1. Manuals
  2. Brands
  3. Siemens Manuals
  4. I/O Systems
  5. SIMATIC PCS 7
  6. Configuration

Siemens SIMATIC PCS 7 Configuration

Hide thumbs Also See for SIMATIC PCS 7:
Table of Contents

Advertisement

Quick Links

See also: Programming and Operating Manual , Service Manual
Application description 03/2015
Configuration of redundant
I/O Modules in
SIMATIC PCS 7
https://support.industry.siemens.com/cs/ww/en/view/28430682

Advertisement

Table of Contents
loading

Related Manuals for Siemens SIMATIC PCS 7

Summary of Contents for Siemens SIMATIC PCS 7

  • Page 1 Application description 03/2015 Configuration of redundant I/O Modules in SIMATIC PCS 7 https://support.industry.siemens.com/cs/ww/en/view/28430682...

  • Page 2: Warranty And Liability

    Siemens recommends strongly that you regularly check for product updates. For the secure operation of Siemens products and solutions, it is necessary to take suitable preventive action (e.g. cell protection concept) and integrate each component into a holistic, state-of-the-art industrial security concept. Third-party products that may be in use should also be considered.

  • Page 3: Preface

    This documentation is intended for persons involved in configuration, commissioning and servicing of automation systems and who have basic knowledge of SIMATIC PCS 7. Validity Valid from SIMATIC PCS 7 V8.1. Configuration of Redundant I/O Modules Entry-ID: 28430682, V2.0, 03/2015...
  • Page 4 Technical specifications about the signal modules ET 200M Marshalled Termination Assemblies Commissioning the MTA boards Remote I/O Modules SIMATIC PCS 7 Process Control System Description of the PCS 7 channel blocks Advanced Process Library PCS 7 in Practice - Plant Asset Management...

  • Page 5: Table Of Contents

    Table of contents Table of contents Warranty and liability ....................2 Preface ........................3 Introduction ....................6 Redundant I/O ................... 6 Behavior in case of channel interference ..........6 Hardware components ............... 7 1.3.1 High-availability automation system (AS) ........... 8 1.3.2 Interface modules (IM) ...............

  • Page 6: Introduction

    1 Introduction 1.1 Redundant I/O Introduction Redundant I/O The high-availability in PCS 7 is basically applicable to all levels. In this documentation, the focus lies on the application of redundant distributed I/O using ET 200M modules. It explains with particular emphasis the wiring options of the input/output modules as well as the individual configuration steps.

  • Page 7: Hardware Components

    1 Introduction 1.3 Hardware components When switching from the "module-granular passivation behavior" (RedLib V3.x) to "channel-granular passivation behavior" (from RedLib V4.x), you must consider the following points: When upgrading from PCS 7 V7.1 SP4 to PCS 7 V8.1 (with utilization of new functions) new compatible blocks are imported into the project from the library "Redundant IO CGP V52"...

  • Page 8: High-Availability Automation System (As)

    1 Introduction 1.3 Hardware components 1.3.1 High-availability automation system (AS) Fault-tolerant automation systems are used to minimize the risk of production failures. For the S7-400H to remain always available, it is built as a redundant system. This means that all essential components are duplicated, i.e. the central processing unit CPU, power supply and hardware for coupling the two CPUs.

  • Page 9: Interface Modules (Im)

    1 Introduction 1.3 Hardware components 1.3.2 Interface modules (IM) Interface modules (IM) are used by the distributed I/O device ET 200M as a PROFIBUS DP interface. With redundant peripherals, one must ensure that two interface modules (IMs) are used per ET 200M station and that the same bus address is set for both modules (via dip switches).

  • Page 10: Bus Modules

    1 Introduction 1.3 Hardware components 1.3.3 Bus modules As mentioned above, in PCS 7 only active bus modules can be used for redundant applications with ET 200M. This enables removal and insertion of modules during operation. To achieve redundant operation, each ET 200M requires two interface modules IM 153-2 high feature to be mounted on the active bus module.

  • Page 11: Input/Output Module (I/O)

    1 Introduction 1.3 Hardware components 1.3.4 Input/output module (I/O) I/O modules with channel-granular functionality From PCS 7 V7.0 upwards, you can specify how redundant input/output modules behave in case of a channel fault (e.g. wire break, short circuit on the signal line). For a channel fault, one can expect the following reactions depending on the module used and the configuration: If a fault occurs, only the faulty channel is passivated (recommended channel-...

  • Page 12: Mta (Marshalled Termination Assemblies) Terminal Module

    1 Introduction 1.3 Hardware components Special features of HART modules Note When using redundant HART analog input modules, only one transmitter (encoder) can be connected. Redundant HART signal modules work as "Primary Master" and "Secondary Master" to allow simultaneous HART communication via both modules with a field device.
  • Page 13 Pre-assembled cables to connect the MTA with the I/O module with SUB D connector, 50/25-pin, plug socket version, for MTA with Siemens front connector, 40/20-pin, plug socket version, for the ET 200M module On-board simulation capabilities for IBS purposes (wire break, to switch...
  • Page 14 10 channels F-DO 6ES7650-1AL11-6XX0 (safety-related) 16 channels DO relay 6ES7650-1AM30-3XX0 10 channels F-DO 6ES7650-1AM31-6XX0 Relay (safety-related) Note For detailed information about each MTA type, please refer to the product release: https://support.industry.siemens.com/cs/ww/en/view/29289048 Configuration of Redundant I/O Modules Entry-ID: 28430682, V2.0, 03/2015...

  • Page 15: Configuring And Wiring

    2 Configuring and wiring 2.1 Redundant PROFIBUS DP connection Configuring and wiring Redundant PROFIBUS DP connection The transition from the automation system to PROFIBUS DP is done via a CP 443-5 Extended or via one of the two internal PROFIBUS DP interfaces of the CPU.
  • Page 16 Preassembled cable with SUB-D Preassembled cable with SUB-D connector for connection to SIEMENS connector for connection to SIEMENS PCS 7 MTA PCS 7 MTA Configuration of Redundant I/O Modules Entry-ID: 28430682, V2.0,...
  • Page 17 2 Configuring and wiring 2.2 Connecting an MTA terminal module Connection example of sensors to the screw-type terminals on the MTA The following figure shows the encoder connection using the example of digital inputs. Figure 2–3 Anschluss Kanal 1 Anschluss Kanal 1 Connection channel 1 Connection channel 1 Anschluss Kanal 13...

  • Page 18: Redundant Connections Of The Distributed I/O

    Specific notes for the redundant use of certain signal modules, can be found in the manual "SIMATIC Fault-tolerant systems S7-400H" or in the manual "SIMATIC PCS 7 process control system CPU 410-5H Process Automation" Configuration of Redundant I/O Modules Entry-ID: 28430682, V2.0,...

  • Page 19: Digital Input

    2 Configuring and wiring 2.3 Redundant connections of the distributed I/O 2.3.1 Digital input Sensor connection One or two sensors are connected to two redundant SM 321; DI 16 x DC 24 V (1 of 2 structure). Figure 2-5 With one encoder With two encoders To achieve maximum availability, it is recommended to use two encoders.
  • Page 20 2 Configuring and wiring 2.3 Redundant connections of the distributed I/O Connection and schematic circuit diagram of the SM 321; DI 16 x DC 24 V The following picture shows the schematic circuit diagram of the digital input module with channel-granular functionality (6ES7 321-7BH01-0AB0). Figure 2–6 Table 2–1 Digit...
  • Page 21 2 Configuring and wiring 2.3 Redundant connections of the distributed I/O Example An encoder is connected to channel 0 of each of the two SM 321; DI 16 x DC 24 V: Figure 2–2 Configuration of Redundant I/O Modules Entry-ID: 28430682, V2.0, 03/2015...

  • Page 22: Digital Output

    2 Configuring and wiring 2.3 Redundant connections of the distributed I/O 2.3.2 Digital output Controlling the final element control The actuator is connected to two redundant SM322; DO 16 x DC 24 V / 0.5 A (1 of 2 structure). Depending on the type of digital output modules, additional diodes must be used in redundant mode.
  • Page 23 2 Configuring and wiring 2.3 Redundant connections of the distributed I/O Connection and schematic circuit diagram of the SM 322; DO 16 x DC 24 V / 0.5 A The following picture shows the schematic circuit diagram of the digital output module with channel-granular functionality (6ES7 322-8BH01-0AB0).
  • Page 24 2 Configuring and wiring 2.3 Redundant connections of the distributed I/O Example An actuator is connected via channel 8 to each of the two SM 322; DO 16xDC 24V/0.5A: Figure 2–8 Configuration of Redundant I/O Modules Entry-ID: 28430682, V2.0, 03/2015...

  • Page 25: Analog Input

    2 Configuring and wiring 2.3 Redundant connections of the distributed I/O 2.3.3 Analog input Encoder connection The analog input module SM331; AI 8x16 bit can be used with one or two encoders in redundant operation (1 of 2 structure). Figure 2–9 With voltage encoder With current encoder (direct) With current encoder (indirect)
  • Page 26 2 Configuring and wiring 2.3 Redundant connections of the distributed I/O Connection and schematic circuit diagram of the SM 331; AI 8 x 16 bit (voltage measurement) The following two pictures each show the schematic circuit diagram of the analog input module SM331 AI 8x16 bit (6ES7 331-7NF00-0AB0) with channel-granular functionality for voltage and current measurement.
  • Page 27 2 Configuring and wiring 2.3 Redundant connections of the distributed I/O Connection and schematic circuit diagram of the SM 331; AI 8 x 16 bit (current measurement) For current measurements, the voltage terminals are closed in parallel with the corresponding current sensing resistor. Bridge the channel input terminals with the adjacent connector terminals.
  • Page 28 2 Configuring and wiring 2.3 Redundant connections of the distributed I/O Table 2–4 Digit Description Backplane bus interface Electrical isolation Analog-to-Digital Converter (ADC) CH 0 for 4-wire transducer CH 7 for 2-wire transducer (with external supply) Equipotential bonding Connection and schematic circuit diagram of the SM 331; AI 8 x 0/4…20 mA HART The following picture shows the schematic circuit diagram of the analog HART input module SM331 AI 8x0/4...20 mA (6ES7 331-7TF01-0AB0) with channel- granular functionality.
  • Page 29 2 Configuring and wiring 2.3 Redundant connections of the distributed I/O Example of an SM 331; AI 8 x 16 bit The following figure shows the connection of a transmitter to two AI 8 x 16 bit modules for the voltage measurement. Figure 2–13 Configuration of Redundant I/O Modules Entry-ID: 28430682,...
  • Page 30 2 Configuring and wiring 2.3 Redundant connections of the distributed I/O Example of an SM 331; AI 8x0/4…20 mA HART (2-wire transducer) Note A 2-wire transducer must be connected and configured to two redundant HART analog input modules as a 4-wire transducer. You can find more detailed information in the manual "Distributed I/O Device ET 200M HART Analog Modules".
  • Page 31 2 Configuring and wiring 2.3 Redundant connections of the distributed I/O Example of an SM 331; AI 8x0/4…20 mA HART (4-wire transducer) A 4-wire transducer is connected to two redundant HART analog input modules: Figure 2–15 The interconnected Zener diodes are required if the system is to continue functioning while dragging a module.

  • Page 32: Analog Output

    2 Configuring and wiring 2.3 Redundant connections of the distributed I/O 2.3.4 Analog output Controlling the final element control For the high-availability control of a final controlling element, two outputs of two SM 332; AO 8x12 bit are switched in parallel via diodes (1 of 2 structure). Only analog output modules with current outputs can be operated redundantly (0 to 20 mA or 4 to 20 mA).
  • Page 33 2 Configuring and wiring 2.3 Redundant connections of the distributed I/O Connection and schematic circuit diagram of the SM 332; AO 8 x 12 bit (voltage output) The following picture shows the schematic circuit diagram of the analog output module SM332 AO 8x12 bit (6ES7 332-5HF00-0AB0) with channel-granular functionality in the 2 and 4-wire connection for voltage output.
  • Page 34 2 Configuring and wiring 2.3 Redundant connections of the distributed I/O Connection and schematic circuit diagram of the SM 332; AO 8 x 12 bit (current output) The following picture shows the schematic circuit diagram of the analog output module SM332 AO 8x12 bit (6ES7 332-5HF00-0AB0) with channel-granular functionality as current output.
  • Page 35 2 Configuring and wiring 2.3 Redundant connections of the distributed I/O Connection and schematic circuit diagram of the SM 332; AO 8 x 16Bit, 0/4…20mA HART The following picture shows the schematic circuit diagram of the analog HART output module SM332 AO 8x16 bit, 0/4…20mA (6ES7 332-8TF01-0AB0) with channel-granular functionality.
  • Page 36 2 Configuring and wiring 2.3 Redundant connections of the distributed I/O Example of an SM 332; AO 8 x 12 bit The actuator is connected to channel 0 of each of the two redundant SM 332; AO 8 x 12 bit. Figure 2–20 Note Suitable diodes include, for example, types from the series 1N4003 ...
  • Page 37 2 Configuring and wiring 2.3 Redundant connections of the distributed I/O Example of an SM 332; AO 8 x 16Bit, 0/4…20mA HART The actuator is connected to two redundant HART analog output modules. Figure 2–21 Configuration of Redundant I/O Modules Entry-ID: 28430682, V2.0, 03/2015...

  • Page 38: Configuring The Redundant Peripherals

    3 Configuring the redundant peripherals 3.1 CPU settings Configuring the redundant peripherals The following sections describe the configuration of individual components of the distributed IO with PCS 7. It is assumed that a PCS 7 project has been already created with an H station using the Project Wizard. The following configuration steps are described: CPU settings (H parameters) Configuring the first ET 200M (IM 153-2 interface module)
  • Page 39 3 Configuring the redundant peripherals 3.1 CPU settings Procedure Table 3–1 Activity Screenshot Open the SIMATIC H station in the HW Configure. Select the first used CPU in slot 3 of the rack (0) and select the menu command "Edit > Object Properties". Switch to the “Cyclic Interrupts”...
  • Page 40 3 Configuring the redundant peripherals 3.1 CPU settings Activity Screenshot Switch to the "H Parameters" tab. Take note of those data blocks in the field "Data block no.", which are defined as a standard encoder, so that you don't use them elsewhere in your configuration.

  • Page 41: Configuring The Et 200M (Im 153-2 Interface Module)

    3 Configuring the redundant peripherals 3.2 Configuring the ET 200M (IM 153-2 interface module) Configuring the ET 200M (IM 153-2 interface module) Requirements The PCS 7 project with a SIMATIC H station is opened in SIMATIC Manager. In HW Config, a redundant PROFIBUS-DP master system is configured for the SIMATIC H station.

  • Page 42: Configuring The Signal Modules

    3 Configuring the redundant peripherals 3.3 Configuring the signal modules Activity Screenshot Enter the address in the dialog box "PROFIBUS IM 153-2 Interface Properties" and click "OK". The connection to the redundant PROFIBUS DP stream is automatically established. Configuring the signal modules The following section explains the procedure for configuring the standard and HART signal modules.
  • Page 43 3 Configuring the redundant peripherals 3.3 Configuring the signal modules Procedure Table 3–3 Activity Screenshot Select the configured IM 153-2. The module overview is shown in the lower pane. Configuration of Redundant I/O Modules Entry-ID: 28430682, V2.0, 03/2015...
  • Page 44 3 Configuring the redundant peripherals 3.3 Configuring the signal modules In the hardware catalog, under "PROFIBUS DP > ET 200M", select the same interface module, which you have already dragged to the PROFIBUS DP master system via drag- and-drop. Select a redundancy capable signal module in the subdirectories and drag-and-drop it into a free slot of the IM 153-2 (module overview).
  • Page 45 3 Configuring the redundant peripherals 3.3 Configuring the signal modules Repeat steps 1-3 for further signal modules. Configuration of Redundant I/O Modules Entry-ID: 28430682, V2.0, 03/2015...

  • Page 46: Configuring The Second Et 200M

    3 Configuring the redundant peripherals 3.4 Configuring the second ET 200M Configuring the second ET 200M Once you have configured the first ET 200M with all the necessary components (IM 153-2 interface module, signal modules), you must now configure the second redundant ET 200M.
  • Page 47 3 Configuring the redundant peripherals 3.4 Configuring the second ET 200M Activity Screenshot Select one of the PROFIBUS DP streams and paste the copied ET 200M. Allocate the address of the redundant slave in the appearing properties dialog "PROFIBUS Interface IM 153-2" and click "OK".

  • Page 48: Signal Module Settings

    3 Configuring the redundant peripherals 3.5 Signal module settings Signal module settings Once you have configured both ET 200M stations, you have to change various settings in your standard and HART signal modules. Redundant modules must be in the process image of the inputs or outputs. Redundant modules are always accessed using the process image.
  • Page 49 3 Configuring the redundant peripherals 3.5 Signal module settings Activity Screenshot Then select the "Redundancy" tab. In the "Redundancy" drop-down list, select the entry "2 modules". Click on the "Find" button. The dialog window "Find Redundant Module" opens. In the "Subsystem" list, select the DP master system in which the redundant signal module is configured.
  • Page 50 3 Configuring the redundant peripherals 3.5 Signal module settings Activity Screenshot The redundant signal modules are now listed in the "Module Overview" field. You can also set additional parameters (see chapter 3.6 Additional parameter settings for the configuration of the redundant AI modules").

  • Page 51: Additional Parameter Settings For The Configuration Of The Redundant Ai Modules

    3 Configuring the redundant peripherals 3.6 Additional parameter settings for the configuration of the redundant AI modules Additional parameter settings for the configuration of the redundant AI modules This chapter is intended to assist you in configuring the various parameters that must be set for redundant AI modules.
  • Page 52 3 Configuring the redundant peripherals 3.6 Additional parameter settings for the configuration of the redundant AI modules Discrepancy time / deviation time As described in the help for AI modules, the deviation time of AI modules should be a multiple of the update time. To calculate the update time, the following parameters must be considered: Update time of the AI modules Cycle time of the PROFIBUS (can be ignored if the baud rate is...
  • Page 53 3 Configuring the redundant peripherals 3.6 Additional parameter settings for the configuration of the redundant AI modules To obtain the update time of the (partial) process image (TPA), in the first step, the assigned (partial) process image of the AI module in question must be found, as shown in this picture.
  • Page 54 3 Configuring the redundant peripherals 3.6 Additional parameter settings for the configuration of the redundant AI modules The factor 2 is the smallest factor that may be used. If the process conditions allow a higher value, the factor can also be 3 or 4. Table 3–8.

  • Page 55: Configuring The Hart Field Devices

    3 Configuring the redundant peripherals 3.7 Configuring the HART field devices Configuring the HART field devices Requirements The PCS 7 project with an H CPU has been created and is open in SIMATIC Manager. A redundant PROFIBUS-DP master system is configured for the SIMATIC H station in HW ConFigure In HW Config, the interface module IM 153-2 is configured for the ET 200M at the redundant PROFIBUS DP.

  • Page 56: Symbolic Name Assignment

    3 Configuring the redundant peripherals 3.8 Symbolic name assignment Activity Screenshot The HART field device is opened in SIMATIC PDM. Here you can adjust other device parameters (such as TAG). Select again the HART field device in the hardware catalog and drag-and-drop it into a free slot of the redundant partner (HART signal module of the second ET 200M).
  • Page 57 3 Configuring the redundant peripherals 3.8 Symbolic name assignment Procedure Table 3–10 Activity Screenshot Open HW KonFigure Select one of the two interface modules IM 153-2 in the working range. The module overview shows you all input/output modules that you have already added in the HW ConFigure.

  • Page 58: Cfc Configuration

    3 Configuring the redundant peripherals 3.9 CFC configuration Activity Screenshot If necessary, edit additional symbols and save your entries by clicking the "OK" button. The dialog box "Edit Symbols" is closed. Select each signal module, one after the other, in the module overview and assign them symbolic names.
  • Page 59 3 Configuring the redundant peripherals 3.9 CFC configuration Activity Screenshot Click on the relative symbol with which you want to connect the block. You can select between the symbols that you assigned in the HW Config during the symbol assignment (see chapter 3.8). In the final compilation, the module drivers are automatically generated for the corresponding blocks.

  • Page 60: Function Mechanisms

    4 Function mechanisms 4.1 Example of a flowchart Function mechanisms Example of a flowchart The following figure shows an example of a flowchart for redundant I/O modules and the signal processing in the AS. Note The example shows the use of two sensors. In the process industry, the connection of a sensor to a redundant module pair is also typical (see chapter 2.3).
  • Page 61 4 Function mechanisms 4.1 Example of a flowchart Description of the upper part of the flowchart In the upper part, two temperature measurements are transferred by two encoders via two redundant AI modules and written via two addresses (EW512, EW560) in the process image partition of the inputs.

  • Page 62: Library Functions

    4 Function mechanisms 4.2 Library functions Library functions The following section describes the blocks/functions used from the PCS 7 and the Redundant IO CGP libraries. 4.2.1 PCS 7 Basic Library V8.1 OR_M_16C The block OR_M_16C serves to form a channel-granular value status from two redundant signal modules.

  • Page 63: Os Messages Of The Modules

    4 Function mechanisms 4.3 OS messages of the modules RED_INIT With the FC 450 "RED_INIT", the peripheral redundancy is initialized in the startup of an H system. When the FC 450 is called up, it generates administration data blocks for functional peripheral redundancy and it either occupies it with default values or else it updates pre-existing administration DBs.
  • Page 64 4 Function mechanisms 4.3 OS messages of the modules Reporting behavior of a module with diagnostic capability (MOD_D1) Possible module fault (output parameter QMODF = TRUE): – External auxiliary voltage missing – Front connector missing – Module parameters not set –...

  • Page 65: Diagnostics

    5 Diagnostics 5.1 Failure scenario Diagnostics This chapter presents an example of the diagnostic possibilities with PCS 7 in terms of redundant peripherals. Failure scenario A channel fault due to a wire break is simulated on a digital input module with the running system.

  • Page 66: Os Messages

    5 Diagnostics 5.2 OS messages OS messages In the OS, you receive corresponding error messages via the button "New List". Figure 5–2 Configuration of Redundant I/O Modules Entry-ID: 28430682, V2.0, 03/2015...

  • Page 67: Asset Management

    5 Diagnostics 5.3 Asset management Asset management If Asset Management is implemented in your PCS 7 project, you also get data about faults in redundant peripherals. Figure 5–3 You can find further information in the Application Example "PCS 7 in Practice - Note Plant Asset Management".

  • Page 68: Hw Config Online

    5 Diagnostics 5.4 HW Config Online HW Config Online Diagnostics buffer In the online mode of the HW Config, you can see the event information shown Figure 5-4, under the "Diagnostic Buffer" tab inside the "Module State" of the H CPU. In addition to fault messages, even information about the behavior of the modules is listed here.
  • Page 69 5 Diagnostics 5.4 HW Config Online Diagnostic interrupt The "Module state" of the signal module (Figure 5-5) is another diagnostic possibility in HW ConFigure In the "Diagnostic Interrupt" tab you can find the "Standard module diagnostics" and the "Channel-specific diagnostics". Figure 5-5 By clicking on the "Show"...

  • Page 70: Cfc Test Mode

    5 Diagnostics 5.5 CFC test mode CFC test mode The OR_M_16C enables the value status of the redundant signal modules to be diagnosed (Figure 5–6) in the CFC chart. Here, the different connections of the module can be registered in test mode. Figure 5–6 From the outputs QMODF1 and QMODF2, you can see that there is no module fault.
  • Page 71 5 Diagnostics 5.5 CFC test mode The following table shows further connection properties of the OR_M_16C: Table 5–1 Connection Meaning Data Type Default Type Setting MODE1_xx Channel operating mode (xx = 00 – 07 / 00 – 15) DWORD of the primary module MODE2_xx Channel operating mode (xx = 00 –...

  • Page 72: Related Literature

    Download page of this entry https://support.industry.siemens.com/cs/ww/en/ view/28430682 SIMATIC Process Control System - https://support.industry.siemens.com/cs/ww/en/ view/90682535 PCS 7 High-availability Process Control Systems (V8.1) SIMATIC PCS 7 process control https://support.industry.siemens.com/cs/ww/en/ view/74736822 system CPU 410-5H Process Automation SIMATIC Process Control System https://support.industry.siemens.com/cs/ww/en/ view/90683135 PCS 7 Basic Library (V8.1)

Table of Contents