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SIMATIC
Fault-tolerant systems
S7-400H
System Manual
03/2012
A5E00267695-11
Preface
1
Fault-tolerant automation
systems
2
S7-400H setup options
3
Getting Started
4
Assembly of a CPU 41x–H
5
Special functions of a
CPU 41x-H
6
PROFIBUS DP
7
PROFINET
8
Consistent data
9
Memory concept
10
System and operating states
of the S7–400H
11
Link-up and update
12
Using I/Os in S7–400H
13
Communication
14
Configuring with STEP 7
15
Failure and replacement of
components during operation
16
System modific
at
ions during
operation
17
Continued on next page
2
Table of Contents
Table of Contents
5
Preface
19
Fault-Tolerant Automation Systems
25
Redundant SIMATIC Automation Systems
25
Figure 2-1 Operating Objectives of Redundant Automation Systems
25
Increasing the Availability of Plants
27
Figure 2-2 Integrated Automation Solutions with SIMATIC
27
Figure 2-3 Example of Redundancy in a Network Without Error
28
Figure 2-4 Example of Redundancy in a 1-Out-Of-2 System with Error
29
Figure 2-5 Example of Redundancy in a 1-Out-Of-2 System with Total Failure
29
S7-400H Setup Options
31
Figure 3-1 Overview
32
Rules for the Assembly of Fault-Tolerant Stations
33
The S7-400H Basic System
34
Figure 3-2 Hardware of the S7-400H Basic System
34
I/O Modules for S7-400H
36
Communication
37
Tools for Configuration and Programming
38
The User Program
39
Documentation
40
Figure 3-3 User Documentation for Fault-Tolerant Systems
40
Getting Started
41
Requirements
41
Hardware Assembly and Commissioning of the S7-400H
42
Figure 4-1 Hardware Assembly
42
Examples of the Response of the Fault-Tolerant System to Faults
44
Special Layout Features of SIMATIC Manager
45
Assembly of a CPU 41X-H
47
Operator Controls and Display Elements of the Cpus
47
Figure 5-1 Arrangement of the Control and Display Elements on CPU 41X-5H PN/DP
47
Table 5- 1 LED Displays on the Cpus
48
Figure 5-2 Jack Connector
50
Monitoring Functions of the CPU
52
Status and Error Displays
55
Table 5- 2 Possible States of the BUS1F, BUS2F and BUS5F Leds
57
Table 5- 3 Possible States of the LINK and RX/TX Leds
58
Mode Switch
60
Function of the Mode Switch
60
Figure 5-3 Mode Switch Positions
60
Table 5- 4 Mode Switch Positions
61
Performing a Memory Reset
62
Cold Restart / Warm Restart
64
Design and Function of the Memory Cards
65
Figure 5-4 Design of the Memory Card
65
Using Memory Cards
67
Table 5- 5 Types of Memory Card
67
Multi Point Interface MPI/DP (X1)
70
PROFIBUS DP Interface (X2, X3)
71
PROFINET Interface (X5)
71
Overview of the Parameters for the S7-400H Cpus
74
Special Functions of a CPU 41X-H
77
Security Levels
77
Table 6- 1 Security Levels of a CPU
77
Encrypting Blocks
79
Resetting the CPU to the Factory State
81
Table 6- 2 CPU Properties in the Factory Settings
81
Table 6- 3 LED Patterns
82
Updating the Firmware Without a Memory Card
83
Firmware Update in RUN Mode
85
Reading Service Data
86
Profibus Dp
87
CPU 41X-H as PROFIBUS DP Master
87
DP Address Ranges of Cpus 41X-H
88
CPU 41Xh as PROFIBUS DP Master
88
Table 7- 1 Cpus 41X, MPI/DP Interface as PROFIBUS DP Interface
88
Diagnostics of a CPU 41Xh Operating as PROFIBUS DP Master
91
Table 7- 2 Meaning of the "BUSF" LED of the CPU 41X Operating as DP Master
91
Table 7- 3 Reading out the Diagnostics Information with STEP 7
91
Figure 7-1 Diagnostics with CPU 41Xh
92
Table 7- 4 Event Detection of the CPU 41Xh as a DP Master
93
Figure 7-2 Diagnostics Addresses for DP Master and DP Slave
93
Profinet
95
Introduction
95
PROFINET IO Systems
97
Blocks in PROFINET IO
99
Table 8- 1 System and Standard Functions that Are New or Have to be Replaced
99
Table 8- 2 System and Standard Functions of PROFIBUS DP that Can be Emulated in PROFINET IO
100
Table 8- 3 Obs in PROFINET IO and PROFIBUS DP
100
System Status Lists for PROFINET IO
101
Table 8- 4 Comparison of the System Status Lists of PROFINET IO and PROFIBUS DP
101
Device Replacement Without Removable Medium/Programming Device
103
Shared Device
103
Media Redundancy
104
Figure 8-1 Configuration Example of System Redundancy with Media Redundancy
105
System Redundancy
106
Figure 8-2 S7-400H System with IO Devices Connected in System Redundancy
106
Figure 8-3 System Redundancy in Different Views
107
Figure 8-4 PN/IO with System Redundancy
109
Figure 8-5 PN/IO with System Redundancy
110
Consistent Data
111
Consistency of Communication Blocks and Functions
112
9.2 Consistency Rules for SFB 14 "GET" or Read Variable, and SFB 15 "PUT" or Write Variable
113
Consistent Reading and Writing of Data from and to DP Standard Slaves/Io Devices
113
Figure 9-1 Properties - DP Slave
116
Memory Concept
117
Overview of the Memory Concept of S7-400H Cpus
117
Figure 10-1 Memory Areas of the S7-400H Cpus
117
Table 10- 1 Memory Requirements
119
System and Operating States of the S7-400H
121
Introduction
121
Figure 11-1 Synchronizing the Subsystems
122
System States of the S7-400H
124
The System States of the S7-400H
124
Table 11- 1 Overview of S7-400H System States
124
Displaying and Changing the System State of a Fault-Tolerant System
125
System Status Change from the STOP System State
126
System Status Change from the Standalone Mode System Status
126
System Status Change from the Redundant System State
127
System Diagnostics of a Fault-Tolerant System
128
The Operating States of the Cpus
130
Figure 11-2 System and Operating States of the Fault-Tolerant System
130
STOP Mode
131
STARTUP Mode
132
LINK-UP and UPDATE Modes
133
RUN Mode
133
Table 11- 2 Causes of Error Leading to Redundancy Loss
133
HOLD Mode
135
ERROR-SEARCH Mode
135
Self-Test
137
Table 11- 3 Response to Errors During the Self-Test
137
Table 11- 4 Response to a Recurring Comparison Error
138
Table 11- 5 Reaction to Checksum Errors
138
Table 11- 6 Hardware Fault with One-Sided Call of ob 121, Checksum Error, Second Occurrence
139
Evaluation of Hardware Interrupts in the S7-400H System
140
Link-Up and Update
141
Effects of Link-Up and Updating
141
Table 12- 1 Properties of Link-Up and Update Functions
141
Conditions for Link-Up and Update
142
Table 12- 2 Conditions for Link-Up and Update
142
Link-Up and Update Sequence
143
Figure 12-1 Sequence of Link-Up and Update
144
Figure 12-2 Update Sequence
145
Figure 12-3 Example of Minimum Signal Duration of an Input Signal During the Update
146
Link-Up Sequence
147
Update Sequence
149
Switch to CPU with Modified Configuration or Expanded Memory Configuration
152
Disabling of Link-Up and Update
154
Time Monitoring
155
Figure 12-4 Meanings of the Times Relevant for Updates
156
Time Response
158
Determining the Monitoring Times
159
Figure 12-5 Correlation between the Minimum I/O Retention Time and the Maximum Inhibit Time for
160
Performance Values for Link-Up and Update
166
Table 12- 3 Typical Values for the User Program Part
166
Influences on Time Response
167
Special Features in Link-Up and Update Operations
168
Using I/Os in S7-400H
169
Introduction
169
Using Single-Channel, One-Sided I/Os
171
Using Single-Channel Switched I/O
173
Table 13- 1 Interfaces for Use of Single-Channel Switched I/O Configuration at the PROFIBUS DP Interface
173
Figure 13-1 Single-Channel Switched Distributed I/O Configuration at the PROFIBUS DP Interface
173
Table 13- 2 Interface for Use of Single-Channel Switched I/O Configuration at the PROFINET Interface
174
Figure 13-2 Single-Channel Switched Distributed I/O Configuration at the PROFINET Interface
174
Connecting Redundant I/O to the PROFIBUS DP Interface
177
Figure 13-3 Redundant I/O in Central and Expansion Devices
178
Figure 13-4 Redundant I/O in the One-Sided DP Slave
179
Figure 13-5 Redundant I/O in the Switched DP Slave
180
Signal Modules for Redundancy
187
Table 13- 3 Signal Modules for Redundancy
187
Table 13- 4 Interconnecting Digital Output Modules With/Without Diodes
197
Table 13- 5 Analog Input Modules and Encoders
203
Evaluating the Passivation Status
206
Other Options for Connecting Redundant I/Os
207
Table 13- 6 Example of Redundant I/O, ob 1 Part
210
Table 13- 7 Example of Redundant I/O, ob 122 Part
211
Table 13- 8 for the Monitoring Times with Redundant I/O
212
Communication
213
Communication Services
213
Overview of Communication Services
213
PG Communication
214
OP Communication
215
S7 Communication
215
S7 Routing
217
Time Synchronization
222
Data Set Routing
224
SNMP Network Protocol
226
Open Communication Via Industrial Ethernet
227
Basics and Terminology of Fault-Tolerant Communication
231
Usable Networks
235
Usable Communication Services
235
Communication Via S7 Connections
236
Communication Via S7 Connections - One-Sided Mode
237
Communication Via Redundant S7 Connections
240
Communication Via Point-To-Point CP on the ET 200M
241
Custom Connection to Single-Channel Systems
243
Communication Via Fault-Tolerant S7 Connections
244
Communication between Fault-Tolerant Systems
247
Communication between Fault-Tolerant Systems and a Fault-Tolerant CPU
250
Communication between Fault-Tolerant Systems and Pcs
251
Communication Performance
254
General Issues Regarding Communication
256
Configuring with STEP 7
259
Rules for Arranging Fault-Tolerant Station Components
260
Configuring Hardware
260
Assigning Parameters to Modules in a Fault-Tolerant Station
261
Recommendations for Setting the CPU Parameters
262
Networking Configuration
263
Programming Device Functions in STEP 7
264
Failure and Replacement of Components During Operation
265
Failure and Replacement of a CPU
266
Failure and Replacement of a Power Supply Module
268
Failure and Replacement of an Input/Output or Function Module
269
Failure and Replacement of a Communication Module
271
Failure and Replacement of a Synchronization Module or Fiber-Optic Cable
272
Failure and Replacement of an IM 460 and IM 461 Interface Module
275
Failure and Replacement of Components of the Distributed I/Os
276
Failure and Replacement of a PROFIBUS DP Master
276
Failure and Replacement of a Redundant PROFIBUS DP Interface Module
277
Failure and Replacement of a PROFIBUS DP Slave
278
Failure and Replacement of PROFIBUS DP Cables
278
System Modifications During Operation
281
Possible Hardware Modifications
282
Adding Components in PCS 7
286
PCS 7, Step 1: Modification of Hardware
287
PCS 7, Step 2: Offline Modification of the Hardware Configuration
288
PCS 7, Step 3: Stopping the Reserve CPU
288
PCS 7, Step 4: Loading a New Hardware Configuration in the Reserve CPU
289
PCS 7, Step 5: Switch to CPU with Modified Configuration
289
PCS 7, Step 6: Transition to Redundant System Mode
291
PCS 7, Step 7: Editing and Downloading the User Program
292
PCS7, Using Free Channels on an Existing Module
293
Adding Interface Modules in PCS 7
294
Removing Components in PCS 7
295
PCS 7, Step 1: Editing the Hardware Configuration Offline
296
PCS 7, Step 2: Editing and Downloading the User Program
297
PCS 7, Step 3: Stopping the Reserve CPU
298
PCS 7, Step 4: Downloading a New Hardware Configuration to the Reserve CPU
298
PCS 7, Step 5: Switching to CPU with Modified Configuration
299
PCS 7, Step 6: Transition to Redundant System Mode
300
PCS 7, Step 7: Modification of Hardware
301
Removing Interface Modules in PCS 7
302
Adding Components in STEP 7
303
STEP 7, Step 1: Adding Hardware
304
STEP 7, Step 2: Offline Modification of the Hardware Configuration
305
STEP 7, Step 3: Expanding and Downloading Obs
305
STEP 7, Step 4: Stopping the Reserve CPU
306
STEP 7, Step 5: Loading a New Hardware Configuration in the Reserve CPU
306
STEP 7, Step 6: Switch to CPU with Modified Configuration
307
STEP 7, Step 7: Transition to Redundant System Mode
308
STEP 7, Step 8: Editing and Downloading the User Program
309
STEP7, Using Free Channels on an Existing Module
310
Adding Interface Modules in STEP 7
311
Removing Components in STEP 7
313
STEP 7, Step 1: Editing the Hardware Configuration Offline
314
STEP 7, Step 2: Editing and Downloading the User Program
315
STEP 7, Step 3: Stopping the Reserve CPU
315
STEP 7, Step 4: Downloading a New Hardware Configuration to the Reserve CPU
316
STEP 7, Step 5: Switching to CPU with Modified Configuration
317
STEP 7, Step 6: Transition to Redundant System Mode
318
STEP 7, Step 7: Modification of Hardware
319
STEP 7, Step 8: Editing and Downloading Organization Blocks
320
Removing Interface Modules in STEP 7
321
Editing CPU Parameters
323
Step 1: Editing CPU Parameters Offline
325
Step 2: Stopping the Reserve CPU
325
Step 3: Downloading a New Hardware Configuration to the Reserve CPU
326
Step 4: Switching to CPU with Modified Configuration
326
Step 5: Transition to Redundant System Mode
328
Changing the CPU Memory Configuration
329
Expanding Load Memory
329
Changing the Type of Load Memory
331
Re-Parameterization of a Module
334
Step 1: Editing Parameters Offline
335
Step 2: Stopping the Reserve CPU
336
Step 3: Downloading a New Hardware Configuration to the Reserve CPU
336
Step 4: Switching to CPU with Modified Configuration
337
Step 5: Transition to Redundant System Mode
339
Synchronization Modules
341
Synchronization Modules for S7-400H
341
Installation of Fiber-Optic Cables
346
Selecting Fiber-Optic Cables
349
S7-400 Cycle and Response Times
355
Cycle Time
356
Calculating the Cycle Time
358
Different Cycle Times
364
Communication Load
366
Response Time
369
Calculating Cycle and Response Times
375
Examples of Calculating the Cycle and Response Times
376
Interrupt Response Time
379
Example of Calculation of the Interrupt Response Time
381
Reproducibility of Delay and Watchdog Interrupts
382
Technical Data
383
Technical Specification of the CPU 412-5H PN/DP; (6ES7 412-5HK06-0AB0)
383
Technical Specifications of the CPU 414-5H PN/DP; (6ES7 414-5HM06-0AB0)
395
Technical Specifications of the CPU 416-5H PN/DP; (6ES7 416-5HK06-0AB0)
407
Technical Specifications of the CPU 417-5H PN/DP; (6ES7 417-5HK06-0AB0)
419
Technical Data of Memory Cards
431
Runtimes of the Fcs and Fbs for Redundant I/Os
432
Characteristic Values of Redundant Automation Systems
435
Basic Concepts
435
Comparison of MTBF for Selected Configurations
440
System Configurations with Redundant CPU 417-5H
440
System Configurations with Distributed I/Os
442
Comparison of System Configurations with Standard and Fault-Tolerant Communication
446
Stand-Alone Operation
447
Differences between Fault-Tolerant Systems and Standard Systems
453
Function Modules and Communication Processors Supported by the S7-400H
457
Connection Examples for Redundant I/Os
461
SM 321; DI 16 X DC 24 V, 6ES7 321-1BH02-0AA0
461
SM 321; DI 32 X DC 24 V, 6ES7 321-1BL00-0AA0
462
SM 321; DI 16 X AC 120/230V, 6ES7 321-1FH00-0AA0
463
SM 321; DI 8 X AC 120/230 V, 6ES7 321-1FF01-0AA0
464
SM 321; DI 16 X DC 24V, 6ES7 321-7BH00-0AB0
465
SM 321; DI 16 X DC 24V, 6ES7 321-7BH01-0AB0
466
SM 326; DO 10 X DC 24V/2A, 6ES7 326-2BF01-0AB0
467
SM 326; DI 8 X NAMUR, 6ES7 326-1RF00-0AB0
468
SM 326; DI 24 X DC 24 V, 6ES7 326-1BK00-0AB0
469
SM 421; DI 32 X UC 120 V, 6ES7 421-1EL00-0AA0
470
SM 421; DI 16 X DC 24 V, 6ES7 421-7BH01-0AB0
471
SM 421; DI 32 X DC 24 V, 6ES7 421-1BL00-0AB0
472
SM 421; DI 32 X DC 24 V, 6ES7 421-1BL01-0AB0
473
SM 322; DO 8 X DC 24 V/2 A, 6ES7 322-1BF01-0AA0
474
SM 322; DO 32 X DC 24 V/0,5 A, 6ES7 322-1BL00-0AA0
475
SM 322; DO 8 X AC 230 V/2 A, 6ES7 322-1FF01-0AA0
476
SM 322; DO 4 X DC 24 V/10 Ma [Eex Ib], 6ES7 322-5SD00-0AB0
477
SM 322; DO 4 X DC 15 V/20 Ma [Eex Ib], 6ES7 322-5RD00-0AB0
478
SM 322; DO 8 X DC 24 V/0.5 A, 6ES7 322-8BF00-0AB0
479
SM 322; DO 16 X DC 24 V/0.5 A, 6ES7 322-8BH01-0AB0
480
SM 332; AO 8 X 12 Bit, 6ES7 332-5HF00-0AB0
481
SM 332; AO 4 X 0/4
482
SM 422; DO 16 X AC 120/230 V/2 A, 6ES7 422-1FH00-0AA0
483
SM 422; DO 32 X DC 24 V/0.5 A, 6ES7 422-7BL00-0AB0
484
SM 331; AI 4 X 15 Bit [Eex Ib]; 6ES7 331-7RD00-0AB0
485
SM 331; AI 8 X 12 Bit, 6ES7 331-7KF02-0AB0
486
SM 331; AI 8 X 16 Bit; 6ES7 331-7NF00-0AB0
487
SM 331; AI 8 X 16 Bit; 6ES7 331-7NF10-0AB0
488
AI 6Xtc 16Bit Iso, 6ES7331-7PE10-0AB0
489
SM331; AI 8 X 0/4
490
SM 332; AO 4 X 12 Bit; 6ES7 332-5HD01-0AB0
492
SM332; AO 8 X 0/4
493
SM 431; AI 16 X 16 Bit, 6ES7 431-7QH00-0AB0
494
Glossary
495
Index
499
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Siemens SIMATIC S7-400H Specifications
General
Brand
Siemens
Model
SIMATIC S7-400H
Category
Control Unit
Language
English
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