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Siemens SIMATIC S7-400H User Manual

Siemens SIMATIC S7-400H
336 pages
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Preface, Contents
Fault-Tolerant Programmable Logic
Controllers
1
S7-400H Installation Options
2
Getting Started
3
Installation of a CPU 41x-H
4
System and Operating Modes of the
S7-400H
5
Linking and Synchronizing
6
Using I/O on the S7-400H
7
Communication Functions
8
Configuring with STEP 7
9
Failure and Replacement of
Components During Operation
10
Modifying the System During Operation
11
Synchronization module
12
Technical Specifications
13
Appendices
Characteristic Values of Redundant
Programmable Logic Controllers
A
Single Operation
B
Converting from S5-H to S7-400H
C
Differences Between Fault-Tolerant
Systems and Standard Systems
D
Function Modules and Communication
Processors Used on the S7-400H
E
Connection Examples for Redundant I/O
F
Glossary, Index
Edition 07/2003
A5E00068197-07
Automation System S7-400H
Fault-tolerant Systems
Manual
SIMATIC
This manual has the order number:
6ES7988-8HA10-8BA0

Table of Contents

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Siemens SIMATIC S7-400H Specifications

General IconGeneral
CPU TypeS7-400H
RedundancyYes
Operating Temperature0 to 60 °C
Programming languageSTEP 7
Communication InterfacesPROFIBUS, PROFINET, Industrial Ethernet
Backplane busS7-400
Operating voltage24 V DC
MountingRack mounting
Power Supply24 V DC
CPU TypesMultiple variants available (e.g., 412-3H, 414-4H, 417-4H)

Summary

Fault-Tolerant Programmable Logic Controllers

Redundant Programmable Logic Controllers in the SIMATIC Series

Overview of redundant PLCs within the SIMATIC series, emphasizing their role in automation.

Increasing System Availability

How the S7-400H meets requirements for availability through component duplication.

S7-400H Installation Options

Base System of the S7-400H

Describes the minimum hardware configuration for the S7-400H, including racks, CPUs, and power supplies.

I/O Modules for S7-400H

Details available I/O modules and configuration versions for the S7-400H system.

Communication

Discusses communication capabilities, availability, and configuration for the S7-400H.

Tools for Configuration and Programming

Explains the use of STEP 7 and required software for S7-400H configuration.

The User Program

Rules for designing and programming the S7-400H user program.

Documentation

Overview of available documentation for S7-400H components and applications.

Getting Started

Requirements

Lists necessary software and hardware modules for the S7-400H configuration.

Configuring Hardware and Starting Up the S7-400H

Step-by-step guide for installing and configuring the S7-400H hardware.

Examples of Fault-Tolerant System Response to Faults

Demonstrates system behavior during common fault scenarios like power supply or cable failure.

Installation of a CPU 41x-H

Controls and Indicators of the CPUs

Details the operation and display elements of the CPU 414-4H/417-4H.

Monitoring Functions of the CPU

Explains the CPU's monitoring functions and error messages.

Status and Error LEDs

Describes the meaning and status indicated by various CPU LEDs.

Mode Selector

Explains the function and positions of the CPU mode selector switch.

Memory Expansion

Covers determining memory requirements and expanding CPU memory.

Multipoint Interface (MPI)

Details connectable devices and configurations for the MPI interface.

PROFIBUS DP Interface

Explains how to connect devices to the PROFIBUS DP interface.

Overview of the Parameters for the S7-400 CPUs

Lists configurable system properties and default parameter values.

CPU 41x as DP Master

Details properties and specifications for using the CPU as a Profibus DP master.

Consistent data

Explains the concept of consistent data and how to maintain it.

System and Operating Modes of the S7-400H

Introduction

Introduces the S7-400H structure and active redundancy principle.

System Modes of the S7-400H

Overview of the possible system modes based on CPU operating modes.

Operating Modes of the CPUs

Describes CPU behaviors from POWER ON to redundant system mode.

Self-Test

Details the self-test functions for detecting and reporting malfunctions.

Time Response

Discusses instruction run times and I/O direct access impacts on scan time.

Evaluation of Process Interrupts in the S7-400H System

How to evaluate process interrupts and temporary variables in the user program.

Linking and Synchronizing

Effects of Link-up and Update

Explains the impact of link-up and update on user program execution and communication.

Functional Sequence of Link-up and Update

Outlines the step-by-step process of link-up and update.

Time Monitoring

Details monitoring times for scan-cycle extension, communication delay, and blocking times.

Peculiarities during Link-up and Update

Discusses specific behaviors and requirements during link-up and update.

Using I/O on the S7-400H

Introduction

Overview of I/O configurations and availability on the S7-400H.

Using Single-Channel, One-Sided I/O

Explains single-channel, one-way I/O configuration and behavior.

Using Single-Channel, Switched I/O

Details single-channel, switched I/O configuration and its advantages.

Connecting Redundant I/O

Explains configurations for redundant I/O in central, expansion, and distributed devices.

Other possibilities for connecting redundant I/O

Describes alternative methods for connecting redundant I/O on the user level.

Communication Functions

Fundamentals and Basic Concepts

Basic concepts of fault-tolerant communications and redundant systems.

Suitable Networks

Discusses Industrial Ethernet and PROFIBUS as suitable networks for fault-tolerant systems.

Supported Communication Services

Lists supported S7 communication services and those that are not supported.

Communications via Fault-tolerant S7 Connections

Explains availability and configuration of fault-tolerant S7 connections.

Communications via S7 Connections

Details communications with standard systems using S7 connections.

Communication Performance

Evaluates communication performance based on load, response time, and data throughput.

Configuring with STEP 7

Installing the Options Package

Steps for installing the S7 fault-tolerant system option package.

Configuring with STEP 7

Basic approach to configuring S7-400H, creating stations, and hardware.

Programming Device Functions in STEP 7

Explains how system display and editing differ in SIMATIC Manager for fault-tolerant stations.

Failure and Replacement of Components During Operation

Failure and Replacement of Components in Central Racks and Expansion Racks

Details replaceable components in central and expansion racks during operation.

Failure and Replacement of Components of the Distributed I/O

Lists replaceable components in distributed I/O systems during operation.

Modifying the System During Operation

Possible Hardware Modifications

Discusses hardware changes like adding/removing modules during operation.

Adding Components in PCS 7

Step-by-step procedure for adding hardware components using PCS 7.

Removing Components in PCS 7

Step-by-step procedure for removing hardware components using PCS 7.

Adding Components in STEP 7

Step-by-step procedure for adding hardware components using STEP 7.

Removing Components in STEP 7

Step-by-step procedure for removing hardware components using STEP 7.

Changing the CPU Parameters

Details modifiable CPU parameters and recommended settings.

Changing the Memory Components of the CPU

Explains methods for expanding or changing CPU memory components.

Synchronization Module

Synchronization Module for S7-400H

Describes the function and mechanical configuration of the synchronization module.

Routing Cables Using Fiber Optics

Provides guidelines for routing and bending fiber optic cables.

Technical Specifications

Technical Specifications of the CPU 414-4H; (6ES7 414-4HJ00-0AB0)

Detailed technical specifications for the CPU 414-4H.

Technical Specifications of the CPU 417-4H; (6ES7 417-4HL01-0AB0)

Detailed technical specifications for the CPU 417-4H.

Run Times of the FCs and FBs for Redundant I/O

Provides run times for function blocks and function calls used with redundant I/O.

Characteristic Values of Redundant Programmable Logic Controllers

Basic Concepts

Explains reliability, availability, and MTBF parameters for PLCs.

Comparison of MTBFs for Selected Configurations

Compares MTBF factors for various system configurations with central I/O.

Single Operation

Overview

Information on single operation of fault-tolerant CPUs.

Definition

Defines single operation as using a fault-tolerant CPU in a standard station.

Reasons for single operation

Outlines applications requiring fault-tolerant CPUs, like specific connections or fail-safe controllers.

What do you have to take into account for single Operation of a fault-tolerant CPU

Lists differences between standard and fault-tolerant CPUs in single/redundant modes.

Converting from S5-H to S7-400H

General Information

Documentation and prerequisites for converting S5-H systems to S7-400H.

Configuration, Programming and Diagnostics

Compares S5 error diagnostics with S7 diagnostics and programming methods.

Differences Between Fault-Tolerant Systems and Standard Systems

Additional functions of fault-systems

Lists additional programming functions specific to fault-tolerant systems.

Restrictions for the Fault-Tolerant CPU Compared to a Standard CPU

Highlights features not supported by fault-tolerant CPUs compared to standard ones.

Function Modules and Communication Processors Used on the S7-400H

FMs and CPs used centrally

Lists central FMs and CPs usable with S7-400H, noting their release and redundancy support.

FMs and CPs for distributed one-way use

Lists FMs and CPs for distributed one-way use with ET 200M.

FMs and CPs for distributed switched use

Lists FMs and CPs for distributed switched use with ET 200M.

Connection Examples for Redundant I/O

SM 321; DI 8 x AC 120/230 V, 6ES7 321-1FF01-0AA0

Connection diagram for redundant sensors to SM 321 DI 8 x AC 120/230 V.

SM 322; DO 8 x AC 230 V/2 A, 6ES7 322-1FF01-0AA0

Connection diagram for an actuator to redundant SM 322 DO 8 x AC 230 V/2 A.

SM 321; DI 16 x AC 120/230 V, 6ES7 321-1FF00-0AA0

Connection diagram for redundant sensors to SM 321 DI 16 x AC 120/230 V.

SM 331; AI 8 x 16 Bit; 6ES7331-7NF00-0AB0

Connection diagram for a transmitter to redundant SM 331 AI 8 x 16 Bit.

SM 332; AO 4 x 12 Bit; 6ES7 332-5HD01-0AB0

Connection diagram for an actuator to redundant SM 332 AO 4 x 12 Bit.

SM 421; DI 32 x UC 120 V, 6ES7 421-1EL00-0AA0

Connection diagram for redundant sensors to SM 421 DI 32 x UC 120 V.

SM 422; DO 16 x AC 120/230 V/2 A, 6ES7 422-1FH00-0AA0

Connection diagram for an actuator to redundant SM 422 DO 16 x AC 120/230 V/2 A.

SM 321; DI 16 x DC 24 V, 6ES7 321-7BH00-0AB0

Connection diagram for redundant sensors to SM 321 DI 16 x DC 24 V.

SM 322; DO 32 DC 24 V/0.5 A, 6ES7 322-1BL00-0AA0

Connection diagram for an actuator to redundant SM 322 DO 32 DC 24 V/0.5 A.

SM 331; AI 8 12 Bit, 6ES7 331-7KF02-0AB0

Connection diagram for a transducer to redundant SM 331 AI 8 x 12 Bit.

Glossary

1-out-of-2 system

Definition of a dual-channel H system.

Comparison error

Error occurring during memory comparison in fault-tolerant systems.

Dual-channel H system

Definition of an H system with two central modules.

Fail-safe systems

Systems that remain in a safe state or go to a safe state upon failure.

Fault-tolerant systems

Systems designed to reduce downtime via component redundancy.

H station

A station with two central processing units (master and standby).

H system

Fault-tolerant system with at least two CPUs processing programs identically.

I/O, one-way

I/O accessed by only one redundant central processing unit.

Index

Address area, CPU 31x-2

Details address areas for CPU 31x-2.

Availability

Information on communication availability and system availability.

Base system

Information about the base system configuration.

Bus connectors

Details on bus connectors for interfaces.

MPI

Information regarding the MPI interface.

Profibus DP interface

Information regarding the Profibus DP interface.

Central processing unit

Details on central processing units.

Communication

Information on communication functions.

Components

Information on system components.

Configuration types, I/O

Overview of different I/O configuration types.

Configuring

Details on configuring the system.

Configuring networking

Information on configuring network settings.

Connection

Details on system connections.

Fault-tolerant S7

Information specific to fault-tolerant S7 systems.

Consistent data access

Details on consistent data access methods.

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