Page 1 Preface Basics of Fault Tolerance Fault-tolerant Solutions in PCS 7 SIMATIC Advantages of fault-tolerant components Process Control System PCS 7 Fault-tolerant Process Control Component Replacement Systems (V8.1) and Plant Changes Failure, Switchover and Return of Fault-tolerant Function Manual Components Diagnostics Valid for PCS 7 as of V8.1 11/2014 A5E34878832-AA...
Page 2 Note the following: WARNING Siemens products may only be used for the applications described in the catalog and in the relevant technical documentation. If products and components from other manufacturers are used, these must be recommended or approved by Siemens. Proper transport, storage, installation, assembly, commissioning, operation and maintenance are required to ensure that the products operate safely and without any problems.
Page 3: Table Of Contents
Table of contents Preface.................................7 Basics of Fault Tolerance...........................13 Rationale for using fault-tolerant process control systems.............13 System-wide availability analyses..................16 PCS 7 redundancy concept....................17 Overview of the PCS 7 redundancy features.................20 Features for the configuration phase..................22 Features for the commissioning and operation phases............23 Features for servicing and system expansions..............25 Definition of availability......................26 Definition of the standby modes.....................27...
Page 4 Table of contents 3.3.5.2 Fault-tolerant fieldbus based on PROFINET................70 3.3.5.3 Gateway between redundant and non-redundant PROFIBUS DP........71 3.3.5.4 Connection of PROFIBUS PA to PROFIBUS DP..............72 3.3.5.5 Fault-tolerant PROFIBUS PA....................74 3.3.5.6 Connecting the FOUNDATION Fieldbus to PROFIBUS DP..........78 3.3.5.7 Fault-tolerant FOUNDATION Fieldbus...................80 Solutions for integrating a PCS 7 system in a domain............84 Solutions for OS servers......................85 Solutions for OS clients......................89...
Page 5 How to configure an OS client....................154 4.5.9 How to configure an OS client for permanent operability.............156 4.5.10 How to download a SIMATIC PCS 7 project to the target systems........159 4.5.11 Evaluating the "@RM_MASTER" Redundancy Variables with Scripts........160 SIMATIC BATCH Stations....................161 4.6.1...
Page 6 Table of contents OS server..........................196 6.4.1 Failure, failover and restarting of redundant OS servers.............196 BATCH Server........................201 6.5.1 Reaction of BATCH servers to failure..................201 Route Control server......................202 6.6.1 Reaction of Route Control servers to failure................202 OS clients..........................204 6.7.1 Failover reactions of OS clients with permanent operability..........204 BATCH clients........................206 6.8.1 Failover reactions of BATCH clients..................206...
Page 7: Preface
Preface Purpose of this documentation This documentation informs you about the following aspects of configuring fault-tolerant systems with the SIMATIC PCS 7 Process Control System: ● The basic solution concepts ● The functional mechanisms ● The most important configurations It presents the availability solutions on all automation levels (control, process, field).
Page 8 Process Control System; SIMATIC PCS 7 DVD PCS 7 documentation on the ● PCS 7 Readme (DVD version) PCS 7 Readme on the Process Control System; SIMATIC PCS 7 DVD contains important information about PCS 7 and takes precedence over the PCS 7 documentation Process Control supplied with the product.
Page 9 ● In the section "Hardware Manuals for SIMATIC PCS 7 ..." – The link to the latest manuals for components released with a PCS 7 version. – The link to the latest manuals for approved SIMATIC PCS 7 industry software for PCS Catalogs, brochures, customer magazines and demo software...
Page 10 Preface Position in the information landscape The following documentation provides more information about fault-tolerant process control systems and the handling of the individual components. This documentation is part of the PCS 7 software. Manual Contents Process Control Sys‐ Getting Started ●...
Page 11 Preface Manual Contents Manuals for PCS 7 Software Update ● Updating a PCS 7 Project with and without use of new functions ● Upgrading a redundant system during online operation Automation System Manual ● Redundant SIMATIC automation systems S7-400H, Fault-tolerant Systems ●...
Page 12 Preface Guide This manual is organized into the following topics: ● Basics of fault-tolerance in PCS 7 ● Description of fault-tolerant solutions in PCS 7 ● Description of configurations for various redundant components in PCS 7 ● Failure scenarios and diagnostic options ●...
Page 13: Basics Of Fault Tolerance
Basics of Fault Tolerance Rationale for using fault-tolerant process control systems Advantages of fault-tolerant components Process control systems are responsible for controlling, monitoring and documenting production and manufacturing processes. Due to the increasing degree of automation and the demand for improved efficiency, the availability of these systems is playing an increasingly important role.
Page 14 Basics of Fault Tolerance 2.1 Rationale for using fault-tolerant process control systems PS CPU PS CPU CPCPCPCPCP CPCPCPCPCP Legend for the above illustration: Note The following short designations are commonly used in this documentation. Short designation Meaning Engineering Sta‐ Engineering station, PC tion OS server Operator station, PC project data station in the project form "WinCC Server"...
Page 15 Basics of Fault Tolerance 2.1 Rationale for using fault-tolerant process control systems Short designation Meaning OS client Operator station, PC visualization station in the project form "WinCC Client" BATCH server BATCH station, PC recipe and batch data station BATCH client BATCH station, PC recipe creation and batch visualization station Route Control Route Control station, PC Route Control data station...
Page 16: System-Wide Availability Analyses
Basics of Fault Tolerance 2.2 System-wide availability analyses System-wide availability analyses Introduction Availability must be analyzed globally for the system as a whole. Based on the degree of availability needed, each system level, each system and each component within a level should be evaluated.
Page 17: Pcs 7 Redundancy Concept
2.3 PCS 7 redundancy concept PCS 7 redundancy concept Advantages of the PCS 7 redundancy concept Fault-tolerant process control systems can be realized with SIMATIC PCS 7 at minimal cost in all phases of a system lifecycle: ● Configuration ● Commissioning/operation ●...
Page 18 Basics of Fault Tolerance 2.3 PCS 7 redundancy concept Overview of the PCS 7 redundancy concept PCS 7 offers you a redundancy concept that reaches all levels of process automation. Note The numbering of the components in the illustration relates to the descriptions provided below. Fault-tolerant Process Control Systems (V8.1) Function Manual, 11/2014, A5E34878832-AA...
Page 19 Basics of Fault Tolerance 2.3 PCS 7 redundancy concept Number Description Several clients (OS clients, BATCH clients, Route Control clients) can access data on a server (OS server, BATCH server, Route Control server). Communication between the operator stations (client and server) and communication with the engineering station is over a redundant, fault-tolerant terminal bus (Industrial Ethernet).
Page 20: Overview Of The Pcs 7 Redundancy Features
Basics of Fault Tolerance 2.4 Overview of the PCS 7 redundancy features Overview of the PCS 7 redundancy features Introduction The easiest way to increase availability is to keep replacement parts in stock on site and to have fast service at your disposal to replace defective components. In this documentation, we provide you with PCS 7 software and hardware solutions that go well beyond fast service and replacement part warehousing.
Page 21 Basics of Fault Tolerance 2.4 Overview of the PCS 7 redundancy features Basics of increased availability Increased availability in PCS 7 is based on the following principles: ● Duplication of a component Example: Use of duplicate signal modules ● Duplication of a component and a software component that performs an automatic fail-over from active and passive components in the case of malfunction.
Page 22: Features For The Configuration Phase
Basics of Fault Tolerance 2.5 Features for the configuration phase Features for the configuration phase Features for the configuration phase In the configuration phase, PCS 7 provides you with support with the following features. Feature Meaning Fault prevention through simplified configura‐ You do not need additional training to configure the re‐...
Page 23: Features For The Commissioning And Operation Phases
Basics of Fault Tolerance 2.6 Features for the commissioning and operation phases Features for the commissioning and operation phases Features for the commissioning and operation phases The following table lists the features PCS 7 offers for the commissioning and operation phases. The redundant components allows the continuation of the process of a component fails.
Page 24 Basics of Fault Tolerance 2.6 Features for the commissioning and operation phases Feature Meaning Possible error / possible reason Ability of process to con‐ If an OS server fails, the system switches Failure of the OS server tinue to be controlled and over to the configured redundant partner Examples: monitored even when a...
Page 25: Features For Servicing And System Expansions
Diagnostics of components without an additional ple, LEDs) for fast, local error detection. programming device (PG). Faster service from SIEMENS Customer Support. The service is on site within 2 to 48 hours to main‐ tain the availability guarantee. Repairs and component expansions (upgrades, Repair and component expansions can be made in conversions and updates) in runtime.
Page 26: Definition Of Availability
Basics of Fault Tolerance 2.8 Definition of availability Definition of availability Definitions Availability is usually defined as follows: Quotient of MTBF and (MTBF + MTTR) or in short form actual operating condition / nominal operating condition. Whereby: ● MTBF = mean time between two successive error events, repair time excluded ●...
Page 27: Definition Of The Standby Modes
Basics of Fault Tolerance 2.9 Definition of the standby modes Definition of the standby modes Introduction The availability of a system can be increased by additional components in the system (standby components). The operating mode of these components distinguishes them from the components that are active in process mode.
Page 28: Redundancy Nodes
Basics of Fault Tolerance 2.10 Redundancy nodes 2.10 Redundancy nodes Functionality Redundancy nodes provided protection from failure of systems with redundant components. A redundancy node is independent when the failure of one component within the node does not affect the reliability in other nodes or in the entire system. The availability of a complete system is illustrated in block diagrams.
Page 29 Basics of Fault Tolerance 2.10 Redundancy nodes Total failure of a redundancy node The following figure shows a complete system that has ceased to operate due to a failure of the "Field bus (PROFIBUS DP)" redundancy node. Fault-tolerant Process Control Systems (V8.1) Function Manual, 11/2014, A5E34878832-AA...
Page 30 Basics of Fault Tolerance 2.10 Redundancy nodes Fault-tolerant Process Control Systems (V8.1) Function Manual, 11/2014, A5E34878832-AA...
Page 31: Fault-Tolerant Solutions In Pcs 7
Fault-tolerant Solutions in PCS 7 Solutions for the I/O Introduction In this section you will learn about the I/O systems and components that contribute to increasing the availability of your system. This means using the distributed I/O in PCS 7. Distributed I/O Distributed I/O refers to modules (input/output modules and function modules) that are used in a modular, distributed I/O device such as the ET 200M, ET 200SP or ET 200iSP.
Page 32: Redundant I/O
Note Information on which modules are released for the distributed I/O in PCS 7 can be found in PCS 7 - Released modules. You will find this documentation on the Internet the documentation at: http:\\www.siemens.com/pcs7-documentation (http:\\www.siemens.com/pcs7- documentation). 3.1.1 Redundant I/O...
Page 33 Fault-tolerant Solutions in PCS 7 3.1 Solutions for the I/O The ET 200M distributed I/O device is connected as redundant DP slave to a fault-tolerant automation system operating as the DP master via PROFIBUS DP. A redundant configuration is achieved by installing an additional ET 200M and an additional PROFIBUS DP connection. Note Use only active bus modules for the ET 200M in a fault-tolerant system with PCS 7.
Page 34: Switched I/O
Fault-tolerant Solutions in PCS 7 3.1 Solutions for the I/O Installation rules The configuration always has to be symmetrical when using redundant I/O. Observe the following configuration rules: ● Both subsystems of the S7 400H must be configured identically. The same modules are located at the same slots.
Page 35 Fault-tolerant Solutions in PCS 7 3.1 Solutions for the I/O Configuration A switched I/O can be set up in PCS 7 with the following distributed I/O devices: ● ET 200M For this setup, you require an ET 200M with active backplane bus modules and a redundant IM 153-2 interface module.
Page 36: Components In The Distributed I/O
Fault-tolerant Solutions in PCS 7 3.1 Solutions for the I/O The system remains available even when one component in part of a line of the redundancy node fails. There is only one I/O module and therefore no corresponding redundancy node. It is the weakest link in the complete system's chain.
Page 37: Redundant I/O Modules
Fault-tolerant Solutions in PCS 7 3.1 Solutions for the I/O The configuration is provided as an example in the section "Redundant I/O (Page 32)". ● ET 200M with redundant IM 153-2 Two IM 153-2 interface modules are mounted on the active bus module in the distributed I/O device for redundant operation.
Page 38 Fault-tolerant Solutions in PCS 7 3.1 Solutions for the I/O Required software and configuration You select and configure the redundant modules in HW Config. ● In order for both subsystems of the H system to be able to address redundant input/output modules, S7 driver blocks from the "Redundant I/O"...
Page 39: Redundant Actuators And Sensors
Fault-tolerant Solutions in PCS 7 3.1 Solutions for the I/O 3.1.3.3 Redundant actuators and sensors Failure detection Actuators and sensors on the field level can be configured redundantly for PCS 7. Depending on the I/O module to which the redundant actuators or sensors are connected, failure of an actuator or sensor can be detected and reported to the process control system as an error.
Page 40: Solutions For Automation Systems
Fault-tolerant Solutions in PCS 7 3.2 Solutions for automation systems Solutions for automation systems Introduction This chapter presents solutions that can be used to increase the availability of an automation system. S7-400H fault-tolerant programmable controller Only a fault-tolerant automation system can ensure an extremely short process safety time, for example, a switchover time in the milliseconds range.
Page 41 Fault-tolerant Solutions in PCS 7 3.2 Solutions for automation systems Hardware components Communication processors Communication processor CP 443-5 Extended Communication processor CP 443-1 Setup Racks The following racks are available for installing the S7-400H. Normally, the UR2-H rack is used. Type Slots Special feature...
Page 42 Fault-tolerant Solutions in PCS 7 3.2 Solutions for automation systems Synchronization modules Synchronization modules are used to link the two central processing units. They are installed in the central processing units and interconnected with fiber-optic cable. Two synchronization modules are installed in each CPU. Set the rack number for the H CPU as of firmware version V4.X directly on the CPU.
Page 43: How The Simatic S7-400H As Operates
If the active CPU fails, the automation system automatically switches to the redundant CPU Process Control (see section "S7-400H hardware components (Page 40)" and Documentation System, SIMATIC PCS 7, Released Modules ). The failover has no effect on the ongoing process because it is bumpless. Additional information ●...
Page 44: Solutions For Communication
Fault-tolerant Solutions in PCS 7 3.3 Solutions for communication Solutions for communication Introduction In this section, you will learn about the redundancy concepts for the various levels of the process control system. Requirements for communication systems The availability of a process control system is not only determined by the automation system, the environment also plays a considerable role.
Page 45 Fault-tolerant Solutions in PCS 7 3.3 Solutions for communication Overview of the redundant and fault-tolerant bus systems In PCS 7 systems, you can configure fully redundant bus systems with redundant components for the following bus systems: ● Redundant, fault-tolerant terminal bus (Page 53) ●...
Page 46: Network Components
Fault-tolerant Solutions in PCS 7 3.3 Solutions for communication 3.3.1 Network components Introduction Local networks (LAN) form the basis of the communication system. The following are options that can be implemented based on the specific system requirements: ● Electrical ● Optical ●...
Page 47 Fault-tolerant Solutions in PCS 7 3.3 Solutions for communication Network component Bus system Application AFD (Automatic Field Dis‐ Fieldbus Connection of field devices via ring redundancy tributor) ● PROFIBUS PA ● Maximum of 31 fieldbus components on one AFDiS ● FOUNDATION Fieldbus ●...
Page 48 Fault-tolerant Solutions in PCS 7 3.3 Solutions for communication SCALANCE X switches for setting up redundant networks You can find additional information on SCALANCE X switches approved for PCS 7 in the Process Control System PCS 7; Released Modules documentation. The switches must have the necessary functions available to set up the relevant redundant network: ●...
Page 49: Media Redundancy Protocol
Fault-tolerant Solutions in PCS 7 3.3 Solutions for communication 3.3.2 Media Redundancy Protocol Use of media redundancy protocol Note High Speed Redundancy Protocol (HRP) and Media Redundancy Protocol (MRP) The X200 IRT switches cannot serve as redundancy manager and standby manager at the same time.
Page 50 ● Increase the update time to a value that is less than the fastest update of the process image partition (PIP) for this station. ● Increase the number of accepted update cycles with missing I/O data, so that the watchdog time is > 200 ms. See also http://support.automation.siemens.com/ (http://support.automation.siemens.com/ WW/view/en/55422236) Additional information ●...
Page 51: Solutions For The Terminal Bus
Fault-tolerant Solutions in PCS 7 3.3 Solutions for communication 3.3.3 Solutions for the terminal bus 3.3.3.1 Connecting PC stations to the terminal bus You connect the following PC stations to industrial Ethernet via network adapters (communication modules or communication processors): ●...
Page 52 Fault-tolerant Solutions in PCS 7 3.3 Solutions for communication For example, a broken cable in the connection between the modules is tolerated and communication remains uninterrupted. If the terminal bus experiences problems, no process data are sent from the servers to the clients.
Page 53: Redundant, Fault-Tolerant Terminal Bus
Fault-tolerant Solutions in PCS 7 3.3 Solutions for communication Availability If there is a fault in a ring line, the communication between clients and servers via the switches remains unaffected. However, if one of the switches fails, the link between the connected OS servers and the OS clients is interrupted.
Page 54: Redundant, Fault-Tolerant Terminal Bus Based On The Parallel Redundancy Protocol (Prp)
Fault-tolerant Solutions in PCS 7 3.3 Solutions for communication Redundant components The following components are configured redundantly: ● Electrical or optical network with Ethernet switches ● Switches, fiber optic cables and electrical connections ● Ring structures based on switches from the SCALANCE series. You can find additional information on the switches used with PCS 7 in the section "Network components (Page 46)".
Page 55 Fault-tolerant Solutions in PCS 7 3.3 Solutions for communication Configuration limits for the operator station Process Control System PCS 7; You can find information about this in the documentation Licenses and Configuration Limits. Redundant, fault-tolerant terminal bus with SIMATIC NET SOFTNET‑IE RNA All protocols among the redundantly connected components are automatically duplicated, sent and distributed in the mutually redundant networks.
Page 56 Fault-tolerant Solutions in PCS 7 3.3 Solutions for communication Availability - redundant fault-tolerant terminal bus The entire transmission route can be configured redundantly. A transmission route remains operational for communication on the terminal bus if any of the network components fails. Connecting non-redundant networks and components An integrated solution of network components and protection devices can be implemented for a substation or process application using PRP-compatible SCALANCE X products.
Page 57: Redundant, Fault-Tolerant Terminal Bus Based On The Intel Team Mode
Redundancy Protocol (Page 107)" PCS 7 Readme file ● You can find information on the available operating systems in the You can find additional information on this on the Internet http:\\www.siemens.com/pcs7- documentation (http:\\www.siemens.com/pcs7-documentation): SIMATIC NET; Industrial Ethernet; "SCALANCE X204RNA, ● Operating Instructions SCALANCE X204RNA EEC SIMATIC NET;...
Page 58 Fault-tolerant Solutions in PCS 7 3.3 Solutions for communication The following figure shows this configuration. Note Redundant linking of network segments The redundant linking of two network segments is only possible when the linking switches are capable of acting as standby manager. Example: ●...
Page 59 Fault-tolerant Solutions in PCS 7 3.3 Solutions for communication Components The use of switches from the SCALANCE series is recommended. Modules for optical and electrical connection are available for these switches. Configuration of the switches For redundant linking of networks, configure one SCALANCE switch as the standby master and one as the standby slave within a network segment.
Page 60: Solutions For The Plant Bus
Fault-tolerant Solutions in PCS 7 3.3 Solutions for communication Additional information ● Section "How to configure the redundant terminal bus on the basis of the INTEL TEAM mode (Page 108)" SIMATIC NET; Industrial Ethernet Switches SCALANCE X-400 ● Operating instructions 3.3.4 Solutions for the plant bus 3.3.4.1...
Page 61: Fault-Tolerant Plant Bus
Fault-tolerant Solutions in PCS 7 3.3 Solutions for communication License key for AS communication Depending on the network adapters used, you need a license key for PC stations with communication to the AS: Network adapter License key Standard Ethernet network adapter Standard Ethernet network adapter with fault-tol‐...
Page 62 Fault-tolerant Solutions in PCS 7 3.3 Solutions for communication Configuration - ring structure The following figure represents a fault-tolerant plant bus in a ring structure with switches. The following automation systems can be used: ● AS 41xH Availability - ring structure In this system, one CP 443-1 may fail in each subsystem of the AS without this affecting the complete system.
Page 63: Redundant, Fault-Tolerant Plant Bus
Fault-tolerant Solutions in PCS 7 3.3 Solutions for communication Additional information ● Section "How to configure a fault-tolerant plant bus (Page 112)" SIMATIC Net Twisted Pair and Fiber-Optic Networks ● Manual SIMATIC; Communication with SIMATIC ● Manual SIMATIC NET; Industrial Ethernet Switches SCALANCE X-400 ●...
Page 64 Fault-tolerant Solutions in PCS 7 3.3 Solutions for communication Configuration - redundant, fault-tolerant plant bus The figure below shows the basic configuration of the redundant, fault-tolerant plant bus. ● Bus1 shows the functionally correct configuration (shared switches for AS and OS). ●...
Page 65 Fault-tolerant Solutions in PCS 7 3.3 Solutions for communication AS 41xH on redundant, fault-tolerant plant bus You may connect one redundant AS per CPU without redundant communication modules. Connection possibilities: ● Single connection of an AS 41xH with one CP each per CPU. Availability is then reduced accordingly.
Page 66: As 410H On Redundant, Fault-Tolerant Plant Bus
Fault-tolerant Solutions in PCS 7 3.3 Solutions for communication 3.3.4.4 AS 410H on redundant, fault-tolerant plant bus Functionality The plant bus connects automation systems to servers (OS server, Route Control server). An automation system with a SIMATIC S7 410H-type CPU can be connected to a redundant, fault-tolerant plant bus.
Page 67 Fault-tolerant Solutions in PCS 7 3.3 Solutions for communication Note Address areas and IP addresses of the components on the plant bus Always assign IP addresses in different IP address ranges to the network adapters (separate address range for Bus1 and separate address range for Bus2). Example: ●...
Page 68: Solutions For The Fieldbus
Fault-tolerant Solutions in PCS 7 3.3 Solutions for communication 3.3.5 Solutions for the fieldbus 3.3.5.1 Redundant PROFIBUS DP Functionality The field bus is used for data exchange between the automation system (AS) and the distributed I/O. PROFIBUS DP (distributed peripheral)-- the field bus standard for manufacturing and process automation--is used.
Page 69 Fault-tolerant Solutions in PCS 7 3.3 Solutions for communication Availability If the active PROFIBUS DP fails, sensors and H system can communicate with each other over the redundant bus connection. The configuration shown in the following figure provides increased availability due to the redundant interfacing of the distributed I/O. Additional information ●...
Page 70: Fault-Tolerant Fieldbus Based On Profinet
Fault-tolerant Solutions in PCS 7 3.3 Solutions for communication 3.3.5.2 Fault-tolerant fieldbus based on PROFINET Functionality The fieldbus is used for data communication between the automation system (AS) and the distributed I/O. PROFINET is a standard for manufacturing and process automation. The PROFINET-based fieldbus comprises the specifications for the following elements: ●...
Page 71: Gateway Between Redundant And Non-Redundant Profibus Dp
Fault-tolerant Solutions in PCS 7 3.3 Solutions for communication Note Fault-tolerant PROFINET It is absolutely necessary to operate the fieldbus ring with MRP (media redundancy protocol) when using rings with PROFINET. Availability If the communication connection via a CPU fails, the stations of the distributed I/O can communicate with the H system over the fault-tolerant bus line.
Page 72: Connection Of Profibus Pa To Profibus Dp
Fault-tolerant Solutions in PCS 7 3.3 Solutions for communication Configuration Functionality The Y-Link creates a gateway from the redundant DP master system of an S7-400H to a non- redundant DP master system. This enables devices with only one PROFIBUS DP interface to be connected to a redundant DP master system as switched I/O.
Page 73 Fault-tolerant Solutions in PCS 7 3.3 Solutions for communication Configuration Functionality The DP/PA Coupler is a transceiver that interconnects PROFIBUS DP and PROFIBUS PA and decouples the various transmission rates. It is a slave on the PROFIBUS DP and a master on the PROFIBUS PA.
Page 74: Fault-Tolerant Profibus Pa
Fault-tolerant Solutions in PCS 7 3.3 Solutions for communication Physical bus characteristics ● The application protocols for PROFIBUS DP and PROFIBUS PA are defined according to IEC 61158-2 and are identical for these two fieldbus variants. – You can set the transmission speed on the PROFIBUS DP. The maximum transmission speed with the Y-link is 12 Mbps.
Page 75 Fault-tolerant Solutions in PCS 7 3.3 Solutions for communication Fault-tolerant communication solutions The following communication solutions are offered to prevent a possible failure: ● Ring redundancy with the AFD (Active Field Distributor) ● Coupler redundancy with the AFS (Active Field Splitter) The DP/PA coupler can be used stand-alone or in the DP/PA-Link .
Page 76 Fault-tolerant Solutions in PCS 7 3.3 Solutions for communication ● You can connect a maximum of 31 field devices per PROFIBUS PA. ● The maximum power consumption of 1 A must not be exceeded. This figure includes all components connected to the PROFIBUS PA. Configuration Examples for connections of field devices via AFD and AFS are shown in the following figures.
Page 77 Fault-tolerant Solutions in PCS 7 3.3 Solutions for communication Figure 3-2 Connection to a single PROFIBUS DP Transmission rate You have two interfacing options for the gateway between PROFIBUS DP and PROFIBUS PA. These result in different transmission rates on PROFIBUS DP. ●...
Page 78: Connecting The Foundation Fieldbus To Profibus Dp
Fault-tolerant Solutions in PCS 7 3.3 Solutions for communication Additional information ● Section " Connection of PROFIBUS PA to PROFIBUS DP (Page 72)" ● Section "How to configure redundant PROFIBUS PA (Page 123)" SIMATIC; DP/PA Coupler, DP/PA Link and Y Link Bus Couplers ●...
Page 79 Fault-tolerant Solutions in PCS 7 3.3 Solutions for communication Functionality FF Link connects PROFIBUS DP and FOUNDATION Fieldbus with one another and decouples various transmission rates. It is a slave on the PROFIBUS DP and master on the FOUNDATION Fieldbus. From the point of view of the automation system, the FF Link is a modular slave.
Page 80: Fault-Tolerant Foundation Fieldbus
Fault-tolerant Solutions in PCS 7 3.3 Solutions for communication ● If you use a SIMATIC AFDiS as a field barrier between the FF Link and the field devices, you can connect the field devices in hazardous areas of zones 0 or 1. The outputs of the SIMATIC AFDiS fulfill the requirements for types of protection EEx(ia) and EEx(ib).
Page 81 Fault-tolerant Solutions in PCS 7 3.3 Solutions for communication ● Connect an active field splitter (AFS) to a redundant coupler in the case of coupler redundancy. Connect the field devices via AFD (max. 8 AFD). For the purpose of increasing availability, connect a maximum of 4 field devices per AFD.
Page 82 Fault-tolerant Solutions in PCS 7 3.3 Solutions for communication Figure 3-4 Connection to a singular PROFIBUS DP Transmission rate You have two interconnection options for the gateway between PROFIBUS DP and FOUNDATION Fieldbus . These result in different transmission rates on PROFIBUS DP. ●...
Page 83 Fault-tolerant Solutions in PCS 7 3.3 Solutions for communication SIMATIC; PCS 7 process control system; PCS 7 - FOUNDATION Fieldbus ● Documentation SIMATIC; Bus links; FF Link bus link ● Operating instructions Fault-tolerant Process Control Systems (V8.1) Function Manual, 11/2014, A5E34878832-AA...
Page 84: Solutions For Integrating A Pcs 7 System In A Domain
Process Control System PCS 7; Time Synchronization ● Function manual ● On the Internet pages of Customer Support in Whitepaper SIMATIC; Safety Concept PCS 7 and WinCC; Basic document (http://support.automation.siemens.com/WW/view/en/ 26462131) Fault-tolerant Process Control Systems (V8.1) Function Manual, 11/2014, A5E34878832-AA...
Page 85: Solutions For Os Servers
Fault-tolerant Solutions in PCS 7 3.5 Solutions for OS servers Solutions for OS servers Redundant OS servers PCS 7 enables you to configure two OS servers redundantly for fault-tolerant operation. This ensures that you can monitor and control your process at all times. The solution represents the entry level into fault-tolerant process control systems.
Page 86 Fault-tolerant Solutions in PCS 7 3.5 Solutions for OS servers OS partner servers (OS_Stby) are configured in the SIMATIC Manager. Using the menu command PLC > Download synchronizes the functionality. Redundant external archive server If an external archive server of a server pair fails, the data is automatically synchronized on the return of the failed external archive server.
Page 87 Fault-tolerant Solutions in PCS 7 3.5 Solutions for OS servers Redundancy connection You need the following components to make the redundancy connection, depending on the distance to be bridged: Maximum distance Required components Connection 10 m Null modem cable Serial connection 100 m ●...
Page 88 Fault-tolerant Solutions in PCS 7 3.5 Solutions for OS servers Note The buses marked with * (terminal bus and plant bus) can be configured redundantly with optical or electronic switch modules. Additional information ● Section "Network components (Page 46)" ● Section "How to configure an OS server and its redundant OS partner server (Page 143)" WinCC ;...
Page 89: Solutions For Os Clients
Fault-tolerant Solutions in PCS 7 3.6 Solutions for OS clients Solutions for OS clients 3.6.1 Additional OS clients Additional OS clients OS clients are PC stations that are used for control and monitoring of an automation process. They are connected to the OS servers through the terminal bus. The OS servers form the process connection to the automation system.
Page 90 Fault-tolerant Solutions in PCS 7 3.6 Solutions for OS clients Preferred server A "preferred server" is an OS server in the redundant OS server pair that the OS client connects to preferentially. A preferred server can be defined separately for each OS client in order to ensure permanent operability.
Page 91: Solutions For Simatic Batch
Fault-tolerant Solutions in PCS 7 3.7 Solutions for SIMATIC BATCH Solutions for SIMATIC BATCH Redundant BATCH servers SIMATIC BATCH enables you to configure two BATCH servers redundantly for fault-tolerant operation. This ensures that you can monitor and control your batch process at all times. Functionality Redundant BATCH servers monitor each other in runtime to detect the failure of a BATCH server as early as possible.
Page 92 Fault-tolerant Solutions in PCS 7 3.7 Solutions for SIMATIC BATCH Redundancy connection You need the following components to make the redundancy connection, depending on the distance to be bridged: Maximum Required components Connection distance 100 m Ethernet connection ● Crossover network cable ●...
Page 93 Fault-tolerant Solutions in PCS 7 3.7 Solutions for SIMATIC BATCH The BATCH servers also communicate with OS servers over the terminal bus. The OS servers are connected to the automation system over the plant bus. Note SIMATIC BATCH in "AS-based" operating mode The BATCH servers are also connected to the plant bus if SIMATIC BATCH is operated "AS- based".
Page 94: Solutions For Route Control Server
Fault-tolerant Solutions in PCS 7 3.8 Solutions for Route Control server Solutions for Route Control server Redundant Route Control servers SIMATIC Route Control allows you to implement two Route Control servers with redundancy functionality for fault-tolerant operation. This ensures that you can monitor and control your route control at all times.
Page 95 Fault-tolerant Solutions in PCS 7 3.8 Solutions for Route Control server Redundancy connection You need the following components to make the redundancy connection, depending on the distance to be bridged: Maximum distance Required components Connection 10 m Null modem cable Serial connection 100 m Ethernet connection...
Page 96: Solutions For Engineering Station
Fault-tolerant Solutions in PCS 7 3.9 Solutions for engineering station Solutions for engineering station Engineering station The engineering station (ES) serves as a central configuration station. There are no redundant engineering stations in PCS 7. The ES is generally used to make changes in the configuration data of project components such as AS, OS and BATCH and to then download the changes to the target systems.
Page 97: Time Synchronization
Fault-tolerant Solutions in PCS 7 3.10 Time synchronization 3.10 Time synchronization Introduction Time synchronization in a PCS 7 plant is of utmost importance for synchronizing, tracing, documenting and archiving all time-critical processes. Time synchronization is particularly important for the redundancy functions in PCS 7 such as the redundancy synchronization between OS servers or BATCH servers.
Page 98 Fault-tolerant Solutions in PCS 7 3.10 Time synchronization Fault-tolerant Process Control Systems (V8.1) Function Manual, 11/2014, A5E34878832-AA...
Page 99: Advantages Of Fault-Tolerant Components
Advantages of fault-tolerant components Creating and expanding a project with pre-configured stations PCS 7 wizards "New Project" and "Extend Project" You can create fault-tolerant stations for the AS and PC stations using the PCS 7 "New Project" and "Expand Project" wizards in the SIMATIC Manager. For redundant PC stations, you configure a redundant multiple station system using the PCS 7 wizard.
Page 100: Simatic H Station
Advantages of fault-tolerant components 4.2 SIMATIC H Station SIMATIC H Station 4.2.1 Overview of configuration tasks Overview of configuration tasks You configure the redundancy functionality of the SIMATIC fault-tolerant station (H station) by performing the following steps: Step What? Inserting a SIMATIC H station in a project (Page 100) Inserting synchronization modules in the H_CPU (Page 102) Configuring redundant communications processors (Page 103) Setting the CPU for the error response of input/output modules (Page 105)
Page 101 Advantages of fault-tolerant components 4.2 SIMATIC H Station Result The configuration in the SIMATIC Manager appears as follows: Configuring the AS in HW Config 1. Double-click the Hardware object in the detail view. The HW Config dialog box opens. 2. Open the catalog and select the profile of the current PCS 7 version. 3.
Page 102: How To Insert Synchronization Modules Into The H Cpu
Advantages of fault-tolerant components 4.2 SIMATIC H Station 4.2.3 How to insert synchronization modules into the H CPU Requirements ● The PCS 7 project is open in SIMATIC Manager. ● HW Config is open. ● The rack has been inserted according to the configuration in HW Config. ●...
Page 103: How To Configure Redundant Communication Processors
Advantages of fault-tolerant components 4.2 SIMATIC H Station Result The following figure shows an example of the configured subsystems of the fault-tolerant station in HW Config: Additional information Process Control System PCS 7; PCS 7 - Released Modules ● Documentation Automation System S7-400H;...
Page 104 Advantages of fault-tolerant components 4.2 SIMATIC H Station Requirements ● The PCS 7 project with a SIMATIC H station is open in SIMATIC Manager. ● HW Config is open. ● The racks for the SIMATIC H station are inserted in HW Config, for example, 2 UR2-H racks. ●...
Page 105: How To Set The Failure Reaction Of The Input/Output Modules On The Cpu
Advantages of fault-tolerant components 4.2 SIMATIC H Station Result The following figure shows an example of configuration in HW Config. Connection to a fault- tolerant plant bus is possible. Additional information Automation System S7-400H; Fault-tolerant Systems ● Manual 4.2.5 How to set the failure reaction of the input/output modules on the CPU Introduction Only perform the following procedure when the libraries "Redundant IO (V3.0)"...
Page 106 Advantages of fault-tolerant components 4.2 SIMATIC H Station As of PCS 7 V7.1, the characteristics of the redundant input/output modules are set for channel- based reaction to channel faults. The function in the AS depends on the employed PCS 7 library and the modules.
Page 107: Communication Connections
Advantages of fault-tolerant components 4.3 Communication connections Communication connections 4.3.1 Overview of configuration tasks Introduction After you have inserted all of the components (AS, OS and ES) in your project, you can use NetPro to configure the network connections between the SIMATIC components. When the configuration of the connections and network is complete, the configuration needs to be compiled, saved and downloaded to the CPU of the automation system.
Page 108: How To Configure The Redundant Terminal Bus On The Basis Of The Intel Team Mode
Ethernet Operating Instructions; SOFTNET-IE RNA . Additional information ● Online help for "SIMATIC NET SOFTNET-IE RNA" software ● You can find additional information on this on the Internet http:\\www.siemens.com/pcs7- documentation (http:\\www.siemens.com/pcs7-documentation): SIMATIC NET; SCALANCE X204RNA, SCALANCE X204RNA – Operating instructions SIMATIC NET PG/PC;...
Page 109 Advantages of fault-tolerant components 4.3 Communication connections Requirements Each redundant PC station (for example, OS server, OS client, domain controller) connected to the terminal bus must meet the following requirements: ● Redundant connection of the PC station to the terminal bus: Two network adapters working in INTEL Team mode on a PC.
Page 110 Advantages of fault-tolerant components 4.3 Communication connections 4. If no onboard network adapters are being used for connecting to the terminal bus, select the internal network adapter of the PC station and deactivate the internal network adapter via the shortcut menu. 5.
Page 111: How To Connect Singular Components To The Redundant Terminal Bus On The Basis Of The Parallel Redundancy Protocol
Advantages of fault-tolerant components 4.3 Communication connections 21.Check the order of network adapters under "Advanced > "Advanced Settings...". In the "Adapters and Connections" tab, the team must be at the top of the list under "Connections": – 1. <Team name>" (in the example, "TerminalBusTeam #0") –...
Page 112: How To Configure A Fault-Tolerant Plant Bus
Advantages of fault-tolerant components 4.3 Communication connections Additional information about configuration You can find additional information on this on the Internet http:\\www.siemens.com/pcs7- documentation (http:\\www.siemens.com/pcs7-documentation): SIMATIC NET; SCALANCE X204RNA, SCALANCE X204RNA EEC ● Operating instructions SIMATIC NET PG/PC; Industrial Ethernet SOFTNET-IE RNA V8.2 ●...
Page 113 Advantages of fault-tolerant components 4.3 Communication connections Example: ● Ring 1: – IP address range: 192.168.1.0 - 192.168.1.255 – Subnet mask: 255.255.255.0 ● Ring 2: – IP address range: 192.168.2.0 - 192.168.2.255 – Subnet mask: 255.255.255.0 Requirements ● The PCS 7 project with a SIMATIC H station is open in SIMATIC Manager. ●...
Page 114: How To Configure A Redundant Profibus Dp
Advantages of fault-tolerant components 4.3 Communication connections Result The following figure shows the resulting configuration: Additional information STEP 7 ● Online help for 4.3.4 How to configure a redundant PROFIBUS DP Introduction The following section describes how to create and connect a redundant PROFIBUS DP. Requirements ●...
Page 115 Advantages of fault-tolerant components 4.3 Communication connections ● The UR2-H rack has been inserted twice in HW Config. ● In HW Config, each mounting rack has been fitted with an H CPU in slot 3 and the required synchronization modules. Procedure Note Steps 1 through 4 are necessary only when a CP 443-5 Extended is used for the connection...
Page 116 Advantages of fault-tolerant components 4.3 Communication connections Result The figure below shows the result of the configuration process in HW Config. Here, a distributed I/O has already been assigned to the DP master systems for the purpose of illustrating the redundancy principle: Additional information STEP 7...
Page 117: How To Configure A Fault-Tolerant Fieldbus On The Basis Of Profinet
Advantages of fault-tolerant components 4.3 Communication connections 4.3.5 How to configure a fault-tolerant fieldbus on the basis of PROFINET Introduction The following section describes how to create and connect a fault-tolerant fieldbus on the basis of PROFINET. ● Configure the components in HW Config. ●...
Page 118 Advantages of fault-tolerant components 4.3 Communication connections Result The following figure shows the result of the configuration in HW Config. The distributed I/O is connected to the PROFINET IO system. The physical setup is configured below with the Topology Editor. Connecting the components with the Topology Editor 1.
Page 119 Advantages of fault-tolerant components 4.3 Communication connections 3. Select the "Graphic view" tab. Note: You can move the displayed objects. You can select the section displayed via the thumbnail view. Position the objects in accordance with the cable sequence in the system. 4.
Page 120: How To Configure A Media-Redundant Fieldbus On The Basis Of Profinet
Advantages of fault-tolerant components 4.3 Communication connections 4.3.6 How to configure a media-redundant fieldbus on the basis of PROFINET Introduction The following section describes how to create and connect a media-redundant ring on the basis of PROFINET. ● Configure the components in HW Config. ●...
Page 121 Advantages of fault-tolerant components 4.3 Communication connections Result The figure below shows the resulting configuration in HW Config for the X5 interface of the CPU. The distributed I/O is connected to the PROFINET IO system. The physical setup is configured below with the Topology Editor. Connecting the components with the Topology Editor 1.
Page 122 Advantages of fault-tolerant components 4.3 Communication connections 3. Select the "Graphic View" tab. Note: You can move the displayed objects. You can select the section displayed via the thumbnail view. Position the objects in accordance with the cable sequence in the system. 4.
Page 123: How To Configure The Redundant Profibus Pa
Advantages of fault-tolerant components 4.3 Communication connections 1. In HW Config, select the PROFINET-capable module (CPU or CP). 2. Open the "Properties" dialog box of the PROFINET interface. 3. Select the "Manager" role on the "Media Redundancy" tab. 4. Click "OK". 5.
Page 124 Advantages of fault-tolerant components 4.3 Communication connections Hardware setting on the DP/PA coupler Note The redundancy mode set on the DP/PA coupler (DIL switch bit 7) must match the configured redundancy mode: ● OFF: coupler redundancy (default setting) ● ON: ring redundancy (line redundancy) If there is a discrepancy between the set redundancy mode and the configured redundancy mode, a diagnostic message is generated.
Page 125 Advantages of fault-tolerant components 4.3 Communication connections Result The following figure shows the resulting configuration in HW Config: Additional information SIMATIC DP/PA Link and Y Link Bus Couplings ● Manual Fault-tolerant Process Control Systems (V8.1) Function Manual, 11/2014, A5E34878832-AA...
Page 126: Distributed I/O
Advantages of fault-tolerant components 4.4 Distributed I/O Distributed I/O 4.4.1 Overview of configuration tasks Introduction The following sections describe configuring redundancy of the individual components of the distributed I/O. Overview This section describes the configuration steps for the following topics: ●...
Page 127 Advantages of fault-tolerant components 4.4 Distributed I/O 4. Double-click the I/O device you want to connect: – ET 200M – ET 200iSP 5. Select the interface module: – For ET 200M: IM 153-2 in the hardware catalog. – For ET 200iSP: IM 152-1 whose hardware catalog description is "..., can be used redundantly in the H system".
Page 128 Advantages of fault-tolerant components 4.4 Distributed I/O Result The following figure shows an example configuration in HW Config: Additional information Process Control System PCS 7; High-Precision Time Stamping ● Function manual DP/PA Link and Y Link Bus Couplings ● Manual Fault-tolerant Process Control Systems (V8.1) Function Manual, 11/2014, A5E34878832-AA...
Page 129: How To Configure Redundant I/O Modules
Advantages of fault-tolerant components 4.4 Distributed I/O 4.4.3 How to configure redundant I/O modules Introduction You configure the redundant I/O modules using HW Config. Note Redundant operation is possible only with certain S7-300 I/O modules of the ET 200M. For additional information, please refer to the following documents: PCS 7 - Released Modules ●...
Page 130 Advantages of fault-tolerant components 4.4 Distributed I/O Example configuration The figure below shows the setup for redundant input modules in a switched distributed configuration. Method of operation in the example configuration "Signal Module 1" is configured redundantly to "Redundant Signal Module 1". As a result, Signals E1.1 and E10.1 are redundant to one another.
Page 131 Advantages of fault-tolerant components 4.4 Distributed I/O Procedure 1. In the component view, select the SIMATIC H station and double-click the "Hardware" object in the detail window. HW Config opens. 2. If the hardware catalog is not visible, select the View > Catalog menu command. The hardware catalog opens.
Page 132 Advantages of fault-tolerant components 4.4 Distributed I/O 12.Click "Find". The "Find Redundant Module" dialog box opens. 13.In the "Subsystem" list, select the DP master system in which the redundant signal module is configured. All the available PROFIBUS addresses in this DP master system are displayed in the "PROFIBUS address"...
Page 133: How To Configure The Redundancy For Hart Field Devices
Advantages of fault-tolerant components 4.4 Distributed I/O Additional information STEP 7 ● Online help on Process Control System PCS 7; PCS 7 - Released Modules ● Documentation Automation System S7-400H; Fault-tolerant Systems ● Manual 4.4.4 How to configure the redundancy for HART field devices HART field devices can be configured with redundant modules.
Page 134 Advantages of fault-tolerant components 4.4 Distributed I/O Procedure 1. Configure redundant modules for HART field devices in HW Config as described in section "How to configure redundant I/O modules (Page 129)". In the example, the module on slot 6 is configured in each case: –...
Page 135 Advantages of fault-tolerant components 4.4 Distributed I/O 3. Place the "HART field device" in the detail view of the redundant module. In the example, module 6 on ET 200M station with PROFIBUS address 6. 4. Select the menu command Station > Save. The settings are saved.
Page 136: How To Configure The Y Link
Advantages of fault-tolerant components 4.4 Distributed I/O 4.4.5 How to configure the Y Link Introduction The Y Link consists of two IM 153-2 interface modules and a Y coupler. The Y Link creates a gateway from a redundant DP master system to a non-redundant DP master system. The following describes how to install and configure the Y Link.
Page 137 Advantages of fault-tolerant components 4.4 Distributed I/O Result The following figure shows an example configuration in HW Config: Additional information DP/ PA Link and Y Link Bus Couplings ● Manual Fault-tolerant Process Control Systems (V8.1) Function Manual, 11/2014, A5E34878832-AA...
Page 138: Configuring Dp/Pa Link
Advantages of fault-tolerant components 4.4 Distributed I/O 4.4.6 Configuring DP/PA Link Functionality When connecting a redundant PROFIBUS DP, the DP/PA Link consists of two IM 153-2 interface modules and one or more DP/PA couplers. The DP/PA coupler is used to build a gateway between a redundant PROFIBUS DP subnet and a non-redundant PROFIBUS PA subnet.
Page 139 Advantages of fault-tolerant components 4.4 Distributed I/O The DP/PA Coupler does not appear in the hardware catalog for the configuration of the bus system. When configuring in HW Config, you only need to set the transmission speed for the selected PROFIBUS DP network in the "Network Settings"...
Page 140: Configuring Ff Link
Advantages of fault-tolerant components 4.4 Distributed I/O 4.4.7 Configuring FF Link Functionality The FF Link consists of two IM 153-2 FF interface modules and one or more FDC157-0 couplers for a connection to a redundant PROFIBUS DP . The FDC157-0 coupler is used to build a gateway between a redundant PROFIBUS DP subnet and a non-redundant FF segment.
Page 141: Configuration Of Redundant Signals
Advantages of fault-tolerant components 4.4 Distributed I/O Procedure Configure the FF Link in the same way as the PA link. You can find information on this in the section "Configuring DP/PA Link (Page 138)". The FDC157-0 coupler does not appear in the hardware catalog for the configuration of the bus system.
Page 142 Advantages of fault-tolerant components 4.4 Distributed I/O Basic procedure 1. Place one channel block in the CFC chart for each redundantly acquired signal. 2. For redundantly registered signals (e.g. input 1.1 and input 10.1), connect the symbol only with the lowest value address (e.g. input 1.1). 3.
Page 143: Operator Stations
Configuring an OS client (Page 154) Configuring an OS client for permanent operability (Page 156) Downloading the SIMATIC PCS 7 project to the target systems (Page 159) 4.5.2 How to configure an OS server and its redundant OS partner server...
Page 144 Advantages of fault-tolerant components 4.5 Operator stations Procedure Note Steps 1 to 11 of this procedure have already been performed if an OS server was created in the project. 1. In the component view of SIMATIC Manager, select the project where you want to add the operator station.
Page 145 Advantages of fault-tolerant components 4.5 Operator stations 18.In the hardware catalog under "SIMATIC PC Station > HMI...", select the "WinCC application (stby)" and insert it in the configuration table by means of drag-and-drop. 19.In the hardware catalog under SIMATIC PC Station > CP Industrial Ethernet, select the communication processor and drag it to the PC station.
Page 146: How To Set The Project Paths Of The Destination Os And Standby Os
Advantages of fault-tolerant components 4.5 Operator stations 4.5.3 How to set the project paths of the destination OS and standby OS Introduction Note The procedure described in this section applies to the following servers: ● OS server ● Maintenance server The description for the OS server is used here.
Page 147: How To Configure A Redundant Connection Between An Os And As
Advantages of fault-tolerant components 4.5 Operator stations 6. Click "OK". You have completed all settings for the master OS. 7. In the component view, select the OS that you want to use as the standby OS. 8. Select the menu command Edit > Object Properties. The "Properties - [name of the OS]"...
Page 148 Advantages of fault-tolerant components 4.5 Operator stations 5. Select the WinCC application of the OS server for which you want to configure a fault- tolerant network connection. The connection table is displayed in the lower window pane. 6. Select the first empty row in the connection table and select the menu command Insert > New Connection.
Page 149 Advantages of fault-tolerant components 4.5 Operator stations Result The following figure shows the redundant network connection of the two OS servers to the SIMATIC H station in NetPro: Additional information ● Section "Network components (Page 46)" ● Section "How to configure a fault-tolerant plant bus (Page 112)" STEP 7 ●...
Page 150: How To Configure Redundancy For Os Servers On The Engineering Station
Advantages of fault-tolerant components 4.5 Operator stations 4.5.5 How to configure redundancy for OS servers on the engineering station Introduction Carry out the following configuration tasks on the Engineering Station. The description for the OS server is used here. Validity The procedure described in this section applies to the following servers: ●...
Page 151 Advantages of fault-tolerant components 4.5 Operator stations 6. Select the following check boxes as required: – Synchronization of Tag Logging after the partner server comes back online – Synchronization of Alarm Logging after the partner server comes back online – Online synchronization for Alarm Logging –...
Page 152: How To Set The Redundancy Connection For Os Servers
Advantages of fault-tolerant components 4.5 Operator stations Additional information WinCC ● Online help for 4.5.6 How to set the redundancy connection for OS servers Introduction You will now select the connection path for the redundancy connection between 2 OS servers. You can make the following settings directly on each of the mutually redundant OS servers.
Page 153: How To Assign An S7 Program To An Os
Advantages of fault-tolerant components 4.5 Operator stations 3. Select the shortcut menu command Redundancy Settings..The "Redundancy Settings" dialog box opens. 4. Select the connection path through which the OS server pair is connected in the drop-down list. – For connection via RJ45 cable: In the "Network adapter"...
Page 154: How To Configure An Os Client
Advantages of fault-tolerant components 4.5 Operator stations 4. If the lower-level objects have a different assignment and you want to have the same assignment for all lower-level objects, check the "Pass on selected assignment to Pass on all the lower-level objects" check box. Note The "Pass on selected assignment to all lower-level objects"...
Page 155 Advantages of fault-tolerant components 4.5 Operator stations Requirements ● The PCS 7 project is open in SIMATIC Manager. ● Each PC has a standard network adapter for connection to the terminal bus. Procedure 1. In the component view of SIMATIC Manager, select the project in which you want to configure the OS clients.
Page 156: How To Configure An Os Client For Permanent Operability
Advantages of fault-tolerant components 4.5 Operator stations Result Your project should now correspond to the project shown in the following figure. You can change the names of the components as you wish. Using reference clients You can set up additional monitoring stations using reference clients. They use configured OS clients as a basis.
Page 157 Advantages of fault-tolerant components 4.5 Operator stations Requirements ● The redundant OS server pair has been configured in SIMATIC Manager. ● WinCC redundancy is configured for the OS server (master). ● The OS server (master) has been compiled such that the server data have been generated. ●...
Page 158 Advantages of fault-tolerant components 4.5 Operator stations Result The "Configure server data" dialog boxes on both OS clients appear as follows: ● Dialog box on OS client 1: ● Dialog box on OS client 2: Fault-tolerant Process Control Systems (V8.1) Function Manual, 11/2014, A5E34878832-AA...
Page 159: How To Download A Simatic Pcs 7 Project To The Target Systems
Process Control System PCS 7; Operator Station ● Configuration manual 4.5.10 How to download a SIMATIC PCS 7 project to the target systems Introduction You can download a PCS 7 project that you created in SIMATIC Manager along with the components of the project (AS, OS, BATCH server/client) to the various target systems in a single step with the menu command PLC >...
Page 160: Evaluating The "@Rm_Master" Redundancy Variables With Scripts
Advantages of fault-tolerant components 4.5 Operator stations Sequence when loading redundant OS servers with "Changes-only download" function The "Changes-only download" function of a redundant OS server is only available if both partner stations are in process mode (runtime). For safety reasons, downloading is not performed to a redundant OS server pair at the same time: ●...
Page 161: Simatic Batch Stations
Advantages of fault-tolerant components 4.6 SIMATIC BATCH Stations SIMATIC BATCH Stations 4.6.1 Overview of configuration tasks Introduction The following sections describe how to configure redundancy for SIMATIC BATCH stations. Overview of configuration tasks You configure the redundancy functionality of the BATCH stations by performing the following steps: Step What?
Page 162 Advantages of fault-tolerant components 4.6 SIMATIC BATCH Stations 4. Enter the Windows name of the computer to be used as the BATCH server in the "Computer name" box. 5. In the component view, select the SIMATIC PC station and double-click the "Configuration" object in the detailed view.
Page 163: How To Configure A Batch Client
Advantages of fault-tolerant components 4.6 SIMATIC BATCH Stations Result The following figure shows an example configuration of a SIMATIC PC station with BATCH application (stby): Additional information Process Control System PCS 7; Engineering System ; section "How ● Configuration manual to Expand a Project with Pre-Configured Stations Using the PCS 7 Wizards"...
Page 164 Advantages of fault-tolerant components 4.6 SIMATIC BATCH Stations Procedure 1. In the component view of SIMATIC Manager, select the project into which you want to insert the BATCH client. 2. Select the menu command Insert > Station > SIMATIC PC Station. A new SIMATIC PC station is inserted in the selected project.
Page 165: How To Set The Redundancy Monitoring Of Batch Servers
Advantages of fault-tolerant components 4.6 SIMATIC BATCH Stations Additional information Process Control System PCS 7; SIMATIC BATCH ● Manual 4.6.4 How to set the redundancy monitoring of BATCH servers Introduction A local Ethernet network needs to be built in PCS 7 for redundancy monitoring of redundant BATCH servers.
Page 166: How To Configure The Redundancy Connection For Batch Servers On The Engineering Station
Advantages of fault-tolerant components 4.6 SIMATIC BATCH Stations 4.6.5 How to configure the redundancy connection for BATCH servers on the engineering station Introduction Additional tasks must be performed in the engineering and for setting up the PC stations for redundant BATCH servers: ●...
Page 167: How To Set The Redundancy Connection For Batch Servers
Advantages of fault-tolerant components 4.6 SIMATIC BATCH Stations Additional information Process Control System PCS 7; SIMATIC BATCH ● Manual 4.6.6 How to set the redundancy connection for BATCH servers Introduction You will now select the connection path for the redundancy connection between 2 BATCH servers.
Page 168 Advantages of fault-tolerant components 4.6 SIMATIC BATCH Stations Requirements ● The PCS 7 project is open in the Component view in the SIMATIC Manager. ● The SIMATIC BATCH configuration is completed. ● The Batch plant is compiled. Downloading via SIMATIC BATCH 1.
Page 169: Simatic Route Control Stations
Advantages of fault-tolerant components 4.7 SIMATIC Route Control stations SIMATIC Route Control stations 4.7.1 Overview of configuration tasks Introduction The following sections describe how to configure redundancy for SIMATIC Route Control stations. Overview of configuration tasks You configure the redundancy functionality of the SIMATIC Route Control stations by performing the following steps: Step What?
Page 170 Advantages of fault-tolerant components 4.7 SIMATIC Route Control stations 3. Select the SIMATIC PC station, select the menu command Edit > Object Properties and enter the desired name (in the example, Route Control server). 4. Enter the Windows name of the computer to be used as the Route Control server in the "Computer name"...
Page 171: How To Configure A Route Control Client
Advantages of fault-tolerant components 4.7 SIMATIC Route Control stations Result The following figure shows an example configuration of a SIMATIC PC station with Route Control application (stby): Additional information Process Control System PCS 7; Engineering System ; section "How ● Configuration manual to Expand a Project with Pre-Configured Stations Using the PCS 7 Wizards"...
Page 172 Advantages of fault-tolerant components 4.7 SIMATIC Route Control stations Requirements ● The SIMATIC Route Control software package (Route Control Engineering) has been installed in addition to the PCS 7 software. ● The PCS 7 project is open in SIMATIC Manager. Procedure 1.
Page 173 Advantages of fault-tolerant components 4.7 SIMATIC Route Control stations Result The following figure shows the SIMATIC PC station with Route Control application client (RC application client) configured in HW Config: Shared client for OS and Route Control If a Route Control client and OS client are operated together on a SIMATIC PC station, configure both client applications in HW Config in one SIMATIC PC station.
Page 174: How To Configure A Redundant Connection Between A Route Control Server And As
Advantages of fault-tolerant components 4.7 SIMATIC Route Control stations 4.7.4 How to configure a redundant connection between a Route Control server and Introduction The redundant connections between the Route Control server and the AS are created in NetPro using SIMATIC Route Control wizards. Requirements ●...
Page 175 Advantages of fault-tolerant components 4.7 SIMATIC Route Control stations Result The following figure shows the redundant network connection to the automation system for both Route Control servers in NetPro. The example plant is configured with a redundant fault- tolerant plant bus. Each PC station and each CPU is connected to the plant bus with 2 network adapters: Additional information ●...
Page 176: How To Set The Redundancy Connection For Route Control Servers
Advantages of fault-tolerant components 4.7 SIMATIC Route Control stations 4.7.5 How to set the redundancy connection for Route Control servers Introduction You will now select the connection path for the redundancy connection between two Route Control servers. You can make the following settings directly on each of the mutually redundant Route Control servers.
Page 177: How To Set The Redundancy Of The Route Control Servers
Advantages of fault-tolerant components 4.7 SIMATIC Route Control stations 4. Select the connection path through which the Route Control server pair is connected in the drop-down list. – For connection via RJ45 cable: In the "Network adapter" drop-down list, select the network adapter to which you want to attach the network cable for the redundant connection between the two PC stations of a server pair.
Page 178: Archive Servers (Process Historian And Information Server)
Advantages of fault-tolerant components 4.8 Archive servers (Process Historian and Information Server) Archive servers (Process Historian and Information Server) 4.8.1 How to configure a Process Historian and its redundant partner server Introduction This section describes the individual steps involved in creating the Process Historian and its redundant partner server.
Page 179 Advantages of fault-tolerant components 4.8 Archive servers (Process Historian and Information Server) 10.Select the menu command Insert > Station > SIMATIC PC Station. A new SIMATIC PC station is inserted in the selected project. 11.Select the SIMATIC PC station, select the menu command Edit > Object Properties and enter the desired name (in the example: Archive 2).
Page 180 Advantages of fault-tolerant components 4.8 Archive servers (Process Historian and Information Server) Fault-tolerant Process Control Systems (V8.1) Function Manual, 11/2014, A5E34878832-AA...
Page 181: Component Replacement And Plant Changes
Component Replacement and Plant Changes Failure and replacement of bus components 5.1.1 Replacement of SIMATIC components in runtime Continuous operation A crucial factor for continuous operation of fault-tolerant process control systems is the replacement of faulty or failed components in runtime. Replacement of defective components is only possible if fault-tolerant components are used.
Page 182: Replacement Of Bus Components In Runtime
Component Replacement and Plant Changes 5.1 Failure and replacement of bus components The following table is an overview of the descriptions: Automation System S7-400H; Fault-tolerant For the procedure used to re‐ ..refer to the manual Systems in section ... place components ...
Page 183: Replacement Of Operator Stations In Runtime
Component Replacement and Plant Changes 5.1 Failure and replacement of bus components Before making a replacement, the following aspects must be taken into consideration: ● Bus topology (for example ring structure, spur lines, redundancy connections, disrupted bus cable) ● Connection of the bus system to "master systems": –...
Page 184: Replacement Of Batch Stations In Runtime
Component Replacement and Plant Changes 5.1 Failure and replacement of bus components Replacing an OS server Follow the steps below to replace an OS server: Step What? Switch OS clients over to the server that will be remaining in operation. Deactivate and replace the OS server, Check the network addresses and download the configuration data.
Page 185: Replacement Of Route Control Stations In Runtime
Component Replacement and Plant Changes 5.1 Failure and replacement of bus components ● The same IP address is used for the new PC. ● The MAC address is adapted in the project. Replacing the BATCH server Follow the steps below to replace a BATCH server: Step What? Replace the BATCH server.
Page 186 Component Replacement and Plant Changes 5.1 Failure and replacement of bus components Replace the Route Control server. Follow the steps below to replace a Route Control server: Step What? Replace the Route Control server. On the engineering station: Open Route Control Engineering and download the Route Control server Start Route Control (Route Control starts as standby server).
Page 187: Plant Changes In Runtime
Component Replacement and Plant Changes 5.2 Plant changes in runtime Plant changes in runtime Plant changes in runtime In addition to the options for replacing failed components in runtime as described in the section titled "Failure and replacement of components during operation", the CPU (41x-xH) also supports a system modification without interrupting the running program.
Page 188 Component Replacement and Plant Changes 5.2 Plant changes in runtime changes Possible modifications Adding or removing mod‐ ● DP slaves with redundant interface modules (for example, ET 200M, ules components in distrib‐ DP/PA Link, Y Link) uted I/O modules ● Non-redundant DP slaves in any DP master system ●...
Page 189: Failure, Switchover And Return Of Fault-Tolerant Components
Failure, Switchover and Return of Fault-tolerant Components 6.1.1 Failure of redundant interface modules Functionality Interface modules can be configured redundantly in the distributed I/O device (ET 200M, ET 200iSP). The interface modules provide the interface to the automation system through the PROFIBUS DP.
Page 190 Failure, Switchover and Return of Fault-tolerant Components 6.1 I/O Failure scenarios The following faults may occur in a module: ● Hardware or power failure in the module ● Detected signal interference (e.g. wire break, discrepancy) ● Fault on the assigned bus line to an interface module The driver blocks detect a disturbance: ●...
Page 191 Failure, Switchover and Return of Fault-tolerant Components 6.1 I/O ● Following a prompt from the user program via an acknowledgement signal, for example, on an OS with a "Depassivation" button at the block ● After pulling/plugging a module ● Following a diagnostic interrupt (e.g. wire break, measured value) Additional information STEP 7 ●...
Page 192: Automation System
Failure, Switchover and Return of Fault-tolerant Components 6.2 Automation system Automation system 6.2.1 Failure of the master CPU Functionality The initial situation is that the S7-400H is in "Redundant" system mode. The processing of the user program is synchronized on both CPUs of the H system and, for example, CPU0 is the master CPU and CPU1 is the backup CPU.
Page 193 Failure, Switchover and Return of Fault-tolerant Components 6.2 Automation system Example: Failure of a fiber-optic cable If a fiber-optic cable fails, the REDF LED and the IFM1F or IFM2F LED light up on the two CPUs depending on the location of the fiber-optic cable failure. The H system goes to "Solo" system mode and the user program continues to be processed by the master CPU used up to this point (CPU0).
Page 194 Failure, Switchover and Return of Fault-tolerant Components 6.2 Automation system Result When the CPU in Rack 1 is back online, the "Operating mode" dialog box appears as follows: Fault-tolerant Process Control Systems (V8.1) Function Manual, 11/2014, A5E34878832-AA...
Page 195: Communication
Failure, Switchover and Return of Fault-tolerant Components 6.3 Communication Communication 6.3.1 Failure of redundant bus components Functionality As soon as a fault occurs on a transmission path, the second transmission path takes over and forwards the signals. Failure scenarios The following problems can occur on a bus component: ●...
Page 196: Os Server
Failure, Switchover and Return of Fault-tolerant Components 6.4 OS server OS server 6.4.1 Failure, failover and restarting of redundant OS servers Introduction This section describes the criteria by which the master/standby identification of an OS server changes. Examples are given to illustrate how the system reacts to failures. Note Information on updating operator stations with redundant OS servers in runtime can be found in "guidelines on updating a redundant OS in runtime (Page 208)".
Page 197 Failure, Switchover and Return of Fault-tolerant Components 6.4 OS server Example configuration Startup of an OS server pair The following applies, in general: An OS server pair consists of the OS server and its OS partner server. The two PCs are configured with WinCC Redundancy in a redundant grouping. When the OS server pair starts up, WinCC Redundancy first checks which of the two OS servers is to be assigned the master identification.
Page 198 Failure, Switchover and Return of Fault-tolerant Components 6.4 OS server WinCC project is deactivated A functionally equivalent WinCC project is activated on both OS servers. If the WinCC project is deactivated on OS Server 1 (master identification), WinCC Redundancy triggers the following reactions: ●...
Page 199 Failure, Switchover and Return of Fault-tolerant Components 6.4 OS server The terminal bus as a whole and the communication between the AS and OS servers remains unaffected. Both OS servers are started and begin processing an activated WinCC project. If a disruption in the network connection to the OS partner server occurs in this situation, WinCC Redundancy reacts as follows: ●...
Page 200 Failure, Switchover and Return of Fault-tolerant Components 6.4 OS server after process connection error" option must be selected in the "General" tab of the "Redundancy" dialog box for this. ● The OS partner server saves the date and the time of day marking the return of the OS server.
Page 201: Batch Server
Failure, Switchover and Return of Fault-tolerant Components 6.5 BATCH Server BATCH Server 6.5.1 Reaction of BATCH servers to failure Functionality BATCH applications and any configured WinCC applications are active on BATCH servers. A BATCH client visualizes the batch data of the BATCH server to which it is connected. Failure of the master BATCH server If the master BATCH server fails, for example, due to an operating system failure or an application error, the standby BATCH server detects that the master is no longer available...
Page 202: Route Control Server
Failure, Switchover and Return of Fault-tolerant Components 6.6 Route Control server Route Control server 6.6.1 Reaction of Route Control servers to failure Functionality Route Control applications and any configured WinCC applications are active on Route Control servers. A Route Control client visualizes the route list of the Route Control server to which it is interconnected.
Page 203 Failure, Switchover and Return of Fault-tolerant Components 6.6 Route Control server Additional information Process Control System PCS 7; SIMATIC Route Control ● Manual Fault-tolerant Process Control Systems (V8.1) Function Manual, 11/2014, A5E34878832-AA...
Page 204: Os Clients
Failure, Switchover and Return of Fault-tolerant Components 6.7 OS clients OS clients 6.7.1 Failover reactions of OS clients with permanent operability Functionality If the network for the configured OS server is interrupted, the process values on the OS clients are no longer updated. After successful failover to the partner server, the process can be operated again on all assigned OS clients.
Page 205 Failure, Switchover and Return of Fault-tolerant Components 6.7 OS clients Once OS Server 1 becomes available again, OS Client 1 is connected to the returning OS Server 1 because it is the configured preferred server. Permanent operability is restored after the failover is complete. OS Client 1 is not available for the duration of the failover to OS Server 1.
Page 206: Batch Clients
Failure, Switchover and Return of Fault-tolerant Components 6.8 BATCH clients BATCH clients 6.8.1 Failover reactions of BATCH clients Functionality If the master BATCH server fails, the BATCH clients automatically switch to the redundant BATCH server. Reactions during failover During a failover, a message window is displayed on the screen of the BATCH client indicating the failover.
Page 207: Route Control Clients
Failure, Switchover and Return of Fault-tolerant Components 6.9 Route Control clients Route Control clients 6.9.1 Failover reaction of Route Control clients Functionality If the master Route Control server fails, the Route Control clients are automatically switched over to the redundant Route Control server. Reactions during failover During a failover, a message window is displayed on the screen of the Route Control client indicating the failover.
Page 208: Guidelines For Updating A Redundant Os In Runtime
Failure, Switchover and Return of Fault-tolerant Components 6.10 Guidelines for updating a redundant OS in runtime 6.10 Guidelines for updating a redundant OS in runtime 6.10.1 Introduction Introduction Below, you will find guidelines for updating a redundant OS in runtime. This means that the operation of the PCS 7 system is not disrupted, the AS does not change to STOP mode and the automation process can continue to be operated and monitored.
Page 209 Failure, Switchover and Return of Fault-tolerant Components 6.10 Guidelines for updating a redundant OS in runtime Checking time synchronization To avoid any jumps in time (UTC/local standard time) when "updating redundant systems in runtime", check the time synchronization of the OS in the updated PCS 7 project on the ES: 1.
Page 210: Overview Of The Required Tasks
Failure, Switchover and Return of Fault-tolerant Components 6.10 Guidelines for updating a redundant OS in runtime The procedure described below must be repeated for all client-server relationships in the system, as appropriate. ● If you have several redundant servers, first update only the clients interconnected with the standby server that has already been updated or that has been defined as the preferred server for these clients.
Page 211 Failure, Switchover and Return of Fault-tolerant Components 6.10 Guidelines for updating a redundant OS in runtime Initial situation ● Server_1 is master server. ● Server_2 is standby server. ● Client_1 is connected to Server_1 because this server is configured as its preferred server. Client_1 represents all OS clients connected to Server_1.
Page 212 Failure, Switchover and Return of Fault-tolerant Components 6.10 Guidelines for updating a redundant OS in runtime Phase Step Phase 1: 1. Server_2: Deactivate and exit WinCC Updating Serv‐ 2. Server_2: er_2 Back up the PCS 7 project Back up the operating system and the PCS 7 software installation 3.
Page 213 Failure, Switchover and Return of Fault-tolerant Components 6.10 Guidelines for updating a redundant OS in runtime Phase Step Phase 4: 1. Client_1: Deactivate and exit WinCC Update the OS 2. Client_1: clients that are Back up the PCS 7 project interconnected Back up the operating system and the PCS 7 software installation 3.
Page 214: Phase 1: Updating Server_2
Failure, Switchover and Return of Fault-tolerant Components 6.10 Guidelines for updating a redundant OS in runtime The updating of your redundant operator stations is complete. Note Encrypted communication If you have used encrypted communication, it is activated in migration mode for all PC stations in the system.
Page 215 Failure, Switchover and Return of Fault-tolerant Components 6.10 Guidelines for updating a redundant OS in runtime Procedure - Phase 1 Note that you will need to work alternately on Server_1 and Server_2. Phase 1 / 1. Server_2: Deactivate and exit WinCC ●...
Page 216 Failure, Switchover and Return of Fault-tolerant Components 6.10 Guidelines for updating a redundant OS in runtime Phase 1 / 7. Server_2: Check and save the "Redundancy" dialog box ● Open the "Redundancy" editor and check the settings in the dialog box. Click "OK" to exit the dialog box even if you have made no changes.
Page 217: Phase 2: Updating Os Clients Interconnected With Server_2
Failure, Switchover and Return of Fault-tolerant Components 6.10 Guidelines for updating a redundant OS in runtime 6.10.4 Phase 2: Updating OS clients interconnected with Server_2 Introduction In Phase 2, you update the OS clients that were interconnected with Server_2. The system can be controlled at all times using Client_1, which is interconnected with the not- yet-updated Server_1.
Page 218 Failure, Switchover and Return of Fault-tolerant Components 6.10 Guidelines for updating a redundant OS in runtime Phase 2 / 2. Client_2: Installation of the operating system, PCS 7 Installation "OS client" ● Install or update the operating system (you can find information about this in the manual Process Control System PCS 7;...
Page 219: Phase 3: Downloading The Connections, Gateways And Changes To The As
Failure, Switchover and Return of Fault-tolerant Components 6.10 Guidelines for updating a redundant OS in runtime 6.10.5 Phase 3: Downloading the connections, gateways and changes to the AS Introduction In Phase 3, connections, gateways and CFC charts are downloaded to the AS from NetPro by downloading changes only.
Page 220: Phase 4: Updating The Os Clients Interconnected With Server_1
Failure, Switchover and Return of Fault-tolerant Components 6.10 Guidelines for updating a redundant OS in runtime The system reacts as follows: ● The system can be controlled and monitored from all clients. Result after Phase 3 ● Server_1 is master server in the PCS 7 project. ●...
Page 221 Failure, Switchover and Return of Fault-tolerant Components 6.10 Guidelines for updating a redundant OS in runtime Phase 4 / 2. Client_1: Backup of the PCS 7 project, of the operating system and of the PCS 7 software installation ● Back up your previous operating system, the previous PCS 7 software installation and your current PCS 7 project as a fallback strategy.
Page 222: Phase 5: Updating Server_2
Failure, Switchover and Return of Fault-tolerant Components 6.10 Guidelines for updating a redundant OS in runtime ● Client_1 is updated (deactivated or connected to Server_2). ● OS Client_2 is interconnected with its preferred Server_2. 6.10.7 Phase 5: Updating Server_2 Introduction While you perform the steps in phase 5, your system runs only with Server_2.
Page 223 Failure, Switchover and Return of Fault-tolerant Components 6.10 Guidelines for updating a redundant OS in runtime Procedure - Phase 5 Phase 5 / 1. Server_1: Deactivate and exit WinCC ● Deactivate WinCC Runtime on Server_1. ● Exit WinCC on Server_1. ●...
Page 224 Failure, Switchover and Return of Fault-tolerant Components 6.10 Guidelines for updating a redundant OS in runtime Phase 5 / 8. Server_1: Check and save the "Redundancy" dialog box ● Open the "Redundancy" editor and check the settings in the dialog box. Click "OK" to exit the dialog box even if you have made no changes.
Page 225 Failure, Switchover and Return of Fault-tolerant Components 6.10 Guidelines for updating a redundant OS in runtime Note Encrypted communication If you have used encrypted communication, it is activated in migration mode for all PC stations in the system. Use encrypted communication in migration mode only as a temporary solution. Deactivate migration mode in the entire system.
Page 226: Guide To Updating A Redundant Batch Server In Runtime
Failure, Switchover and Return of Fault-tolerant Components 6.11 Guide to updating a redundant BATCH server in runtime 6.11 Guide to updating a redundant BATCH server in runtime 6.11.1 Software update (migration) Information is available in the SIMATIC BATCH product documentation: SIMATIC Process Control System PCS 7;...
Page 227: Guide To Updating A Redundant Route Control Server In Runtime
Failure, Switchover and Return of Fault-tolerant Components 6.12 Guide to updating a redundant Route Control server in runtime 6.12 Guide to updating a redundant Route Control server in runtime 6.12.1 Updating a redundant Route Control server in runtime For servers and single-station systems which are used for OS and Route Control, please observe the following information.
Page 228 Failure, Switchover and Return of Fault-tolerant Components 6.12 Guide to updating a redundant Route Control server in runtime Default Master Default Standby Start RC server (or WinCC Runtime) – starts as New version – Runtime standby (you may have to update the project) The database is read.
Page 229: Diagnostics
Diagnostics Process Control System PCS 7; Service Support and Information is available in the manual Diagnostics . Fault-tolerant Process Control Systems (V8.1) Function Manual, 11/2014, A5E34878832-AA...
Page 230: Advanced Self-Diagnostics Of Communication Connections
Diagnostics 7.1 Advanced self-diagnostics of communication connections Advanced self-diagnostics of communication connections PCS 7 features advanced self-diagnostics for redundant software systems (servers). If this diagnostics routine detects an internal fault, and in the event that the redundant partner server is fully functioning, all communication connections on the server affected by the fault are disconnected (terminal and plant bus).
Page 231 Diagnostics 7.1 Advanced self-diagnostics of communication connections Fault-tolerant Process Control Systems (V8.1) Function Manual, 11/2014, A5E34878832-AA...
Page 232: State Of Redundant Operator Stations In Diagnostic Pictures
Diagnostics 7.2 State of redundant operator stations in diagnostic pictures State of redundant operator stations in diagnostic pictures When using a Maintenance Station, the block icons show the redundancy state of the redundant OS servers in the diagnostic area. You can find information on the block icons Process Control System PCS 7;...
Page 233: Index
Index Channel-based, 105 Client, 89, 154 Configuring, 154 Communication connections, 107 Actuators, 39 Configuring, 107 Adding, 187 Communication lines, 44 Components of the distributed I/O, 187 Communication modules, 40 Modules in central and expansion racks, 187 Communication solutions, 44, 51, 53, 66, 68 Advantages of fault-tolerant components, 100 Fault-tolerant terminal bus, 51 Note, 100...
Page 234 Index Connecting Fault, 196 Plant bus, 51 Network connection from the OS client to the OS Terminal bus, 51 server, 196 Continuation, 16 Network connection to the AS, 196 Bumpless, 16 Network connection to the OS partner CP 1613, 51 server, 196 CP 1623, 51 Fault tolerance with redundancy nodes, 17...
Page 235 Index How to set the redundancy of the BATCH servers, 166 How to set the redundancy of the Route Control servers, 177 Open HW Config Existing STEP 7 project, 134 Starting, 134 Operating principle, 43, 85, 89, 129 OS server, 85 Permanent operability, 89 Redundant I/O modules, 129 I/O, 31, 32, 34, 39...
Page 236 Index Components, 63 Redundant interfacing, 189 Setup, 63, 66 Hot restart, 189 Plant changes in runtime, 187 Response to failure, 189 Power supply Redundant OS servers, 85 S7-400H, 40 Configuring, 143 Preface, 7 Creating, 143 Preferred server, 89 Redundant Route Control servers, 94 Process control system PCS 7, 13 Redundant systems, 208 Process Historian...
Page 237 OS compilation, 153 Quick guide, 210, 214, 219, 222 Redundant connection between AS and OS, 147 Setting the project path, 146 SIMATIC PCS 7 overview of features, 20 For servicing and system expansion, 25 For the configuration phase, 22 Validity, 7...
Page 238 Index WinCC project, 196 Deactivating, 196 WinCC Redundancy, 150 Configuring, 150 WinCC Server, 85 Windows domain Synchronizing, 97 Y Link, 71, 136 Configuring, 136 Requirements, 136 Setup, 136 Fault-tolerant Process Control Systems (V8.1) Function Manual, 11/2014, A5E34878832-AA...

Siemens SIMATIC PCS 7 Function Manual

1 Preface

2 Basics of Fault Tolerance

3 Fault-Tolerant Solutions in PCS 7

4 Advantages of Fault-Tolerant Components

5 Component Replacement and Plant Changes

6 Failure, Switchover and Return of Fault-Tolerant Components

7 Diagnostics

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Summary of Contents for Siemens SIMATIC PCS 7

Table of Contents