Title: High-available%20SIMATIC%20S7-400H
1Automation and Drives
S
IMATIC S7-400H
The Fault-tolerant Automation System
2Different Concepts
Redundant automation systems
Overview
Fault-tolerant 1-out-of-2 systems Objective Redu
ce the probability of production losses by
switching to a standby system
Fail-safe 1-out-of-2 systems Objective Protect
life, the environment and investments by safely
disconnecting to a secure off position
3Overview
- Why do we have fault-tolerant programmable logic
controllers? - The objective of using high-availability
programmable logic controllers is a reduction
of production losses. It does not matter whether
the losses are caused by an error or as a result
of maintenance work. - The higher the costs of a stoppage, the more
worthwhile it is to use a fault-tolerant
system. The generally higher investment costs of
fault-tolerant systems are quickly compensated by
avoiding production losses.
4Benefits
- Avoidance of control system failures due to
individual faults - This is attained primarily through a redundant
configuration - Fault-tolerance is required in the following
cases - When processing valuable materials
- When downtimes or production failures would be
expensive - When a control system failure would result in
high restart costs - In order to enable operation without supervisory
or maintenance personnel
Overview
5Software redundancy
In a large number of applications, requirements
for the quality of redundancy or the number of
system sections that necessitate redundant PLCs
are not high enough to warrant the use of a
specific fault-tolerant system. Frequently,
simple software mechanisms are sufficient to
allow continuation of a failed control task on a
substitute system in the event of an error. The
SIMATIC S7 Software Redundancy options software
can run on S7-300 and S7-400 standard systems to
control processes that tolerate transfer times to
a substitute system within seconds, such as water
works, water treatment systems or traffic flows.
Overview
6- Hardware Redundancy
- For Fast Processes Switch Over
time few M. Sec. - Software Redundancy
- For Slow Processes Switch Over
time few Sec.
Overview
7Industries (1)
- Power generation and distribution(oil, gas,
electricity) - Power plants
- Pipelines
- Offshore
- District heating systems
- Chemical, electrochemical, petrochemical and
pharmaceutical industries - Mining
- Environmental engineering
- Water treatment
- Refuse incineration
- Pulp and paper
- Steel and metal
Overview
8Industries (2)
- Food and beverages
- Glass industry
- Semiconductor industry (utilities)
- Transport
- Tunnel automation
- Marine automation
- Airports
- Runway lighting
- Baggage transport
Overview
9System architecture
Overview
Clients Parallel redundancy
Management level
Server Parallel redundancy With archive-matching
PC network/terminal bus
Fault-tolerantcommunication
Ethernet
Media redundancy
Process level
H CPUs Hot stand-by
SW redundancy Warm stand-by
Redundant power supply
ET 200M
Field level
Redundant PROFIBUS
Redundant IM 153
10System integration
- Hidden redundancy
- Transparent programming(programming same as for
non-redundant systems) - Standard system parameterization
- Standard handling
- All SIMATIC programming languages can be used
without
restriction - Platform for F andFH systems
Overview
11Sample System
12ConfigurationRedundant link
Replaceable Sync modules
Fiber-optics (FO)
Configuration
Fiber-optics (FO)
13Hardware of the S7-400H base system Minimum
Configuration
Central processing units At the heart of the
S7-400H are the two central processing units.
Setting of the synchronization submodules, which
have to be plugged into the CPU, defines the rack
numbers. In the following we will refer to the
CPU in rack 0 as CPU 0,and to the CPU in rack 1
as CPU 1.
14Setting the Rack Number
15ConfigurationHighlights new CPUs
- Performance Increase
- Average Increase
- 417-4H appr. x 2,5-3
- 414-4H appr. x 1,2-2,2
- More Memeory
- 417-4H from 4 MB to 20MB
- 414-4H from 768KB to 1,4MB
- Higher Reliability
- Memory with automatic Error Detection and
Correction (EDC) - New Feature
- Distance between the Controller up to 10km
(before 500m)
Konfiguration
16ConfigurationTechnical specifications for the
CPUs
- Two CPU types available
- CPU 417-4H with 20MB onboard
- CPU 414-4H with1,4MB onboard
- General technical specifications,e.g. CPU 417-4
or CPU 414-3 - 4 integrated interfaces
- Two for the Sync modules
- One DP interface
- One MPI/DP interface
Configuration
17Central Controller Configuration
- Distance between the Controller up to 10m
- Use of the Sync-Modules for Patch Cables up to
10m - MLFB Module 6ES7 960-1AA04-0XA0
- MLFB FO-Cable 1m 6ES7 960-1AA04-5AA0
- MLFB FO-Cable 2m 6ES7 960-1AA04-5BA0
- MLFB FO-Cable 10m 6ES7 960-1AA04-5KA0
- Distance between the Controller up to 10km
- Use of the Sync-Modules for Cables up to 10km
- MLFB Module 6ES7 960-1AB04-0XA0
- Monomode FO-Cable LC/LC Duplex crossed 9/125µ
Konfiguration
18Expanding the Working Memory of the CPU 417-4 H
with Memory Modules
19Expanding the Working Memory of the CPU 417-4 H
with Memory Modules
20Mounting rack for S7-400H
- It is recommended that you use the UR2-H
mounting rack for the S7- - 400H. The mounting rack makes it possible to
configure two - separate subsystems, each containing nine
slots, and is suitable for - installation in 19 cabinets.
- Alternatively, you can also configure the
S7-400H on two separate - mounting racks.
- Two mounting racks, the UR1 and UR2, are
available for this purpose.
21Central controller configurations
- With two standard subracks
Redundant power supply (PS) optional
PS
PS
CPU
PS
PS
CPU
Max. cable length 10km
With H subrack (with split backplane bus)
Configuration
PS
PS
CPU
PS
PS
CPU
22Power supply
- As a power supply, you will require for each
fault-tolerant CPU a - power supply module from the standard range
of the S7-400. - Power supply modules for rated input voltages
of 24 VDC and - 120/230 VAC are available with 10 and 20 A
output current. - Redundant Power Supply
- To enhance the availability of the power supply,
you can also use two redundant power supplies in
each subsystem. In this case you should use the
PS 407 10A R power supply module for rated
voltages of 120/230 VAC with an output power of
10 A.
Configuration
23What is single-channel, one-way I/O?
- With the single-channel, one-way configuration
single input/output modules are present
(single-channel). The input/output modules are
located in just one of the subsystems and are
only addressed by that subsystem. - A single-channel, one-way I/O configuration is
possible in - Central controllers and expansion units
- Distributed I/Os
- The single-channel, one-way I/O configuration is
to be recommended for individual input/output
channels for which normal availability of the I/O
is sufficient.
Configuration
24Failure of the single-channel, one-way I/O
- In the event of a malfunction the S7-400H with a
single-channel, one-way I/O behaves like a
standard S7-400 system, in other words - When the I/O fails, the defective I/O is no
longer available. - When a subsystem fails, the entire process I/O
of that subsystem is not - available any more.
25Using Single-Channel, Switched I/O
- In Redundant mode they
- may be addressed by both
- subsystems.
- In single mode, the master
- subsystem can always
- address all switched
- I/O .
Configuration
26Using Single-Channel, Switched I/O
- ET 200M distributed I/O device equipped with an
active backplane bus and a redundant PROFIBUS-DP
slave interface module IM 153-2 or IM 153-2FO.
permissible IM are - IM153-2 6ES7 153-2AA02-0XB0 version 7
or later - IM 153-2FO 6ES7 153-2AB01-0XB0 version 6 or
later
Configuration
27Using Single-Channel, Switched I/O
- Rules
- When you use a single-channel, switched I/O, the
configuration must - always be symmetrical, in other words
- The fault-tolerant CPU and other DP masters
must be located in - identical slots and both subsystems (e.g.
in slot 4 on both subsystems) - The DP masters must be connected on both
subsystems to the same - integrated interface (e.g. to the
PROFIBUS-DP interfaces of the two - fault-tolerant CPUs).
Configuration
28I/O configurationSwitched I/O
Redundant IM 153-2
PROFIBUS DP
ET 200M with active backplane bus
L
L
Configuration
Special bus module (BM)
IM
Active backplane bus
IM
29I/O configurationSwitched I/O mode of operation
- Both DP masters are active
and functioning properly - Reading inputsThe inputs are read only from
the preferred channelside (active IM) - Writing outputsThe data are accepted by both
channels.Only the data in the preferred channel
are forwarded to the outputs.
Configuration
30I/O configurationConnecting PROFIBUS PA via PA
link
PROFIBUS DP
2 x IM 157
DP-PA link
Configuration
31I/O configurationY-Link
Rack 0
Rack 1
IM 153-2 with ET 200M
- The Y-link bus coupler creates a network portal
from the redundant DP master system to a
one-channel DP master system
Configuration
IM 157 with PA bus
Y-Link with DP bus
32I/O configurationY-Link hardware configuration
- IM 157
- 6ES7 157-0AA82-0XA0
- Y-Link
- 6ES7 197-1LB00-0XA0
- Bus module BM IM 157
- 6ES7 195-7HD80-0XA0
- Bus module BM Y-Link
- 6ES7 654-7HY00-0XA0
- Collective Order No.
- 6ES7 197-1LA02-0XA0
Y-Link
IM 157
Configuration
33I/O configurationY-Link configuration
Configuration
34Installation notes
- Insert the synchronization submodules into the
CPUs. Then screw up - the additional front bezels to activate them
. - Connect the fiber-optic cables (always connect
the two upper - synchronization submodules and the two lower
synchronization - submodules of the CPUs). Lay the fiber-optic
cable so that it is protected - from any damage.
- Make sure with the route wires in addition that
the two fiber-optic - cables are always laid so that they are
isolated from each other. Laying - them separately enhances their availability
and protects then from - potential dual faults in the event, say, of
simultaneous interruption of - the fiber-optic cables.
- In addition, make sure that the fiber-optic
cables are plugged into the - two CPUs before turning on the power supply
or turning on the system.
35Setting the Rack Number
36Sample System
37Installation notes
- Connect the programming device to the first
fault-tolerant CPU - (CPU0). This CPU should be the master CPU
of the S7-400H. - A high-quality RAM test is performed after
power on. It requires - approximately 8 seconds per megabyte of
RAM. During this time the - CPU cannot be addressed via the multipoint
interface and the STOP - LED flashes. If there is a backup battery,
the test will not be - performed on further POWER ONs.
- Perform a memory reset for both CPUs using the
mode selector. This - applies the set mounting rack numbers of
the synchronization - modules to the operating system of the CPU.
- Switch the two CPUs of the S7-400H to STOP.
Load the user program - into CPU0
- Start the S7-400H PLC by switching the mode
selector, first for CPU0 - and then for CPU1, to RUN-P.
38Installation notes
- Result
- CPU0 starts up as the master CPU and CPU1 as the
standby CPU. - After the link-up and update of the standby CPU
the S7-400H switches to redundant system mode and
executes the user program (run light on digital
output module).
39What does active redundancy mean?
- Active redundancy, frequently referred to as
functional redundancy - too, means that all redundant resources
are constantly in operation - and are simultaneously involved in the
execution of the control task. - This means for the S7-400H that the user
program in the two CPUs is - completely identical and is executed
simultaneously (synchronously) - by the two CPUs.
- To identify the two subsystems, we use the
traditional expressions of - master and standby for two-channel
fault-tolerant systems in this - description. The standby always operates
so that it is synchronized - with the events on the master.
- The standby CPU switches to STOP mode in the
event of the redundant - link failing, whereas the master CPU
remains in RUN mode.
40Redundancy principle (1)
Redundancy with identical components(homogeneous
redundancy)
Redundancy features
Passive redundancy
Active redundancy
Majority redundancy
A
B
m-v-n
A
R
?1
1-v-2
1-v-2
2oo2
2oo2
A
B
C
Fault-tolerant
Hot stand-by automatic switchover lt 100
ms Warm stand-by automatic switchover in
seconds range
Redundancy principle S7-400H
m-of-n Fault-tolerant and failsafe
A
B
?
2-v-2
A
R
1-v-2
1oo2
HW or SW voting
2oo2
Cold stand-by manual switchover
Failsafe
41Redundancy principle (2)
Synchronization, information and status exchange
Redundancy features
IM
DI
AI
AO
DO
IM
FM
Process
42Bumpless master-stand-by switchover
- Switchover time
- Switchover time lt 100ms
- Outputs are retained during switchover
- No information or alarm/interrupt is lost
- Switchover criteria
- Master failure
- Power supply
- Rack
- Sync module
- Sync cable
- CPU
- Failure of a DP string or DP slave interface
module does not force a switchover
Redundancy features
43Master/standby assignment
- When the S7-400H is turned on for the first time,
the first CPU to be stated up becomes the master
CPU the other CPU becomes the standby CPU. - Once the master/standby assignment has been
established, it remains like that upon
simultaneous POWER ON. - The master/standby assignment is modified by
- 1. The standby CPU starting before the master CPU
(interval of at least 3 s) - 2. Failure or STOP of the master CPU in redundant
system mode
44Automatic event synchronization
- Synchronization procedure
Event synchronization
Redundancy features
Cycle synchronization
Time synchronization
Command synchronization
No synchronization
Subcontroller B
Subcontroller A
Subcontroller A
Subcontroller B
Subcontroller A
Subcontroller A
Subcontroller B
Subcontroller B
45Automatic event synchronization
Redundancy features
Synchronization, Information and status exchange
A
I 10.0
A
I 10.0
S
O 8.0
S
O 8.0
Value
Synchronization
L
PW100
L
PW100
Ackn.
L
DW 10
L
DW 10
F
F
Synchronization
T
PW130
Switchover
46Automatic event synchronization
Redundancy features
Self-test
Self-test
PII exchange
PII
PII
Synchronization
User program
User program
Match-up
PIO
PIO
47Automatic event synchronization
- Customer benefits
- Transparent programming
- All standard SIMATIC-S7 programming languages
- No command restrictions
- Easy porting of the user programfrom standard
CPU to fault-tolerant CPU - Bumpless switchover
- No loss of information
- No loss of alarms/interrupts
- Because all redundancy-specific functions are
handled by the operating system, the user can
feel assured that he/she has done everything
right as far as redundancy is concerned
Redundancy features
48Comprehensive self-test functions
- Self-test
- Scope
- CPU
- Memory
- Synchronization link
- Organization
- Startup self-test
- Complete test
- Self-test in cyclic mode
- Executes permanently as
background task - Executes in its entirety within a specifiable
amount of time (default 90 minutes)
Redundancy features
49Programming
- Handling, programming, configuring and
communication are the - same in SIMATIC S7-400H programmable
controller systems as in - standard systems.
- Redundancy-specific functions are performed by
the operating - system.
- S7-H Package is required to configure the
hardware. - When both CPUs are in STOP mode and you want
to load a - configuration, you must make sure you load
User Program into the - master CPU. Only then are the system data
blocks transferred to the - I/O modules. Hardware Config can be
downloaded to each CPU.
50Online programming
- Online modifications same as for standard system
- All modifications are automatically copied to
both CPUs - Connecting a PG
- At MPI interface
- Via bus
Redundancy features
PROFIBUS/Ethernet
MPI/DP
51Online programming
- Programming/parameter assignmentSIMATIC Manager
H-station view
Redundancy features
52Online Programming
- Programming Hardware configuration
Redundancy features
53Configuration in RUN (CIR)
- CPU memory configuration
- Adding or removing
- Central I/O or CP
- DP slaves
- PA interface and PA slaves
- Y-link and slaves
- Modules in modular DP slaves
- CPU parameter
Redundancy features
54Automatic CPU re-incorporation following repair
- Connect and update stand-by CPU (1)
MASTER
STAND-BY
Redundancy features
RUN solo
STOP
Stand-by requests link-up
DisableDelete, Copy and Generate Blocks functions
Master copies all data to stand-by
Execute start routine and self-test
CPU 1 requests update
Terminate communication via configured
links. Disable low-priority alarms
Master copies dynamic data
User program
OS
55Automatic CPU re-incorporation following repair
- Connect and update stand-by CPU (2)
MASTER
STAND-BY(link-up)
Redundancy features
Disable all alarms/ interrupts
Dynamic data which have changed since the last
update
Inputs, outputs, timers, counters, memory bits
Enable alarms/interrupts and communication
Redundant, synchronous operation
56(No Transcript)
57Replacing modules in RUN mode
- Modules which can be removed and inserted in Run
mode - I/O and CP
- Sync module
- Redundant IM 153-2
- Redundant power supplies
- Redundant components which can be replaced with
the power off - Standard power supplies
- Central IM
- CPU
- CPU is automatically updated following
replacement(program and data)
Redundancy features
58Procedure to change a central processing unit
- Requirements for a replacement
- has the same operating system version / revision
as the failed CPU and the same main memory and
load memory as the failed CPU.
Redundancy features
59Examples of Fault-Tolerant System Response to
Faults
- Example 1 Failure of a central processing unit
or power supply - Initial situation The S7-400H is in redundant
system mode. - 1. Cause CPU0 to fail by turning off the power
supply. - Result The LEDs REDF, IFM1F and IFM2F light on
CPU1. CPU1 goes into - solo mode, and the user program continues to run.
- 2. Turn the power supply back on.
- Result
- CPU0 performs an automatic LINK-UP and UPDATE.
- CPU0 changes to RUN and now operates as the
standby CPU. - The S7-400H is now in redundant system mode.
Redundancy features
60Examples of Fault-Tolerant System Response to
Faults
- Example 2 Failure of a fiber-optic cable
- Initial situation The S7-400H is in redundant
system mode. The mode selector of each CPU is at
the RUN or RUN-P position. - 1. Disconnect one of the fiber-optic cables.
- Result The LEDs REDF and IFM1F or IFM2F
(depending on which fiber-optic - cable was disconnected) now light on the two
CPUs. The original master CPU (CPU0) changes to
single mode and the user program continues to
run. - 2. Reconnect the fiber-optic cable that you
disconnected earlier. - 3. Restart the original standby CPU (CPU1), which
is now at STOP, by means of STEP7 operating
status, for example. - Result
- CPU1 performs an automatic LINK-UP and UPDATE.
- The S7-400H reverts to redundant system mode.
Redundancy features
61Communications via Fault-tolerant S7 Connections
Communication
62Communications via Fault-tolerant S7 Connections
- The hardware configuration of the two subsystems
integrated in a fault-tolerant system must be
identical. This is especially true of the slots. - Depending on the network being used, the
following CPs can be used for - fault-tolerant communications
- Industrial Ethernet
- S7 CP 443-1
- PROFIBUS
- S7 CP 443-5 Extended (not configured as DP
master system) - To be able to use fault-tolerant S7 connections
between a fault-tolerant system and a PC, you
must install the S7-REDCONNECT software package
on the PC.
Communication
63Redundant communicationPrinciple
- Redundant communication is attained through
redundant connections, which are then used when a
problem occurs. Redundant connections can be
created from H stations to - Other H stations (one- or two-channel)
- HMI PCs (software Redconnect required)
Active connection
Stand-by connection
Communication
64Redundant communicationConfiguration with
redundant bus (1)
Ethernet
H-CPU in single mode
Equivalent circuit diagram
Communication
PS
Bus
CP
CP
PS
CPU
CPU
PS
Bus
CP
CP
PS
CPU
CPU
65Redundant communicationConfiguration with
redundant bus (2)
Ethernet
H-CPU in single mode
Equivalent circuit diagram
Communication
CP
CP
PS
CPU
CPU
PS
Bus
CP
CP
CP
CP
Bus
PS
CPU
CPU
PS
CP
CP
66Redundant communicationConfiguration with single
bus
Ethernet
H-CPU in single mode
Equivalent circuit diagram
Communication
PS
CPU
CP
CP
CPU
PS
Bus
PS
CPU
CP
CP
CPU
PS
67Redundant communicationConfiguration with ring
bus
Ring bus
S7-400H
S7-400H
H-CPU in single mode
Equivalent circuit diagram
Communication
PS
CPU
CP
CP
CPU
PS
Bus
PS
CPU
CP
CP
CPU
PS
Bus
68Redundant I/O
New Redundant IO
Redundant Communication
Redundant Controller
PROFIBUS DP
Redundant Profibus
Sensor/control element
Redundant I/O
Redundant IM
69Redundant I/OPossible redundancy structures (1)
Central I/O modules
Distributed I/O modules
Redundant I/O
70Redundant I/OPossible redundancy structures (2)
Distributed switchedI/O modules
H-CPU in single mode
Redundant I/O
71Redundant I/ORedundant quality stages
- Highest quality level
- Use of F-IO by exploiting the high-quality
diagnostic functions required for failsafe
operation - Medium quality level
- Use of modules with diagnostic functions
- Low-cost quality level
- Use of modules without diagnostic functions
Redundant I/O
72Redundant I/OHardware configuration
- Slot
- DP address
- Redundant DI
- Time discrepancy in ms
- Response time followingdiscrepancy
- Possible options
- AND gate
- OR gate
- Use last valid value
Redundant I/O
73Redundant I/OHardware configuration
- Redundancy tabAppears only for
redundancy-capable modules. - Type of redundancy(none or 2)
- Station 2,PROFIBUSaddress 3,slot 4 contains a
compatiblemodule. This module is selected as
redundant
DI
Redundant I/O
74Redundant I/O Wiring digital inputs
With two sensors
With one sensor
DI
Master I/O
Both Inputs are read in parallel. The correct
value is selected and processed automatically
Redundant Profibus
Redundant I/O
Redundant I/O
DI
Since the function is not suitable for all module
types, the manual or Internet should be
consulted to find out which modules can
currently be used.
75Redundant I/O Wiring analog inputs
With voltage sensor
With current sensor
With 2 sensors
With current sensor
AI-I
AI-I
I
4-wire transducers only
AI
Master I/O
The CPU reads both inputs. The correct value is
selected and processed automatically
I
R
Redundant Profibus
Redundant I/O
Redundant I/O
AI
Since the function is not suitable for every
module type, the manual or Internet should be
consulted to find out which modules can
currently be used.
76Redundant I/O Wiring digital outputs
Without diodes
With diodes
Dependant on the module type
DQ
DQ
DO
Master I/O
Actuator
Both Outputs are set
Redundant Profibus
Redundant I/O
Redundant I/O
DO
Since the function is not suitable for every
module type, the manual or Internet should be
consulted to find out which modules can
currently be used.
77Redundant I/O Wiring analog outputs
Each Output outputs half the value. When one of
the modules fails, the output that is still
intact provides the full value
AO
Master I/O
Actuator
Both Outputs are set
I
Redundant Profibus
Redundant I/O
Redundant I/O
AO
Since the function is not suitable for all module
types, the manual or Internet should be
consulted to find out which modules can
currently be used
78Redundant I/O Integrating the user program
- The user program is integrated with the
"Functional I/O Redundancy" library, which is
part of STEP7 V5.3 - The redundant I/O are available to the user for
programming as transparent I/O - The rules state that the lowest address must
always be used for programming. - Method of operation
- The inputs are read by FB RED_IN and copied back
to the POI following the discrepancy analysis - The user writes the outputs to the lowest address
in the usual manner. FB RED_OUT automatically
copies the relevant value to the second address.
Redundant I/O
79Block library Functional I/O Redundancy
- The Functional I/O Redundancy block library,
which offers support for redundant I/O, contains
the following blocks - FC 450 RED_INIT Initialization function
- FC 451 RED_DEPA Trigger depassivation
- FB 450 RED_IN Function block for reading
redundant inputs - FB 451 RED_OUT Function block for
controlling redundant outputs - FB 452 RED_DIAG Function block for
diagnostics of redundant I/O - FB 453 RED_STATUS Function block for
redundancy status information - The blocks are located in the library Redundant
IO(V1) under - STEP 7\S7_LIBS\RED_IO.
80Activities
- Reading the system status list (SSL) with SFC51
- CPU 1/0 ? Master/Standby (H status)
- Reading the connection status with SFC87
- Error OBs
- OB70
81Reliability of modules
- The reliability of SIMATIC components is
extremely high as a consequence of wide-ranging
quality assurance measures in development and
manufacture. - The following average values apply to SIMATIC
modules - MTBF of a central processing unit 15 years
- MTBF of an I/O module 50 years
82Thank you