Siemens SIMATIC S7-400H - Characteristic Values of Redundant Programmable Logic Controllers

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Automation System S7-400H Fault-tolerant Systems

A5E00068197-07

Characteristic Values of Redundant

Programmable Logic Controllers

The present appendix presents a brief introduction to the characteristic values of

redundant programmable logic controllers and shows the practical effects of

redundant configuration types by means of a few selected configurations.

An overview of the MTBF for a variety of SIMATIC products is available in the

SIMATIC FAQs at

http://www.siemens.com/automation/service&support

under the ID 1160399.

In Section You Will Find On Page

A.1 Basic Concepts A-2

A.2 Comparison of MTBFs for Selected Configurations A-4

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 - Characteristic Values of Redundant Programmable Logic Controllers

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