Page 1 Security information Preface Basics of high availability SIMATIC High availability solutions in PCS 7 Process Control System PCS 7 High Availability Process Control Advantages of high availability components Systems (V9.0) Replacing components and plant changes Function Manual Failure, switchover and reintegration of high availability components Diagnostics...
Page 2 Note the following: WARNING Siemens products may only be used for the applications described in the catalog and in the relevant technical documentation. If products and components from other manufacturers are used, these must be recommended or approved by Siemens. Proper transport, storage, installation, assembly, commissioning, operation and maintenance are required to ensure that the products operate safely and without any problems.
Page 3: Table Of Contents
Table of contents Security information............................7 Preface.................................9 Basics of high availability..........................15 Motivation for using high availability process control systems..........15 Plant-wide availability considerations..................18 PCS 7 redundancy concept....................19 3.3.1 Advantages of the PCS 7 redundancy concept ..............19 3.3.2 PCS 7 redundancy concept 1 (fieldbus based on PROFIBUS DP) ........20 3.3.3 PCS 7 redundancy concept 2 (fieldbus based on PROFINET IO) ........22 Features of the PCS 7 redundancy concept at a glance............24...
Page 4 Table of contents 4.3.4.2 High availability plant bus.......................69 4.3.4.3 Redundant, high availability plant bus..................71 4.3.4.4 AS 410H on redundant, high availability plant bus..............74 4.3.5 Solutions for the fieldbus......................76 4.3.5.1 Redundant PROFIBUS DP....................76 4.3.5.2 High availability fieldbus based on PROFINET..............78 4.3.5.3 Gateway between redundant and non-redundant PROFIBUS DP........80 4.3.5.4 Connecting PROFIBUS PA to PROFIBUS DP..............81...
Page 5 How to configure an OS client....................163 5.5.9 How to configure an OS client for permanent operability.............165 5.5.10 How to download a SIMATIC PCS 7 project to the target system........168 5.5.11 Evaluating the redundancy tag "@RM_MASTER" with scripts..........169 SIMATIC BATCH stations....................170 5.6.1...
Page 6 Table of contents Automation system.......................202 7.2.1 Failure of the master CPU....................202 7.2.2 Failure of a fiber-optic cable....................202 Communication........................204 7.3.1 Failure of redundant bus components..................204 OS server..........................205 7.4.1 Failure, switchover and restarting redundant OS servers............205 BATCH server........................210 7.5.1 Failure of BATCH servers....................210 Route Control server......................211 7.6.1 Reaction of Route Control servers to failures..............211...
Page 7: Security Information
In order to protect plants, systems, machines and networks against cyber threats, it is necessary to implement – and continuously maintain – a holistic, state-of-the-art industrial security concept. Siemens’ products and solutions only form one element of such a concept. Customer is responsible to prevent unauthorized access to its plants, systems, machines and networks.
Page 8 Security information High Availability Process Control Systems (V9.0) Function Manual, 05/2017, A5E39221836-AA...
Page 9: Preface
Preface Purpose of this documentation This documentation informs you about the following aspects of configuring high availability systems with the SIMATIC PCS 7 Process Control System: ● The basic solution concepts ● The functional mechanisms ● The most important configurations It presents the availability solutions on all automation levels (control, process, field).
Page 10 Preface Full versions of the documentation are available from the "Technical Documentation SIMATIC PCS 7" website: http:\\www.siemens.com/pcs7-documentation (http:\\www.siemens.com/ pcs7-documentation) Process Control System PCS 7; You can find additional information in the product overview PCS 7 - Documentation ; Section "Options for accessing the documentation".
Page 11: Diagnostics
Preface Manual Contents Configuration manual ● Getting Started WinCC ● Operating principle of WinCC redundancy ● User archives ● Creating the "Project_Redundancy_Server" example project ● Description of the WinCC projects ● Server project Manual ● Structure of a redundant WinCC system WinCC Hardware Options, ●...
Page 12 Preface Manual Contents Manual ● Configuration options ET 200iSP ● Mounting Distributed I/O Device ● Wiring ● Commissioning and diagnostics Operating instructions ● Configuration options SIMATIC NET; ● Mounting Industrial Ethernet Switches ● Wiring SCALANCE X-200 ● Commissioning and diagnostics Operating instructions ●...
Page 13 If you use the operating system Windows 10, you will find the Siemens SIMATIC programs in the Start menu under the menu command All apps > Siemens Automation.
Page 14 Preface Connecting the FOUNDATION Fieldbus to PROFIBUS DP (Page 87) Solutions for the terminal bus (Page 61) High Availability Process Control Systems (V9.0) Function Manual, 05/2017, A5E39221836-AA...
Page 15: Basics Of High Availability
Basics of high availability Motivation for using high availability process control systems Advantages of high availability components Process control systems are responsible for controlling, monitoring and documenting production and manufacturing processes. Due to the increasing degree of automation and the demand for improved efficiency, the availability of these systems is playing an increasingly important role.
Page 16 Basics of high availability 3.1 Motivation for using high availability process control systems PS CPU CPCPCPCPCP PS CPU CPCPCPCPCP Legend for the above illustration: Note The following short designations are commonly used in this documentation. Short designation Meaning Engineering sta‐ Engineering station, PC tion OS server...
Page 17 Basics of high availability 3.1 Motivation for using high availability process control systems Short designation Meaning OS client Operator station, PC visualization station in the project form "WinCC Client" BATCH server BATCH station, PC recipe and batch data station BATCH client BATCH station, PC recipe creation and batch visualization station Route Control Route Control station, PC Route Control data station...
Page 18: Plant-Wide Availability Considerations
Basics of high availability 3.2 Plant-wide availability considerations Plant-wide availability considerations Introduction Availability must be analyzed globally for the system as a whole. Based on the degree of availability needed, each system level, each system and each component within a level should be evaluated.
Page 19: Pcs 7 Redundancy Concept
PCS 7 redundancy concept 3.3.1 Advantages of the PCS 7 redundancy concept Phases of a system lifecycle High availability process control systems can be realized with SIMATIC PCS 7 at minimal cost in all phases of a system lifecycle: ● Configuration ● Commissioning/operation ●...
Page 20: Pcs 7 Redundancy Concept 1 (Fieldbus Based On Profibus Dp)
Basics of high availability 3.3 PCS 7 redundancy concept 3.3.2 PCS 7 redundancy concept 1 (fieldbus based on PROFIBUS DP) Overview of the PCS 7 redundancy concept PCS 7 offers you a redundancy concept that reaches all levels of process automation. Figure 3-1 PCS 7 redundancy concept 1 (fieldbus based on PROFIBUS DP) High Availability Process Control Systems (V9.0)
Page 21 Basics of high availability 3.3 PCS 7 redundancy concept Note The numbering of the components in the illustration relates to the descriptions provided below. Number Description Several clients (OS clients, BATCH clients, Route Control clients) can access data on a server (OS server, BATCH server, Route Control server).
Page 22: Pcs 7 Redundancy Concept 2 (Fieldbus Based On Profinet Io)
Basics of high availability 3.3 PCS 7 redundancy concept 3.3.3 PCS 7 redundancy concept 2 (fieldbus based on PROFINET IO) Overview of the PCS 7 redundancy concept for PROFINET IO PCS 7 offers you a redundancy concept that reaches all levels of process automation. Figure 3-2 PCS 7 redundancy concept 2 (fieldbus based on PROFINET IO) Note...
Page 23 The ET 200SP HA IO Redundancy is optimized for usage with one sensor/actor per redundant channel pair. For more information on usage of SIMATIC PCS 7 with PROFINET, refer SIMATIC PCS 7 with PROFINET (https://support.industry.siemens.com/cs/ww/en/view/72887082).
Page 24: Features Of The Pcs 7 Redundancy Concept At A Glance
Basics of high availability 3.4 Features of the PCS 7 redundancy concept at a glance Features of the PCS 7 redundancy concept at a glance Introduction The easiest way to increase availability is to keep replacement parts in stock on site and to have fast service at your disposal to replace defective components.
Page 25 Basics of high availability 3.4 Features of the PCS 7 redundancy concept at a glance Basics of increased availability Increased availability in PCS 7 is based on the following principles: ● Duplication of a component Example: Use of duplicate signal modules ●...
Page 26: Features For The Configuration Phase
Basics of high availability 3.5 Features for the configuration phase Features for the configuration phase Features for the configuration phase In the configuration phase, PCS 7 provides you with support with the following features. Feature Meaning Fault prevention through simplified configura‐ You do not need additional training to configure the re‐...
Page 27: Features For The Commissioning And Operation Phases
Basics of high availability 3.6 Features for the commissioning and operation phases Features for the commissioning and operation phases Features for the commissioning and operation phases The following table lists the features PCS 7 offers for the commissioning and operation phases. The redundant components allows the continuation of the process if a component fails.
Page 28 Basics of high availability 3.6 Features for the commissioning and operation phases Feature Meaning Possible error / possible reason Ability of process to con‐ If an OS server fails, the system switches Failure of the OS server tinue to be controlled and over to the configured redundant partner Examples: monitored even when a...
Page 29: Features For Servicing And System Expansions
Diagnostics of components without an additional ple, LEDs) for fast, local error detection. programming device (PG). Faster service from SIEMENS Customer Support. The service is on site within 2 to 48 hours to main‐ tain the availability guarantee. Repairs and component expansions (upgrades, Repair and component expansions can be made in conversions and updates) in runtime.
Page 30: Definition Of Availability
Basics of high availability 3.8 Definition of availability Definition of availability Definitions Availability is usually defined as follows: Quotient of MTBF and (MTBF + MTTR) or in short form actual operating condition / nominal operating condition. Whereby: ● MTBF = mean time between failure; average amount of time between two successive error events, repair time excluded ●...
Page 31: Definition Of The Standby Modes
Basics of high availability 3.9 Definition of the standby modes Definition of the standby modes Introduction The availability of a system can be increased by additional components in the system (standby components). The operating mode of these components distinguishes them from the components that are active in process mode.
Page 32: Redundancy Nodes
Basics of high availability 3.10 Redundancy nodes 3.10 Redundancy nodes Functionality Redundancy nodes provided protection from failure of systems with redundant components. A redundancy node is independent when the failure of one component within the node does not affect the reliability in other nodes or in the entire system. The availability of a complete system is illustrated in block diagrams.
Page 33 Basics of high availability 3.10 Redundancy nodes Total failure of a redundancy node The following figure shows a complete system that has ceased to operate due to a failure of the "Field bus" redundancy node. High Availability Process Control Systems (V9.0) Function Manual, 05/2017, A5E39221836-AA...
Page 34 Basics of high availability 3.10 Redundancy nodes High Availability Process Control Systems (V9.0) Function Manual, 05/2017, A5E39221836-AA...
Page 35: High Availability Solutions In Pcs 7
High availability solutions in PCS 7 Solutions for the I/O Introduction In this section you will learn about the I/O systems and components that contribute to increasing the availability of your system. This means using the distributed I/O in PCS 7. Distributed I/O Distributed I/O refers to modules (input/output modules and function modules) that are used in a modular, distributed I/O device (such as the ET 200SP HA, ET 200M, ET 200SP or...
Page 36 High availability solutions in PCS 7 4.1 Solutions for the I/O Network components that are integrated at the fieldbus belong to the distributed I/O. These include, for example, the following network components: ● Bus links – DP/PA-Link The DP/PA‑Link enables the connection of a lower-level bus system such as PROFIBUS PA to a redundant PROFIBUS DP.
Page 37 Information on which modules are released for the distributed I/O in PCS 7 can be found in PCS 7 - Released modules. You can find this documentation on the Internet the documentation at: http:\\www.siemens.com/pcs7-documentation (http:\\www.siemens.com/pcs7- documentation). High Availability Process Control Systems (V9.0)
Page 38: Redundant I/O
High availability solutions in PCS 7 4.1 Solutions for the I/O 4.1.1 Redundant I/O Redundant I/O Redundant I/O describes the situation when the I/O modules (SM) for processing a process signal are doubly available and can be addressed by both CPUs. The CPU signal or process signal will continue to be processed by a functioning module even when its partner fails.
Page 39 High availability solutions in PCS 7 4.1 Solutions for the I/O Availability The block diagram shows an example configuration with ET 200M without a fault. If a fault occurs in a maximum of one signal path per redundancy node (e.g. bus line (bus = PROFIBUS DP) in the first redundancy node and an input module (SM) in the second redundancy node), the overall system remains operable.
Page 40 High availability solutions in PCS 7 4.1 Solutions for the I/O Installation rules The configuration always has to be symmetrical when using redundant I/O. Follow these installation rules: ● Using ET 200M as distributed I/O device: Both subsystems of the S7 400H must be configured identically.
Page 41 High availability solutions in PCS 7 4.1 Solutions for the I/O The following figure illustrates this configuration. Signals from redundant sensors can be registered and IO-modules can drive actors. Availability The block diagram shows an example configuration with Redundant I/O in ET 200SP HA without a fault.
Page 42: Switched I/O
High availability solutions in PCS 7 4.1 Solutions for the I/O Installation rules The configuration always has to be symmetrical when using redundant I/O. Follow these installation rules: ● The first module in Redundant I/O must be placed at an odd-numbered slot on a terminal block (TB45...).
Page 43 High availability solutions in PCS 7 4.1 Solutions for the I/O Configuration A switched I/O can be set up in PCS 7 with the following distributed I/O devices: ● ET 200M For this setup, you require an ET 200M with active backplane bus modules and a redundant IM 153-2 interface module.
Page 44 High availability solutions in PCS 7 4.1 Solutions for the I/O Availability The block diagram shows the availability of the configuration illustrated above. When both systems are operating without fault, the block diagram appears as follows: The following figure shows how one component may fail without this affecting the operation of the complete system.
Page 45: Components In The Distributed I/O
High availability solutions in PCS 7 4.1 Solutions for the I/O Installation rules The configuration always has to be symmetrical when using switched I/O. Follow these installation rules: ● CPU 41x-xH and additional DP masters must be located in the same slots in each subsystem (for example, in slot 4 of both subsystems).
Page 46: Redundant I/O Modules
High availability solutions in PCS 7 4.1 Solutions for the I/O The configuration is provided as an example in the section "Redundant I/O (Page 38)". ● ET 200M with redundant IM 153-2 Two IM 153-2 interface modules are mounted on the active bus module in the distributed I/O device for redundant operation.
Page 47 High availability solutions in PCS 7 4.1 Solutions for the I/O Note In case of using the I/O modules redundancy, the diagnostic feature or capability needs to be activated. Redundant operation of I/O modules of ET 200SP HA The following requirements must be met to operate redundant I/O modules of ET 200SP HA: ●...
Page 48: Redundant Actuators And Sensors
High availability solutions in PCS 7 4.1 Solutions for the I/O Reaction to a channel fault You can define the passivation characteristics, for example how redundant input/output modules react to a channel fault (such as broken wire, short-circuit on the signal line). The reaction to a channel fault depends on the following aspects: ●...
Page 49 High availability solutions in PCS 7 4.1 Solutions for the I/O Note No redundant Actuators and sensors with ET 200SP HA ET 200SP HA is optimized for Redundant I/O and uses a single sensor/actor connected to a pair of I/O-modules (redundant channel pair). So you can't connect a pair of actuators/sensors.
Page 50: Solutions For Automation Systems
High availability solutions in PCS 7 4.2 Solutions for automation systems Solutions for automation systems Introduction This chapter presents solutions that can be used to increase the availability of an automation system. S7-400H high availability programmable controller Only a high availability automation system can ensure an extremely short process safety time, for example, a switchover time in the milliseconds range.
Page 51 High availability solutions in PCS 7 4.2 Solutions for automation systems Hardware components Communication processors Communication processor CP 443-5 Extended Communication processor CP 443-1 Setup Racks The following racks are available for installing the S7-400H. Normally, the UR2-H rack is used. Type Slots Special feature...
Page 52 High availability solutions in PCS 7 4.2 Solutions for automation systems Synchronization modules Synchronization modules are used to link the two central processing units. They are installed in the central processing units and interconnected with fiber-optic cable. Two synchronization modules are installed in each CPU. Set the rack number for the H CPU as of firmware version V4.X directly on the CPU.
Page 53: How The Simatic S7-400H As Operates
If the active CPU fails, the automation system automatically switches to the redundant CPU Process (see section "Hardware components of the S7-400H (Page 50)" and documentation Control System, SIMATIC PCS 7, Released Modules ). The switchover has no effect on the ongoing process because it is bumpless. Additional information ●...
Page 54: Solutions For Communication
High availability solutions in PCS 7 4.3 Solutions for communication Solutions for communication Introduction In this section, you will learn about the redundancy concepts for the various levels of the process control system. Requirements for communication systems The availability of a process control system is not only determined by the automation system, the environment also plays a considerable role.
Page 55 High availability solutions in PCS 7 4.3 Solutions for communication Overview of the redundant and high availability bus systems In PCS 7 systems, you can configure fully redundant bus systems with redundant components for the following bus systems: ● Redundant, high availability terminal bus (Page 63) ●...
Page 56: Network Components
High availability solutions in PCS 7 4.3 Solutions for communication 4.3.1 Network components Introduction Local networks (LAN) form the basis of the communication system. The following are options that can be implemented based on the specific system requirements: ● Electrical ●...
Page 57 High availability solutions in PCS 7 4.3 Solutions for communication Network component Bus system Application AFD (Automatic Field Dis‐ Fieldbus Connection of field devices via ring redundancy tributor) ● PROFIBUS PA ● Maximum of 31 fieldbus components on one AFDiSD ●...
Page 58 High availability solutions in PCS 7 4.3 Solutions for communication SCALANCE X switches for setting up redundant networks You can find additional information on SCALANCE X switches approved for PCS 7 in the Process Control System PCS 7; Released Modules documentation. The switches must have the necessary functions available to set up the relevant redundant network: ●...
Page 59: Media Redundancy Protocol
High availability solutions in PCS 7 4.3 Solutions for communication 4.3.2 Media Redundancy Protocol Use of media redundancy protocol Note High Speed Redundancy Protocol (HRP) and Media Redundancy Protocol (MRP) The X200 IRT switches cannot serve as redundancy manager and standby manager at the same time.
Page 60 ● You can find information about configuration of PROFINET in the manual; System Description. You can find more information on internet (http:// support.industry.siemens.com/cs/ww/en/view/19292127). ● You can find information about HRP and MRP in the documentation of the Industrial Ethernet switches.
Page 61: Solutions For The Terminal Bus
High availability solutions in PCS 7 4.3 Solutions for communication 4.3.3 Solutions for the terminal bus 4.3.3.1 Connecting PC stations to the terminal bus You connect the following PC stations to industrial Ethernet via network adapters (communication modules or communication processors): ●...
Page 62 High availability solutions in PCS 7 4.3 Solutions for communication For example, a broken cable in the connection between the modules is tolerated and communication remains uninterrupted. If the terminal bus experiences problems, no process data are sent from the servers to the clients.
Page 63: Redundant, High Availability Terminal Bus
High availability solutions in PCS 7 4.3 Solutions for communication Availability If there is a fault in a ring line, the communication between clients and servers via the switches remains unaffected. However, if one of the switches fails, the link between the connected OS servers and the OS clients is interrupted.
Page 64: Redundant, High Availability Terminal Bus Based On The Parallel Redundancy Protocol (Prp)
High availability solutions in PCS 7 4.3 Solutions for communication Redundant components The following components are configured redundantly: ● Electrical or optical network with Ethernet switches ● Switches, fiber optic cables and electrical connections ● Ring structures based on switches from the SCALANCE series. You can find additional information on the switches used with PCS 7 in the section "Network components (Page 56)".
Page 65 High availability solutions in PCS 7 4.3 Solutions for communication Configuration limits for the operator station Process Control System PCS 7; You can find information about this in the documentation Licenses and Configuration Limits. Redundant, high availability terminal bus with SIMATIC NET SOFTNET‑IE RNA All protocols among the redundantly connected components are automatically duplicated, sent and distributed in the mutually redundant networks.
Page 66 High availability solutions in PCS 7 4.3 Solutions for communication Encrypted communication "Encrypted communication" is not approved for stations with SIMATIC NET SOFTNET‑IE RNA. Note It does not apply for WinCC/SCS secure communication. Availability - redundant high availability terminal bus The entire transmission route can be configured redundantly.
Page 67 High availability solutions in PCS 7 4.3 Solutions for communication Requirements ● A maximum of 2 non-redundant networks and components with only one network connection for each SCALANCE X204RNA ● Two separate, redundant terminal bus networks ● Maximum distance to network node (component/switch): –...
Page 68: Solutions For The Plant Bus
Redundancy Protocol (Page 115)" PCS 7 Readme file ● You can find information on the available operating systems in the You can find additional information on this on the Internet http:\\www.siemens.com/pcs7- documentation (http:\\www.siemens.com/pcs7-documentation): SIMATIC NET; Industrial Ethernet; "SCALANCE X204RNA, ● Operating Instructions SCALANCE X204RNA EEC SIMATIC NET;...
Page 69: High Availability Plant Bus
High availability solutions in PCS 7 4.3 Solutions for communication Network adapters for connection to the redundant, high availability plant bus (2 rings) You need network adapters with an integrated processor for connection to the redundant, high availability plant bus. Network adapter Number of con‐...
Page 70 High availability solutions in PCS 7 4.3 Solutions for communication High availability communication solutions The following communication solutions are offered to prevent a possible failure: ● Ring structure in an electrical network. The connection to the switches is electrical. ● Ring structure in an optical network with switches and FO cable. The connection to the switches is electrical or optical.
Page 71: Redundant, High Availability Plant Bus
High availability solutions in PCS 7 4.3 Solutions for communication To guard against the failure of all switches, however, the redundant double ring described in the following section can be used. Additional information ● Section "How to configure a high availability plant bus (Page 117)" SIMATIC Net Twisted Pair and Fiber-Optic Networks ●...
Page 72 High availability solutions in PCS 7 4.3 Solutions for communication Configuration - redundant, high availability plant bus The figure below shows the basic configuration of the redundant, high availability plant bus. ● Bus1 shows the functionally correct configuration (shared switches for AS and OS). ●...
Page 73 High availability solutions in PCS 7 4.3 Solutions for communication You may connect one redundant AS per CPU without redundant communication modules. Connection possibilities: ● Single connection of an AS 41xH with one CP each per CPU. Availability is then reduced accordingly.
Page 74: As 410H On Redundant, High Availability Plant Bus
High availability solutions in PCS 7 4.3 Solutions for communication 4.3.4.4 AS 410H on redundant, high availability plant bus Functionality The plant bus connects automation systems to servers (OS server, Route Control server). An automation system with a SIMATIC S7 410H-type CPU can be connected to a redundant, high availability plant bus.
Page 75 High availability solutions in PCS 7 4.3 Solutions for communication Note Address areas and IP addresses of the components on the plant bus Always assign IP addresses in different IP address ranges to the network adapters (separate address range for Bus1 and separate address range for Bus2). Example: ●...
Page 76: Solutions For The Fieldbus
High availability solutions in PCS 7 4.3 Solutions for communication 4.3.5 Solutions for the fieldbus 4.3.5.1 Redundant PROFIBUS DP Functionality The field bus is used for data exchange between the automation system (AS) and the distributed I/O. PROFIBUS DP (distributed peripheral)-- the field bus standard for manufacturing and process automation--is used.
Page 77 High availability solutions in PCS 7 4.3 Solutions for communication Availability If the active PROFIBUS DP fails, sensors and H system can communicate with each other over the redundant bus connection. The configuration shown in the following figure provides increased availability due to the redundant interfacing of the distributed I/O. Additional information ●...
Page 78: High Availability Fieldbus Based On Profinet
High availability solutions in PCS 7 4.3 Solutions for communication 4.3.5.2 High availability fieldbus based on PROFINET Functionality The fieldbus is used for data communication between the automation system (AS) and the distributed I/O. PROFINET is a standard for manufacturing and process automation. The PROFINET-based fieldbus comprises the specifications for the following elements: ●...
Page 79 High availability solutions in PCS 7 4.3 Solutions for communication Figure 4-2 Sample for high availability PROFINET with ET 200M Figure 4-3 Sample for high availability PROFINET with ET 200SP HA High Availability Process Control Systems (V9.0) Function Manual, 05/2017, A5E39221836-AA...
Page 80: Gateway Between Redundant And Non-Redundant Profibus Dp
● Manual SIMATIC STEP 7; Modifying the System during Operation via CiR ● Manual ● Application example Configuration examples for the S7-400H with PROFINET SIMATIC S7-400H as of V6.0 (https://support.industry.siemens.com/cs/ww/en/view/90885106) 4.3.5.3 Gateway between redundant and non-redundant PROFIBUS DP Y Link The Y-Link consists of two IM 153-2 interface modules and a Y coupler that are interconnected through the corresponding bus modules (BM IM/IM and BM Y coupler).
Page 81: Connecting Profibus Pa To Profibus Dp
High availability solutions in PCS 7 4.3 Solutions for communication Configuration Functionality The Y-Link creates a gateway from the redundant DP master system of an S7-400H to a non- redundant DP master system. This enables devices with only one PROFIBUS DP interface to be connected to a redundant DP master system as switched I/O.
Page 82 High availability solutions in PCS 7 4.3 Solutions for communication Configuration Functionality The DP/PA coupler connects PROFIBUS DP and PROFIBUS PA and decouples the various transmission rates. It is a slave on the PROFIBUS DP and a master on the PROFIBUS PA. Seen from the automation system, the PA Link is a modular slave.
Page 83: High Availability Profibus Pa
High availability solutions in PCS 7 4.3 Solutions for communication Physical bus characteristics ● The application protocols for PROFIBUS DP and PROFIBUS PA are defined according to IEC 61158-2 and are identical for these two fieldbus variants. – You can set the transmission speed on the PROFIBUS DP. The maximum transmission speed with the Y-link is 12 Mbps.
Page 84 High availability solutions in PCS 7 4.3 Solutions for communication High availability communication solutions The following communication solutions are offered to prevent a possible failure: ● Ring redundancy with the AFD (Active Field Distributor) ● Coupler redundancy with the AFS (Active Field Splitter) The DP/PA coupler can be used stand-alone or in the PA-Link .
Page 85 High availability solutions in PCS 7 4.3 Solutions for communication ● You can connect a maximum of 31 field devices per PROFIBUS PA. ● The maximum power consumption of 1 A must not be exceeded. This figure includes all components connected to the PROFIBUS PA. Configuration Examples for connections of field devices via AFD and AFS are shown in the following figures.
Page 86 High availability solutions in PCS 7 4.3 Solutions for communication Figure 4-6 Connection to a single PROFIBUS DP Transmission rate You have two interfacing options for the gateway between PROFIBUS DP and PROFIBUS PA. These result in different transmission rates on PROFIBUS DP. ●...
Page 87: Connecting The Foundation Fieldbus To Profibus Dp
High availability solutions in PCS 7 4.3 Solutions for communication Additional information ● Section " Connection of PROFIBUS PA to PROFIBUS DP (Page 81)" ● Section "How to configure redundant PROFIBUS PA (Page 128)" DP/PA coupler, Active Field Distributor, PA Link and Y Link ●...
Page 88 High availability solutions in PCS 7 4.3 Solutions for communication Configuration The following figure is an example of the configuration of a bus link based on the Compact FF Link. Functionality The bus link connects PROFIBUS DP and FOUNDATION Fieldbus with one another and decouples various transmission rates.
Page 89 High availability solutions in PCS 7 4.3 Solutions for communication Versions You can connect one FF segment to the PROFIBUS DP for each bus link. The following variants can be realized: ● Connection to a singular PROFIBUS DP – Connection via Compact FF Link (1 x Compact FF Link) –...
Page 90: High Availability Foundation Fieldbus
High availability solutions in PCS 7 4.3 Solutions for communication 4.3.5.7 High availability FOUNDATION Fieldbus Functionality PCS 7 enables the connection of field devices to the FOUNDATION Fieldbus H1 (referred to only as FOUNDATION Fieldbus or FF from this point). A high availability FOUNDATION Fieldbus is connected to the redundantly configured Compact FF Link.
Page 91 High availability solutions in PCS 7 4.3 Solutions for communication Configuration Examples using the FF Link for connections to field devices via AFD and AFS are shown in the following figures. Figure 4-7 Connection to a redundant PROFIBUS DP Transmission rate You have two interconnection options for the gateway between PROFIBUS DP and FOUNDATION Fieldbus .
Page 92 High availability solutions in PCS 7 4.3 Solutions for communication The communications connection to the field devices remains established, even when an FF cable or a module fails. The AFD or AFS automatically switches the connection to the available signal path. Figure 4-8 Schematic view for the installation with FF Link (2x IM 153‑2 FF, 2 x FDC 157) Additional information...
Page 93: Solutions For Integrating A Pcs 7 System In A Domain
Process Control System PCS 7; Time Synchronization ● Function manual ● On the Internet pages of Customer Support in Whitepaper SIMATIC; Safety Concept PCS 7 and WinCC; Basic document (https://support.industry.siemens.com/cs/ww/en/view/ 60119725) High Availability Process Control Systems (V9.0) Function Manual, 05/2017, A5E39221836-AA...
Page 94: Solutions For Os Servers
High availability solutions in PCS 7 4.5 Solutions for OS servers Solutions for OS servers Redundant OS servers PCS 7 enables you to configure two OS servers redundantly for high availability operation. This ensures that you can monitor and control your process at all times. The solution represents the entry level into high availability process control systems.
Page 95 High availability solutions in PCS 7 4.5 Solutions for OS servers OS partner servers (OS_Stby) are configured in the SIMATIC Manager. Using the menu command PLC > Download synchronizes the functionality. Redundant external archive server You use the Process Historian for central acquisition of archive information of the process control system.
Page 96 High availability solutions in PCS 7 4.5 Solutions for OS servers Redundancy connection You need the following components to make the redundancy connection, depending on the distance to be bridged: Maximum distance Required components Connection 10 m Null modem cable Serial connection 100 m Ethernet connection...
Page 97: Solutions For Os Clients
High availability solutions in PCS 7 4.6 Solutions for OS clients Solutions for OS clients 4.6.1 Additional OS clients Additional OS clients OS clients are PC stations that are used for control and monitoring of an automation process. They are connected to the OS servers through the terminal bus. The OS servers form the process connection to the automation system.
Page 98 High availability solutions in PCS 7 4.6 Solutions for OS clients Preferred server A "preferred server" is an OS server in the redundant OS server pair that is preferred by the OS client for a connection. A preferred server can be defined separately for each OS client in order to ensure permanent operability.
Page 99: Solutions For Simatic Batch
High availability solutions in PCS 7 4.7 Solutions for SIMATIC BATCH Solutions for SIMATIC BATCH Redundant BATCH servers SIMATIC BATCH enables you to configure two BATCH servers redundantly for high availability operation. This ensures that you can monitor and control your batch process at all times. Functionality Redundant BATCH servers monitor each other in runtime to detect the failure of a BATCH server as early as possible.
Page 100 High availability solutions in PCS 7 4.7 Solutions for SIMATIC BATCH Redundancy connection You need the following components to make the redundancy connection, depending on the distance to be bridged: Maximum Required components Connection distance 100 m Ethernet connection ● Crossover network cable ●...
Page 101 High availability solutions in PCS 7 4.7 Solutions for SIMATIC BATCH The BATCH servers also communicate with OS servers over the terminal bus. The OS servers are connected to the automation system over the plant bus. Note SIMATIC BATCH in "AS-based" operating mode The BATCH servers are also connected to the plant bus if SIMATIC BATCH is operated "AS- based".
Page 102: Solutions For The Route Control Server
High availability solutions in PCS 7 4.8 Solutions for the Route Control server Solutions for the Route Control server Redundant Route Control servers SIMATIC Route Control allows you to implement two Route Control servers with redundancy functionality for high availability operation. This ensures that you can monitor and control your route control at all times.
Page 103 High availability solutions in PCS 7 4.8 Solutions for the Route Control server Redundancy connection You need the following components to make the redundancy connection, depending on the distance to be bridged: Maximum distance Required components Connection 10 m Null modem cable Serial connection 100 m Ethernet connection...
Page 104: Solutions For The Engineering Station
High availability solutions in PCS 7 4.9 Solutions for the engineering station Solutions for the engineering station Engineering station The engineering station (ES) serves as a central configuration station. There are no redundant engineering stations in PCS 7. The ES is generally used to make changes to the configuration data of project components such as AS, OS and BATCH and then download the changes to the target systems.
Page 105: Time Synchronization
High availability solutions in PCS 7 4.10 Time synchronization 4.10 Time synchronization Introduction Time synchronization in a PCS 7 plant is of utmost importance for synchronizing, tracing, documenting and archiving all time-critical processes. Time synchronization is particularly important for the redundancy functions in PCS 7 such as the redundancy synchronization between OS servers or BATCH servers.
Page 106 High availability solutions in PCS 7 4.10 Time synchronization High Availability Process Control Systems (V9.0) Function Manual, 05/2017, A5E39221836-AA...
Page 107: Advantages Of High Availability Components
Advantages of high availability components Creating and expanding a project with pre-configured stations PCS 7 wizards "New Project" and "Extend Project" You can create high availability stations for the AS and PC stations using the PCS 7 "New Project" and "Expand Project" wizards in the SIMATIC Manager. For redundant PC stations, you configure a redundant multiple station system using the PCS 7 wizard.
Page 108: Simatic H Station
Advantages of high availability components 5.2 SIMATIC H station SIMATIC H station 5.2.1 Overview of configuration steps Overview of configuration steps You configure the redundancy functionality of the SIMATIC H station by performing the following steps: Step What? Inserting a SIMATIC H station in a project (Page 108) Plugging synchronization modules into the H_CPU (Page 110) Configuring redundant communications processors (Page 111) Setting the CPU for the error response of input/output modules (Page 113)
Page 109 Advantages of high availability components 5.2 SIMATIC H station Result The configuration in the SIMATIC Manager appears as follows: Configuring the AS in HW Config 1. Double-click the Hardware object in the detail view. The HW Config dialog box opens. 2.
Page 110: How To Insert Synchronization Modules Into The H Cpu
Advantages of high availability components 5.2 SIMATIC H station 5.2.3 How to insert synchronization modules into the H CPU Requirements ● The PCS 7 project is open in SIMATIC Manager. ● HW Config is open. ● The rack has been inserted according to the configuration in HW Config. ●...
Page 111: How To Configure Redundant Communication Processors
Advantages of high availability components 5.2 SIMATIC H station Result The following figure shows an example of the configured subsystems of the high availability station in HW Config: Additional information Process Control System PCS 7; PCS 7 - Released Modules ●...
Page 112 Advantages of high availability components 5.2 SIMATIC H station Requirements ● The PCS 7 project with a SIMATIC H station is open in SIMATIC Manager. ● HW Config is open. ● The racks for the SIMATIC H station are inserted in HW Config, for example, 2 UR2-H racks. ●...
Page 113: How To Set The Cpu For The Reaction Of The Input/Output Modules To Channel Faults
Advantages of high availability components 5.2 SIMATIC H station Result The following figure shows an example of a configuration in HW Config: Connection to a high availability plant bus is possible. Additional information Automation System S7-400H; High Availability Systems ● Manual 5.2.5 How to set the CPU for the reaction of the input/output modules to channel faults Introduction...
Page 114 Advantages of high availability components 5.2 SIMATIC H station As of PCS 7 V7.1, the characteristics of the redundant input/output modules are set for channel- based reaction to channel faults. The function in the AS depends on the employed PCS 7 library and the modules.
Page 115: Communications Connections
Advantages of high availability components 5.3 Communications connections Communications connections 5.3.1 Overview of configuration steps Introduction After you have inserted all of the components (AS, OS and ES) in your project, you can use NetPro to configure the network connections between the SIMATIC components. When the configuration of the connections and network is complete, the configuration needs to be compiled, saved and downloaded to the CPU of the automation system.
Page 116: How To Connect Singular Components To The Redundant Terminal Bus On The Basis Of The Parallel Redundancy Protocol
Ethernet Operating Instructions; SOFTNET-IE RNA . Additional information ● Online help for "SIMATIC NET SOFTNET-IE RNA" software ● You can find additional information on this on the Internet http:\\www.siemens.com/pcs7- documentation (http:\\www.siemens.com/pcs7-documentation): SIMATIC NET; SCALANCE X204RNA, SCALANCE X204RNA – Operating instructions SIMATIC NET PG/PC;...
Page 117: How To Configure A High Availability Plant Bus
3. Configure the SCALANCE X204RNA. Messages ● SCALANCE X204RNA has signaling contacts. Additional information about configuration You can find additional information on this on the Internet http:\\www.siemens.com/pcs7- documentation (http:\\www.siemens.com/pcs7-documentation): ● Operating instructions SIMATIC NET; SCALANCE X204RNA, SCALANCE X204RNA EEC SIMATIC NET PG/PC; Industrial Ethernet SOFTNET-IE RNA V8.2 ●...
Page 118 Advantages of high availability components 5.3 Communications connections Requirements ● The PCS 7 project with a SIMATIC H station is open in SIMATIC Manager. ● The hardware configuration of the subsystems of the H system is the same. ● One of the following network adapters is configured in HW Config for the connection to the plant bus: –...
Page 119: How To Configure Redundant Profibus Dp
Advantages of high availability components 5.3 Communications connections Result The following figure shows the resulting configuration: Additional information STEP 7 ● Online help for 5.3.4 How to configure redundant PROFIBUS DP Introduction The following section describes how to create and connect a redundant PROFIBUS DP. Requirements ●...
Page 120 Advantages of high availability components 5.3 Communications connections ● The UR2-H rack has been inserted twice in HW Config. ● In HW Config, each mounting rack has been fitted with an H CPU in slot 3 and the required synchronization modules. Procedure Note Steps 1 through 4 are necessary only when a CP 443-5 Extended is used for the connection...
Page 121 Advantages of high availability components 5.3 Communications connections Result The figure below shows the result of the configuration process in HW Config. Here, a distributed I/O has already been assigned to the DP master systems for the purpose of illustrating the redundancy principle: Additional information STEP 7...
Page 122: How To Configure A High Availability Fieldbus On The Basis Of Profinet
Advantages of high availability components 5.3 Communications connections 5.3.5 How to configure a high availability fieldbus on the basis of PROFINET Introduction The following section describes how to create and connect a high availability fieldbus on the basis of PROFINET. ●...
Page 123 Advantages of high availability components 5.3 Communications connections Result The figure below shows the result of the configuration process in HW Config. The distributed I/O is connected to the PROFINET IO system. The physical setup is configured below with the Topology Editor.
Page 124 Advantages of high availability components 5.3 Communications connections 3. Select the "Graphic View" tab. Note: You can move the displayed objects. You can select the section displayed via the thumbnail view. Position the objects in accordance with the cable sequence in the system. 4.
Page 125: How To Configure A Media-Redundant Fieldbus On The Basis Of Profinet
Advantages of high availability components 5.3 Communications connections 5.3.6 How to configure a media-redundant fieldbus on the basis of PROFINET Introduction The following section describes how to create and connect a media-redundant ring on the basis of PROFINET. ● Configure the components in HW Config. ●...
Page 126 Advantages of high availability components 5.3 Communications connections Result The figure below shows the resulting configuration in HW Config for the X5 interface of the CPU. The distributed I/O is connected to the PROFINET IO system. The physical setup is configured below with the Topology Editor.
Page 127 Advantages of high availability components 5.3 Communications connections 3. Select the "Graphic View" tab. Note: You can move the displayed objects. You can select the section displayed via the thumbnail view. Position the objects in accordance with the cable sequence in the system. 4.
Page 128: How To Configure The Redundant Profibus Pa
Advantages of high availability components 5.3 Communications connections If you are operating multiple MRP rings, the MRP manager must be configured. In most cases the CPU is configured as MRP manager. 1. Select any one member on PROFINET IO. 2. In HW Config, select the menu Edit > PROFINET IO > Domain Management..3.
Page 129 Advantages of high availability components 5.3 Communications connections You can find configuration variants in the section "High availability PROFIBUS PA (Page 83)". Requirements ● The PCS 7 project with a SIMATIC H station is open in SIMATIC Manager. ● Two DP master systems are configured for the SIMATIC H station in HW Config and these are used as connection paths for the redundant interface.
Page 130: How To Configure The Redundant Foundation Fieldbus
Advantages of high availability components 5.3 Communications connections 12.Click "OK" in the dialog boxes that were opened for this procedure. 13.Repeat steps 1 to 13 for the second DP/PA coupler for coupler redundancy. Result The following figure shows the resulting configuration in HW Config: Additional information DP/PA coupler, Active Field Distributor, DP/PA Link and Y Link ●...
Page 131 Advantages of high availability components 5.3 Communications connections Setting redundant mode at the bus link The redundant mode set at the bus link has to match the configured redundant mode. FF Link - Setting at coupler FDC 157-0 (DIP switch bit 7) or Compact FF Link - Setting at Compact FF Link (DIP switch "RING"...
Page 132 Advantages of high availability components 5.3 Communications connections 6. Optional steps for a redundant FOUNDATION Fieldbus: These steps depend on the bus link that is used for the interconnection to the PROFIBUS DP: Select the following modules depending on the bus link used: ●...
Page 133: Distributed I/O
Advantages of high availability components 5.4 Distributed I/O Distributed I/O 5.4.1 Overview of configuration steps Introduction The following sections describe configuring redundancy of the individual components of the distributed I/O. Overview This section describes the configuration steps for the following topics: ●...
Page 134 Advantages of high availability components 5.4 Distributed I/O Procedure 1. In the component view, select the SIMATIC H station and double-click the "Hardware" object in the detail window. HW Config opens. 2. If the hardware catalog is not visible, select the View > Catalog menu command. The hardware catalog opens.
Page 135 Advantages of high availability components 5.4 Distributed I/O Result The following figure shows an example configuration in HW Config: Additional information Process Control System PCS 7; High-Precision Time Stamping ● Function manual DP/PA Link and Y Link Bus Couplings ● Manual High Availability Process Control Systems (V9.0) Function Manual, 05/2017, A5E39221836-AA...
Page 136: How To Configure Redundant Input/Output Modules (Profibus Dp)
Advantages of high availability components 5.4 Distributed I/O 5.4.3 How to configure redundant input/output modules (PROFIBUS DP) Introduction You configure the redundant I/O modules using HW Config. Note Redundant operation is possible only with certain S7-300 I/O modules of the ET 200M. For additional information, please refer to the following documents: PCS 7 - Released Modules ●...
Page 137 Advantages of high availability components 5.4 Distributed I/O Example configuration The figure below shows the setup for redundant input modules in a switched distributed configuration. Method of operation in the example configuration "Signal Module 1" is configured redundantly to "Redundant Signal Module 1". As a result, Signals E1.1 and E10.1 are redundant to one another.
Page 138 Advantages of high availability components 5.4 Distributed I/O Procedure 1. In the component view, select the SIMATIC H station and double-click the "Hardware" object in the detail window. HW Config opens. 2. If the hardware catalog is not visible, select the View > Catalog menu command. The hardware catalog opens.
Page 139 Advantages of high availability components 5.4 Distributed I/O 12.Click "Find". The "Find Redundant Module" dialog box opens. 13.In the "Subsystem" list, select the DP master system in which the redundant signal module is configured. All the available PROFIBUS addresses in this DP master system are displayed in the "PROFIBUS address"...
Page 140: How To Configure Redundant Input/Output Modules (Profinet Io)
Advantages of high availability components 5.4 Distributed I/O Additional information STEP 7 ● Online help for Process Control System PCS 7; PCS 7 - Released Modules ● Documentation Automation System S7-400H; High Availability Systems ● Manual 5.4.4 How to configure redundant input/output modules (PROFINET IO) Introduction You configure the redundant I/O modules in Redundant I/O using HW Config.
Page 141 Advantages of high availability components 5.4 Distributed I/O Example configuration The figure below shows the setup for peripheral modules in IO Redundancy in a ET 200SP HA configuration. Sensor Method of operation in the example configuration "Signal Module 1" is configured redundantly to "Redundant Signal Module 1". As a result, Signals I1.1 and I2.1 are redundant to one another.
Page 142: How To Configure The Redundancy For Hart Field Devices
Advantages of high availability components 5.4 Distributed I/O 4. In the hardware catalog, select a signal module that supports redundancy. Using drag-and-drop, move the signal module onto a free slot in the IM 155-6 HA (lower window pane). 5. Repeat steps 3 and 4 for the second signal module. The modules for which redundancy is to be configured are inserted.
Page 143 Advantages of high availability components 5.4 Distributed I/O Procedure 1. Configure redundant modules for HART field devices in HW Config as described in section "How to configure redundant input/output modules (PROFIBUS DP) (Page 136)". In the example, the module on slot 6 is configured in each case: –...
Page 144 Advantages of high availability components 5.4 Distributed I/O 3. Place the "HART field device" in the detail view of the redundant module. In the example, module 6 on ET 200M station with PROFIBUS address 6. 4. Select the menu command Station > Save. The settings are saved.
Page 145: How To Configure The Y Link
Advantages of high availability components 5.4 Distributed I/O 5.4.6 How to configure the Y Link Introduction The Y Link consists of two IM 153-2 interface modules and a Y coupler. The Y Link creates a gateway from a redundant DP master system to a non-redundant DP master system. The following describes how to install and configure the Y Link.
Page 146 Advantages of high availability components 5.4 Distributed I/O Result The following figure shows an example configuration in HW Config: Additional information DP/ PA Link and Y Link Bus Couplings ● Manual High Availability Process Control Systems (V9.0) Function Manual, 05/2017, A5E39221836-AA...
Page 147: Configuring A Bus Link For Profibus Pa
Advantages of high availability components 5.4 Distributed I/O 5.4.7 Configuring a bus link for PROFIBUS PA Bus links are gateways between bus systems and enable the communication connection of the bus systems. The DP/PA Link is a bus link for communications between PROFIBUS DP and PROFIBUS Functionality When connecting a redundant PROFIBUS DP, the DP/PA Link consists of two IM 153-2 interface modules and one or more DP/PA couplers.
Page 148: Configuring A Bus Link For Ff And Compact Ff Segment
Advantages of high availability components 5.4 Distributed I/O Procedure Configure the DP/PA Link as described in the section "How to configure the Y Link (Page 145)". The DP/PA Coupler does not appear in the hardware catalog for the configuration of the bus system.
Page 149 Advantages of high availability components 5.4 Distributed I/O Functionality The field devices connected to the FF segment are addressed directly from the PLC. In PCS 7 there are the following possibilities for the installation of a bus link when connecting to a redundant PROFIBUS DP: ●...
Page 150 Advantages of high availability components 5.4 Distributed I/O Procedure During configuration in HW Config, you can only select the FF Link interface module in SIMATIC Manager: ● IM 153-2 FF (for FF Link) ● IM 655-5 FF (for Compact FF Link) Configure the FF Link and Compact FF link bus link in the same way as the DP/PA link.
Page 151: Configuration Of Redundant Signals
Advantages of high availability components 5.4 Distributed I/O 5.4.9 Configuration of redundant signals You configure only one signal in CDC for redundantly acquired signals. Basic procedure 1. Place one channel block in the CFC for each redundantly acquired signal. 2. For redundantly detected signals (e.g. input 1.1 and input 10.1), interconnect only the symbol with the least significant address (e.g.
Page 152: Operator Stations
Configuring an OS client (Page 163) Configuring an OS client for permanent operability (Page 165) Downloading the SIMATIC PCS 7 project to the target systems (Page 168) 5.5.2 How to configure an OS server and its redundant OS partner server...
Page 153 Advantages of high availability components 5.5 Operator stations Procedure Note Steps 1 to 11 of this procedure have already been performed if an OS server was created in the project. 1. In the component view of SIMATIC Manager, select the project where you want to add the operator station.
Page 154 Advantages of high availability components 5.5 Operator stations 18.In the hardware catalog under "SIMATIC PC Station > HMI...", select the "WinCC application (stby)" and insert it in the configuration table by means of drag-and-drop. 19.In the hardware catalog under SIMATIC PC Station > CP Industrial Ethernet, select the communication processor and drag it to the PC station.
Page 155: How To Set The Project Path Of The Target Os And Standby Os
Advantages of high availability components 5.5 Operator stations 5.5.3 How to set the project path of the target OS and standby OS Introduction Note The procedure described in this section applies to the following servers: ● OS server ● Maintenance server The description for the OS server is used here.
Page 156: How To Set The Redundancy Connection For Between An Os And As
Advantages of high availability components 5.5 Operator stations 6. Click "OK". You have completed all settings for the master OS. 7. In the component view, select the OS that you want to use as the standby OS. 8. Select the menu command Edit > Object Properties. The "Properties - [name of the OS]"...
Page 157 Advantages of high availability components 5.5 Operator stations 5. Select the WinCC application of the OS server for which you want to configure a high availability network connection. The connection table is displayed in the lower window pane. 6. Select the first empty row in the connection table and select the menu command Insert > New Connection.
Page 158 Advantages of high availability components 5.5 Operator stations Result The following figure shows the redundant network connection of the two OS servers to the SIMATIC H station in NetPro: Additional information ● Section "Network components (Page 56)" ● Section "How to configure a high availability plant bus (Page 117)" STEP 7 ●...
Page 159: How To Configure Redundancy For Os Servers On The Engineering Station
Advantages of high availability components 5.5 Operator stations 5.5.5 How to configure redundancy for OS servers on the engineering station Introduction Carry out the following configuration tasks on the Engineering Station. The description for the OS server is used here. Validity The procedure described in this section applies to the following servers: ●...
Page 160 Advantages of high availability components 5.5 Operator stations 6. Select the following check boxes as required: – Synchronization of Tag Logging after the partner server comes back online – Synchronization of Alarm Logging after the partner server comes back online –...
Page 161: How To Set The Redundancy Connection For Os Servers
1. Select the PC station (workplace) in the tree view of Windows Explorer. 2. Select the "Simatic Shell" folder. If you are using the Windows 10 operating system, you can find the Siemens SIMATIC programs in the "Start" menu under All apps > Siemens Automation.
Page 162: How To Determine The S7 Programs You Want To Assign To A Given Os
Advantages of high availability components 5.5 Operator stations 3. Select the shortcut menu command Redundancy Settings..The "Redundancy Settings" dialog box opens. 4. Select the connection path through which the OS server pair is connected in the drop-down list. – For connection via RJ45 cable: In the "Network adapter"...
Page 163: How To Configure An Os Client
Advantages of high availability components 5.5 Operator stations 4. If the lower-level objects have another assignment but you prefer all lower-level objects to have the same assignment, select the "Pass on selected assignment to lower-level objects" check box. Note The "Pass on selected assignment to all lower-level objects" check box is active if the lower- level objects have another assignment or no assignment.
Page 164 Advantages of high availability components 5.5 Operator stations Requirements ● The PCS 7 project is open in SIMATIC Manager. ● Each PC has a standard network adapter for connection to the terminal bus. Procedure 1. In the component view of SIMATIC Manager, select the project in which you want to configure the OS clients.
Page 165: How To Configure An Os Client For Permanent Operability
Advantages of high availability components 5.5 Operator stations Result Your project should now correspond to the project shown in the following figure. You can change the names of the components as you wish. Using reference clients You can set up additional monitoring stations using reference clients. They use configured OS clients as a basis.
Page 166 Advantages of high availability components 5.5 Operator stations Requirements ● The redundant OS server pair has been configured in SIMATIC Manager. ● WinCC redundancy is configured for the OS server (master). ● The OS server (master) has been compiled such that the server data have been generated. ●...
Page 167 Advantages of high availability components 5.5 Operator stations Result The "Configure server data" dialog boxes on both OS clients appear as follows: ● Dialog box on OS client 1: ● Dialog box on OS Client 2: High Availability Process Control Systems (V9.0) Function Manual, 05/2017, A5E39221836-AA...
Page 168: How To Download A Simatic Pcs 7 Project To The Target System
Process Control System PCS 7; Operator Station ● Configuration manual 5.5.10 How to download a SIMATIC PCS 7 project to the target system Introduction You can download a PCS 7 project that you created in SIMATIC Manager along with the components of the project (AS, OS, BATCH server/client) to the various target systems in a single step with the menu command PLC >...
Page 169: Evaluating The Redundancy Tag "@Rm_Master" With Scripts
Advantages of high availability components 5.5 Operator stations Sequence when loading redundant OS servers with "Changes-only download" function The "Changes-only download" function of a redundant OS server is only available if both partner stations are in process mode (runtime). For safety reasons, downloading is not performed to a redundant OS server pair at the same time: ●...
Page 170: Simatic Batch Stations
Advantages of high availability components 5.6 SIMATIC BATCH stations SIMATIC BATCH stations 5.6.1 Overview of configuration steps Introduction The following sections describe how to configure redundancy for SIMATIC BATCH stations. Overview of configuration steps You configure the redundancy functionality of the BATCH stations by performing the following steps: Step What?
Page 171 Advantages of high availability components 5.6 SIMATIC BATCH stations 4. Enter the Windows name of the computer to be used as the BATCH server in the "Computer name" box. 5. In the component view, select the SIMATIC PC station and double-click the "Configuration" object in the detailed view.
Page 172: How To Configure A Batch Client
Advantages of high availability components 5.6 SIMATIC BATCH stations Result The following figure shows an example configuration of a SIMATIC PC station with BATCH application (stby): Additional information Process Control System PCS 7; Engineering System ; section "How ● Configuration manual to Expand a Project with Pre-Configured Stations Using the PCS 7 Wizards"...
Page 173 Advantages of high availability components 5.6 SIMATIC BATCH stations Procedure 1. In the component view of SIMATIC Manager, select the project into which you want to insert the BATCH client. 2. Select the menu command Insert > Station > SIMATIC PC Station. A new SIMATIC PC station is inserted in the selected project.
Page 174: How To Set The Redundancy Monitoring Of Batch Servers
Advantages of high availability components 5.6 SIMATIC BATCH stations Additional information Process Control System PCS 7; SIMATIC BATCH ● Manual 5.6.4 How to set the redundancy monitoring of BATCH servers Introduction A local Ethernet network needs to be built in PCS 7 for redundancy monitoring of redundant BATCH servers.
Page 175: How To Configure The Redundancy Connection For Batch Servers On The Engineering Station
Advantages of high availability components 5.6 SIMATIC BATCH stations 5.6.5 How to configure the redundancy connection for BATCH servers on the engineering station Introduction Additional tasks must be performed in the engineering and for setting up the PC stations for redundant BATCH servers: ●...
Page 176: How To Set The Redundancy Connection For Batch Servers
1. Select the PC station (workplace) in the tree view of Windows Explorer. 2. Select the "Simatic Shell" folder. If you are using the Windows 10 operating system, you can find the Siemens SIMATIC programs in the "Start" menu under All apps > Siemens Automation.
Page 177 Advantages of high availability components 5.6 SIMATIC BATCH stations Requirements ● The PCS 7 project is open in SIMATIC Manager in the component view. ● The SIMATIC BATCH configuration is completed. ● The batch plant is compiled. Download via SIMATIC BATCH 1.
Page 178: Simatic Route Control Stations
Advantages of high availability components 5.7 SIMATIC Route Control stations SIMATIC Route Control stations 5.7.1 Overview of configuration steps Introduction The following sections describe how to configure redundancy for SIMATIC Route Control stations. Overview of configuration steps You configure the redundancy functionality of the SIMATIC Route Control stations by performing the following steps: Step What?
Page 179 Advantages of high availability components 5.7 SIMATIC Route Control stations 3. Select the SIMATIC PC station, select the menu command Edit > Object Properties and enter the desired name (in the example, Route Control server). 4. Enter the Windows name of the computer to be used as the Route Control server in the "Computer name"...
Page 180: How To Configure A Route Control Client
Advantages of high availability components 5.7 SIMATIC Route Control stations Result The following figure shows an example configuration of a SIMATIC PC station with Route Control application (stby): Additional information Process Control System PCS 7; Engineering System ; section "How ●...
Page 181 Advantages of high availability components 5.7 SIMATIC Route Control stations Requirements ● The SIMATIC Route Control software package (Route Control Engineering) has been installed in addition to the PCS 7 software. ● The PCS 7 project is open in SIMATIC Manager. Procedure 1.
Page 182 Advantages of high availability components 5.7 SIMATIC Route Control stations Result The following figure shows the SIMATIC PC station with Route Control application client (RC application client) configured in HW Config: Shared client for OS and Route Control If a Route Control client and OS client are operated together on a SIMATIC PC station, configure both client applications in HW Config in one SIMATIC PC station.
Page 183: How To Configure A Redundant Connection Between A Route Control Server And As
Advantages of high availability components 5.7 SIMATIC Route Control stations 5.7.4 How to configure a redundant connection between a Route Control server and Introduction The redundant connections between the Route Control server and the AS are created in NetPro using SIMATIC Route Control wizards. Requirements ●...
Page 184 Advantages of high availability components 5.7 SIMATIC Route Control stations Result The following figure shows the redundant network connection to the automation system for both Route Control servers in NetPro. The example plant is configured with a redundant high availability plant bus. Each PC station and each CPU is connected to the plant bus with 2 network adapters: Additional information ●...
Page 185: How To Set The Redundancy Connection For Route Control Servers
1. Select the PC station (workplace) in the tree view of Windows Explorer. 2. Select the "Simatic Shell" folder. If you are using the Windows 10 operating system, you can find the Siemens SIMATIC programs in the "Start" menu under All apps > Siemens Automation.
Page 186: How To Set The Redundancy Of The Route Control Servers
Advantages of high availability components 5.7 SIMATIC Route Control stations 4. Select the connection path through which the Route Control server pair is connected in the drop-down list. – For connection via RJ45 cable: In the "Network adapter" drop-down list, select the network adapter to which you want to attach the network cable for the redundant connection between the two PC stations of a server pair.
Page 187: Archive Servers (Process Historian And Information Server)
Advantages of high availability components 5.8 Archive servers (Process Historian and Information Server) Archive servers (Process Historian and Information Server) 5.8.1 How to configure a Process Historian and its redundant partner server Introduction This section describes the individual steps involved in creating the Process Historian and its redundant partner server.
Page 188 Advantages of high availability components 5.8 Archive servers (Process Historian and Information Server) 10.Select the menu command Insert > Station > SIMATIC PC Station. A new SIMATIC PC station is inserted in the selected project. 11.Select the SIMATIC PC station, select the menu command Edit > Object Properties and enter the desired name (in the example, Archive 2).
Page 189: Replacing Components And Plant Changes
Replacing components and plant changes Failure and replacement of components 6.1.1 Replacement of SIMATIC components in runtime Continuous operation A crucial factor for continuous operation of high availability process control systems is the replacement of faulty or failed components in runtime. Replacement of defective components is only possible if high availability components are used.
Page 190 Replacing components and plant changes 6.1 Failure and replacement of components Additional information The following table shows where you can find the step-by-step instructions for replacing components: Automaton System S7-400H; High Availability You can find the procedure used to ..in the manual Systems in the section ...
Page 191: Replacement Of Bus Components In Runtime
Replacing components and plant changes 6.1 Failure and replacement of components 6.1.2 Replacement of bus components in runtime Introduction The information in this section relates to the following bus components ● Bus cable ● Bus links ● Switches, bridges Failure and replacement of bus components Components of a bus system (plant bus, terminal bus, fieldbus) can be replaced when there is no risk of accidentally affecting other components as a result of the replacement.
Page 192: Replacement Of Operator Stations In Runtime
Replacing components and plant changes 6.1 Failure and replacement of components Additional information The following table shows where you can find the step-by-step instructions for replacing components: You can find the procedure used to ..in the following documentation replace components ... SIMATIC;...
Page 193: Replacement Of Batch Stations In Runtime
Replacing components and plant changes 6.1 Failure and replacement of components Replacing an OS server Follow the steps below to replace an OS server: Step What? Switch OS clients over to the server that will be remaining in operation. Deactivate and replace the OS server, Check the network addresses and download the configuration data.
Page 194: Replacement Of Route Control Stations In Runtime
Replacing components and plant changes 6.1 Failure and replacement of components ● The name of the replaced PC is used for the new PC. ● The same IP address is used for the new PC. ● The MAC address is adapted in the project. Replacing the BATCH server Follow the steps below to replace a BATCH server: Step...
Page 195 Replacing components and plant changes 6.1 Failure and replacement of components Replacing the Route Control server. Follow the steps below to replace a Route Control server: Step What? Replacing the Route Control server. On the engineering station: Open Route Control Engineering and download the Route Control server Start Route Control (Route Control starts as standby server).
Page 196: Plant Changes In Runtime
Replacing components and plant changes 6.2 Plant changes in runtime Plant changes in runtime Plant changes in runtime In addition to the options for replacing failed components in runtime as described in the section titled "Failure and replacement of components during operation", the CPU (41x-xH) also supports a system modification without interrupting the running program.
Page 197 Replacing components and plant changes 6.2 Plant changes in runtime changes Possible modifications Adding or removing mod‐ ● DP slaves with redundant interface modules (for example, ET 200M, ules components in distrib‐ DP/PA Link, Y Link) uted I/O modules ● IO devices with redundant interface modules (for example: ET 200SP HA) ●...
Page 198 Replacing components and plant changes 6.2 Plant changes in runtime High Availability Process Control Systems (V9.0) Function Manual, 05/2017, A5E39221836-AA...
Page 199: Failure, Switchover And Reintegration Of High Availability Components
Failure, switchover and reintegration of high availability components 7.1.1 Failure of redundant interface modules Functionality Interface modules can be configured redundantly in the distributed I/O device (ET 200M, ET 200iSP, ET 200SP HA). The interface modules provide the interface to the automation system through the fieldbus system at the CPU.
Page 200 Failure, switchover and reintegration of high availability components 7.1 I/O Failure scenarios The following faults may occur in a module: ● Hardware or power failure in the module ● Detected signal interference (e.g. wire break, discrepancy) ● Fault on the assigned bus line to an interface module The driver blocks detect a disturbance: ●...
Page 201 Failure, switchover and reintegration of high availability components 7.1 I/O ● Following a prompt from the user program via an acknowledgement signal, for example, on an OS with a "Depassivation" button at the block ● After pulling/plugging a module ● Following a diagnostic interrupt (e.g. wire break, measured value) Additional information STEP 7 ●...
Page 202: Automation System
Failure, switchover and reintegration of high availability components 7.2 Automation system Automation system 7.2.1 Failure of the master CPU Functionality The initial situation is that the S7-400H is in "Redundant" system mode. The execution of the user program is synchronized on both CPUs of the H system and, for example, CPU0 is the master CPU and CPU1 is the backup CPU.
Page 203 Failure, switchover and reintegration of high availability components 7.2 Automation system Example: Failure of a fiber-optic cable If a fiber-optic cable fails, the REDF LED and the IFM1F or IFM2F LED light up on the two CPUs depending on the location of the fiber-optic cable failure. The H system goes to "Solo" system mode and the user program continues to be processed by the master CPU used up to this point (CPU0).
Page 204: Communication
Failure, switchover and reintegration of high availability components 7.3 Communication Communication 7.3.1 Failure of redundant bus components Functionality As soon as a fault occurs on a transmission path, the second transmission path takes over and forwards the signals. Failure scenarios The following problems can occur on a bus component: ●...
Page 205: Os Server
Failure, switchover and reintegration of high availability components 7.4 OS server OS server 7.4.1 Failure, switchover and restarting redundant OS servers Introduction This section describes the criteria by which the master/standby identification of an OS server changes. Examples are given to illustrate how the system reacts to failures. Note Information on updating operator stations with redundant OS servers in runtime can be found in "guidelines on updating a redundant OS in runtime (Page 217)".
Page 206 Failure, switchover and reintegration of high availability components 7.4 OS server Example configuration Startup of an OS server pair The following applies, in general: An OS server pair consists of the OS server and its OS partner server. The two PCs are configured with WinCC Redundancy in a redundant grouping. When the OS server pair starts up, WinCC Redundancy first checks which of the two OS servers is to be assigned the master identification.
Page 207 Failure, switchover and reintegration of high availability components 7.4 OS server WinCC project is deactivated A functionally equivalent WinCC project is activated on both OS servers. If the WinCC project is deactivated on OS Server 1 (master identification), WinCC Redundancy triggers the following reactions: ●...
Page 208 Failure, switchover and reintegration of high availability components 7.4 OS server The terminal bus as a whole and the communication between the AS and OS servers remains unaffected. Both OS servers are started and begin processing an activated WinCC project. If a disruption in the network connection to the OS partner server occurs in this situation, WinCC Redundancy reacts as follows: ●...
Page 209 Failure, switchover and reintegration of high availability components 7.4 OS server after process connection error" option must be selected in the "General" tab of the "Redundancy" dialog box for this. ● The OS partner server saves the date and the time of day marking the return of the OS server.
Page 210: Batch Server
Failure, switchover and reintegration of high availability components 7.5 BATCH server BATCH server 7.5.1 Failure of BATCH servers Functionality BATCH applications and any configured WinCC applications are active on BATCH servers. A BATCH client visualizes the batch data of the BATCH server to which it is connected. Failure of the master BATCH server If the master BATCH server fails, for example, due to an operating system failure or an application error, the standby BATCH server detects that the master is no longer available...
Page 211: Route Control Server
Failure, switchover and reintegration of high availability components 7.6 Route Control server Route Control server 7.6.1 Reaction of Route Control servers to failures Functionality Route Control applications and any configured WinCC applications are active on Route Control servers. A Route Control client visualizes the route list of the Route Control server to which it is interconnected.
Page 212 Failure, switchover and reintegration of high availability components 7.6 Route Control server Additional information Process Control System PCS 7; SIMATIC Route Control ● Manual High Availability Process Control Systems (V9.0) Function Manual, 05/2017, A5E39221836-AA...
Page 213: Os Clients
Failure, switchover and reintegration of high availability components 7.7 OS clients OS clients 7.7.1 Switchover characteristics OS clients with permanent operability Functionality If the connection to the configured OS server is interrupted, the process values on the OS clients are no longer updated. After successful switchover to the partner server, the process can be operated again on all OS clients.
Page 214 Failure, switchover and reintegration of high availability components 7.7 OS clients Once OS Server 1 becomes available again, OS Client 1 is switched over to the returning OS Server 1 because it is the configured preferred server. Permanent operability is restored after the switchover is complete. OS Client 1 is not available for the duration of the switchover to OS Server 1.
Page 215: Batch Clients
Failure, switchover and reintegration of high availability components 7.8 BATCH clients BATCH clients 7.8.1 Switchover characteristics of BATCH clients Functionality If the master BATCH server fails, the BATCH clients automatically switch to the redundant BATCH server. Reactions during switchover During a switchover, a message window is displayed on the screen of the BATCH client indicating the switchover.
Page 216: Route Control Clients
Failure, switchover and reintegration of high availability components 7.9 Route Control clients Route Control clients 7.9.1 Switchover characteristics of Route Control clients Functionality If the master Route Control server fails, the Route Control clients are automatically switched over to the redundant Route Control server. Reactions during switchover During a switchover, a message window is displayed on the screen of the Route Control client indicating a switchover.
Page 217: Guide To Updating A Redundant Os In Runtime
Failure, switchover and reintegration of high availability components 7.10 Guide to updating a redundant OS in runtime 7.10 Guide to updating a redundant OS in runtime 7.10.1 Introduction Introduction You can find a guide to updating a redundant OS in runtime below. This means that the operation of the PCS 7 system is not disrupted, the AS does not switch to STOP mode and the automation process can continue to be operated and monitored.
Page 218 Failure, switchover and reintegration of high availability components 7.10 Guide to updating a redundant OS in runtime Checking time synchronization To avoid any jumps in time (UTC/local standard time) when "updating redundant systems in runtime", check the time synchronization of the OS in the updated PCS 7 project on the ES: 1.
Page 219: Overview Of The Required Tasks
Failure, switchover and reintegration of high availability components 7.10 Guide to updating a redundant OS in runtime The procedure described below must be repeated for all client-server relationships in the system, as appropriate. ● If you have several redundant servers, first update only the clients interconnected with the standby server that has already been updated or that has been defined as the preferred server for these clients.
Page 220 Failure, switchover and reintegration of high availability components 7.10 Guide to updating a redundant OS in runtime Initial situation ● Server_1 is master server. ● Server_2 is standby server. ● Client_1 is connected to Server_1 because this server is configured as its preferred server. Client_1 represents all OS clients connected to Server_1.
Page 221 Failure, switchover and reintegration of high availability components 7.10 Guide to updating a redundant OS in runtime Overview of the required tasks NOTICE Interrupted redundancy Perform the steps described from Phase 1 to Phase 5 without extended interruptions because the redundancy is not available during the update. Upgrading Process Historian before the OS servers in runtime You must first upgrade the Process Historian server to Process Historian 2014 SP2 (PCS 7 V9.0) before you:...
Page 222 Failure, switchover and reintegration of high availability components 7.10 Guide to updating a redundant OS in runtime Phase Step Phase 1: 1. Server_2: Deactivate and exit WinCC Updating Serv‐ 2. Server_2: er_2 Back up the PCS 7 project Back up the operating system and the PCS 7 software installation 3.
Page 223 Failure, switchover and reintegration of high availability components 7.10 Guide to updating a redundant OS in runtime Phase Step Phase 4: 1. Client_1: Deactivate and exit WinCC Update the OS 2. Client_1: clients that are Back up the PCS 7 project interconnected Back up the operating system and the PCS 7 software installation 3.
Page 224: Phase 1: Updating Server_2
Failure, switchover and reintegration of high availability components 7.10 Guide to updating a redundant OS in runtime The updating of your redundant operator stations is complete. Note Encrypted communication If you have used encrypted communication, it is activated in migration mode for all PC stations in the system.
Page 225 Failure, switchover and reintegration of high availability components 7.10 Guide to updating a redundant OS in runtime Procedure - Phase 1 Note that you will need to work alternately on Server_1 and Server_2. Phase 1 / 1. Server_2: Deactivate and exit WinCC ●...
Page 226 Failure, switchover and reintegration of high availability components 7.10 Guide to updating a redundant OS in runtime Phase 1 / 7. Server_2: Check and save the "Redundancy" dialog box ● Open the "Redundancy" editor and check the settings in the dialog box. Click "OK" to exit the dialog box even if you have made no changes.
Page 227: Phase 2: Updating Os Clients Interconnected To Server_2
Failure, switchover and reintegration of high availability components 7.10 Guide to updating a redundant OS in runtime ● Server_2 can be either master or standby, depending on the configuration. ● The archives will be synchronized between Server_1 and Server_2. ● Client_1 is connected to Server_1. ●...
Page 228 Failure, switchover and reintegration of high availability components 7.10 Guide to updating a redundant OS in runtime Procedure - Phase 2 Phase 2 / Step 1. Client_2: Backup of the PCS 7 project, of the operating system and of the PCS 7 software installation ●...
Page 229: Phase 3: Download Of Connections, Gateways And Changes To The As
Failure, switchover and reintegration of high availability components 7.10 Guide to updating a redundant OS in runtime ● Updated Client_2 is connected to its preferred server Server_2. ● The system can be controlled from all OS clients. Note Maintenance client If Server_2 is the maintenance server (last OS server pair to be updated in the project), then the maintenance client (Client_2) can be started.
Page 230: Phase 4: Updating Os Clients Interconnected To Server_1
Failure, switchover and reintegration of high availability components 7.10 Guide to updating a redundant OS in runtime If there was no download to the AS during the project update, you now need to download to the AS. ● Select an AS in SIMATIC Manager. ●...
Page 231 Failure, switchover and reintegration of high availability components 7.10 Guide to updating a redundant OS in runtime Initial situation before phase 4 ● Server_1 is master server in the PCS 7 project. ● The updated Server_2 is standby server in the updated PCS 7 project. ●...
Page 232: Phase 5: Updating Server_1
Failure, switchover and reintegration of high availability components 7.10 Guide to updating a redundant OS in runtime Phase 4 / 6. Client_1: Select the operability of the clients Options: ● If all clients should remain operable, set the preferred server for Client_1 to Server_2. Client_1 is operable after you have completed Phase 4.
Page 233 Failure, switchover and reintegration of high availability components 7.10 Guide to updating a redundant OS in runtime Requirements ● The PCS 7 project you are updating has already been updated on the ES. ● Archive synchronization is complete. – Message: "REDRT: <name of the OS server> finished". –...
Page 234 Failure, switchover and reintegration of high availability components 7.10 Guide to updating a redundant OS in runtime Note that Windows administration of PCs should be performed by a Windows administrator. You can find a detailed description of the PCS 7 installation and the required PCS 7-specific Process Control System PCS 7;...
Page 235 Failure, switchover and reintegration of high availability components 7.10 Guide to updating a redundant OS in runtime Result after Phase 5 ● Updated Server_1 is standby server. ● Updated Server_2 is master server. ● Updated Client_1 is connected to its preferred server Server_1. ●...
Page 236: Guide To Updating A Redundant Batch Server In Runtime
Failure, switchover and reintegration of high availability components 7.11 Guide to updating a redundant BATCH server in runtime 7.11 Guide to updating a redundant BATCH server in runtime 7.11.1 Software update (migration) Information is available in the SIMATIC BATCH product documentation: SIMATIC Process Control System PCS 7;...
Page 237: Guide To Updating A Redundant Route Control Server In Runtime
Failure, switchover and reintegration of high availability components 7.12 Guide to updating a redundant Route Control server in runtime 7.12 Guide to updating a redundant Route Control server in runtime 7.12.1 Updating a redundant Route Control server in runtime For servers and single-station systems which are used for OS and Route Control, please observe the following information.
Page 238 Failure, switchover and reintegration of high availability components 7.12 Guide to updating a redundant Route Control server in runtime Default Master Default Standby Start RC server (or WinCC Runtime) – starts as New version – Runtime standby (you may have to update the project) The database is read.
Page 239: Redundancy Behavior Of The Pcs 7 Os, Simatic Batch And Simatic Route Control Servers
Failure, switchover and reintegration of high availability components 7.13 Redundancy behavior of the PCS 7 OS, SIMATIC BATCH and SIMATIC Route Control servers 7.13 Redundancy behavior of the PCS 7 OS, SIMATIC BATCH and SIMATIC Route Control servers Error-free System A redundant server pair is considered to be fault-free when the following conditions are met: ●...
Page 240 Failure, switchover and reintegration of high availability components 7.13 Redundancy behavior of the PCS 7 OS, SIMATIC BATCH and SIMATIC Route Control servers Order of the reactions Reactions Failure at the master server (Serv‐ Failure at the standby server (Serv‐ er_a) er_b) For OS server or com‐...
Page 241 Failure, switchover and reintegration of high availability components 7.13 Redundancy behavior of the PCS 7 OS, SIMATIC BATCH and SIMATIC Route Control servers Failure of the redundant connection Order of the reactions Reactions Master server Standby server Only for BATCH serv‐ The dialog "Restart request"...
Page 242 Failure, switchover and reintegration of high availability components 7.13 Redundancy behavior of the PCS 7 OS, SIMATIC BATCH and SIMATIC Route Control servers Automatic restart The following is required for the automatic restart: ● Automatic restart has to be activated for all applications that are take part in process mode. ●...
Page 243: Diagnostics
Diagnostics Process Control System PCS 7; Service Support and Information is available in the manual Diagnostics . High Availability Process Control Systems (V9.0) Function Manual, 05/2017, A5E39221836-AA...
Page 244: Advanced Self-Diagnostics Of Communication Connections
Diagnostics 8.1 Advanced self-diagnostics of communication connections Advanced self-diagnostics of communication connections PCS 7 features advanced self-diagnostics for redundant software systems (servers). If this diagnostics routine detects an internal fault, and in the event that the redundant partner server is fully functioning, all communication connections on the server affected by the fault are disconnected (terminal and plant bus).
Page 245: State Of Redundant Operator Stations In Diagnostic Pictures
Diagnostics 8.2 State of redundant operator stations in diagnostic pictures State of redundant operator stations in diagnostic pictures When using a Maintenance Station, the block icons show the redundancy state of the redundant OS servers in the diagnostic area. You can find information on the block icons Process Control System PCS 7;...
Page 246 Diagnostics 8.2 State of redundant operator stations in diagnostic pictures High Availability Process Control Systems (V9.0) Function Manual, 05/2017, A5E39221836-AA...
Page 247: Index
Index Client, 97, 163 Configuring, 163 Communication lines, 54 Communication modules, 50 Actuators, 48 Communication solutions, 54, 61, 63, 74, 76 Adding, 196 High availability terminal bus, 61 Components of the distributed I/O, 196 Redundant field bus, 76 Modules in central and expansion racks, 196 Redundant fieldbus, 78 Advantages of high availability components, 108 Redundant terminal bus, 63...
Page 248 Index Configuring redundant BATCH servers, 170 Fault, 205 Configuring the Batch client, 172 Network connection from the OS client to the OS Connecting server, 205 FF Bus Link, 87 Network connection to the AS, 205 Plant bus, 61 Network connection to the OS partner Terminal bus, 61 server, 205 Continuation, 18...
Page 249 Index How to configure the redundant PROFIBUS PA, 128 How to download a SIMATIC BATCH project to the target system, 176 How to set the redundancy of the BATCH Open servers, 175 Existing STEP 7 project, 143 How to set the redundancy of the Route Control Operating principle, 53, 94, 97, 136, 140 servers, 186 OS server, 94...
Page 250 Index Plant bus, redundant high availability, 71 Redundant I/O, 38, 40 Availability, 71 Redundant interface, 199 Components, 71 Hot restart, 199 Setup, 71, 74 Response to failure, 199 Plant changes in runtime, 196 Redundant OS servers, 94 Power supply Configuring, 152 S7-400H, 50 Creating, 152 Preface, 9...
Page 251 Setting the project path, 155 Redundant system, 217 SIMATIC PCS 7 redundancy concept, 19 Updating a redundant system in runtime, 217 SIMATIC PCS 7 overview of features, 24 Updating redundant systems, 219, 224, 229, 232 For commissioning, 27 Phase 2, 227...
Page 252 Index Validity, 9 WinCC client, 97 WinCC project, 205 Deactivating, 205 WinCC Redundancy, 159 Configuring, 159 WinCC Server, 94 Windows domain Synchronizing, 105 Y Link, 80, 145 Configuring, 145 Requirements, 145 Setup, 145 High Availability Process Control Systems (V9.0) Function Manual, 05/2017, A5E39221836-AA...

Siemens Simatic PCS 7 Function Manual

1 Security Information

2 Preface

3 Basics of High Availability

4 High Availability Solutions in PCS 7

5 Advantages of High Availability Components

6 Replacing Components and Plant Changes

7 Failure, Switchover and Reintegration of High Availability Components

8 Diagnostics

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Summary of Contents for Siemens Simatic PCS 7

Table of Contents