Siemens SIMATIC S7-400H - Failure and Replacement of Components in Central Racks and Expansion Racks

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Failure and Replacement of Components During Operation

10-2

Automation System S7-400H Fault-tolerant Systems

A5E00068197-07

10.1 Failure and Replacement of Components in Central

Racks and Expansion Racks

Which components can be replaced?

The following components can be replaced during operation:

• central processing units – for example, CPU 417-4H

• power supply modules – for example, PS 405 and PS 407

• signal and function modules

• communication processors

• synchronization submodules and fiber-optic cables

• interface modules – for example, IM 460 and IM 461

Main Page

Table of Contents1
Safety Guidelines2
Qualified Personnel2
Correct Usage2
Warning2
A5E000681973
Changes Compared to the Previous Version4
Certification4
Online Help5
Finding Your Way5
Training Centers7
H/F Competence Center7
Recycling and Disposal7
A&D Technical Support8
Service & Support on the Internet9
Fault-Tolerant Programmable Logic11
- Fault-Tolerant Programmable Logic Controllers19
- Operating Objectives of Redundant Programmable Logic Controllers20
- Redundant Programmable Logic Controllers in the SIMATIC Series20
- Increasing System Availability22
- System-Wide Universality22
- Universal Automation Solutions with SIMATIC22
- Example of Redundancy in a 2-Out-Of-2 System with Total Failure23
- Example of Redundancy in a Network Without Malfunction23
  - Failure of a Redundant Node (Total Failure)23
  - Redundant Nodes23
- S7-400H Installation Options25
- Base System of the S7-400H27
- Central Processing Units27
- Hardware of the S7-400H Base System27
- I/O Modules for S7-400H29
- Communication30
- The User Program31
- Tools for Configuration and Programming31
- Specific Blocks for S7-400H32
- User Documentation for Fault-Tolerant Systems33
Getting Started33
- Getting Started35
- Requirements36
- Configuring Hardware and Starting up the S7-400H37
- Hardware Configuration37
  - Installing Hardware37
  - Starting up the S7-400H38
- Examples of Fault-Tolerant System Response to Faults39
  - Failure of a Central Processing Unit or Power Suppl39
  - Failure of a Fiber-Optic Cabl39
- Installation of a CPU 41X-H41
- Controls and Indicators of the Cpus42
- Layout of the Controls and Indicators of the CPU 414-4H/417-4H42
- Operation and Display Elements of the CPU 414-4H/417-4H42
- Leds of the Cpus43
  - Operating Mode Selector43
  - RAM Cards43
  - Slot for Memory Cards43
  - Interface for Expanded Memory44
  - MPI/DP Interface44
  - Profibus-DP Interface44
  - Slot for Interface Modules44
  - Connecting External Backup Current to the “EXT. BATT.” Socket45
  - Monitoring and Error Messages46
- Monitoring Functions of the CPU46
  - Leds MSTR, RACK0 and RACK148
  - Leds RUN and STOP48
- Status and Error Leds48
  - Leds BUSF1 and BUSF249
  - Leds INTF, EXTF and FRCE49
  - Diagnostics Buffer50
  - Led Redf50
  - Leds IFM1F and IFM2F50
  - Function of the Mode Selector51
- Mode Selector51
  - Positions51
  - Positions of the Mode Selector51
- Positions of the Mode Selector52
  - Protection Levels52
  - Setting the Protection Levels52
  - Cold Restart53
  - Operating Sequence for Memory Reset53
- Protection Levels of a S7-400 CPU53
  - Operating Sequence at Cold Restart54
  - Operation Sequence for Reboot/Warm Start54
  - Reboot (Warm Restart)54
  - Determining Memory Requirements with the SIMATIC Manager55
- Expanded Memory55
- Generating Block–Specific Messages56
- Design of the Memory Card57
- Expanding Load Memory with Memory Cards57
  - Function of the Memory Card57
  - Order Numbers57
- Types of Memory Cards58
  - Types of Memory Cards for the S7-40058
  - What the Memory Card Contains58
  - Which Type of Memory Card to Use58
- RAM Card59
- FLASH Card59
- Which Memory Card Capacity to Use59
- Changing Memory Cards60
- Technical Specifications61
S7-400H61
- Expanding the Working Memory of the CPU 417-4 H with Memory Modules62
  - Fitting Memory Cards in the CPU62
  - Memory Expansion62
- Fitting Memory Cards in the Cpus63
  - Memory Card63
  - Communication and Interrupt Response Times64
  - Connectable Devices64
- Multipoint Interface (MPI)64
  - PG/OP-CPU Communication64
  - Connectors65
- PROFIBUS DP Interface65
- Default Values66
- Overview of the Parameters for the S7-400 Cpus66
  - Parameter Blocks66
  - Changing the Rack Number of an H CPU67
  - Parameter Assignment Tool67
  - Specially Saved Parameters67
  - Changing from Redundant to Single Mode68
  - Changing from Single to Redundant Mode, Module Rack Number 068
  - Changing from Single to Redundant Mode, Module Rack Number 168
  - Changing the Operating Mode of an H CPU68
- CPU 41X-H as Profibus DP Master69
- CPU 41X as DP Master70
- Cpus 41X (MPI/DP Interface as Profibus DP)70
- DP Address Areas of the Cpus 41X70
  - From en 50170 to DPV171
  - Monitor/Modify, Programming Via PROFIBUS71
  - Power-Up of the DP Master System71
  - PROFIBUS Address of the DP Master71
  - Compatibility between DPV1 and en 5017072
  - Components Supporting Profibus DPV1 Features72
  - What Are the Operating Modes for DPV1 Components?72
- Overview: System Configuration for Modification73
  - System Modifications During Ongoing Operation73
  - Hardware Requirements for System Modification During Operation74
  - Permitted System Modifications: Overview74
  - Software Requirements for System Modification During Operation74
- Diagnostics of the CPU 41X as DP Master75
- Diagnostics Using Leds75
- Meaning of the BUSF Leds of the CPU 41X as DP Master75
- Reading out the Diagnostics Information with STEP 776
- Diagnostics with CPU 41X77
- Evaluating the Diagnosis in the User Program77
- Diagnostics Addresses for the DP Master and DP Slave78
  - Diagnostics Addresses in Connection with DP Slave Functionality78
  - Evaluation in the User Program79
- Event Detection of the Cpus 41X as DP Master79
  - Consistent Data80
  - Consistency for Communication Blocks and Functions81
  - Sfc 81 “Ublkmov”81
  - Access to the Working Memory of the CPU82
  - Consistency Rules for SFB 14 “GET” and Reading Tags83
- Data Transmission Without Data Consistency83
- Consistency Rules for SFB 15 “PUT” or Write Tag84
- Data Transmission Without Data Consistency84
  - Upper Limit for the Transmission of Consistent User Data on a DP Slave86
  - Consistent Data Access Without the Use of SFC 14 or SFC 1587
  - System and Operating Modes of the S7-400H89
  - Declaration90
  - Master/Standby Assignment90
  - What Does Active Redundancy Mean?90
  - Continued Operation – Free from Discontinuities91
  - Event-Driven Synchronization Procedure91
- Synchronizing the Subsystems91
- Overview of the S7-400H System Modes92
  - Self-Test92
  - System Modes of the S7-400H92
  - Operating Modes from POWER on to Redundant System Mode93
  - Operating Modes of the Cpus93
- System and Operating Modes of the Fault-Tolerant System93
- Explanations Relating to Figure 5-2 System and Operating Modes of the Fault-Tolerant System94
- Memory Reset94
- STOP Operating Mode94
- Operating States LINK–UP and UPDATE95
- STARTUP Operating Mode95
- Startup Processing by the Master CPU95
- Causes of Error Leading to the Termination of Redundant System Mode96
  - Operating State RUN96
  - Redundant Modules96
  - Single Mode, Link–Up, Update96
  - Operating States HOLD97
  - When Is HOLD Mode Possible?97
  - TROUBLESHOOTING Operating State98
  - Hardware Fault with One-Way ob 121 Call99
  - Processing Self-Tests99
- Response to Errors During the Self-Test99
  - Checksum Errors100
  - RAM/PAA Comparison Error100
- Response to a Recurring Comparison Error100
- Response to Checksum Errors100
- Influencing the Cyclical Self-Test101
- Instruction Run Times102
- Processing I/O Direct Access102
- Reaction Time102
- Time Response102
Linking and Synchronizing103
- Effects of Link-Up and Update104
- Properties of Link-Up and Update104
  - Functional Sequence of Link-Up and Update105
  - How to Start Link-Up and Update105
- Functional Sequence of Link-Up and Update106
- Process Diagram for Link-Up and Update106
- Process for Update107
- Significance of the Times Relevant During the Update117
- Max. Blocking Time for Priority Classes > 15121
- Premium for the Monitoring Times of Redundant I/O121
- Relationship between the Minimum I/O Retention Time and the Maximum Blocking Time for Priority Classes122
- Influences on the Time Response126
- Calculation of the Max. Scan-Cycle Time Extension126
- Calculation of the Max. Communication Delay126
- Deliberate Delaying of the Update127
- Performance Values for Link–Up and Update127
- Peculiarities During Link-Up and Update129
- Requirement of Input Signals During the Update129
- Communication Links and Functions129
- Reset Instruction on Aborting Link-Up129
Using I/O on the S7-400H131
- Addressing132
- I/O Configuration Types132
- Limits of I/O Configuration132
- Single-Channel, One-Way I/O Configuration133
  - Using Single-Channel, One-Sided I/O133
  - What Is Single-Channel, One-Way I/O?133
  - Failure of the Single-Channel, One-Way I/O134
  - Single-Channel, One-Way I/Os and User Program134
  - Using Single-Channel, Switched I/O135
  - What Is Single-Channel, Switched I/O?135
- Single-Channel, Switched ET 200M Distributed I/O136
  - Failure of the Single-Channel, Switched I/O137
  - Single-Channel, Switched I/O and User Program137
  - Duration of Switch-Over of the Active Channel138
  - No Pulses During Switch-Over of the Active Channel139
  - Switch-Over of the Active Channel on Link-Up and Update139
  - System Configuration and Design139
  - Connecting Redundant I/O140
- Redundant I/O in Central- and Expansion Devices140
- Redundant I/O in the One-Way DP Slave141
- Redundant I/O in the Switched DP Slave142
- Block Library “Functional I/O Redundancy”143
- Redundant I/O in Single Mode143
- Hardware Installation and Configuration of the Redundant I/O144
- Signal Modules for Redundancy145
  - Which Faults Can be Overcome Using Redundant I/O?146
  - Using Digital Input Modules as Redundant I/O147
- Fault-Tolerant Digital Input Module in a 1-Out-Of-2 Configuration148
  - Using Digital Input Modules with Non-Redundant Sensor148
  - Additional Marginal Conditions for Various Modules149
- Fault-Tolerant Digital Input Modules in a 1-Out-Of-2 Configuration150
- Using Redundant Digital Input Modules with Redundant Sensors150
- Digital Output Module Connected Through/Without Diodes151
- Fault-Tolerant Digital Output Module in a 1-Of-2 Configuration151
  - Redundant Digital Output Modules151
  - Using Analog Input Modules as Redundant I/O153
- Fault-Tolerant Analog Input Modules in a 1-Out-Of-2 Configuration154
  - Redundant Analog Input Modules for Voltage Measurement154
  - Redundant Analog Input Modules with Non-Redundant Sensors154
  - Redundant Analog Input Modules for Indirect Current Measurement155
  - Redundant Analog Input Module for Direct Current Measurements158
- Fault-Tolerant Analog Input Modules in a 1-Out-Of-2 Configuration160
- Redundant Analog Input Modules with Redundant Sensors160
- Analog Input Modules and Sensors161
- Depassivation of Modules162
- Redundant Analog Output Modules in a 1-Of-2 Structure162
- Assignment of the Status Byte163
  - Determining the Passivation Status with the Status Byte163
  - Determining the Status of the Passivation163
- Assignment of the Status Bytes164
  - Other Possibilities for Connecting Redundant I/O165
  - Redundant I/O on the User Level165
- Redundant One-Way and Switched I/Os165
- Redundant I/O in the User Program167
- Flowchart for OB1168
- Example of STL169
- Ob 122170
Communication Functions171
- Fundamentals and Basic Concepts172
- Redundant Communication System172
- Fault-Tolerant Communications172
- Connection (S7 Connection)173
- Fault-Tolerant S7 Connections173
- Example of an S7 Connection173
- Electrical Network175
- Industrial Ethernet175
- Resource Requirements of Fault-Tolerant S7 Connections175
- Suitable Networks175
- Profibus176
- Optical Network176
- Supported Communication Services178
- Communications Via Fault-Tolerant S7 Connections178
- Availability of Communicating Systems178
- Programming179
- Communications between Fault-Tolerant Systems180
- Example of Redundancy with Fault-Tolerant System and Redundant Ring181
- Example of a Fault-Tolerant System with Additional CP Redundancy181
- Response to Failure182
- Redundant S7 Connections182
- Communications between Fault-Tolerant Systems and Pcs184
- Communications Via S7 Connections185
- Communications with Standard Systems185
- Communications Via S7 Connections – One-Sided Mode186
- Two-Fiber Ring and Bus System187
- Communications over Redundant S7 Connections188
- Communications Via a Point-To-Point CP on the ET 200M189
- Connection Via ET 200M189
- Random Connection with Single-Channel Systems190
- Connection Via a PC as Gateway190
- Communication Performance191
- Definition of Communication Load191
- Response Time Via Communication Load (Basic Trend)192
- Data Throughput Via Communication Load (Basic Trend)192
- Work Area192
- Standard and H Systems193
- Which Sizes Influence the Communication Load?193
- General Information on Communication194
- Connecting Standard Systems to H Systems195
- S7 Communication (SFB 12 “BSEND” and SFB 13 “BRCV”)195
- S7 Communication (SFB 8 “USEND” and SFB 9 “URCV”)195
- SIMATIC Ops, SIMATIC Mps195
- OPC Server196
Configuring with STEP 7197
- Reading the Readme File198
- Installing the Options Package198
- Software Requirements198
- Installation of the Options Package198
- Rules for Fitting a Fault-Tolerant Station199
- Creating a Fault-Tolerant Station199
- Installation Rules200
- Configuring Hardware200
- Special Features in Presenting the Hardware Configuration200
- Assigning Parameters to Modules in a Fault-Tolerant Station201
- Central Processing Unit (Exception)201
- Modules in the I/O Address Area201
- Recommendations for Setting the CPU Parameters201
- Number of Messages in the Diagnostics Buffer202
- Monitoring Time for Transferring Parameters to Modules202
- Downloading the Network Configuration to the Fault-Tolerant Station203
- Configuring Networks203
- Programming Device Functions in STEP 7204
- Display in SIMATIC Manager204
- Failure and Replacement of Components During Operation205
- Failure and Replacement of a Central Processing Unit207
- Starting Situation for Replacement of the Complete CPU207
- Starting Situation for Replacement of the Load Memory208
- Failure and Replacement of a Power Supply Module209
- Initial Situation209
- Failure and Replacement of an Input/Output or Function Module210
- Failure and Replacement of a Communication Processor211
- Failure and Replacement of an IM 460 and IM 461 Interface Module215
- Failure and Replacement of Components of the Distributed I/O216
- Failure and Replacement of a PROFIBUS-DP Master217
- Failure and Replacement of a PROFIBUS-DP Slave219
- Failure and Replacement of PROFIBUS-DP Cables220
Modifying the System During Operation221
- How Is a Hardware Change Made?222
- Possible Hardware Modifications222
- Which Components Can be Modified?222
- What Should I Note at the System Planning Stage?223
- Modification of the Hardware Configuration224
- Modifications to the User Program and the Connection Configuration224
- Adding Components in PCS 7226
- PCS 7, Step 1: Modification of Hardware227
- PCS 7, Step 3: Stopping the Standby CPU229
- Behavior of the I/O231
- PCS 7, Step 5: Switch to CPU with Modified Configuration231
- PCS 7, Step 6: Transition to Redundant System Mode232
- Response if Monitoring Times Are Exceeded232
- PCS 7, Step 7: Changing and Loading User Program233
- Adding Interface Modules in PCS 7234
- Removing Components in PCS 7236
- PCS 7, Step II: Changing and Loading User Program238
- PCS 7, Step III: Stopping the Standby CPU239
- PCS 7, Step IV: Loading New Hardware Configuration in the Standby CPU239
- PCS 7, Step V: Switch to CPU with Modified Configuration240
- PCS 7, Step VI: Transition to Redundant System Mode241
- PCS 7, Step VII: Modification of Hardware242
- Removing Interface Modules in PCS 7243
- Adding Components in STEP 7244
- STEP 7, Step 1: Modification of Hardware245
- STEP 7, Step 4: Stopping the Standby CPU247
- STEP 7, Step 5: Loading New Hardware Configuration in the Standby CPU247
- STEP 7, Step 6: Switch to CPU with Modified Configuration248
- STEP 7, Step 7: Transition to Redundant System Mode249
- STEP 7, Step 8: Changing and Loading User Program250
- Adding Interface Modules in STEP 7251
- Removing Components in STEP 7252
- STEP 7, Step II: Changing and Loading User Program254
- STEP 7, Step III: Stopping the Standby CPU255
- STEP 7, Step V: Switch to CPU with Modified Configuration256
- STEP 7, Step VI: Transition to Redundant System Mode257
- STEP 7, Step VII: Modification of Hardware258
- STEP 7, Step VIII: Modifying and Loading Organization Blocks259
- Removing Interface Modules in STEP 7260
- Changing the CPU Parameters261
- Modifiable CPU Parameters261
- Step A: Changing the CPU Parameters Offline263
- Step B: Stopping the Standby CPU263
- Step C: Loading Modified CPU Parameters in the Standby CPU264
- Step D: Switch to CPU with Modified Configuration265
- Step E: Transition to Redundant System Mode266
- Changing the Memory Components of the CPU267
- Expanding the Main And/Or Load Memory267
- Changing the Type of Load Memory269
- Writing to a FLASH Card in the H System271
Synchronization Module273
- Synchronization Module for S7-400H274
- Function of the Synchronization Module274
- Removing and Inserting When Voltage Is Applied275
- Setting the Rack Number276
- Fiber Optic Cable for Connecting Two Synchronization Modules276
- Cable Length up to 500M277
Technical Specifications277
- Bending Radius278
- Cable Routing278
- Laying Fiber Optic Cables for Synchronized Coupling of S7-400H278
- Routing Cables Using Fiber Optics278
- Technical Specifications of the CPU 414-4H;280
- Run Times of the Fcs and Fbs for Redundant I/O288
- Characteristic Values of Redundant Programmable Logic Controllers291
- Basic Concepts292
- Reliability292
- Reliability of Modules292
- Reliability of Programmable Logic Controllers292
- Availability293
- Comparison of Mtbfs for Selected Configurations294
- Standard and Fault-Tolerant CPU in Single Operation294
- System Configurations with Central I/O294
- Redundant Cpus in Different Mounting Racks295
- Redundant Cpus with a Single-Channel, One-Way or Switched I/O296
- System Configurations with Distributed I/O296
- Redundant Cpus with Redundant I/O297
- Single–Channel Switch I/O297
- Single–Channel, One–Way I/O297
- MTBF Factor for Redundant I/O298
  - Redundant I/O298
  - Fault-Tolerant Communication299
  - Standard Communication299
  - Systems with Standard and Fault-Tolerant Communications299
  - Reasons for Single Operation301
  - Single Operation301
- Differences between S7-400 and S7-400H302
- Special Fault Tolerant Leds304
- Configuring Single Operation304
- Upgrading to a Fault-Tolerant System305
- Installing and Starting the Fault-Tolerant System305
- Converting from S5-H to S7-400H307
- Configuration, Programming and Diagnostics308
- Differences between Fault-Tolerant Systems and Standard Systems309
- Additional Functions of Fault-Systems309
- Restrictions for the Fault-Tolerant CPU Compared to a Standard CPU310
- Function Modules and Communication Processors Used on the S7-400H313
- Fms and Cps Used Centrally313
- Fms and Cps for Distributed One-Way Use314
- Fms and Cps for Distributed Switched Use314
- Connection Examples for Redundant I/O315
- SM 321; DI 8 X AC 120/230 V, 6ES7 321-1FF01-0AA0316
- SM 322; DO 8 X AC 230 V/2 A, 6ES7 322-1FF01-0AA0317
- SM 321; DI 16 X AC 120/230 V, 6ES7 321-1FF00-0AA0318
- SM 331; AI 8 X 16 Bit; 6ES7331-7NF00-0AB0319
- SM 332; AO 4 X 12 Bit; 6ES7 332-5HD01-0AB0320
- SM 421; DI 32 X UC 120 V, 6ES7 421-1EL00-0AA0321
- Sm 321; DI 16 DC 24 V, 6Es7 321-7Bh00-0Ab0323
- Sm 322; Do 32 DC 24 V/0.5 A, 6Es7 322-1Bl00-0Aa0324
- SM 331; AI 8 12 Bit, 6ES7 331-7KF02-0AB0325
- Glossary327
- I/O, Redundant328
- I/O, Single–Channel328
- I/O, Switched328
- Linking328
- Redundancy, Functional329
- Redundant Mode329
- Redundant Systems329
- Redundant Link329
- Index331

Siemens SIMATIC S7-400H - Failure and Replacement of Components in Central Racks and Expansion Racks

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