Siemens SIMATIC S7-400H

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Characteristic values of redundant automation systems

A.2 Comparison of MTBF for selected configurations

S7-400H

System Manual, 03/2012, A5E00267695-11

441

Redundant CPU 417–5H in two separate racks, CCF = 1 % Factor

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5DFN855DFN85

36$

&38+

36$

&38+

approx. 38

Main Page

Table of Contents5
Preface19
Fault-Tolerant Automation Systems25
Redundant SIMATIC Automation Systems25
Figure 2-1 Operating Objectives of Redundant Automation Systems25
Increasing the Availability of Plants27
Figure 2-2 Integrated Automation Solutions with SIMATIC27
Figure 2-3 Example of Redundancy in a Network Without Error28
Figure 2-4 Example of Redundancy in a 1-Out-Of-2 System with Error29
Figure 2-5 Example of Redundancy in a 1-Out-Of-2 System with Total Failure29
S7-400H Setup Options31
Figure 3-1 Overview32
Rules for the Assembly of Fault-Tolerant Stations33
The S7-400H Basic System34
Figure 3-2 Hardware of the S7-400H Basic System34
I/O Modules for S7-400H36
Communication37
Tools for Configuration and Programming38
The User Program39
Documentation40
Figure 3-3 User Documentation for Fault-Tolerant Systems40
Getting Started41
Requirements41
Hardware Assembly and Commissioning of the S7-400H42
Figure 4-1 Hardware Assembly42
Examples of the Response of the Fault-Tolerant System to Faults44
Special Layout Features of SIMATIC Manager45
Assembly of a CPU 41X-H47
Operator Controls and Display Elements of the Cpus47
Figure 5-1 Arrangement of the Control and Display Elements on CPU 41X-5H PN/DP47
Table 5- 1 LED Displays on the Cpus48
Figure 5-2 Jack Connector50
Monitoring Functions of the CPU52
Status and Error Displays55
Table 5- 2 Possible States of the BUS1F, BUS2F and BUS5F Leds57
Table 5- 3 Possible States of the LINK and RX/TX Leds58
Mode Switch60
Function of the Mode Switch60
Figure 5-3 Mode Switch Positions60
Table 5- 4 Mode Switch Positions61
Performing a Memory Reset62
Cold Restart / Warm Restart64
Design and Function of the Memory Cards65
Figure 5-4 Design of the Memory Card65
Using Memory Cards67
Table 5- 5 Types of Memory Card67
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 Cpus74
Special Functions of a CPU 41X-H77
Security Levels77
Table 6- 1 Security Levels of a CPU77
Encrypting Blocks79
Resetting the CPU to the Factory State81
Table 6- 2 CPU Properties in the Factory Settings81
Table 6- 3 LED Patterns82
Updating the Firmware Without a Memory Card83
Firmware Update in RUN Mode85
Reading Service Data86
Profibus Dp87
CPU 41X-H as PROFIBUS DP Master87
DP Address Ranges of Cpus 41X-H88
CPU 41Xh as PROFIBUS DP Master88
Table 7- 1 Cpus 41X, MPI/DP Interface as PROFIBUS DP Interface88
Diagnostics of a CPU 41Xh Operating as PROFIBUS DP Master91
Table 7- 2 Meaning of the "BUSF" LED of the CPU 41X Operating as DP Master91
Table 7- 3 Reading out the Diagnostics Information with STEP 791
Figure 7-1 Diagnostics with CPU 41Xh92
Table 7- 4 Event Detection of the CPU 41Xh as a DP Master93
Figure 7-2 Diagnostics Addresses for DP Master and DP Slave93
Profinet95
Introduction95
PROFINET IO Systems97
Blocks in PROFINET IO99
Table 8- 1 System and Standard Functions that Are New or Have to be Replaced99
Table 8- 2 System and Standard Functions of PROFIBUS DP that Can be Emulated in PROFINET IO100
Table 8- 3 Obs in PROFINET IO and PROFIBUS DP100
System Status Lists for PROFINET IO101
Table 8- 4 Comparison of the System Status Lists of PROFINET IO and PROFIBUS DP101
Device Replacement Without Removable Medium/Programming Device103
Shared Device103
Media Redundancy104
Figure 8-1 Configuration Example of System Redundancy with Media Redundancy105
System Redundancy106
Figure 8-2 S7-400H System with IO Devices Connected in System Redundancy106
Figure 8-3 System Redundancy in Different Views107
Figure 8-4 PN/IO with System Redundancy109
Figure 8-5 PN/IO with System Redundancy110
Consistent Data111
Consistency of Communication Blocks and Functions112
9.2 Consistency Rules for SFB 14 "GET" or Read Variable, and SFB 15 "PUT" or Write Variable113
Consistent Reading and Writing of Data from and to DP Standard Slaves/Io Devices113
Figure 9-1 Properties - DP Slave116
Memory Concept117
Overview of the Memory Concept of S7-400H Cpus117
Figure 10-1 Memory Areas of the S7-400H Cpus117
Table 10- 1 Memory Requirements119
System and Operating States of the S7-400H121
Introduction121
Figure 11-1 Synchronizing the Subsystems122
System States of the S7-400H124
The System States of the S7-400H124
Table 11- 1 Overview of S7-400H System States124
Displaying and Changing the System State of a Fault-Tolerant System125
System Status Change from the STOP System State126
System Status Change from the Standalone Mode System Status126
System Status Change from the Redundant System State127
System Diagnostics of a Fault-Tolerant System128
The Operating States of the Cpus130
Figure 11-2 System and Operating States of the Fault-Tolerant System130
STOP Mode131
STARTUP Mode132
LINK-UP and UPDATE Modes133
RUN Mode133
Table 11- 2 Causes of Error Leading to Redundancy Loss133
HOLD Mode135
ERROR-SEARCH Mode135
Self-Test137
Table 11- 3 Response to Errors During the Self-Test137
Table 11- 4 Response to a Recurring Comparison Error138
Table 11- 5 Reaction to Checksum Errors138
Table 11- 6 Hardware Fault with One-Sided Call of ob 121, Checksum Error, Second Occurrence139
Evaluation of Hardware Interrupts in the S7-400H System140
Link-Up and Update141
Effects of Link-Up and Updating141
Table 12- 1 Properties of Link-Up and Update Functions141
Conditions for Link-Up and Update142
Table 12- 2 Conditions for Link-Up and Update142
Link-Up and Update Sequence143
Figure 12-1 Sequence of Link-Up and Update144
Figure 12-2 Update Sequence145
Figure 12-3 Example of Minimum Signal Duration of an Input Signal During the Update146
Link-Up Sequence147
Update Sequence149
Switch to CPU with Modified Configuration or Expanded Memory Configuration152
Disabling of Link-Up and Update154
Time Monitoring155
Figure 12-4 Meanings of the Times Relevant for Updates156
Time Response158
Determining the Monitoring Times159
Figure 12-5 Correlation between the Minimum I/O Retention Time and the Maximum Inhibit Time for160
Performance Values for Link-Up and Update166
Table 12- 3 Typical Values for the User Program Part166
Influences on Time Response167
Special Features in Link-Up and Update Operations168
Using I/Os in S7-400H169
Introduction169
Using Single-Channel, One-Sided I/Os171
Using Single-Channel Switched I/O173
Table 13- 1 Interfaces for Use of Single-Channel Switched I/O Configuration at the PROFIBUS DP Interface173
Figure 13-1 Single-Channel Switched Distributed I/O Configuration at the PROFIBUS DP Interface173
Table 13- 2 Interface for Use of Single-Channel Switched I/O Configuration at the PROFINET Interface174
Figure 13-2 Single-Channel Switched Distributed I/O Configuration at the PROFINET Interface174
Connecting Redundant I/O to the PROFIBUS DP Interface177
Figure 13-3 Redundant I/O in Central and Expansion Devices178
Figure 13-4 Redundant I/O in the One-Sided DP Slave179
Figure 13-5 Redundant I/O in the Switched DP Slave180
Signal Modules for Redundancy187
Table 13- 3 Signal Modules for Redundancy187
Table 13- 4 Interconnecting Digital Output Modules With/Without Diodes197
Table 13- 5 Analog Input Modules and Encoders203
Evaluating the Passivation Status206
Other Options for Connecting Redundant I/Os207
Table 13- 6 Example of Redundant I/O, ob 1 Part210
Table 13- 7 Example of Redundant I/O, ob 122 Part211
Table 13- 8 for the Monitoring Times with Redundant I/O212
Communication213
Communication Services213
Overview of Communication Services213
PG Communication214
OP Communication215
S7 Communication215
S7 Routing217
Time Synchronization222
Data Set Routing224
SNMP Network Protocol226
Open Communication Via Industrial Ethernet227
Basics and Terminology of Fault-Tolerant Communication231
Usable Networks235
Usable Communication Services235
Communication Via S7 Connections236
Communication Via S7 Connections - One-Sided Mode237
Communication Via Redundant S7 Connections240
Communication Via Point-To-Point CP on the ET 200M241
Custom Connection to Single-Channel Systems243
Communication Via Fault-Tolerant S7 Connections244
Communication between Fault-Tolerant Systems247
Communication between Fault-Tolerant Systems and a Fault-Tolerant CPU250
Communication between Fault-Tolerant Systems and Pcs251
Communication Performance254
General Issues Regarding Communication256
Configuring with STEP 7259
Rules for Arranging Fault-Tolerant Station Components260
Configuring Hardware260
Assigning Parameters to Modules in a Fault-Tolerant Station261
Recommendations for Setting the CPU Parameters262
Networking Configuration263
Programming Device Functions in STEP 7264
Failure and Replacement of Components During Operation265
Failure and Replacement of a CPU266
Failure and Replacement of a Power Supply Module268
Failure and Replacement of an Input/Output or Function Module269
Failure and Replacement of a Communication Module271
Failure and Replacement of a Synchronization Module or Fiber-Optic Cable272
Failure and Replacement of an IM 460 and IM 461 Interface Module275
Failure and Replacement of Components of the Distributed I/Os276
Failure and Replacement of a PROFIBUS DP Master276
Failure and Replacement of a Redundant PROFIBUS DP Interface Module277
Failure and Replacement of a PROFIBUS DP Slave278
Failure and Replacement of PROFIBUS DP Cables278
System Modifications During Operation281
Possible Hardware Modifications282
Adding Components in PCS 7286
PCS 7, Step 1: Modification of Hardware287
PCS 7, Step 2: Offline Modification of the Hardware Configuration288
PCS 7, Step 3: Stopping the Reserve CPU288
PCS 7, Step 4: Loading a New Hardware Configuration in the Reserve CPU289
PCS 7, Step 5: Switch to CPU with Modified Configuration289
PCS 7, Step 6: Transition to Redundant System Mode291
PCS 7, Step 7: Editing and Downloading the User Program292
PCS7, Using Free Channels on an Existing Module293
Adding Interface Modules in PCS 7294
Removing Components in PCS 7295
PCS 7, Step 1: Editing the Hardware Configuration Offline296
PCS 7, Step 2: Editing and Downloading the User Program297
PCS 7, Step 3: Stopping the Reserve CPU298
PCS 7, Step 4: Downloading a New Hardware Configuration to the Reserve CPU298
PCS 7, Step 5: Switching to CPU with Modified Configuration299
PCS 7, Step 6: Transition to Redundant System Mode300
PCS 7, Step 7: Modification of Hardware301
Removing Interface Modules in PCS 7302
Adding Components in STEP 7303
STEP 7, Step 1: Adding Hardware304
STEP 7, Step 2: Offline Modification of the Hardware Configuration305
STEP 7, Step 3: Expanding and Downloading Obs305
STEP 7, Step 4: Stopping the Reserve CPU306
STEP 7, Step 5: Loading a New Hardware Configuration in the Reserve CPU306
STEP 7, Step 6: Switch to CPU with Modified Configuration307
STEP 7, Step 7: Transition to Redundant System Mode308
STEP 7, Step 8: Editing and Downloading the User Program309
STEP7, Using Free Channels on an Existing Module310
Adding Interface Modules in STEP 7311
Removing Components in STEP 7313
STEP 7, Step 1: Editing the Hardware Configuration Offline314
STEP 7, Step 2: Editing and Downloading the User Program315
STEP 7, Step 3: Stopping the Reserve CPU315
STEP 7, Step 4: Downloading a New Hardware Configuration to the Reserve CPU316
STEP 7, Step 5: Switching to CPU with Modified Configuration317
STEP 7, Step 6: Transition to Redundant System Mode318
STEP 7, Step 7: Modification of Hardware319
STEP 7, Step 8: Editing and Downloading Organization Blocks320
Removing Interface Modules in STEP 7321
Editing CPU Parameters323
Step 1: Editing CPU Parameters Offline325
Step 2: Stopping the Reserve CPU325
Step 3: Downloading a New Hardware Configuration to the Reserve CPU326
Step 4: Switching to CPU with Modified Configuration326
Step 5: Transition to Redundant System Mode328
Changing the CPU Memory Configuration329
Expanding Load Memory329
Changing the Type of Load Memory331
Re-Parameterization of a Module334
Step 1: Editing Parameters Offline335
Step 2: Stopping the Reserve CPU336
Step 3: Downloading a New Hardware Configuration to the Reserve CPU336
Step 4: Switching to CPU with Modified Configuration337
Step 5: Transition to Redundant System Mode339
Synchronization Modules341
Synchronization Modules for S7-400H341
Installation of Fiber-Optic Cables346
Selecting Fiber-Optic Cables349
S7-400 Cycle and Response Times355
Cycle Time356
Calculating the Cycle Time358
Different Cycle Times364
Communication Load366
Response Time369
Calculating Cycle and Response Times375
Examples of Calculating the Cycle and Response Times376
Interrupt Response Time379
Example of Calculation of the Interrupt Response Time381
Reproducibility of Delay and Watchdog Interrupts382
Technical Data383
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 Cards431
Runtimes of the Fcs and Fbs for Redundant I/Os432
Characteristic Values of Redundant Automation Systems435
Basic Concepts435
Comparison of MTBF for Selected Configurations440
System Configurations with Redundant CPU 417-5H440
System Configurations with Distributed I/Os442
Comparison of System Configurations with Standard and Fault-Tolerant Communication446
Stand-Alone Operation447
Differences between Fault-Tolerant Systems and Standard Systems453
Function Modules and Communication Processors Supported by the S7-400H457
Connection Examples for Redundant I/Os461
SM 321; DI 16 X DC 24 V, 6ES7 321-1BH02-0AA0461
SM 321; DI 32 X DC 24 V, 6ES7 321-1BL00-0AA0462
SM 321; DI 16 X AC 120/230V, 6ES7 321-1FH00-0AA0463
SM 321; DI 8 X AC 120/230 V, 6ES7 321-1FF01-0AA0464
SM 321; DI 16 X DC 24V, 6ES7 321-7BH00-0AB0465
SM 321; DI 16 X DC 24V, 6ES7 321-7BH01-0AB0466
SM 326; DO 10 X DC 24V/2A, 6ES7 326-2BF01-0AB0467
SM 326; DI 8 X NAMUR, 6ES7 326-1RF00-0AB0468
SM 326; DI 24 X DC 24 V, 6ES7 326-1BK00-0AB0469
SM 421; DI 32 X UC 120 V, 6ES7 421-1EL00-0AA0470
SM 421; DI 16 X DC 24 V, 6ES7 421-7BH01-0AB0471
SM 421; DI 32 X DC 24 V, 6ES7 421-1BL00-0AB0472
SM 421; DI 32 X DC 24 V, 6ES7 421-1BL01-0AB0473
SM 322; DO 8 X DC 24 V/2 A, 6ES7 322-1BF01-0AA0474
SM 322; DO 32 X DC 24 V/0,5 A, 6ES7 322-1BL00-0AA0475
SM 322; DO 8 X AC 230 V/2 A, 6ES7 322-1FF01-0AA0476
SM 322; DO 4 X DC 24 V/10 Ma [Eex Ib], 6ES7 322-5SD00-0AB0477
SM 322; DO 4 X DC 15 V/20 Ma [Eex Ib], 6ES7 322-5RD00-0AB0478
SM 322; DO 8 X DC 24 V/0.5 A, 6ES7 322-8BF00-0AB0479
SM 322; DO 16 X DC 24 V/0.5 A, 6ES7 322-8BH01-0AB0480
SM 332; AO 8 X 12 Bit, 6ES7 332-5HF00-0AB0481
SM 332; AO 4 X 0/4482
SM 422; DO 16 X AC 120/230 V/2 A, 6ES7 422-1FH00-0AA0483
SM 422; DO 32 X DC 24 V/0.5 A, 6ES7 422-7BL00-0AB0484
SM 331; AI 4 X 15 Bit [Eex Ib]; 6ES7 331-7RD00-0AB0485
SM 331; AI 8 X 12 Bit, 6ES7 331-7KF02-0AB0486
SM 331; AI 8 X 16 Bit; 6ES7 331-7NF00-0AB0487
SM 331; AI 8 X 16 Bit; 6ES7 331-7NF10-0AB0488
AI 6Xtc 16Bit Iso, 6ES7331-7PE10-0AB0489
SM331; AI 8 X 0/4490
SM 332; AO 4 X 12 Bit; 6ES7 332-5HD01-0AB0492
SM332; AO 8 X 0/4493
SM 431; AI 16 X 16 Bit, 6ES7 431-7QH00-0AB0494
Glossary495
Index499

Siemens SIMATIC S7-400H - Page 441

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