, conductor impedance, polarity convention, reference conductor, shield grounding, termination endpoints, bias, isolation, baud, parity and node identity into initial conditions, one stimulus and observable pass criteria. The acceptance record should show this result: another person can repeat the case without guessing the intended result. Record initial conditions, the exact stimulus and the observation point so another learner can repeat the case without relying on your memory.

Fault challenge. Introduce or analyse “The expected result is unclear” as one bounded deviation. Inspect requirement, initial state, actor, stimulus, units and pass condition The working interpretation is that the learner, instructor and assessor may be solving different versions of the task. The next proving action is to rewrite one observable acceptance case before continuing. Change only one condition before observing the result, and preserve timestamps or measurements where timing matters.

Review and recovery. The most common trap here is using page completion or an animation as the acceptance criterion. After restoring the cause, repeat the normal case and at least one stop, timeout, disconnect or restart boundary relevant to this topic. Remove temporary forces and bypasses, return the model to a known state and retain the evidence that both operation and recovery are deliberate.

Explain it aloud: How should RS-485 Modbus devices be wired? A defensible short answer is: Use the device-approved bus topology, consistent polarity, suitable cable, common reference or isolation strategy, endpoint termination and biasing as required.

Case 02

predict → observe → prove

Prove map the evidence path

Engineering context. transceiver through differential pair and topology to remote transceiver, UART settings, RTU frame, addressed server, response, register interpretation and process value. Separate request, internal state, output or service, physical or user-visible result and independent feedback so each boundary can be inspected. Begin with a written normal condition and identify which request, state, physical result or communication value will provide independent confirmation. Do not begin by changing the configuration; the initial state is part of the evidence and should remain reproducible.

Controlled setup. Use the “Build the map” stage of the workflow: document transceiver through differential pair and topology to remote transceiver, uart settings, rtu frame, addressed server, response, register interpretation and process value and name who owns each state or decision. The acceptance record should show this result: every request and result has a source, destination and useful inspection point. Record initial conditions, the exact stimulus and the observation point so another learner can repeat the case without relying on your memory.

Fault challenge. Introduce or analyse “Internal state changes but the outcome does not” as one bounded deviation. Inspect request, final owner, output or service boundary and independent feedback The working interpretation is that a software or interface indication proves intent at one layer, not the complete outcome. The next proving action is to trace the first boundary after the changing state. Change only one condition before observing the result, and preserve timestamps or measurements where timing matters.

Review and recovery. The most common trap here is using the same value as command, status and independent feedback. After restoring the cause, repeat the normal case and at least one stop, timeout, disconnect or restart boundary relevant to this topic. Remove temporary forces and bypasses, return the model to a known state and retain the evidence that both operation and recovery are deliberate.

Explain it aloud: Where should RS-485 termination resistors be installed? A defensible short answer is: Typically at the physical ends of the bus, but follow the transceiver, cable and network design instructions rather than adding termination to every node.

Case 03

predict → observe → prove

Prove prove normal operation

Engineering context. one known request and response repeat reliably across the intended bus while raw and engineering values match a controlled state. Run more than one cycle from a known state and retain the values, timings or artifacts that demonstrate repeatability. Begin with a written normal condition and identify which request, state, physical result or communication value will provide independent confirmation. Do not begin by changing the configuration; the initial state is part of the evidence and should remain reproducible.

Controlled setup. Use the “Run the baseline” stage of the workflow: apply one known request and response repeat reliably across the intended bus while raw and engineering values match a controlled state from a clean start and record the expected evidence. The acceptance record should show this result: repeated runs produce the same bounded result. Record initial conditions, the exact stimulus and the observation point so another learner can repeat the case without relying on your memory.

Fault challenge. Introduce or analyse “Normal case passes but an edge case fails” as one bounded deviation. Inspect limits, timing, simultaneous events, reset and restart assumptions The working interpretation is that the implementation contains a hidden assumption exposed by the changed condition. The next proving action is to add the failed boundary as a permanent regression case. Change only one condition before observing the result, and preserve timestamps or measurements where timing matters.

Review and recovery. The most common trap here is changing several parameters before a baseline exists. After restoring the cause, repeat the normal case and at least one stop, timeout, disconnect or restart boundary relevant to this topic. Remove temporary forces and bypasses, return the model to a known state and retain the evidence that both operation and recovery are deliberate.

Explain it aloud: What should I learn first about RS-485 bus wiring and Modbus communication evidence? A defensible short answer is: Start with the operating contract and evidence path: two-wire or four-wire interface, trunk and stubs, conductor impedance, polarity convention, reference conductor, shield grounding, termination endpoints, bias, isolation, baud, parity and node identity, followed by transceiver through differential pair and topology to remote transceiver, uart settings, rtu frame, addressed server, response, register interpretation and process value. Add advanced features only after the baseline is predictable.

Case 04

predict → observe → prove

Prove exercise a boundary case

Engineering context. reversed pair, star wiring, long stub, missing common, excess termination, shield path, duplicate address, parity mismatch, noise, timeout and reconnect. Choose minimum, maximum, simultaneous, delayed or restart conditions that reveal assumptions hidden by the happy path. Begin with a written normal condition and identify which request, state, physical result or communication value will provide independent confirmation. Do not begin by changing the configuration; the initial state is part of the evidence and should remain reproducible.

Controlled setup. Use the “Challenge assumptions” stage of the workflow: test reversed pair, star wiring, long stub, missing common, excess termination, shield path, duplicate address, parity mismatch, noise, timeout and reconnect without changing the acceptance contract. The acceptance record should show this result: limits, timing and restart behavior reach defined states. Record initial conditions, the exact stimulus and the observation point so another learner can repeat the case without relying on your memory.

Fault challenge. Introduce or analyse “The failure disappears after reset” as one bounded deviation. Inspect original symptom, histories, diagnostics, timestamps and active cause The working interpretation is that reset changed evidence or state without proving the initiating cause. The next proving action is to reproduce under a controlled condition and preserve pre/post-event data. Change only one condition before observing the result, and preserve timestamps or measurements where timing matters.

Review and recovery. The most common trap here is testing only one ideal sequence. After restoring the cause, repeat the normal case and at least one stop, timeout, disconnect or restart boundary relevant to this topic. Remove temporary forces and bypasses, return the model to a known state and retain the evidence that both operation and recovery are deliberate.

Explain it aloud: How do I practise RS-485 bus wiring and Modbus communication evidence effectively? A defensible short answer is: Use short cases with known initial conditions, a written prediction, one action and an observable result. Then alter a boundary or fault and explain why the evidence changed.

Case 05

predict → observe → prove

Prove diagnose a controlled fault

Engineering context. a transceiver, conductor, topology, termination, bias, reference, EMC, serial, identity, protocol or data mismatch. Preserve the first symptom, divide the system at a measurable boundary and change one condition only after predicting the result. Begin with a written normal condition and identify which request, state, physical result or communication value will provide independent confirmation. Do not begin by changing the configuration; the initial state is part of the evidence and should remain reproducible.

Controlled setup. Use the “Isolate one failure” stage of the workflow: introduce or analyse a transceiver, conductor, topology, termination, bias, reference, emc, serial, identity, protocol or data mismatch and locate the first disagreement. The acceptance record should show this result: the proving action distinguishes the leading hypotheses. Record initial conditions, the exact stimulus and the observation point so another learner can repeat the case without relying on your memory.

Fault challenge. Introduce or analyse “Simulator and target disagree” as one bounded deviation. Inspect model boundary, software version, task timing, I/O behavior, data types and configuration The working interpretation is that a learning model and the intended target do not share one of the recorded assumptions. The next proving action is to reduce the case and verify against current target documentation. Change only one condition before observing the result, and preserve timestamps or measurements where timing matters.

Review and recovery. The most common trap here is resetting, forcing or replacing before evidence is retained. After restoring the cause, repeat the normal case and at least one stop, timeout, disconnect or restart boundary relevant to this topic. Remove temporary forces and bypasses, return the model to a known state and retain the evidence that both operation and recovery are deliberate.

Explain it aloud: What counts as proof of competence? A defensible short answer is: A repeatable artifact or system result plus an explanation of the signal path is stronger than time spent, screenshots or a copied answer. Physical competence requires separate supervised evidence.

Case 06

predict → observe → prove

Prove transfer and hand over

Engineering context. the installed link inspected and tested on target cable and devices using current manuals, captures and controlled communication-loss cases. Restore normal state, remove temporary changes, repeat affected checks and document which claims remain limited to the learning environment. Begin with a written normal condition and identify which request, state, physical result or communication value will provide independent confirmation. Do not begin by changing the configuration; the initial state is part of the evidence and should remain reproducible.

Controlled setup. Use the “Close the evidence loop” stage of the workflow: complete the installed link inspected and tested on target cable and devices using current manuals, captures and controlled communication-loss cases and repeat the affected regression cases. The acceptance record should show this result: a learner completes the surface by explaining the result, passing a changed case and identifying what still requires supervised target-equipment practice. Record initial conditions, the exact stimulus and the observation point so another learner can repeat the case without relying on your memory.

Fault challenge. Introduce or analyse “The result cannot be explained” as one bounded deviation. Inspect prediction, observation, proving action, alternative hypotheses and limitations The working interpretation is that activity occurred but the evidence is not yet transferable or reviewable. The next proving action is to have the learner defend the signal path and repeat a changed case. Change only one condition before observing the result, and preserve timestamps or measurements where timing matters.

Review and recovery. The most common trap here is treating an acknowledged message or one successful rerun as handover. After restoring the cause, repeat the normal case and at least one stop, timeout, disconnect or restart boundary relevant to this topic. Remove temporary forces and bypasses, return the model to a known state and retain the evidence that both operation and recovery are deliberate.

Explain it aloud: Why test faults and restart behavior? A defensible short answer is: Because a transceiver, conductor, topology, termination, bias, reference, emc, serial, identity, protocol or data mismatch or reversed pair, star wiring, long stub, missing common, excess termination, shield path, duplicate address, parity mismatch, noise, timeout and reconnect can expose assumptions that never appear during ideal startup and steady operation.

Answer surface / 07

Questions people ask about RS-485 Modbus wiring lesson

These concise answers define the operating, training and product boundaries most often missed in broad summaries. The full workflow and diagnostic table above provide the evidence behind them.

How should RS-485 Modbus devices be wired?

Use the device-approved bus topology, consistent polarity, suitable cable, common reference or isolation strategy, endpoint termination and biasing as required.

Where should RS-485 termination resistors be installed?

Typically at the physical ends of the bus, but follow the transceiver, cable and network design instructions rather than adding termination to every node.

What should I learn first about RS-485 bus wiring and Modbus communication evidence?

Start with the operating contract and evidence path: two-wire or four-wire interface, trunk and stubs, conductor impedance, polarity convention, reference conductor, shield grounding, termination endpoints, bias, isolation, baud, parity and node identity, followed by transceiver through differential pair and topology to remote transceiver, uart settings, rtu frame, addressed server, response, register interpretation and process value. Add advanced features only after the baseline is predictable.

How do I practise RS-485 bus wiring and Modbus communication evidence effectively?

Use short cases with known initial conditions, a written prediction, one action and an observable result. Then alter a boundary or fault and explain why the evidence changed.

What counts as proof of competence?

A repeatable artifact or system result plus an explanation of the signal path is stronger than time spent, screenshots or a copied answer. Physical competence requires separate supervised evidence.

Why test faults and restart behavior?

Because a transceiver, conductor, topology, termination, bias, reference, emc, serial, identity, protocol or data mismatch or reversed pair, star wiring, long stub, missing common, excess termination, shield path, duplicate address, parity mismatch, noise, timeout and reconnect can expose assumptions that never appear during ideal startup and steady operation.

Can browser practice replace official software or hardware?

No. It can build concepts and diagnostic reasoning. Exact firmware, I/O electrical behavior, networking, safety and commissioning require current official tools, documentation and target equipment.

How should progress be documented?

Keep the requirement, initial state, program or configuration, observed values, fault hypothesis, proving action, recovery result and a concise limitations statement.