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Table Of Contents - Siemens SIMATIC S7-400H Manual

Automation system, fault-tolerant systems

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Table of Contents

Table Of Contents1

Safety Guidelines2

Qualified Personnel2

Changes Compared To The Previous Version4

Finding Your Way5

Recycling And Disposal7

H/F Competence Center7

Training Centers7

A&D Technical Support8

Service & Support On The Internet9

Fault-Tolerant Programmable Logic11

Fault-Tolerant Programmable Logic Controllers19

Redundant Programmable Logic Controllers In The Simatic Series20

Operating Objectives Of Redundant Programmable Logic Controllers20

Why Do We Have Fault-Tolerant Programmable Logic Controllers?21

Software Redundancy21

Increasing System Availability22

System-Wide Universality22

Graduated Availability By Duplicating Components22

Universal Automation Solutions With Simatic22

Redundant Nodes23

Example Of Redundancy In A Network Without Malfunction23

Failure Of A Redundant Node (Total Failure)23

Example Of Redundancy In A 2-Out-Of-2 System With Total Failure23

S7-400H Installation Options25

Further Information26

Redundant Profibus-Dp26

Base System Of The S7-400H27

Central Processing Units27

Hardware Of The S7-400H Base System27

Mounting Rack For S7-400H28

Synchronization Submodules28

Fiber-Optic Cables28

I/O Modules For S7-400H29

I/O Configuration Versions29

Communication30

Communication Availability30

Programming And Configuration30

Tools For Configuration And Programming31

The User Program31

Required Software31

Optional Software31

Specific Blocks For S7-400H32

User Documentation For Fault-Tolerant Systems33

Getting Started33

Configuring Hardware And Starting Up The S7-400H37

Installing Hardware37

Hardware Configuration37

Starting Up The S7-400H38

Examples Of Fault-Tolerant System Response To Faults39

Failure Of A Central Processing Unit Or Power Suppl39

Failure Of A Fiber-Optic Cabl39

Installation Of A Cpu 41X-H41

Controls And Indicators Of The Cpus42

Operation And Display Elements Of The Cpu 414-4H/417-4H42

Layout Of The Controls And Indicators Of The Cpu 414-4H/417-4H42

Operating Mode Selector43

Slot For Memory Cards43

Leds Of The Cpus43

Interface For Expanded Memory44

Slot For Interface Modules44

Mpi/Dp Interface44

Profibus-Dp Interface44

Connecting External Backup Current to the "EXT. BATT." Socket45

Monitoring Functions Of The Cpu46

Monitoring And Error Messages46

Status And Error Leds48

Leds Run And Stop48

Leds Mstr, Rack0 And Rack148

Leds Intf, Extf And Frce49

Leds Busf1 And Busf249

Leds Ifm1F And Ifm2F50

Diagnostics Buffer50

Mode Selector51

Function Of The Mode Selector51

Positions Of The Mode Selector51

Protection Levels52

Setting The Protection Levels52

Protection Levels Of A S7-400 Cpu53

Operating Sequence For Memory Reset53

Reboot (Warm Restart)54

Operation Sequence For Reboot/Warm Start54

Operating Sequence At Cold Restart54

Expanded Memory55

Determining Memory Requirements With The Simatic Manager55

Generating Block–Specific Messages56

Expanding Load Memory With Memory Cards57

Order Numbers57

Function Of The Memory Card57

Design Of The Memory Card57

What The Memory Card Contains58

Types Of Memory Cards For The S7-40058

Which Type Of Memory Card To Use58

Types Of Memory Cards58

Which Memory Card Capacity To Use59

Changing Memory Cards60

Technical Specifications61

Expanding The Working Memory Of The Cpu 417-4 H With Memory Modules62

Memory Expansion62

Fitting Memory Cards In The Cpu62

Fitting Memory Cards In The Cpus63

Multipoint Interface (Mpi)64

Connectable Devices64

Pg/Op-Cpu Communication64

Communication And Interrupt Response Times64

Profibus Dp Interface65

Overview Of The Parameters For The S7-400 Cpus66

Default Values66

Parameter Blocks66

Parameter Assignment Tool67

Specially Saved Parameters67

Changing The Rack Number Of An H Cpu67

Changing The Operating Mode Of An H Cpu68

Changing From Redundant To Single Mode68

Changing From Single To Redundant Mode, Module Rack Number 068

Changing From Single To Redundant Mode, Module Rack Number 168

Cpu 41X-H As Profibus Dp Master69

Dp Address Areas Of The Cpus 41X70

Cpus 41X (Mpi/Dp Interface As Profibus Dp)70

Cpu 41X As Dp Master70

Monitor/Modify, Programming Via Profibus71

Power-Up Of The Dp Master System71

Profibus Address Of The Dp Master71

From En 50170 To Dpv171

Components Supporting Profibus Dpv1 Features72

What Are The Operating Modes For Dpv1 Components?72

Compatibility Between Dpv1 And En 5017072

System Modifications During Ongoing Operation73

Overview: System Configuration For Modification73

Hardware Requirements For System Modification During Operation74

Software Requirements For System Modification During Operation74

Permitted System Modifications: Overview74

Diagnostics Of The Cpu 41X As Dp Master75

Diagnostics Using Leds75

Meaning Of The Busf Leds Of The Cpu 41X As Dp Master75

Reading Out The Diagnostics Information With Step 776

Evaluating The Diagnosis In The User Program77

Diagnostics With Cpu 41X77

Diagnostics Addresses In Connection With Dp Slave Functionality78

Diagnostics Addresses For The Dp Master And Dp Slave78

Event Detection Of The Cpus 41X As Dp Master79

Evaluation In The User Program79

Consistent Data80

Sfc 81 "Ublkmov"81

Consistency For Communication Blocks And Functions81

Access To The Working Memory Of The Cpu82

Consistency Rules for SFB 14 "GET" and Reading Tags83

Data Transmission Without Data Consistency83

Consistency Rules for SFB 15 "PUT" or Write Tag84

Upper Limit For The Transmission Of Consistent User Data On A Dp Slave86

Consistent Data Access Without The Use Of Sfc 14 Or Sfc 1587

System And Operating Modes Of The S7-400H89

What Does Active Redundancy Mean?90

Master/Standby Assignment90

Synchronizing The Subsystems91

Event-Driven Synchronization Procedure91

Continued Operation – Free From Discontinuities91

System Modes Of The S7-400H92

Overview Of The S7-400H System Modes92

Operating Modes Of The Cpus93

Operating Modes From Power On To Redundant System Mode93

System And Operating Modes Of The Fault-Tolerant System93

Stop Operating Mode94

Explanations Relating To Figure 5-2 System And Operating Modes Of The Fault-Tolerant System94

Startup Operating Mode95

Startup Processing By The Master Cpu95

Operating States Link–Up And Update95

Operating State Run96

Single Mode, Link–Up, Update96

Redundant Modules96

Causes Of Error Leading To The Termination Of Redundant System Mode96

Operating States Hold97

When Is Hold Mode Possible?97

Troubleshooting Operating State98

Processing Self-Tests99

Response To Errors During The Self-Test99

Hardware Fault With One-Way Ob 121 Call99

Ram/Paa Comparison Error100

Response To A Recurring Comparison Error100

Checksum Errors100

Response To Checksum Errors100

Influencing The Cyclical Self-Test101

Time Response102

Instruction Run Times102

Processing I/O Direct Access102

Reaction Time102

Linking And Synchronizing103

Effects Of Link-Up And Update104

Properties Of Link-Up And Update104

Functional Sequence Of Link-Up And Update105

How To Start Link-Up And Update105

Process Diagram For Link-Up And Update106

Process For Update107

Minimum Signal Duration Of Input Signals During The Update108

Process Of Link-Up109

Link-Up To Achieve Redundant System Mode109

Link-Up With Master/Standby Switch-Over109

Switch To Cpu With Expanded Memory Configuration110

Updating Procedure111

What Happens During Update?111

Delayed Notification Functions113

Communication Functions With Derived Jobs113

Switch To Cpu With Modified Configuration114

Working Memory114

Block Link-Up And Update115

Example Of A Time-Critical Process115

Time Monitoring116

Max. Scan-Cycle Time Extension116

Max. Communication Delay116

Minimum I/O Retention Time117

Significance Of The Times Relevant During The Update117

Response To Time-Out118

Time Response During Link-Up118

Determination Of The Monitoring Times119

Time Response During The Update119

Determination With Step7 Or Formulas119

Monitoring Time Accuracy120

Use Of Redundant Input And Output Modules120

Configuration Of The Monitoring Times121

Calculating The Minimum I/O Retention Time121

Premium For The Monitoring Times Of Redundant I/O121

Max. Blocking Time For Priority Classes > 15121

Relationship Between The Minimum I/O Retention Time And The Maximum Blocking Time For Priority Classes122

Calculation Of The Max. Communication Delay126

Calculation Of The Max. Scan-Cycle Time Extension126

Influences On The Time Response126

Deliberate Delaying Of The Update127

Performance Values For Link–Up And Update127

Peculiarities During Link-Up And Update129

Requirement Of Input Signals During The Update129

Communication Links And Functions129

Reset Instruction On Aborting Link-Up129

Using I/O On The S7-400H131

I/O Configuration Types132

Limits Of I/O Configuration132

Using Single-Channel, One-Sided I/O133

What Is Single-Channel, One-Way I/O?133

Single-Channel, One-Way I/O Configuration133

Single-Channel, One-Way I/Os And User Program134

Failure Of The Single-Channel, One-Way I/O134

Using Single-Channel, Switched I/O135

What Is Single-Channel, Switched I/O?135

Single-Channel, Switched Et 200M Distributed I/O136

Single-Channel, Switched I/O And User Program137

Failure Of The Single-Channel, Switched I/O137

Duration Of Switch-Over Of The Active Channel138

Switch-Over Of The Active Channel On Link-Up And Update139

No Pulses During Switch-Over Of The Active Channel139

System Configuration And Design139

Connecting Redundant I/O140

Redundant I/O In Central- And Expansion Devices140

Redundant I/O In The One-Way Dp Slave141

Redundant I/O In The Switched Dp Slave142

Block Library "Functional I/O Redundancy"143

Redundant I/O In Single Mode143

Hardware Installation And Configuration Of The Redundant I/O144

Signal Modules For Redundancy145

Which Faults Can Be Overcome Using Redundant I/O?146

Using Digital Input Modules As Redundant I/O147

Using Digital Input Modules With Non-Redundant Sensor148

Fault-Tolerant Digital Input Module In A 1-Out-Of-2 Configuration148

Additional Marginal Conditions For Various Modules149

Using Redundant Digital Input Modules With Redundant Sensors150

Fault-Tolerant Digital Input Modules In A 1-Out-Of-2 Configuration150

Redundant Digital Output Modules151

Digital Output Module Connected Through/Without Diodes151

Fault-Tolerant Digital Output Module In A 1-Of-2 Configuration151

Using Analog Input Modules As Redundant I/O153

Redundant Analog Input Modules With Non-Redundant Sensors154

Redundant Analog Input Modules For Voltage Measurement154

Fault-Tolerant Analog Input Modules In A 1-Out-Of-2 Configuration154

Redundant Analog Input Modules For Indirect Current Measurement155

Redundant Analog Input Module For Direct Current Measurements158

Redundant Analog Input Modules With Redundant Sensors160

Analog Input Modules And Sensors161

Redundant Analog Output Modules In A 1-Of-2 Structure162

Depassivation Of Modules162

Determining The Status Of The Passivation163

Determining The Passivation Status With The Status Byte163

Assignment Of The Status Byte163

Assignment Of The Status Bytes164

Other Possibilities For Connecting Redundant I/O165

Redundant I/O On The User Level165

Redundant One-Way And Switched I/Os165

Redundant I/O In The User Program167

Flowchart For Ob1168

Example Of Stl169

Communication Functions171

Fundamentals And Basic Concepts172

Redundant Communication System172

Fault-Tolerant Communications172

Connection (S7 Connection)173

Fault-Tolerant S7 Connections173

Example Of An S7 Connection173

Suitable Networks175

Resource Requirements Of Fault-Tolerant S7 Connections175

Industrial Ethernet175

Electrical Network175

Optical Network176

Supported Communication Services178

Communications Via Fault-Tolerant S7 Connections178

Availability Of Communicating Systems178

Communications Between Fault-Tolerant Systems180

Example Of Redundancy With Fault-Tolerant System And Redundant Ring181

Example Of A Fault-Tolerant System With Additional Cp Redundancy181

Response To Failure182

Redundant S7 Connections182

Communications Between Fault-Tolerant Systems And Pcs184

Communications Via S7 Connections185

Communications With Standard Systems185

Communications Via S7 Connections – One-Sided Mode186

Two-Fiber Ring And Bus System187

Communications Over Redundant S7 Connections188

Communications Via A Point-To-Point Cp On The Et 200M189

Connection Via Et 200M189

Random Connection With Single-Channel Systems190

Connection Via A Pc As Gateway190

Communication Performance191

Definition Of Communication Load191

Data Throughput Via Communication Load (Basic Trend)192

Response Time Via Communication Load (Basic Trend)192

Standard And H Systems193

Which Sizes Influence The Communication Load?193

General Information On Communication194

Connecting Standard Systems To H Systems195

S7 Communication (SFB 12 "BSEND" and SFB 13 "BRCV")195

S7 Communication (SFB 8 "USEND" and SFB 9 "URCV")195

Simatic Ops, Simatic Mps195

Configuring With Step 7197

Installation Of The Options Package198

Software Requirements198

Installing The Options Package198

Reading The Readme File198

Rules For Fitting A Fault-Tolerant Station199

Creating A Fault-Tolerant Station199

Installation Rules200

Configuring Hardware200

Special Features In Presenting The Hardware Configuration200

Assigning Parameters To Modules In A Fault-Tolerant Station201

Central Processing Unit (Exception)201

Modules In The I/O Address Area201

Recommendations For Setting The Cpu Parameters201

Number Of Messages In The Diagnostics Buffer202

Monitoring Time For Transferring Parameters To Modules202

Configuring Networks203

Downloading The Network Configuration To The Fault-Tolerant Station203

Programming Device Functions In Step 7204

Display In Simatic Manager204

Failure And Replacement Of Components During Operation205

Failure And Replacement Of A Central Processing Unit207

Starting Situation For Replacement Of The Complete Cpu207

Starting Situation For Replacement Of The Load Memory208

Failure And Replacement Of A Power Supply Module209

Initial Situation209

Failure And Replacement Of An Input/Output Or Function Module210

Failure And Replacement Of A Communication Processor211

Failure And Replacement Of An Im 460 And Im 461 Interface Module215

Failure And Replacement Of Components Of The Distributed I/O216

Failure And Replacement Of A Profibus-Dp Master217

Failure And Replacement Of A Profibus-Dp Slave219

Failure And Replacement Of Profibus-Dp Cables220

Modifying The System During Operation221

Possible Hardware Modifications222

How Is A Hardware Change Made?222

Which Components Can Be Modified?222

What Should I Note At The System Planning Stage?223

Modification Of The Hardware Configuration224

Modifications To The User Program And The Connection Configuration224

Adding Components In Pcs 7226

Pcs 7, Step 1: Modification Of Hardware227

Pcs 7, Step 3: Stopping The Standby Cpu229

Pcs 7, Step 5: Switch To Cpu With Modified Configuration231

Behavior Of The I/O231

Pcs 7, Step 6: Transition To Redundant System Mode232

Response If Monitoring Times Are Exceeded232

Pcs 7, Step 7: Changing And Loading User Program233

Adding Interface Modules In Pcs 7234

Removing Components In Pcs 7236

Pcs 7, Step Ii: Changing And Loading User Program238

Pcs 7, Step Iii: Stopping The Standby Cpu239

Pcs 7, Step Iv: Loading New Hardware Configuration In The Standby Cpu239

Pcs 7, Step V: Switch To Cpu With Modified Configuration240

Pcs 7, Step Vi: Transition To Redundant System Mode241

Pcs 7, Step Vii: Modification Of Hardware242

Removing Interface Modules In Pcs 7243

Adding Components In Step 7244

Step 7, Step 1: Modification Of Hardware245

Step 7, Step 4: Stopping The Standby Cpu247

Step 7, Step 5: Loading New Hardware Configuration In The Standby Cpu247

Step 7, Step 6: Switch To Cpu With Modified Configuration248

Step 7, Step 7: Transition To Redundant System Mode249

Step 7, Step 8: Changing And Loading User Program250

Adding Interface Modules In Step 7251

Removing Components In Step 7252

Step 7, Step Ii: Changing And Loading User Program254

Step 7, Step Iii: Stopping The Standby Cpu255

Step 7, Step V: Switch To Cpu With Modified Configuration256

Step 7, Step Vi: Transition To Redundant System Mode257

Step 7, Step Vii: Modification Of Hardware258

Step 7, Step Viii: Modifying And Loading Organization Blocks259

Removing Interface Modules In Step 7260

Changing The Cpu Parameters261

Modifiable Cpu Parameters261

Step A: Changing The Cpu Parameters Offline263

Step B: Stopping The Standby Cpu263

Step C: Loading Modified Cpu Parameters In The Standby Cpu264

Step D: Switch To Cpu With Modified Configuration265

Step E: Transition To Redundant System Mode266

Changing The Memory Components Of The Cpu267

Expanding The Main And/Or Load Memory267

Changing The Type Of Load Memory269

Writing To A Flash Card In The H System271

Synchronization Module273

Synchronization Module For S7-400H274

Function Of The Synchronization Module274

Removing And Inserting When Voltage Is Applied275

Setting The Rack Number276

Fiber Optic Cable For Connecting Two Synchronization Modules276

Cable Length Up To 500M277

Routing Cables Using Fiber Optics278

Cable Routing278

Bending Radius278

Laying Fiber Optic Cables For Synchronized Coupling Of S7-400H278

Technical Specifications Of The Cpu 414-4H;280

Run Times Of The Fcs And Fbs For Redundant I/O288

Characteristic Values Of Redundant Programmable Logic Controllers291

Basic Concepts292

Reliability Of Modules292

Reliability Of Programmable Logic Controllers292

Availability293

Comparison Of Mtbfs For Selected Configurations294

System Configurations With Central I/O294

Standard And Fault-Tolerant Cpu In Single Operation294

Redundant Cpus In Different Mounting Racks295

System Configurations With Distributed I/O296

Redundant Cpus With A Single-Channel, One-Way Or Switched I/O296

Redundant Cpus With Redundant I/O297

Single–Channel, One–Way I/O297

Single–Channel Switch I/O297

Redundant I/O298

Mtbf Factor For Redundant I/O298

Systems With Standard And Fault-Tolerant Communications299

Standard Communication299

Fault-Tolerant Communication299

Single Operation301

Reasons For Single Operation301

Differences Between S7-400 And S7-400H302

Special Fault Tolerant Leds304

Configuring Single Operation304

Upgrading To A Fault-Tolerant System305

Installing And Starting The Fault-Tolerant System305

Converting From S5-H To S7-400H307

Configuration, Programming And Diagnostics308

Differences Between Fault-Tolerant Systems And Standard Systems309

Additional Functions Of Fault-Systems309

Restrictions For The Fault-Tolerant Cpu Compared To A Standard Cpu310

Function Modules And Communication Processors Used On The S7-400H313

Fms And Cps Used Centrally313

Fms And Cps For Distributed One-Way Use314

Fms And Cps For Distributed Switched Use314

Connection Examples For Redundant I/O315

Sm 321; Di 8 X Ac 120/230 V, 6Es7 321-1Ff01-0Aa0316

Sm 322; Do 8 X Ac 230 V/2 A, 6Es7 322-1Ff01-0Aa0317

Sm 321; Di 16 X Ac 120/230 V, 6Es7 321-1Ff00-0Aa0318

Sm 331; Ai 8 X 16 Bit; 6Es7331-7Nf00-0Ab0319

Sm 332; Ao 4 X 12 Bit; 6Es7 332-5Hd01-0Ab0320

Sm 421; Di 32 X Uc 120 V, 6Es7 421-1El00-0Aa0321

Sm 321; Di 16 Dc 24 V, 6Es7 321-7Bh00-0Ab0323

Sm 322; Do 32 Dc 24 V/0.5 A, 6Es7 322-1Bl00-0Aa0324

Sm 331; Ai 8 12 Bit, 6Es7 331-7Kf02-0Ab0325

I/O, Redundant328

I/O, Single–Channel328

I/O, Switched328

Redundancy, Functional329

Redundant Mode329

Redundant Systems329

Redundant Link329

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