Page 2 S7-1500R/H redundant system Introduction Safety information New properties/functions SIMATIC Industrial cybersecurity System overview S7-1500 S7-1500R/H redundant system Application planning Installation Wiring System Manual Configuration Basics of program execution Protection Commissioning Display Maintenance Test and service functions Technical specifications Dimension drawings Accessories/spare parts Use over 2 000 m above sea level and extended...
Page 3 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 4: Table Of Contents
Table of contents Introduction ............................11 S7-1500R/H Documentation Guide ..................13 1.1.1 Information classes S7-1500R/H ..................13 1.1.2 SIMATIC Technical Documentation ..................14 Safety information ..........................17 Warnings in this document ....................17 Safety-related symbols ....................... 17 2.2.1 Devices without explosion protection ................. 17 2.2.2 Devices with explosion protection ..................
Page 5 Access control ........................43 4.7.4 Handling of sensitive data ....................43 4.7.5 Regular firmware updates ....................44 4.7.6 Notifications about security vulnerabilities (Siemens Security Advisories) ......44 4.7.7 Data backup ........................45 4.7.8 Security checks ........................45 4.7.9 Secure decommissioning ....................45 4.7.9.1...
Page 6 Table of contents 5.2.2 Structure of the S7-1500H redundant system ..............86 5.2.3 Configuration of a fail-safe system with SIMATIC S7-1500HF ..........87 5.2.4 Configuration with communications processors ..............89 5.2.5 Configuration with PROFIBUS DP connection ..............92 5.2.6 Components ........................93 S7-1500 R/H-CPUs ......................
Page 7 Table of contents 6.4.1 Introduction ........................172 6.4.2 Failure of the primary CPU ....................173 6.4.3 Failure of the backup CPU ....................175 6.4.4 Failure of the PROFINET cable in the PROFINET ring ............177 6.4.5 Failure of the primary CPU with communications processor ..........179 6.4.6 Specific redundancy scenarios for S7-1500R ..............
Page 8 Table of contents Installing a system power supply ..................250 Installing a load current supply ..................252 Installing R/H-CPUs ......................253 Installing a communications processor ................255 Wiring ..............................258 Rules and regulations for operation .................. 258 Operation on grounded infeed ..................260 Electrical configuration ....................
Page 9 Table of contents Basics of program execution ......................317 10.1 Programming the S7-1500R/H ..................317 10.2 Restrictions ........................321 10.3 Events and OBs ........................ 323 10.4 Special instructions for S7-1500R/H redundant systems ............ 329 10.4.1 Disabling/enabling SYNCUP with the RH_CTRL instruction ..........329 10.4.2 Determining the primary CPU with "RH_GetPrimaryID"...
Page 10 Table of contents 12.5.2 Manual memory reset ...................... 419 12.6 Backing up and restoring the CPU configuration ............... 421 12.7 Time synchronization ....................... 425 12.7.1 Example: Configuring the NTP server ................426 12.8 Identification and maintenance data ................427 12.8.1 Reading out and entering I&M data ..................
Page 11 Table of contents Dimension drawings .......................... 494 Accessories/spare parts ........................497 Use over 2 000 m above sea level and extended temperature range ..........499 Ambient temperature and installation altitude ..............499 CPUs ..........................499 Restrictions ........................501 Glossary ............................. 503 Index ..............................
Page 12: Introduction
When using HF-CPUs in safety mode, note the description of the F-system SIMATIC Safety Programming and Operating Manual SIMATIC Safety - Configuring and Programming (https://support.industry.siemens.com/cs/ww/en/view/54110126). Conventions STEP 7: In this documentation, "STEP 7" is used as a synonym for all versions of the configuration and programming software "STEP 7 (TIA Portal)".
Page 13 Industry Mall The Industry Mall is the catalog and order system of Siemens AG for automation and drive solutions on the basis of Totally Integrated Automation (TIA) and Totally Integrated Power (TIP).
Page 14: S7-1500R/H Documentation Guide
The documentation for the redundant S7-1500R/H system is arranged into three areas. This arrangement enables you to access the specific content you require. You can download the documentation free of charge from the Internet (https://support.industry.siemens.com/cs/ww/en/view/109742691). Basic information The System Manual and Getting Started describe in detail the configuration, installation, wiring and commissioning of the redundant S7-1500R/H system.
Page 15: Simatic Technical Documentation
S7-1500R/H system gathered together in one file. You can find the Manual Collection on the Internet. (https://support.industry.siemens.com/cs/ww/en/view/86140384) SIMATIC S7-1500 comparison list for programming languages The comparison list contains an overview of which instructions and functions you can use for which controller families.
Page 16 Industry Online Support International (https://support.industry.siemens.com/cs/ww/en/view/109742705) Watch this short video to find out where you can find the overview directly in Siemens Indus- try Online Support and how to use Siemens Industry Online Support on your mobile device: Quick introduction to the technical documentation of automation products per video (https://support.industry.siemens.com/cs/us/en/view/109780491)
Page 17 Manuals, characteristics, operating manuals, certificates • Product master data You can find "mySupport" on the Internet. (https://support.industry.siemens.com/My/ww/en) Application examples The application examples support you with various tools and examples for solving your automation tasks. Solutions are shown in interplay with multiple components in the system - separated from the focus on individual products.
Page 18: Safety Information
Safety information Warnings in this document You can find explanations of the warnings used in this document in the "Legal information" section. Safety-related symbols 2.2.1 Devices without explosion protection The following table contains an explanation of the symbols located in your SIMATIC device, its packaging or the accompanying documentation.
Page 19: Devices With Explosion Protection
Safety information 2.2 Safety-related symbols Symbol Meaning Be aware that the device is only approved for the industrial field and only for in- door use. Note that an enclosure is required for installing the device. Enclosures are consid- ered: • Standing control cabinet •...
Page 20: Intended Use
• Do not remove or paste over safety instructions on the device. • Do not tape over, cover or install ventilation slots. • Only use original spare parts and accessories. • Only use the software provided by Siemens. S7-1500R/H redundant system System Manual, 01/2024, A5E41814787-AF...
Page 21: Target Group And Personnel Qualifications
Safety information 2.5 Target group and personnel qualifications Target group and personnel qualifications All persons working with this device require the following knowledge: • Contents of this document as well as contents of the enclosed documents. • Handling the device (after instruction) •...
Page 22: Open Source Software
Germany Keyword: Open Source Request (please specify Product name and version, if applicable) SIEMENS may charge a handling fee of up to 5 EUR to fulfil the request. Warranty regarding further use of the Open Source Software SIEMENS' warranty obligations are set forth in your agreement with SIEMENS. If you modify the product or the OSS components or use them in a way other than that specified by SIEMENS, the warranty will be voided and no technical support will be provided.
Page 23: Safe Working
Safety information 2.8 Safe working Safe working 2.8.1 Working on electrical parts • Only work on electrical parts if you are a qualified specialist (see section Target group and personnel qualification (Page 20)). • Always observe the country-specific safety rules. •...
Page 24: Conductive Pollution
Safety information 2.9 Residual risks Installation and connection • Only work on electrical parts if you are a qualified specialist (see section Target group and personnel qualification (Page 20)). • Adhere to the protective measures for safe working on electrical parts (see section Working on electrical parts (Page 22)) •...
Page 25: Overheating
Safety information 2.9 Residual risks 2.9.4 Overheating Smoke development and fire due to overheating of the device and lines lead to burns and life-threatening injuries (death). To avoid overheating: • Ensure the correct installation position. • Ensure sufficient air supply (for example, do not mask or cover ventilation slots, maintain mounting clearances).
Page 26: Behavior In Case Of Emergency
Safety information 2.10 Behavior in case of emergency 2.10 Behavior in case of emergency • Force EMERGENCY OFF. When the safe operating state has been restored: • Unlock the EMERGENCY OFF mechanism. • The person responsible for the system ensures that the system starts up in a controlled and defined manner.
Page 27: New Properties/Functions
New properties/functions What's new in the redundant S7-1500R/H system System Manual, edition 01/2024 compared to edition 01/2023 What's What are the customer benefits? Where can I find the infor- new? mation? New con- "Industrial cybersecu- Due to the digitalization and increasing networking Section Industrial cybersecurity tents rity"...
Page 28 V3.1. You can find more information on the active back- plane bus (e.g. installation, configuring, technical specifications) in the Active backplane bus (https://support.industry.siemens.com/cs/de/de/view /109778694/en) Equipment Manual. The active backplane bus can be ordered as an ac- cessory/spare part.
Page 29 New properties/functions What's What are the customer benefits? Where can I find the infor- new? mation? User files As of firmware version V3.1, the S7-1500R/H re- STEP 7 online help dundant system supports user files. User files are user-specific files that are stored on the SIMATIC Memory Card and in the "UserFiles"...
Page 30 New properties/functions What's What are the customer benefits? Where can I find the infor- new? mation? Local user manage- As of TIA Portal version V19 and FW version V3.1, Section Local user management ment R/H-CPUs have improved management of users, (Page 342) roles, and CPU function rights (User Management &...
Page 31 New properties/functions What's new in the System Manual S7-1500R/H redundant system, edition 11/2022 compared to edition 05/2021 What's What are the customer benefits? Where can I find the infor- new? mation? New con- Support As of FW version V3.0, the S7-1500H redundant As of the System overview tents PROFINET system...
Page 32 New properties/functions What's new in the S7-1500R/H redundant system System Manual, edition 05/2021 compared to edition 11/2019 What's new? What are the customer benefits? Where can I find the infor- mation? New con- CPU 1518HF-4 PN The CPU 1518HF-4 PN expands the R/H-CPU As of the System overview tents portfolio with an HF-CPU.
Page 33 New properties/functions What's new? What are the customer benefits? Where can I find the infor- mation? OB 72 (CPU redundancy As of FW version V2.9, the operating system Programming the S7-1500R/H error) calls OB 72 on further events: (Page 317) section •...
Page 34 New properties/functions What's new in the S7-1500R/H redundant system System Manual, edition 11/2019 compared to edition 10/2018 What's new? What are the customer benefits? Where can I find the infor- mation? New con- Switched S1 device The "Switched S1 device" function of the CPU Redundancy (Page 97) section tents enables operation of standard IO devices in...
Page 35 New properties/functions What's new? What are the customer benefits? Where can I find the infor- mation? Changed Download modified user You can download a modified user program Sec. Downloading projects to contents program in RUN-Redundant into the R/H CPUs in the RUN-Redundant sys- the CPUs (Page 372) system state tem state.
Page 36: Industrial Cybersecurity
Siemens' products and solutions undergo continuous development to make them more secure. Siemens strongly recommends that product updates are applied as soon as they are available and that the latest product versions are used. Use of product versions that are no longer supported, and failure to apply the latest updates may increase customers' exposure to cyber threats.
Page 37: Security Update Notification
Introduction (Page 11) section. Set up notification of security updates To receive notifications about security updates, proceed as follows: 1. Register with mySiePortal (https://sieportal.siemens.com/en-ww/home). 2. Enter the keyword "Security" in the search engine. 3. Choose the "Search in Knowledge base" option.
Page 38: Objectives Of Industrial Cybersecurity
Integrated security concept and security strategies 4.4.1 Comprehensive security concept "Defense in Depth" With Defense in Depth, Siemens provides a multi-layer security concept that offers industrial plants comprehensive and far-reaching protection in accordance with the recommendations of the IEC 62443 international standard.
Page 39: Security Management
Siemens will provide you with information and support. Subscribe to the RSS feed (https://www.siemens.com/cert) for vulnerabilities. Register with mySiePortal (https://sieportal.siemens.com/en-ww/home) and create filters to be notified when important information is published.
Page 40 These include, for example, security updates throughout the product life cycle, including guidelines for secure disposal of the product. Siemens plans and announces the provision of security updates, total discontinuation of products and cancellation of product support. Employee awareness Regular training in cybersecurity and continuous testing of training success are essential so that cybersecurity measures are internalized in processes and work instructions.
Page 41: Operational Application Environment And Security Assumptions
Industrial cybersecurity 4.5 Operational application environment and security assumptions Consideration of the risks posed by cyber attacks in the Threat and Risk Assessment (TRA) Make an inventory of all software, hardware, and infrastructure devices, in order to identify risks to the location or organization. Incident response procedures must be incorporated into all IT and manufacturing processes.
Page 42: Requirements For The Operational Application Environment And Security Assumptions
4.5 Operational application environment and security assumptions 4.5.2 Requirements for the operational application environment and security assumptions Siemens recommends the following security measures: • Conducting a threat and risk assessment (as part of security management) • Network security concepts – Network segmentation –...
Page 43: Security Properties Of The Devices
Security properties of the devices The security properties of the individual devices are listed in the Equipment Manuals. Secure operation of the system This section describes measures recommended by Siemens to protect your system from manipulation and unauthorized access. 4.7.1...
Page 44: Secure Configuration
• Consider the default states of ports and services in your security concept. You can find an overview of all ports and services used in the Communication Function Manual (https://support.industry.siemens.com/cs/ww/en/view/59192925). 4.7.3 Access control In addition to physical protection, also establish logical safeguards to control access to your system: •...
Page 45: Regular Firmware Updates
Siemens ProductCERT If Siemens identifies or fixes security gaps (Vulnerabilities) in the products, this will be published in the Security Advisories. You can find the documents for SIMATIC on the following Siemens AG Web page: Siemens ProductCERT and Siemens CERT (https://new.siemens.com/global/en/products/services/cert.html?s=SIMATIC#SecurityPublicati ons) Enter "SIMATIC"...
Page 46: Data Backup
– Measures – Availability – Etc. • Report possible vulnerabilities yourself at (https://new.siemens.com/global/en/products/services/cert.html#ContactInformation) Set up an RSS feed to receive notifications about security-related topics. 4.7.7 Data backup Secure your configuration and parameter settings so that you can quickly restore this data if needed.
Page 47: Securely Removing Data
Industrial cybersecurity 4.7 Secure operation of the system 4.7.9.1 Securely removing data Before disposing of components of the S7-1500R/H redundant system, you must securely delete all data from the storage media of these components. NOTICE Data misuse resulting from non-secure deletion of data Incomplete or non-secure deletion of data from data memories can result in data misuse by third parties.
Page 48: Recycling And Disposal
Industrial cybersecurity 4.7 Secure operation of the system 2. Restore the factory settings of the CPU. We recommend resetting the CPU in STEP 7. When you reset a CPU to factory settings, select the options shown in the figure before the reset. Figure 4-1 Resetting the CPU to factory settings Note...
Page 49: Secure Operation Of The Engineering Software
For more information on secure operation of the engineering software, refer to the TIA Portal online help. Secure operation of CPUs This section describes measures recommended by Siemens to protect your device from manipulation and unauthorized access. 4.9.1 Secure configuration Information about ports, services, and default states can be found in the Communication Function Manual (https://support.industry.siemens.com/cs/ww/en/view/59192925) and the...
Page 50: Assigning Secure Passwords
• Establish guidelines for assigning passwords and intervals for password changes. • Settings for checking guidelines during password assignment or changes can be configured in the TIA Portal. For more information, please refer to the Communication Function Manual (https://support.industry.siemens.com/cs/ww/en/view/59192925). S7-1500R/H redundant system System Manual, 01/2024, A5E41814787-AF...
Page 51: Setting Protection Levels
STEP 7 online help (TIA Portal). 4.9.2.5 Certificate management You can find all relevant information about "Certificate management" in the Communication Function Manual (https://support.industry.siemens.com/cs/ww/en/view/59192925). 4.9.3 Protection functions Integrated protection functions of the CPU protect against unauthorized access. You can find an overview of the protection functions supported by your CPU in the respective Equipment Manual.
Page 52: Secure Communication/Opc Ua
Additional protection is provided by the protection functions of the secure communication and OPC UA server protocols. Information about the Secure Communication and OPC UA server protocols can be found in the Communication Function Manual (https://support.industry.siemens.com/cs/ww/en/view/59192925). 4.9.6 Sensitive data Security-relevant and sensitive data can be protected through appropriate measures such as passwords and protection functions.
Page 53: Additional Protective Measures For Network Security
Using a Web server When using Web servers, traditional firewalls are no longer sufficient to protect modern networks. Information about potential risks when using Web servers can be found in the Web server Function Manual (https://support.industry.siemens.com/cs/ww/en/view/59193560). 4.9.10 Recording Security events Syslog storage Syslog stands for "System Logging Protocol", a standard for storing, transmitting and...
Page 54: Syslog Messages
If you want to access the local cache with the syslog messages, use the Web API of the web server (API method Syslog.Browse). You can find information on the procedure in the "Web server (https://support.industry.siemens.com/cs/us/en/view/59193560)" Function Manual. You have the option of transferring the events collected by the CPU to a syslog server in the network.
Page 55 Industrial cybersecurity 4.9 Secure operation of CPUs Forwarding to a syslog server From STEP 7 V19 and a CPU as of FW version V3.1, it is possible to transfer syslog messages to a server, e.g. SINEC INS. The syslog messages are transferred to the syslog server via the syslog protocol.
Page 56 More information on network management with SINEC INS is available in the "SIMATIC NET: Network management SINEC INS V1.0 SP2" (https://support.industry.siemens.com/cs/us/en/view/109781023) manual. You can find information on the structure of syslog messages in the Structure of the Syslog messages (Page 59) section.
Page 57: Transfer The Syslog Messages To A Syslog Server
Industrial cybersecurity 4.9 Secure operation of CPUs 4.9.11.1 Transfer the syslog messages to a syslog server Requirements If you want to transfer the syslog messages of a CPU to a syslog server, the following requirements must be met: • STEP 7 as of version V19 •...
Page 58 Industrial cybersecurity 4.9 Secure operation of CPUs Result: You have configured the transfer of syslog messages to a syslog server. Figure 4-3 Transfer of syslog messages to a syslog server configured Selecting the client certificate STEP 7 provides the required client certificate for a CPU for the TLS transport protocol. If the certificate is managed within the CPU, you can either choose an existing certificate or create a new certificate.
Page 59 Industrial cybersecurity 4.9 Secure operation of CPUs Selecting the server authentication After selecting the TLS transport protocol, the configured syslog server must authenticate itself. This ensures that the CPU only connects to a trusted server. If you want to waive server authentication, activate the automatic acceptance of server certificates during runtime.
Page 60: Structure Of The Syslog Messages
Industrial cybersecurity 4.9 Secure operation of CPUs 4.9.11.2 Structure of the Syslog messages A CPU collects syslog messages in a local cache. These syslog messages are structured according to the syslog protocol (RFC 5424) and consist of the following elements: •...
Page 61 Industrial cybersecurity 4.9 Secure operation of CPUs The following table describes the parameters in the prescribed order. Parameter Description PRI encodes the priority of the syslog message, divided into Severity (severity of the message) and Facility (origin of the message). The PRI value is formed as follows: •...
Page 62 Industrial cybersecurity 4.9 Secure operation of CPUs Parameter Description PROCID The process ID serves to clearly identify the individual processes, for example during analysis and troubleshooting. "-" is output if information is missing. MSGID ID to identify the message. "-" is output if information is missing. Structure of the STRUCTURED-DATA element STRUCTURED-DATA provides information in an interpretable and decomposable data format.
Page 63: Secure Operation Of I/O Modules
Industrial cybersecurity 4.10 Secure operation of I/O modules 4.10 Secure operation of I/O modules Device-specific security information and instructions for I/O modules can be found in the respective Equipment Manual. 4.11 Secure operation of the power supply modules Device-specific security information and instructions for the power supply modules can be found in the respective Equipment Manual.
Page 64: System Overview
System overview What is the S7-1500R/H redundant system? S7-1500R/H redundant system For the S7-1500R/H redundant system, the CPUs are duplicated, in other words redundant. The two CPUs process the same project data and the same user program in parallel. The two CPUs are synchronized over two redundancy connections.
Page 65: Areas Of Application
System overview 5.1 What is the S7-1500R/H redundant system? 5.1.1 Areas of application Objective The S7-1500R/H redundant system offers a high degree of reliability and system availability. A redundant configuration of the most important automation components reduces the probability of production downtimes and the consequences of component errors. The higher the risks and costs of a production downtime, the more worthwhile the use of a redundant system.
Page 66 The fans continue to operate. You can find a detailed description of tunnel automation with S7-1500H in Getting started (https://support.industry.siemens.com/cs/ww/en/view/109757712) Redundant system S7- 1500R/H. S7-1500R/H redundant system...
Page 67 System overview 5.1 What is the S7-1500R/H redundant system? Example 2: Avoiding high system restart costs as a result of data loss Automation task A logistics company needs a matching automation solution for controlling the storage and retrieval unit in a high-bay warehouse. Feature The failure of a controller would have serious consequences.
Page 68 System overview 5.1 What is the S7-1500R/H redundant system? Example 3: Avoiding equipment and material damage Automation task A steel works needs a matching automation solution to control a blast furnace for the steel production. Feature Failures, especially in the process industry, can result in damages to the system, workpieces or material.
Page 69: Operating Principle Of The S7-1500R/H Redundant System
System overview 5.1 What is the S7-1500R/H redundant system? Reference You can find an example for SIMATIC Safety Integrated with the 1518HF-4 PN CPUs in the section Safety (Page 106). 5.1.2 Operating principle of the S7-1500R/H redundant system Introduction S7-1500R/H redundant systems tolerate the failure of one of the two CPUs. The S7-1500R and S7-1500H systems differ in structure, configuration limits and performance.
Page 70 System overview 5.1 What is the S7-1500R/H redundant system? The following picture shows a configuration of the S7-1500R in the PROFINET ring. ① R-CPU (CPU 1515R-2 PN) ② PROFINET cable (redundancy connections, PROFINET ring) ③ IO device ④ Switch Figure 5-4 S7-1500R configuration in PROFINET ring Principle of operation One of the two CPUs in the redundant system takes on the role of primary CPU.
Page 71 System overview 5.1 What is the S7-1500R/H redundant system? S7-1500H configuration and operating principle The S7-1500H redundant system consists of: • Two CPUs S7-1500H ① • PROFINET ring with Media Redundancy Protocol ② (only when configured as ring topology) • Two redundancy connections ③ •...
Page 72 System overview 5.1 What is the S7-1500R/H redundant system? The following figure shows a configuration of the S7-1500H in a PROFINET ring. ① H-CPU ② PROFINET cable (PROFINET ring) ③ Redundancy connections (fiber-optic cables) ④ IO device ⑤ Switch Figure 5-5 S7-1500H configuration with IO devices in the PROFINET ring S7-1500R/H redundant system System Manual, 01/2024, A5E41814787-AF...
Page 73 System overview 5.1 What is the S7-1500R/H redundant system? The following figure shows a configuration of the S7-1500H with R1 devices in two separate PROFINET rings. ① H-CPU ② Redundancy connections (fiber-optic cables) ③ PROFINET cable (PROFINET ring 1) ④ PROFINET cable (PROFINET ring 2) ⑤...
Page 74 System overview 5.1 What is the S7-1500R/H redundant system? The figure below shows a configuration of the S7-1500H with S2 devices in a line topology. ① H-CPU ② Redundancy connections (fiber-optic cables) ③ IO device (with system redundancy S2) ④ Switch ⑤...
Page 75 System overview 5.1 What is the S7-1500R/H redundant system? The figure below shows a configuration of the S7-1500H with R1 devices in a line topology ① H-CPU ② Redundancy connections (fiber-optic cables) ③ PROFINET cable (line topology 1) ④ PROFINET cable (line topology 2) ⑤...
Page 76 System overview 5.1 What is the S7-1500R/H redundant system? Principle of operation Unlike in S7-1500R, the PROFINET ring (PROFINET network) and redundancy connections in S7-1500H are separate. The two redundancy connections are fiber-optic cables that connect the CPUs directly over synchronization modules. One of the two CPUs in the redundant system takes on the role of primary CPU.
Page 77 System overview 5.1 What is the S7-1500R/H redundant system? Differences between S7-1500R and S7-1500H Table 5- 1 S7-1500R and S7-1500H system differences S7-1500R S7-1500H CPU 1513R-1 PN CPU 1517H-3 PN CPU 1515R-2 PN CPU 1518HF-4 PN Performance • Transfer rate of 100 Mbps (for synchronization •...
Page 78 System overview 5.1 What is the S7-1500R/H redundant system? S7-1500R S7-1500H Configuration PROFINET ring with S2 devices, switched S1 de- • PROFINET networks with S2 devices, switched versions vices S1 devices • PROFINET networks with R1 devices • PROFINET networks with R1 devices, S2 devic- es, switched S1 devices in a combined topolo- •...
Page 79 System overview 5.1 What is the S7-1500R/H redundant system? S7-1500 S7-1500R/H OPC UA client ✓ ✓ Motion Control ✓ ✓ PID control ✓ ✓ ✓ ✓ Security Integrated ✓ ✓ ✓ ✓ Protection function: Copy ✓ ✓ protection ✓ ✓ Safety mode ✓...
Page 80: Plant Components And Automation Levels
System overview 5.1 What is the S7-1500R/H redundant system? 5.1.3 Plant components and automation levels Plant components and automation levels The schematic diagram below shows the key components of the redundant system from the management level to the control level and the field level. Figure 5-10 Possible configuration at the management, control and field level using the example of S7-1500R From the management level, the master PC accesses the various devices at the control and...
Page 81: Scalability
System overview 5.1 What is the S7-1500R/H redundant system? 5.1.4 Scalability Introduction Redundant systems are more cost-intensive to use than non-redundant systems: • There are two CPUs. • The physical connections (PROFINET ring and redundancy connections) can be required over large distances. The S7-1500R/H redundant system is scalable.
Page 82 System overview 5.1 What is the S7-1500R/H redundant system? The redundancy connections in S7-1500R are the PROFINET ring with MRP. The CPUs are synchronized over the PROFINET ring. ① System power/load current supply (optional) ② CPU S7-1515R-2 PN ③ PROFINET cable (redundancy connections, PROFINET ring) ④...
Page 83 System overview 5.1 What is the S7-1500R/H redundant system? S7-1500H You connect the CPUs to the Industrial Ethernet over a PROFINET interface or using an additional switch. S7-1500H supports the following number of PROFINET devices (switches, S7-1500H CPUs, S7-1500 CPUs (V2.5 or later), HMI devices, and IO devices such as ET 200MP and ET 200SP): max.
Page 84 System overview 5.1 What is the S7-1500R/H redundant system? The figure below shows a configuration example of the S7-1500H in the PROFINET ring. ① Load current supply (optional) ② CPU 1517H-3 PN ③ PROFINET cable (PROFINET ring) ④ Redundancy connections (2 duplex fiber-optic cables) ⑤...
Page 85: Overview Of Features
System overview 5.1 What is the S7-1500R/H redundant system? 5.1.5 Overview of features The following figure summarizes the main features of the redundant S7-1500R/H system. Figure 5-13 S7-1500R/H features S7-1500R/H redundant system System Manual, 01/2024, A5E41814787-AF...
Page 86: Configuration
System overview 5.2 Configuration Configuration 5.2.1 Structure of the S7-1500R redundant system Configuration The S7-1500R redundant system comprises the following components: • 2 R-CPUs • 2 SIMATIC Memory Cards • PROFINET cable (redundancy connections, PROFINET ring) • If applicable, IO devices •...
Page 87: Structure Of The S7-1500H Redundant System
System overview 5.2 Configuration 5.2.2 Structure of the S7-1500H redundant system Configuration The S7-1500H redundant system comprises the following components: • 2 H-CPUs • 2 SIMATIC Memory Cards • 4 synchronization modules (two synchronization modules in each H-CPU) • 2 redundancy connections (two duplex fiber-optic cables) •...
Page 88: Configuration Of A Fail-Safe System With Simatic S7-1500Hf
System overview 5.2 Configuration 5.2.3 Configuration of a fail-safe system with SIMATIC S7-1500HF Configuration Fail-safe automation systems (F-systems) are used in systems with higher safety requirements. F-systems control processes and ensure that they are in a safe state immediately after shutdown. In other words, F-systems control processes in which an immediate shutdown does not endanger persons or the environment.
Page 89 System overview 5.2 Configuration Configuration example ① CPU 1518HF-4 PN ② Redundancy connections (fiber-optic cables) ③ ET 200SP IO device ④ PROFINET cable (PROFINET ring) ⑤ ET 200MP IO device with fail-safe and non-fail-safe modules ⑥ ET 200SP IO device with fail-safe and non-fail-safe modules Figure 5-16 Example configuration of redundant system with two CPUs 1518HF-4 PN in PROFINET ring...
Page 90: Configuration With Communications Processors
System overview 5.2 Configuration More information You can find more information on the configuration variants in the Specific configuration variants for S7-1500H (Page 150) section. For more information on the fail-safe modules for ET 200SP / ET 200SP HA / ET 200MP, refer to the associated system and device manuals.
Page 91 System overview 5.2 Configuration The redundant design of the CPs (per R/H CPU) increases the availability of the redundant system for the communication tasks: • S7-1500R: max. 2 CPs per R-CPU • S7-1500H: max. 6 CPs per H-CPU On the rail you can mount the CPs via U-connector or via the active backplane bus: •...
Page 92 System overview 5.2 Configuration H-CPU configuration with CP 1543-1 and active backplane bus on an Industrial Ethernet ① Engineering station ② CPU 1 ③ CPU 2 ④ CP 1543-1 ⑤ PROFINET cable (PROFINET ring) ⑥ Two fiber-optic cables (redundancy connections) Figure 5-18 S7-1500H configuration with CP 1543-1 and active backplane bus Configuration with CP 1543-1 at a redundant Industrial Ethernet...
Page 93: Configuration With Profibus Dp Connection
System overview 5.2 Configuration 5.2.5 Configuration with PROFIBUS DP connection Configuration with IE/PB LINK HA The IE/PB LINK HA connects PROFINET IO and PROFIBUS DP as a gateway. This enables the IE/PB LINK HA to access all DP devices connected to the lower-level PROFIBUS network. In the redundant S7-1500R/H system, the IE/PB LINK HA is integrated into the PROFINET network as an S2 device.
Page 94: Components
(from firmware version V3.0). You can find more information on the active backplane bus (e.g. selection, installing, configuring, technical specifications) in the Active backplane bus (https://support.industry.siemens.com/cs/de/de/view/1097786 94/en) Equipment Manual. The active backplane bus can be ordered as an accessory/spare part (Page 497).
Page 95 The following lengths of fiber-optic cables can be ordered: • • • 10 m • Up to 40 km (you can find more information on longer fiber-optic cables in the Industry Mall (https://mall.industry.siemens.com)). S7-1500R/H redundant system System Manual, 01/2024, A5E41814787-AF...
Page 96: S7-1500 R/H-Cpus
System overview 5.3 S7-1500 R/H-CPUs Component Function Diagram 4-pin connection plug The 4-pin connection plug provides the supply voltage. for CPU supply voltage System power supply The system power supply is a diagnostics-capable power sup- (PS) ply module that is connected to the backplane bus. A system power supply is required when the power fed from the CPU into the backplane bus is not sufficient to supply the connected modules with power.
Page 97: Overview Of The Cpu Technical Specifications
CPU and takes control of the process as the primary CPU at the point of interruption. The switchover time can lengthen the cycle time. More information The full technical specifications can be found in the manuals for the CPUs and on the Internet (https://mall.industry.siemens.com). S7-1500R/H redundant system System Manual, 01/2024, A5E41814787-AF...
Page 98: Redundancy
System overview 5.3 S7-1500 R/H-CPUs 5.3.2 Redundancy Introduction In the following section you will get an overview how to achieve a higher network and plant availability in S7-1500R/H redundant systems. The Media Redundancy Protocol (MRP) enables the connection of IO devices based on ring topologies.
Page 99 System overview 5.3 S7-1500 R/H-CPUs Media redundancy Media redundancy is a function for ensuring network and plant availability. If the transmission link in the ring is interrupted at any point, e.g., due to interruption of the PROFINET line or failure of a station, the redundancy manager immediately activates the alternative communication path.
Page 100 System overview 5.3 S7-1500 R/H-CPUs Conditions: • H-Sync forwarding is not relevant for redundant S7-1500H systems. With the redundant S7-1500H system, the H-Sync frames are transmitted exclusively via the fiber-optic cables. • When you use PROFINET devices with more than two ports (e.g. switch) in the PROFINET ring of an R-system, then H-Sync Forwarding is mandatory for these devices.
Page 101 System overview 5.3 S7-1500 R/H-CPUs If the cyclic program exceeds the cycle monitoring time, the time error OB (OB 80) may be started. Redundancy is lost if the time error OB (OB 80) is not present or the double cycle monitoring time was exceeded with OB 80.
Page 102 System overview 5.3 S7-1500 R/H-CPUs System redundancy R1 As of FW version V3.0, the S7-1500H redundant system supports IO devices with system redundancy R1. System redundancy R1 is the connection of an IO device via two interface modules, each of which supports an AR to an IO controller in the redundant system.
Page 103 System overview 5.3 S7-1500 R/H-CPUs Switched S1 device As of FW version V2.8, the S7-1500R/H redundant system supports the "Switched S1 device" function. The "Switched S1 device" function of the CPU enables operation of standard IO devices on the S7-1500R/H redundant system. Standard IO devices are always assigned to both CPUs of the S7-1500R/H redundant system.
Page 104 • HMI device as I-device ("Direct key" function) – The GSD files for SIMATIC Comfort Panel and SIMATIC Mobile Panel can be found in this application example (https://support.industry.siemens.com/cs/ww/en/view/73502293). Assign the device configured via GSD file to the S7-1500R/H redundant system.
Page 105 System overview 5.3 S7-1500 R/H-CPUs The S7-1500R/H CPUs support MRP interconnection as of firmware version V2.9. Observe the maximum number of devices that can be connected for R/H-CPUs. Additional information can be found in the manuals for the R/H CPUs. 4 devices for MRP interconnection connections 2 MRP interconnection connections provide redundant coupling between 2 MRP rings.
Page 106 System overview 5.3 S7-1500 R/H-CPUs Example The following figure shows the redundant coupling based on the example of S7-1500R in 2 rings: ① Primary MIC ② Media Redundancy Interconnection Manager (MIM) ③ Secondary Link ④ Secondary Coupled MIC ⑤ Primary Coupled MIC ⑥...
Page 107: Safety
For more information on media redundancy, system redundancy S2, system redundancy R1 and switched S1 device can be found in the PROFINET Function Manual (https://support.industry.siemens.com/cs/ww/en/view/49948856). More information on MRP interconnection can be found in the PROFINET Function Manual and in the configuration manual SCALANCE XM-400/XR-500 Web Based Management (WBM).
Page 108 System overview 5.3 S7-1500 R/H-CPUs Advantages and customer benefits SIMATIC Safety Integrated offers the following advantages: • Engineering with SIMATIC STEP 7 Safety Advanced in STEP 7, same engineering and operating concept for standard and fail-safe automation tasks. • Use of instructions approved by the German Technical Inspectorate from the system library Safety in the safety program, for example for protective door, emergency stop, monitored feedback loop circuit and user acknowledgment;...
Page 109 System overview 5.3 S7-1500 R/H-CPUs Feature You need the 1518HF-4 PN CPUs. With the integrated F-functionality, you evaluate the emergency stop buttons via PROFIsafe. Solution If one of the CPUs fails (loss of redundancy), the S7-1500HF redundant system switches from the RUN-Redundant system state to the RUN-Solo system state.
Page 110: Security
• Integration in integrated system diagnostics More information You can find a detailed description of F-CPU configuration and programming in the SIMATIC Safety – Configuring and Programming (https://support.industry.siemens.com/cs/ww/en/view/54110126) programming and operating manual. 5.3.4 Security Security means the protection of technical systems against sabotage, espionage and human error.
Page 111 5.3 S7-1500 R/H-CPUs You can find more information about the security mechanisms of the SIMATIC automation systems in the Security with SIMATIC S7 controllers (https://support.industry.siemens.com/cs/ww/en/view/77431846) document and in the Communication (https://support.industry.siemens.com/cs/ww/en/view/59192925) Function Manual. Integrity protection of the SIMATIC Memory Card, CPU as of FW version V3.1 For CPUs as of FW version V3.1, the integrity protection of the SIMATIC Memory Card is...
Page 112: Diagnostics
You can find more information on the protection functions described in the Protection (Page 341) section and in the STEP 7 online help. Siemens products and solutions are only one element of a comprehensive industrial security concept. Please note the additional information on Industrial Security (http://www.siemens.com/industrialsecurity).
Page 113 System overview 5.3 S7-1500 R/H-CPUs Displaying faults in an IO device The various components of the S7-1500R/H redundant system are connected over PROFINET/Industrial Ethernet (IE). The devices detect faults in their modules (for example IO device ET 200SP) and send diagnostics data to the assigned CPU. The CPU analyzes this diagnostic information and notifies the connected display media.
Page 114: Trace
System overview 5.3 S7-1500 R/H-CPUs More information You will find more information on diagnostics in the Diagnostics (https://support.industry.siemens.com/cs/ww/en/view/59192926) function manual. 5.3.6 Trace The trace functionality facilitates troubleshooting and optimization for the user program. Trace records device tags and evaluates the recordings. This allows you to analyze defective signal responses.
Page 115 System overview 5.3 S7-1500 R/H-CPUs The signal table ③ lists the signals of the selected measurement and provides setting options for specific properties. ① Trace recordings for S7-1500R/H in the project tree ② Trend diagram ③ Signal table Figure 5-25 Trace measurement for S7-1500R/H Advantages and customer benefits The trace function offers the following advantages:...
Page 116: Pid Control
More information You can find more information on the trace function in the Test functions (Page 471) section and in the Using the trace and logic analyzer (http://support.automation.siemens.com/WW/view/en/64897128) Function Manual. 5.3.7 PID control PID controllers are built into all R/H-CPUs as standard. PID controllers measure the actual value of a physical variable, for example, temperature or pressure, and compare the actual value with the setpoint.
Page 117 System overview 5.3 S7-1500 R/H-CPUs Example closed loop control of a valve in a mixer tap The automation task is to control the valve of a mixer tap according to a desired temperature setting. You configure the opening and closing of the valve in the PID_3Step technology object.
Page 118 • Automatic calculation of the control parameters and tuning during operation. • No additional hardware and software required. More information You can find more information on PID controllers PID Control Function Manual (https://support.industry.siemens.com/cs/ww/en/view/108210036). S7-1500R/H redundant system System Manual, 01/2024, A5E41814787-AF...
Page 119: Communication
System overview 5.4 Communication Communication 5.4.1 System and device IP addresses Device IP addresses For the interfaces of the CPUs and the IO devices to be accessible, the interfaces require IP addresses that are unique within the network (device IP addresses). MAC addresses The CPUs have a unique MAC address for each interface and its ports.
Page 120 System overview 5.4 Communication Advantages of system IP addresses over device IP addresses • Targeted communication of the communication partner with the primary CPU. • The S7-1500R/H redundant system can continue to communicate over a system IP address even if the primary CPU fails. Configuration example The figure below shows a configuration in which the S7-1500R/H redundant system communicates with other devices over the system IP address X2.
Page 121 MAC address in the Configuring R-CPUs with communications processor CP 1543-1 (Page 304) section. More information You can find more information on the system IP address in the S7-1500R/H redundant system in the Communication (https://support.industry.siemens.com/cs/ww/en/view/59192925) Function Manual. S7-1500R/H redundant system System Manual, 01/2024, A5E41814787-AF...
Page 122: Integrated Interfaces For Communication
Communication mainly over system IP address: If the communication partner uses a device IP address and the CPU with this device IP address fails, communication between the communication partner and S7-1500R/H also fails. More information For more information on communication options, please refer to the Communication (https://support.industry.siemens.com/cs/ww/en/view/59192925) Function Manual. S7-1500R/H redundant system System Manual, 01/2024, A5E41814787-AF...
Page 123: Hmi Devices
More information You can find more information on using HMI devices in the Using HMI devices (Page 228) section and in the Communication Function Manual (https://support.industry.siemens.com/cs/ww/en/view/59192925). You can find an overview of all available HMI devices in the Industry Mall (https://mall.industry.siemens.com/mall/en/WW/Catalog/Products/9109999?tree=CatalogTree) 5.4.4...
Page 124: Ie/Pb Link Ha
System overview 5.4 Communication 5.4.5 IE/PB LINK HA The IE/PB LINK HA provides a connection of the redundant S7-1500 R/H system to PROFIBUS The table below gives an overview of the main properties and functions. Short designation IE/PB LINK HA Article number 6GK1411-5BB00 (as of FW version V4.1) Equipment Manual...
Page 125: Power Supply
System overview 5.5 Power supply Power supply The R/H CPUs of the redundant system have an integrated system power supply. You can supplement the integrated system power supply with a system power or load current supply. System power supply (PS) The system power supply only provides internally required system voltage and supplies the communications processors.
Page 126 SITOP modular) can be used: • With redundant installation (https://support.industry.siemens.com/cs/ww/en/view/109768676) of the 24 V power supply as protection against failure of a power supply unit • With buffering of the 24 V power supply (e.g. with DC UPS) as protection against power failure •...
Page 127: Software
System overview 5.6 Software Software 5.6.1 TIA Portal The SIMATIC controllers are integrated into the Totally Integrated Automation Portal. Engineering with TIA Portal offers: • Configuration and programming • Shared data management • A uniform operating concept for control, visualization and drives The TIA Portal simplifies integrated engineering in all configuration phases of a plant.
Page 128: Sinetplan
5.6.3 PRONETA SIEMENS PRONETA (PROFINET network analysis) allows you to analyze the plant network during commissioning. PRONETA features two core functions: • The topology overview independently scans PROFINET and all connected components. • The IO check is a rapid test of the wiring and the module configuration of a plant.
Page 129 System overview 5.6 Software • Downloading from CPU, downloading to CPU or deleting recipe data from a CPU • Downloading from CPU or deleting data log data from a CPU • Backup/restore of data from/to a backup file for CPUs and HMI devices •...
Page 130: Application Planning
Application planning Requirements Introduction Please note the following requirements for use of the S7-1500R/H redundant system. Hardware requirements Table 6- 1 Hardware requirements Property Requirement S7-1500R/H CPUs • 2 identical R-CPUs or H-CPUs in the redundant system • Identical article numbers and firmware versions for the two CPUs •...
Page 131 I/O modules for the IM 155-6 PN R1 interface module can be found in the Product information for the documentation of the ET 200SP (https://support.industry.siemens.com/cs/en/en/view/73021864) distributed I/O sys- tem. The R1 capability is also specified in the technical specifications of the I/O mod- ules.
Page 132 Application planning 6.1 Requirements Property Requirement System power supply (PS) System power supply PS for the R/H CPUs The use of the PS is optional. Suitable system power supplies: • PS 25W 24V DC • PS 60W 24/48/60V DC • PS 60 W 120/230V AC/DC Load current supply PM Load current supply PM for the R/H CPUs...
Page 133: Restrictions Compared To The S7-1500 Automation System
PS 60W 24/48/60V DC • PS 60 W 120/230V AC/DC Cycle and response times Longer cycle and response times: You can find more information in the Cycle and response times (https://support.industry.siemens.com/cs/ww/en/view/59193558) Function Manual. S7-1500R/H redundant system System Manual, 01/2024, A5E41814787-AF...
Page 134 • Data access only via server interfaces. The standard SIMATIC server interface is not supported. For more information, please refer to the S7-1500/ET 200MP, S7- 1500R/H (https://support.industry.siemens.com/cs/ww/en/view/68052815) Product Information and the Communication (https://support.industry.siemens.com/cs/ww/en/view/59192925) Function Manual. OPC UA client Not supported...
Page 135: Configuration Versions
Web server S7-1500R/H supports only the Web API of the Web server. An over- view of which mechanisms and methods support the R/H CPUs can be found in the Web server (https://support.industry.siemens.com/cs/de/en/view/59193560) Function Manual. Configuration versions Introduction You can configure different versions of the S7-1500R/H redundant system.
Page 136: S7-1500R/H Configuration With Io Devices In The Profinet Ring
Application planning 6.3 Configuration versions 6.3.1 S7-1500R/H configuration with IO devices in the PROFINET ring Introduction The following sections set out configurations of the S7-1500R/H redundant system with IO devices in the PROFINET ring. Advantages/benefits • IO devices with S2 system redundancy enable uninterrupted process data exchange with the S7-1500R/H redundant system in the event of a CPU failure.
Page 137: Configuration Of S7-1500R/H With Switches And Additional Line Topology
Application planning 6.3 Configuration versions S7-1500H configuration ① CPU 1 ② CPU 2 ③ Two fiber-optic cables (redundancy connections) ④ IO device ET 200SP (with system redundancy S2) ⑤ IO device ET 200MP (with system redundancy S2) ⑥ Standard IO device ET 200SP ⑦...
Page 138 Application planning 6.3 Configuration versions S7-1500R configuration ① CPU 1 ② CPU 2 ③ PROFINET cable (redundancy connections, PROFINET ring) ④ IO device ET 200SP (with system redundancy S2) ⑤ IO device ET 200MP (with system redundancy S2) ⑥ Switch ⑦...
Page 139 Application planning 6.3 Configuration versions S7-1500H configuration ① CPU 1 ② CPU 2 ③ Two fiber-optic cables (redundancy connections) ④ IO device ET 200MP (with system redundancy S2) ⑤ IO device ET 200SP (with system redundancy S2) ⑥ Standard IO device ET 200MP ⑦...
Page 140: Configuration With Communications Processors On Industrial Ethernet
Application planning 6.3 Configuration versions 6.3.3 Configuration with communications processors on Industrial Ethernet Introduction The following configuration shows the redundant S7-1500R/H system with communications processors on Industrial Ethernet. Advantages/benefits You can extend the redundant S7-1500R/H system by an interface for Industrial Ethernet via CP 1543-1 communications processors.
Page 141 Application planning 6.3 Configuration versions S7-1500R configuration ① Engineering station ② Switch ③ CPU 1 ④ CPU 2 ⑤ CP 1543-1 ⑥ PROFINET cable (redundancy connections, PROFINET ring) ⑦ IO device ET 200SP ⑧ IO device ET 200MP Figure 6-6 S7-1500R configuration with CP 1543-1 S7-1500R/H redundant system System Manual, 01/2024, A5E41814787-AF...
Page 142: Configuration With Communications Processors On Redundant Industrial Ethernet
Application planning 6.3 Configuration versions S7-1500H configuration ① Engineering station ② Switch ③ CPU 1 ④ CPU 2 ⑤ CP 1543-1 ⑥ Two fiber-optic cables (redundancy connections) ⑦ IO device ET 200SP ⑧ IO device ET 200MP Figure 6-7 S7-1500H configuration with CP 1543-1 6.3.4 Configuration with communications processors on redundant Industrial Ethernet...
Page 143 Application planning 6.3 Configuration versions Advantages/benefits You can connect the S7-1500R/H to parallel, separate Industrial Ethernet structures (LAN A, LAN B) via CP 1543-1 communications processors. The two separate networks increase the availability of the communication connections. S7-1500R configuration ① Engineering station at LAN A ②...
Page 144 Application planning 6.3 Configuration versions S7-1500H configuration ① Engineering station to LAN A ② Engineering station to LAN B ③ Switch ④ CPU 1 ⑤ CPU 2 ⑥ CP 1543-1 with connection to LAN A ⑦ CP 1543-1 with connection to LAN B ⑧...
Page 145: Configuration With Communications Processors And System Power/Load Current Supply
Application planning 6.3 Configuration versions 6.3.5 Configuration with communications processors and system power/load current supply Introduction The following configuration shows the redundant S7-1500R/H system with communications processors and a system power/load current supply. Benefits/advantages The redundant system can be extended with up to 2 (R-system)/6 (H-system) CP 1543-1 communications processors per CPU.
Page 146 Application planning 6.3 Configuration versions S7-1500R configuration with CPs and system power/load current supply ① Engineering station ② Switch ③ System power/load current supply PS/PM ④ CPU 1 ⑤ CPU 2 ⑥ CP 1543-1 ⑦ PROFINET cable (redundancy connections, PROFINET ring) ⑧...
Page 147 Application planning 6.3 Configuration versions S7-1500H configuration with active backplane bus, CPs, and redundant system power supplies ① Engineering station ② Switch ③ CPU 1 ④ CPU 2 ⑤ Redundant system power supplies (e.g. PS 60 W 120/230 V AC/DC, each connected to supply voltage 230 V AC L1/N and L2/N) ⑥...
Page 148: Configuration With Ie/Pb Link Ha
Application planning 6.3 Configuration versions Note Diagnostic message in case of failure of both system power supplies on the identical slots of the respective H-CPUs A diagnostic message is issued in case of failure of both system power supplies on the identical slots of the H-CPUs.
Page 149 Application planning 6.3 Configuration versions S7-1500R configuration with IE/PB LINK HA ① CPU 1 ② CPU 2 ③ PROFINET cable (redundancy connections, PROFINET ring) ④ IO device ET 200SP (with system redundancy S2) ⑤ IO device ET 200MP (with system redundancy S2) ⑥...
Page 150 Application planning 6.3 Configuration versions S7-1500H configuration with IE/PB LINK HA ① CPU 1 ② CPU 2 ③ Two fiber-optic cables (redundancy connections) ④ IO device ET 200MP (with system redundancy S2) ⑤ IO device ET 200SP (with system redundancy S2) ⑥...
Page 151: Specific Configuration Variants For S7-1500H
Application planning 6.3 Configuration versions Note Configuration variant PROFINET rings with R1 devices and Y-switch with IE/PB LINK HA (as S2 device) You can also operate the IE/PB LINK HA in a configuration with R1 devices. The IE/PB LINK HA is then connected to the PROFINET rings via a Y-switch (and other switches).
Page 152 Application planning 6.3 Configuration versions S7-1500H configuration with S2 devices and switch in a line topology ① CPU 1 ② CPU 2 ③ Two fiber-optic cables (redundancy connections) ④ IO device ET 200MP (with system redundancy S2) ⑤ IO device ET 200SP (with system redundancy S2) ⑥...
Page 153: Configuration Of Profinet Rings With R1 Devices
Application planning 6.3 Configuration versions Note Migration of a PROFINET ring to a line topology If you want to migrate a configuration scenario with PROFINET ring into a line topology, note the following changes: • Remove a ring segment (PROFINET cable) at X1 interfaces of the H-CPUs, e.g., directly connected PROFINET cable at X1 P2 interfaces.
Page 154 Application planning 6.3 Configuration versions Configuration of S7-1500H with R1 devices in the PROFINET ring ① CPU 1 ② CPU 2 ③ Two fiber-optic cables (redundancy connections) ④ PROFINET cable (PROFINET ring 1) ⑤ PROFINET cable (PROFINET ring 2) ⑥ IO device ET 200SP HA (with system redundancy R1) ⑦...
Page 155 Application planning 6.3 Configuration versions Not recommended configuration variants The following configuration variants are not recommended: Configuration variant 1 The H-CPUs are each configured in a separate PROFINET ring 1 and 2. Some or all R1 devices are connected to these PROFINET rings via 2 switches. The R1 devices themselves are connected via a line topology.
Page 156 Application planning 6.3 Configuration versions Configuration variant 2 The H-CPUs are each configured in a separate PROFINET ring 1 and 2. Switches are used to extend PROFINET rings 1 and 2 by PROFINET rings 3 and 4. The extension of PROFINET rings 3 and 4 is connected without MRP interconnection.
Page 157: Configuration Of Profinet Rings With R1 Devices And Switches With Mrp Interconnection
Application planning 6.3 Configuration versions 6.3.7.3 Configuration of PROFINET rings with R1 devices and switches with MRP interconnection Introduction The section below shows you the configuration of the S7-1500H redundant system with R1 devices and switches with MRP interconnection in a PROFINET ring. Advantages/benefits •...
Page 158 Application planning 6.3 Configuration versions S7-1500H configuration with R1 devices and switches with MRP interconnection in the PROFINET ring ① CPU 1 ② CPU 2 ③ Two fiber-optic cables (redundancy connections) ④ PROFINET cable (PROFINET ring 1) ⑤ PROFINET cable (PROFINET ring 2) ⑥...
Page 159: Configuration Of Profinet Rings With R1 Devices And Y-Switch With S2 Devices
S2/S1 devices at the Y-switches and increases the availability of the network. For more information on DNA redundancy, refer to the SCALANCE XB-200/XC- 200/XF-200BA/XP-200/XR-300WG Web Based Management (https://support.industry.siemens.com/cs/ww/en/view/109780061) configuration manual. Note Special features of the parameter assignment of the switches and Y-switches For more information, refer to the section Configuring other configuration variants (Page 302).
Page 160 Application planning 6.3 Configuration versions S7-1500H configuration with R1 devices and Y-switch in the PROFINET ring ① CPU 1 ② CPU 2 ③ Two fiber-optic cables (redundancy connections) ④ PROFINET cable (PROFINET ring 1) ⑤ PROFINET cable (PROFINET ring 2) ⑥...
Page 161 Application planning 6.3 Configuration versions Configuration of S7-1500H with R1 devices and Y-switches with DNA redundancy in PROFINET ring ① CPU 1 ② CPU 2 ③ Two fiber-optic cables (redundancy connections) ④ PROFINET cable (PROFINET ring 1) ⑤ PROFINET cable (PROFINET ring 2) ⑥...
Page 162: Configuration Of Line Topology With R1 Devices
Application planning 6.3 Configuration versions 6.3.7.5 Configuration of line topology with R1 devices Introduction The section below shows you the configuration of the S7-1500H redundant system with R1 devices in a line topology. Advantages/benefits • Less wiring effort required for a line topology compared to ring topologies. Only one PROFINET line is connected to each of the PROFINET interfaces X1 of the H-CPUs.
Page 163 Application planning 6.3 Configuration versions S7-1500H configuration with R1 devices in a line topology ① CPU 1 ② CPU 2 ③ Two fiber-optic cables (redundancy connections) ④ PROFINET cable (line topology 1) ⑤ PROFINET cable (line topology 2) ⑥ IO device ET 200SP HA (with system redundancy R1) ⑦...
Page 164: Line Topology Configuration With R1 Devices And Switches
Application planning 6.3 Configuration versions Not recommended configuration variant The following configuration variants are not recommended: • Integration into the line topology by looping through the R1 device via port 2 of the two interface modules. • Direct connection of ports 1 of the two interface modules on the R1 device. Result: No redundancy of the network available.
Page 165 Application planning 6.3 Configuration versions Configuration of S7-1500H with R1 devices and switches in a line topology ① CPU 1 ② CPU 2 ③ Two fiber-optic cables (redundancy connections) ④ PROFINET cable (line topology) ⑤ Switch ⑥ PROFINET cable (PROFINET ring 1) ⑦...
Page 166: Line Topology Configuration With R1 Devices And Y-Switch With S2 Devices
S2/S1 devices at the Y-switches and increases the availability of the network. For more information on DNA redundancy, refer to the SCALANCE XB-200/XC- 200/XF-200BA/XP-200/XR-300WG Web Based Management (https://support.industry.siemens.com/cs/ww/en/view/109780061) configuration manual. Note Special features of the parameter assignment of the switches and Y-switches For more information, refer to the section Configuring other configuration variants (Page 302).
Page 167 Application planning 6.3 Configuration versions Configuration of S7-1500H with R1 devices and Y-switch in a line topology ① CPU 1 ② CPU 2 ③ Two fiber-optic cables (redundancy connections) ④ PROFINET cable (line topology 1) ⑤ PROFINET cable (line topology 2) ⑥...
Page 168 Application planning 6.3 Configuration versions Configuration of S7-1500H with R1 devices and Y-switches with DNA redundancy in a line topology ① CPU 1 ② CPU 2 ③ Two fiber-optic cables (redundancy connections) ④ PROFINET cable (line topology 1) ⑤ PROFINET cable (line topology 2) ⑥...
Page 169: Configuration Of Combined Topology With S2 Devices
Application planning 6.3 Configuration versions 6.3.7.8 Configuration of combined topology with S2 devices Introduction The section below shows you the configuration of the S7-1500H redundant system with S2 devices in a combined topology. Advantages/benefits • Within the combined topology, any topology is allowed: –...
Page 170: Configuration Of Combined Topology With R1 Devices
Application planning 6.3 Configuration versions S7-1500H configuration with S2 devices and backbone ring ① CPU 1 ② CPU 2 ③ Two fiber-optic cables (redundancy connections) ④ Switch ⑤ Backbone ring (existing combined topology) ⑥ IO device ET 200SP (with system redundancy S2) Figure 6-27 S7-1500H configuration with S2 devices and backbone ring 6.3.7.9...
Page 171 Application planning 6.3 Configuration versions S7-1500H configuration with R1 devices in a combined topology ① CPU 1 ② CPU 2 ③ Two fiber-optic cables (redundancy connections) ④ Combined topology 1 ⑤ Combined topology 2 ⑥ IO device ET 200SP HA (with system redundancy R1) ⑦...
Page 172: Configuration Without Additional Devices
Application planning 6.3 Configuration versions Configuration of S7-1500H with R1 devices and backbone rings ① CPU 1 ② CPU 2 ③ Two fiber-optic cables (redundancy connections) ④ Switch ⑤ Backbone ring 1 (existing combined topology) ⑥ Backbone ring 2 (existing combined topology) ⑦...
Page 173: Redundancy Scenarios
Application planning 6.4 Redundancy scenarios Advantages/benefits The configuration is suitable for all applications that do not require any further devices at the PROFINET interface X1 P1R/X1 P2R of the H-CPUs. Example: In a plant, the S7-1500H redundant system communicates with third-party devices via Modbus/TCP.
Page 174: Failure Of The Primary Cpu
Application planning 6.4 Redundancy scenarios 6.4.2 Failure of the primary CPU Introduction The following redundancy scenario describes the effects of a defective primary CPU using the example of a PROFINET ring. Redundancy scenario ① Primary CPU → failed ② Backup CPU → becomes new primary CPU ③...
Page 175 Application planning 6.4 Redundancy scenarios Sequence of events 1. The primary CPU of the redundant system fails in the RUN-Redundant system state. 2. The redundant system switches to the backup CPU. The backup CPU becomes the new primary CPU. The redundant system switches to the RUN-Solo system state. You can find additional information on the RUN-Solo system state in the section Operating and system states (Page 380).
Page 176: Failure Of The Backup Cpu
Application planning 6.4 Redundancy scenarios 6.4.3 Failure of the backup CPU Introduction The following redundancy scenario describes the effects of a defective backup CPU using the example of a PROFINET ring. Redundancy scenario ① Primary CPU ② Backup CPU → failed ③...
Page 177 Application planning 6.4 Redundancy scenarios Diagnostics System state, operating states and error displays after primary-backup switchover: • Redundant system → RUN-Solo system state • Primary CPU → RUN operating state – MAINT LED → yellow light: The R/H system is not in the RUN-Redundant system state. No partner CPU has been found in the redundant system.
Page 178: Failure Of The Profinet Cable In The Profinet Ring
Application planning 6.4 Redundancy scenarios 6.4.4 Failure of the PROFINET cable in the PROFINET ring Introduction The following redundancy scenario describes the effects of a defective PROFINET cable in the PROFINET ring. Redundancy scenario ① Primary CPU ② Backup CPU ③...
Page 179 Application planning 6.4 Redundancy scenarios Sequence of events 1. A defective or disconnected PROFINET cable interrupts the PROFINET ring of the redundant system. 2. The redundant system remains in the RUN-Redundant system state: The primary and backup CPUs remain in the RUN-Redundant operating state. 3.
Page 180: Failure Of The Primary Cpu With Communications Processor
Application planning 6.4 Redundancy scenarios 6.4.5 Failure of the primary CPU with communications processor Introduction The following redundancy scenario describes the effects of a defective primary CPU with communications processor CP 1543-1. Redundancy scenario ① Primary CPU → failed ② Backup CPU ③...
Page 181: Specific Redundancy Scenarios For S7-1500R
Application planning 6.4 Redundancy scenarios Diagnostics System state, operating states, and error displays after failure of the primary CPU: • Redundant system → RUN-Solo system state • Primary CPU → failed • Backup CPU → RUN operating state – MAINT LED → lights up yellow: The R/H system is not in the RUN-Redundant system state.
Page 182: Specific Redundancy Scenarios For S7-1500H
Application planning 6.4 Redundancy scenarios Sequence 1. The CP 1543-1 at the primary CPU fails. 2. The primary CPU switches to the STOP operating state. 3. The redundant system switches to the backup CPU. The backup CPU becomes the new primary CPU.
Page 183 Application planning 6.4 Redundancy scenarios Redundancy scenario ① Primary CPU ② Backup CPU ③ One fiber-optic cable (redundancy connection) → interrupted ④ IO device ET 200SP ⑤ IO device ET 200MP ⑥ PROFINET cable (PROFINET ring) Figure 6-37 Failure of a redundancy connection Sequence of events 1.
Page 184: Failure Of Both Redundancy Connections In S7-1500H > 55 Ms Apart
Application planning 6.4 Redundancy scenarios Diagnostics System state, operating states and error displays after the failure of a redundancy connection: • Redundant system → RUN-Redundant system state • Primary CPU/Backup CPU → RUN-Redundant operating state – MAINT LED → yellow light: There is only one redundancy connection remaining in the H system.
Page 185 Application planning 6.4 Redundancy scenarios Redundancy scenario ① Primary CPU (S7-1500H) ② Backup CPU (S7-1500H) ③ Two fiber-optic cables (redundancy connections) → interrupted ④ IO device ET 200MP ⑤ IO device ET 200SP ⑥ PROFINET cable (PROFINET ring) Figure 6-38 Failure of both redundancy connections (>...
Page 186: Failure Of Both Redundancy Connections And The Profinet Cable In The Profinet Ring
Application planning 6.4 Redundancy scenarios Diagnostics System state, operating states and error displays after the failure of both redundancy connections: • Redundant system → RUN-Solo system state • Primary CPU → RUN operating state – MAINT LED → yellow light: The H-system is not in the RUN-Redundant system state. No partner CPU has been found in the H-system.
Page 187 Application planning 6.4 Redundancy scenarios Redundancy scenario ① Primary CPU ② Backup CPU ③ Two fiber-optic cables (redundancy connections) → interrupted ④ IO device ET 200SP ⑤ IO device ET 200MP ⑥ PROFINET cable (PROFINET ring) ⑦ PROFINET cable (PROFINET ring) → interrupted Figure 6-39 Failure of both redundancy connections and a PROFINET cable in the PROFINET ring Sequence of events...
Page 188 Application planning 6.4 Redundancy scenarios Diagnostics System state, operating states and error displays after the failure of the redundancy connections and PROFINET cable: • Redundant system → RUN-Solo system state • Primary CPU → RUN operating state – MAINT LED → yellow light: The H-system is not in the RUN-Redundant system state. No partner CPU has been found in the H-system.
Page 189: Failure Of The Two Profinet Cables In The Profinet Ring On The Backup Cpu
Application planning 6.4 Redundancy scenarios 6.4.7.4 Failure of the two PROFINET cables in the PROFINET ring on the backup CPU Introduction The following redundancy scenario describes the effects of a defect of both PROFINET cables in the PROFINET ring at the backup CPU. Redundancy scenario ①...
Page 190 Application planning 6.4 Redundancy scenarios Diagnostics System state, operating states and error displays after the failure of both PROFINET cables on the backup CPU: • Redundant system → RUN-Redundant system state • Primary CPU/Backup CPU → RUN-Redundant operating state – MAINT LED → yellow light: The PROFINET ring is open. No backup AR. Note To get detailed diagnostics information, evaluate the diagnostics buffer.
Page 191: Failure Of An Interface Module In An R1 Device In A Profinet Ring
Application planning 6.4 Redundancy scenarios 6.4.7.5 Failure of an interface module in an R1 device in a PROFINET ring Introduction The following redundancy scenario describes the effects of a failure of an interface module in an R1 device in the PROFINET ring. Redundancy scenario ①...
Page 192 For a complete evaluation of diagnostic information, you must also look at the STEP 7 online diagnostics and evaluate the diagnostics buffer. You can find more information in the Diagnostics (https://support.industry.siemens.com/cs/ww/en/view/59192926) function manual. Solution Replace the defective interface module of the R1 device. You can find additional information on the procedure in the section Replacing defective I/O devices/switches (Page 455).
Page 193: Failure Of The Two Profinet Lines In Profinet Ring 1 At The Primary Cpu With R1 Devices
Application planning 6.4 Redundancy scenarios 6.4.7.6 Failure of the two PROFINET lines in PROFINET ring 1 at the primary CPU with R1 devices Introduction The following redundancy scenario describes the effects in case of a defect of both PROFINET lines in PROFINET ring 1 at the primary CPU with R1 devices. Failure scenario ①...
Page 194 Application planning 6.4 Redundancy scenarios Sequence of events 1. Both PROFINET lines in PROFINET ring 1 on the primary CPU fail. The redundant system will not execute a primary-backup switchover. The redundant system will remain in the RUN- Redundant system state. 2.
Page 195: Failure Of Both Profinet Lines Between Two R1 Devices In A Line Topology
Application planning 6.4 Redundancy scenarios 6.4.7.7 Failure of both PROFINET lines between two R1 devices in a line topology Introduction The following redundancy scenario describes the effects of a failure of both PROFINET lines between two R1 devices in a line topology. Redundancy scenario ①...
Page 196 Application planning 6.4 Redundancy scenarios Sequence of events 1. Both PROFINET lines between the R1 devices fail. 2. The redundant system will remain in the RUN-Redundant system state: The primary and backup CPUs remain in the RUN-Redundant operating state. The roles of the primary and backup CPUs do not change.
Page 197: Failure Of A Profinet Line Between Two S2 Devices In A Line Topology
Application planning 6.4 Redundancy scenarios 6.4.7.8 Failure of a PROFINET line between two S2 devices in a line topology Introduction The following redundancy scenario describes the effects of a PROFINET line failure between two S2 devices in a line topology. Redundancy scenario ①...
Page 198: Failure Of A Communications Processor At The Primary Cpu
Application planning 6.4 Redundancy scenarios Diagnostics System state, operating states and error displays after the failure of the PROFINET cable: • Redundant system → RUN-Redundant system state • Primary CPU/Backup CPU → RUN-Redundant operating state – MAINT LED → yellow light: No backup AR. Note To get detailed diagnostics information, evaluate the diagnostics buffer.
Page 199: Failure Scenarios
Application planning 6.5 Failure scenarios Sequence 1. The CP 1543-1 at the primary CPU fails. 2. The connection to Industrial Ethernet is maintained via the IP address assigned to the CP 1543-1 (device IP address) at the backup CPU. 3. The redundancy of the system is restricted. The connection to the device IP address of the left CPU and the connection to the assigned system IP address of the CPs remain permanently interrupted.
Page 200: Failure Of An Io Device In The Profinet Ring
Application planning 6.5 Failure scenarios 6.5.1 Failure of an IO device in the PROFINET ring Introduction The following failure scenario describes the effects of a defective IO device in the PROFINET ring. Failure scenario ① Primary CPU ② Backup CPU ③...
Page 201: Failure Of A Switch (With Additional Line Topology) In The Profinet Ring
Application planning 6.5 Failure scenarios Diagnostics System state, operating states and error displays after the failure of an IO device: • Redundant system → RUN-Redundant system state • Primary CPU/Backup CPU → RUN-Redundant operating state – MAINT LED: → yellow light: The PROFINET ring is open. Singular redundancy connection available.
Page 202 Application planning 6.5 Failure scenarios Failure scenario ① Primary CPU ② Backup CPU ③ PROFINET cable (redundancy connections, PROFINET ring) ④ IO device ET 200MP ⑤ IO device ET 200SP ⑥ Switch → failed ⑦ IO device ET 200SP ⑧ HMI device Figure 6-48 Failure of a switch in the PROFINET ring (using S7-1500R as an example)
Page 203: Specific Failure Scenarios With S7-1500R
Application planning 6.5 Failure scenarios Diagnostics System state, operating states and error displays after the failure of a switch: • Redundant system → RUN-Redundant system state • Primary CPU/Backup CPU → RUN-Redundant operating state – MAINT LED → yellow light: The PROFINET ring is open. –...
Page 204 Application planning 6.5 Failure scenarios Failure scenario ① Primary CPU ② Backup CPU ③ PROFINET ring → interrupted at two points ④ IO device ET 200MP ⑤ IO device ET 200SP Figure 6-49 Two cable interruptions in the PROFINET ring (> 1500 ms apart) Sequence of events 1.
Page 205: Two Cable Interruptions In The Profinet Ring In S7-1500R Within ≤ 1500 Ms
Application planning 6.5 Failure scenarios Diagnostics System state, operating states and error displays after the cable interruptions: • Redundant system → RUN-Solo system state • Primary CPU → RUN operating state – MAINT LED → yellow light: The R-system is not in the RUN-Redundant system state. No partner CPU has been found in the R-system.
Page 206 Application planning 6.5 Failure scenarios Failure scenario ① Primary CPU ② Backup CPU ③ PROFINET ring → interrupted a 2 locations ④ IO device ET 200MP ⑤ IO device ET 200SP Figure 6-50 2 cable interruptions in the PROFINET ring (within ≤ 1500 ms) Sequence of events 1.
Page 207: Failure Of The Primary Cpu When Io Devices Have Failed In The Profinet Ring
Application planning 6.5 Failure scenarios Diagnostics System state and operating states after cable interruptions: • Redundant system → System state defective (undefined: Each R-CPU is in the RUN-Solo system state). • Primary CPU → RUN operating state – MAINT LED → yellow light: The R-system is not in the RUN-Redundant system state. No partner CPU has been found in the R-system.
Page 208 Application planning 6.5 Failure scenarios Failure scenario ① Primary CPU → failed (2nd failure in sequence of events) ② Backup CPU → switches to STOP operating state ③ PROFINET cable (redundancy connections, PROFINET ring) ④ IO device ET 200MP ⑤ IO device ET 200SP →...
Page 209: Failure Of The Backup Cpu And Failure Of The Cp Communications Processor At The Primary Cpu
Application planning 6.5 Failure scenarios Diagnostics System state, operating states and error displays after the failure of the IO device in the PROFINET-Ring and the STOP of Backup CPU: • Redundant system → STOP system state • Primary CPU → failed •...
Page 210 Application planning 6.5 Failure scenarios Failure scenario ① Primary CPU ② Backup CPU → failed ③ CP 1543-1 (at primary CPU) → failed ④ CP 1543-1 (at backup CPU) ⑤ PROFINET cable (redundancy connections, PROFINET ring) Figure 6-52 S7-1500R failure of the backup CPU and failure of the CP 1543-1 at the primary CPU Sequence 1.
Page 211: Specific Failure Scenarios With S7-1500H
Application planning 6.5 Failure scenarios Solution Replace the defective CPU and the communications processor. You can find more information on the procedure in the Replacing defective R/H CPUs (Page 446) and Replacing a defective communications processor (Page 454) sections. 6.5.4 Specific failure scenarios with S7-1500H 6.5.4.1 Failure of both redundancy connections in S7-1500H ≤...
Page 212 Application planning 6.5 Failure scenarios Failure scenario ① Primary CPU ② Backup CPU ③ Two fiber-optic cables (redundancy connections) → interrupted ④ IO device ET 200SP ⑤ IO device ET 200MP ⑥ PROFINET cable (PROFINET ring) Figure 6-53 Failure of both redundancy connections Sequence of events 1.
Page 213 Application planning 6.5 Failure scenarios 3. The two primary CPUs continue to exchange process data with the PROFINET devices. 4. The redundancy of the system is defective. The redundant system is in an undefined system state. The undefined system state can lead to dangerous states in the process. WARNING Undefined system state of the S7-1500H redundant system with simultaneous interruption of the two redundancy connections ≤...
Page 214: Failure Of One Redundancy Connection And The Primary Cpu In S7-1500H
Application planning 6.5 Failure scenarios 6.5.4.2 Failure of one redundancy connection and the primary CPU in S7-1500H Introduction The following failure scenario describes the effects of a defect in a redundancy connection and the primary CPU in S7-1500H using a PROFINET ring as example. In this failure scenario, the time between the failure of the redundancy connection failure and of the primary CPU is >...
Page 215: Failure Of The Two Profinet Cables In The Profinet Ring At The Primary Cpu
Application planning 6.5 Failure scenarios 4. The redundant system does not switch to the backup CPU, but switches to the STOP system state. The role of the backup CPU remains unchanged. Note The backup CPU cannot distinguish between the following scenarios: •...
Page 216 Application planning 6.5 Failure scenarios Failure scenario ① Primary CPU ② Backup CPU ③ Two fiber-optic cables (redundancy connections) ④ IO device ET 200SP ⑤ IO device ET 200MP ⑥ PROFINET cables (PROFINET ring) → interrupted Figure 6-55 Failure of both PROFINET cables in the PROFINET ring at the primary CPU Sequence of events 1.
Page 217: Failure Of The Redundant System Through Safe State Of The Hf-Cpus
F-functionality (CPU 1518HF-4 PN). There are also IO devices with fail-safe modules in the PROFINET ring. You can find more information on data corruption in the safety program in the SIMATIC Safety – Configuring and Programming (https://support.industry.siemens.com/cs/ww/en/view/54110126) programming and operating manual. S7-1500R/H redundant system System Manual, 01/2024, A5E41814787-AF...
Page 218 Application planning 6.5 Failure scenarios Failure scenario ① Primary CPU (CPU 1518HF-4 PN) → Data corruption in the safety program due to incorrect pro- gramming ② Backup CPU (CPU 1518HF-4 PN) ③ Two fiber-optic cables (redundancy connections) ④ IO device ET 200SP ⑤...
Page 219: Failure Of An Interface Module In An R1 Device And Of The Profinet Lines In Two Places Of A Profinet Ring
Application planning 6.5 Failure scenarios Diagnostics System state, operating states and error displays after failure: • Redundant system → STOP system state • Primary CPU/Backup CPU → STOP operating state – MAINT LED → yellow light: The H-system is not in the RUN-Redundant system state Note To get detailed diagnostics information, evaluate the diagnostics buffer.
Page 220 Application planning 6.5 Failure scenarios Failure scenario ① Primary CPU ② Backup CPU ③ Two fiber-optic cables (redundancy connections) ④ PROFINET cable (PROFINET ring 1) ⑤ PROFINET cable (PROFINET ring 2) ⑥ PROFINET line → interrupted (2nd defect) ⑦ IO device ET 200SP HA ⑧...
Page 221: Failure Of The Primary Cpu In Profinet Rings With R1, S2 And S1 Devices
Application planning 6.5 Failure scenarios 5. In addition, the second PROFINET line to the backup CPU fails. 6. The redundant system will remain in the RUN-Redundant system state: The primary and backup CPUs remain in the RUN-Redundant operating state. 7. The failure of the second PROFINET line to the backup CPU has an impact on the process, since the redundant system no longer reaches the upper R device.
Page 222 Application planning 6.5 Failure scenarios Failure scenario ① Primary CPU → failed ② Backup CPU → becomes new primary CPU ③ Two fiber-optic cables (redundancy connections) ④ PROFINET cable (PROFINET ring 1) ⑤ PROFINET cable (PROFINET ring 2) ⑥ IO device ET 200SP HA (R1 device) ⑦...
Page 223: Failure Of Profinet Lines In Two Places In A Line Topology With S2 Devices
Application planning 6.5 Failure scenarios 4. The S1 devices in PROFINET ring 1 are no longer accessible by the new primary CPU. The S1 devices return to the substitute values. 5. The failure of the primary CPU affects the process, since the S1 devices in the PROFINET ring 1 can no longer be accessed from the primary CPU.
Page 224 Application planning 6.5 Failure scenarios Failure scenario ① Primary CPU ② Backup CPU ③ Two fiber-optic cables (redundancy connections) ④ PROFINET lines (line topology) ⑤ IO device ET 200MP ⑥ IO device ET 200SP ⑦ PROFINET line→ interrupted (1st defect) ⑧...
Page 225: Failure Of The Communications Processor At The Primary Cpu With Failure Of The Backup Cpu
Application planning 6.5 Failure scenarios Diagnostics System state, operating states and error displays after the failure of both PROFINET cables: • Redundant system → RUN-Redundant system state • Primary CPU/Backup CPU → RUN-Redundant operating state – MAINT LED → yellow light: No backup AR. –...
Page 226 Application planning 6.5 Failure scenarios Failure scenario ① Primary CPU ② Backup CPU → failed ③ CP 1543-1 (at primary CPU) → failed ④ CP 1543-1 (at backup CPU) ⑤ PROFINET cable (PROFINET ring) ⑥ Two fiber-optic cables (redundancy connections) Figure 6-60 S7-1500H failure of the CP 1543-1 at the primary CPU and backup CPU Sequence...
Page 227: Hardware Configuration
Application planning 6.6 Hardware configuration Note The connection to Industrial Ethernet is interrupted. Solution Replace the defective CPU and the communications processor. You can find more information on the procedure in the Replacing defective R/H CPUs (Page 446) and Replacing a defective communications processor (Page 454) sections.
Page 228 Application planning 6.6 Hardware configuration ① First R-CPU ② Second R-CPU Figure 6-61 Assignment of slot addresses in the R-CPUs (configuration example) ① First H-CPU ② Second H-CPU Figure 6-62 Assignment of slot addresses in the H-CPUs (configuration example) Maximum number of PROFINET devices, IO devices in the redundant system The table below shows the maximum number of PROFINET devices, IO devices in the redundant system.
Page 229: Using Hmi Devices
Application planning 6.7 Using HMI devices Using HMI devices Introduction You can use the same HMI devices for the S7-1500R/H redundant system as for the S7-1500 automation system. If you use HMI devices in the PROFINET ring with S7-1500R, those HMI devices must support media redundancy.
Page 230 Application planning 6.7 Using HMI devices Connecting HMI devices over Industrial Ethernet and the PROFINET ring based on the example of CPU 1518HF-4 PN/CPU 1517H-3 PN/CPU 1515R-2 PN The figure below is an example of how you can connect the CPU 1518HF-4 PN to an HMI device over Industrial Ethernet and the PROFINET ring.
Page 231 Application planning 6.7 Using HMI devices Integrate a switch into the PROFINET ring to connect an HMI device to the PROFINET ring. Use this to establish a connection to the HMI device. The PROFINET ring is set up using the PROFINET IO interfaces (X1) of the CPUs. If you operate HMI devices within the ring, you need to assign the MRP role "Client"...
Page 232: System Power Supply
6.8 System power supply Reference You can find more information on the system IP address in the section Configuration process and in the Communication (https://support.industry.siemens.com/cs/ww/en/view/59192925) function manual. More information on how to set up an HMI connection to the S7-1500R/H redundant system is available in the Communication (https://support.industry.siemens.com/cs/ww/en/view/59192925) Function Manual.
Page 233 Application planning 6.8 System power supply Configuration with system power supply Configuration example with R-CPU and infeed of the supply voltages at 2 system power supplies PS 25 W 24 V DC: Figure 6-65 Configuration example R-CPU with 2 system power supplies Configuration example with H-CPU and infeed of the supply voltages at H-CPU (external) and system power supply PS 25 W 24 V DC: Figure 6-66...
Page 234 Application planning 6.8 System power supply Configuration with redundant system power supplies Configuration with redundant system power supplies is only possible for H-CPUs which have an active backplane bus. Due to the active backplane bus, there is only one power segment in the configuration.
Page 235: Power Balance Calculation
Take care even during planning, that the power fed into the backplane bus is always greater than or equal to the power drawn. The TIA Selection Tool (https://new.siemens.com/global/en/products/automation/topic-areas/tia/tia-selection- tool.html) aids you during planning. The power fed into the backplane bus from the CPU and system power supply is listed in the technical data of the CPU in the corresponding manuals.
Page 236 Application planning 6.8 System power supply Power segment overview with redundant system power supplies for the H-CPUs Recommended configuration variant with redundant system power supplies and a maximum of four CPs In a configuration with redundant system power supplies, the power is fed in via the two system power supplies.
Page 237 Application planning 6.8 System power supply Note Infeed via system power supplies only To ensure that the power segment overview correctly displays the infeed via the system power supplies only, you must configure the following option: 1. In STEP 7, open the "Properties" tab of the R/H CPU. Select "System power supply" in the navigation.
Page 238 Application planning 6.8 System power supply Causes for overload An overload can still occur despite a positive power balance during planning. The cause for overload can be a hardware configuration that does not correspond to the configuration in STEP 7, for example: •...
Page 239: Installation
Installation Basics Installation site All modules of the S7-1500R/H redundant system are unenclosed equipment. You may only install unenclosed equipment in housings, cabinets or electrical operating rooms indoors. The housings, cabinets and electrical operating rooms must guarantee protection against electric shock and spread of fire.
Page 240 Installation 7.1 Basics The rails are available in various lengths. You can order the rails using the online catalog or the online ordering system. The available lengths and article numbers can be found in the appendix Accessories/spare parts (Page 497). Minimum clearances Modules can be mounted along the entire length of the rail.
Page 241: Installing The Mounting Rail
Installation 7.2 Installing the mounting rail Installing the mounting rail Introduction The R/H-CPUs should be mounted either on one mounting rail or on two separate mounting rails. Lengths and drill holes The mounting rails are delivered in six lengths: • 160 mm •...
Page 242 Installation 7.2 Installing the mounting rail Accessories required Use the following screw types for fastening the mounting rails: Table 7- 1 Accessories required For ... use ... Explanation M6 fillister head screws according to Choose a suitable screw length for your •...
Page 243 Installation 7.2 Installing the mounting rail Preparing the 2 000 mm mounting rail for installation Proceed as follows to prepare the 2 000 mm mounting rail for installation: 1. Cut the 2 000 mm mounting rail to the required length. 2.
Page 244 Installation 7.2 Installing the mounting rail Attaching the protective conductor The mounting rails of the S7-1500R/H redundant system must be connected to the protective conductor system of the electrical system to ensure electrical safety. Proceed as follows to connect the protective conductor: 1.
Page 245: Installing The Active Backplane Bus
Installing the active backplane bus You can find more information on the active backplane bus (e.g. installing, configuring, technical specifications) in the Active backplane bus (https://support.industry.siemens.com/cs/de/de/view/109778694/en) Equipment Manual. Installing the standard rail adapter Introduction Use the DIN rail adapter to mount the redundant SIMATIC S7-1500R/H-system on the standardized 35 mm rails.
Page 246 Installation 7.4 Installing the standard rail adapter Article number 6ES7590-6AA00-0AA0 The scope of delivery consists of ten adapters, ten hexagon socket-head screws and ten washers. View The DIN rail adapter consists of a clamp, an adapter frame and a hexagon socket-head screw with washer.
Page 247 Installation 7.4 Installing the standard rail adapter Dimensional drawing ① Position of the adapter frame during mounting to the standard DIN rail 35 mm x 7.5 mm ② Position of the adapter frame during mounting to the standard DIN rail 35 mm x 15 mm Figure 7-5 Dimensional drawing Tools required...
Page 248 Installation 7.4 Installing the standard rail adapter • To ensure optimal stability, the clearance between the two DIN rail adapters must be no more than 250 mm. Figure 7-6 Distance between two DIN rail adapters Note Note that, depending on the mounting rail width, the mounting rail adapter can protrude up to 4 mm on each side due to the drill holes.
Page 249 Installation 7.4 Installing the standard rail adapter Table 7- 3 Additional lateral space required Mounting rail Article number Additional space required with adapter 160.0 mm (with drill holes) 6ES7590-1AB60-0AA0 4 mm 245.0 mm (with drill holes) 6ES7590-1AC40-0AA0 4 mm 482.6 mm (with drill holes) 6ES7590-1AE80-0AA0 8 mm 530.0 mm...
Page 250 Installation 7.4 Installing the standard rail adapter Procedure Mounting on the standard DIN rail 35 mm x 7.5 mm To install DIN rail adapter on the standard DIN rail 35 mm x 7.5 mm, follow these steps: 1. Set the clamp onto the standard DIN rail. 2.
Page 251: Installing A System Power Supply
Note Configuration with active backplane bus You can find the active backplane bus procedure in the Active backplane bus (https://support.industry.siemens.com/cs/de/de/view/109778694/en) Equipment Manual. This section describes the installation of the system power supply via U-connector. Requirements The rail is installed.
Page 252 Installation 7.5 Installing a system power supply 3. Swivel the system power supply to the rear. Figure 7-9 Installing a system power supply 4. Open the front cover. 5. Disconnect the power cable connector from the system power supply. 6. Screw the system power supply tight (torque 1.5 Nm). 7.
Page 253: Installing A Load Current Supply
Tools required Slotted-head screwdriver with 4.5 mm blade Installing a load current supply Watch the video sequence (https://support.industry.siemens.com/cs/ww/en/view/78027451) To install a load current supply, follow these steps: 1. Hook the load current supply on the mounting rail. 2. Swivel the load current supply to the rear.
Page 254: Installing R/H-Cpus
CPUs in the S7-1500R/H redundant system are installed in exactly the same way as CPUs in the S7-1500 automation system. Note Configuration with active backplane bus You can find the procedure for the H-system with the active backplane bus in the Active backplane bus (https://support.industry.siemens.com/cs/de/de/view/109778694/en) Equipment Manual. S7-1500R/H redundant system System Manual, 01/2024, A5E41814787-AF...
Page 255 Tools required Slotted-head screwdriver with 4.5 mm blade Installing R/H-CPUs Watch the video sequence (https://support.industry.siemens.com/cs/ww/en/view/78027451) Follow these steps to install an R/H-CPU: 1. Hook the CPU onto the rail. Only with optional load current supply: Move the CPU to the load current supply on the left.
Page 256: Installing A Communications Processor
Installing a communications processor in the H-system For the H-system, you need an active backplane bus to install the communications processors. You can find more information in the Active backplane bus (https://support.industry.siemens.com/cs/de/de/view/109778694/en) Equipment Manual. S7-1500R/H redundant system System Manual, 01/2024, A5E41814787-AF...
Page 257 Tools required Screwdriver with 4.5 mm blade Installing a communications processor in the R-system Watch the video sequence (https://support.industry.siemens.com/cs/ww/en/view/78027451) Follow these steps to install a communications processor: 1. Mount the U-connector on the back right-hand side of the communications processor.
Page 258 Installation 7.8 Installing a communications processor Uninstalling a communications processor in the R-system The communications processor is wired. Follow these steps to remove a communications processor: 1. Turn off all feed supply voltages. 2. Open the front cover. 3. Remove the RJ45 plug with the Ethernet cable from the communications processor. 4.
Page 259: Wiring
Wiring Rules and regulations for operation Introduction The S7-1500R/H redundant system is a plant and system component. Special rules and regulations must be adhered to in line with the area of application. This section gives an overview of the key rules for integration of the redundant system into a plant or system.
Page 260 Suitable components for the lightning and overvoltage protection are specified in the Defining interference-free controllers (https://support.industry.siemens.com/cs/ww/en/view/59193566) function manual. Requirements for power supplies in the event of voltage interruption Note To ensure adherence to IEC 61131-2, only use power packs/power supply units (e.g.
Page 261: Operation On Grounded Infeed
Reference Additional information can be found in the function manual, Designing interference-free controllers (https://support.industry.siemens.com/cs/ww/en/view/59193566). Operation on grounded infeed Introduction Information is provided below on the overall configuration of an S7-1500R/H redundant system on a grounded incoming supply (TN-S network).
Page 262 Wiring 8.2 Operation on grounded infeed Safe electrical isolation (SELV in accordance with IEC 61131-2 or IEC 61010-2-201) System power/load current supplies with 24 V DC output voltage feature safe electrical separation and voltage limiting (extra-low voltage). System power/load current supplies with a 24 V DC output voltage are not connected to the protective conductor.
Page 263 Wiring 8.2 Operation on grounded infeed Short-circuit and overload protection Various measures as protection against short-circuits and overloads are required for setting up a full installation. The nature of the components and the degree to which the required measures are binding depends on the IEC (DIN VDE) regulation applicable to your plant configuration.
Page 264 Wiring 8.2 Operation on grounded infeed Overall configuration of S7-1500R/H The figure below shows the overall configuration of the S7-1500R/H redundant system (load current supply and grounding concept) with supply from a TN-S network. ① Main switch ② Short-circuit and overload protection Figure 8-1 Operating the S7-1500R/H with grounded reference potential S7-1500R/H redundant system...
Page 265: Electrical Configuration
Wiring 8.3 Electrical configuration Note If you connect the S7-1500R/H redundant system via upstream local power supplies to your own distribution (or batteries), then you do not have to provide any additional protective measures against overvoltage. Electrical configuration Galvanic isolation In the redundant System S7-1500R/H, there is electrical isolation between: •...
Page 266: Wiring Rules
Wiring 8.4 Wiring rules Wiring rules Introduction Use suitable cables to connect the S7-1500R/H redundant system. The tables below set out the wiring rules for the R/H-CPUs and system power/load current supply. R/H CPUs and system power/load current supply Table 8- 2 Wiring rules for R/H-CPUs and system power/load current supply Wiring rules for ...
Page 267: Connecting The Supply Voltage
Wiring 8.5 Connecting the supply voltage Permissible cable temperature Note Permissible cable temperature When selecting the cable, note that the cable temperature during operation can be up to 30 °C higher than the ambient temperature of the S7-1500R/H redundant system. Example: If you use the system in a switchgear cabinet at an ambient temperature of 30 °C, you must use a connecting conductor with a temperature range of at least 60 °C.
Page 268 Wiring 8.5 Connecting the supply voltage Requirements • Only wire the cable connector when the supply voltage is turned off. • Follow the wiring rules (Page 265). Tool-free connection of cables: multi-wire (stranded), with end sleeve or ultrasonic compressed To connect a wire without tools, follow these steps: 1.
Page 269: Connecting The System Power/Load Current Supply
3 to 3.5 mm screwdriver Connecting the supply voltage to a system power supply/load current supply Watch the video sequence (https://support.industry.siemens.com/cs/ww/en/view/78027451) To connect the supply voltage, follow these steps: 1. Swing the front cover of the module up until the front cover latches.
Page 270: Connecting The Cpu To The Load Power Supply
• The connector for connecting the supply voltage to the CPU is already fitted. You can find more information in the section Connecting the supply voltage (Page 266). Tools required 3 to 3.5 mm screwdriver Connecting the CPU to a load current supply Watch the video sequence (https://support.industry.siemens.com/cs/ww/en/view/78027451) S7-1500R/H redundant system System Manual, 01/2024, A5E41814787-AF...
Page 271 Wiring 8.7 Connecting the CPU to the load power supply To connect the cables for the supply voltage, follow these steps: 1. Open the front cover of the load current supply. Pull the 24 V DC output terminal down and off.
Page 272: Connecting Interfaces For Communication With S7-1500R
Wiring 8.8 Connecting interfaces for communication with S7-1500R Connecting interfaces for communication with S7-1500R Connecting interfaces for communication Connect the communication interfaces of the CPUs using standardized plug connectors. Use prefabricated connecting cables for the connection. If you want to prepare communication cables yourself, the interface assignment is specified in the CPU manuals.
Page 273 Wiring 8.8 Connecting interfaces for communication with S7-1500R Procedure To connect the PROFINET ring at SIMATIC S7-1500R, follow these steps: 1. Swing the front cover on the R-CPUs up. 2. Plug the PROFINET cable RJ45 connectors into the RJ45 sockets at PROFINET interfaces X1 P2R on the two R-CPUs.
Page 274: Connecting Interfaces For Communication With S7-1500H
Wiring 8.9 Connecting interfaces for communication with S7-1500H 3. Plug the PROFINET cable RJ45 connectors into the RJ45 sockets at PROFINET interfaces X1 P1R on the two R-CPUs. Connect the other PROFINET devices in the PROFINET ring. Figure 8-7 PROFINET interface X1 P1R: 4.
Page 275: Connecting Redundancy Connections (Fiber-Optic Cables)
40 km (minimum length: 8 km) 6ES7960-1FE00-0AA5 8.9.1.2 Selecting fiber-optic cables Introduction You can find an overview of fiber-optic cables, the necessary conditions and technical specifications in the system manual Industrial Ethernet/PROFINET Passive network components (https://support.industry.siemens.com/cs/ww/en/view/84922825). S7-1500R/H redundant system System Manual, 01/2024, A5E41814787-AF...
Page 276 Wiring 8.9 Connecting interfaces for communication with S7-1500H Rules Observe the following rules: • If you use fiber-optic cables, ensure sufficient strain relief at the synchronization modules. • Comply with the technical specifications for the fiber-optic cables used (attenuation, bandwidth). Cables up to 10 m Use the synchronization module 6ES7960–1CB00–0AA5 in pairs with fiber-optic cables up to 10 m.
Page 277 Wiring 8.9 Connecting interfaces for communication with S7-1500H Please see the following tables for the other specifications applicable to your specific application. Table 8- 4 Specifications for fiber-optic cables used indoors Cabling Necessary components Specifications Complete cabling routed Patch cable for indoors 2 x duplex cables for the redundant system (connector type within a building.
Page 278: Installing Fiber-Optic Cables
Wiring 8.9 Connecting interfaces for communication with S7-1500H Installation of fiber-optic cables through distribution boxes (patch fields) If cabling requires a transition from indoor to outdoor, you need to perform installation of the fiber-optic cables via distribution boxes (patch fields). The distribution boxes (patch fields) connect the different cables (patch and installation cables) and connector types with one another.
Page 279 This makes simultaneous damage of the redundancy connections ≤ 1500 ms apart (R-system) or ≤ 55 ms apart (H-system) unlikely. Reference Observe the installation notes for fiber-optic cables in the system manual Industrial Ethernet/PROFINET Passive network components (https://support.industry.siemens.com/cs/ww/en/view/84922825). S7-1500R/H redundant system System Manual, 01/2024, A5E41814787-AF...
Page 280: Connecting Redundancy Connections (Fiber-Optic Cables) To S7-1500H
– For sync module 1 GB FO 10 km: Additional information on fiber-optic cables in longer versions can be found in the Industry Mall (https://mall.industry.siemens.com). – For sync module 1 GB FO 40 km: Additional information on fiber-optic cables in longer versions can be found in the Industry Mall (https://mall.industry.siemens.com).
Page 281 Wiring 8.9 Connecting interfaces for communication with S7-1500H Safety information WARNING Personal injury or material damage can occur in zone 2 hazardous areas If you remove or attach a synchronization module during operation, personal injury and damage can occur in hazardous areas of zone 2. Always disconnect the R/H-CPU from the power supply before you remove or attach a synchronization module in hazardous areas of zone 2.
Page 282 Wiring 8.9 Connecting interfaces for communication with S7-1500H Inserting synchronization modules and connecting fiber-optic cables To insert the synchronization modules and connect the fiber-optic cables, follow these steps: 1. Remove the blanking plugs from the synchronization modules. 2. Push the two synchronization modules as far as they will go from below into the module slots at the H-Sync interfaces of port 1: CPU 1517H-3 PN: X3 (H-Sync channel 1) and X4 (H-Sync channel 2) CPU 1518HF-4 PN: X4 (H-Sync channel 1) and X5 (H-Sync channel 2)
Page 283 Wiring 8.9 Connecting interfaces for communication with S7-1500H 3. Hold the pre-assembled connectors of the redundancy connection by the housing. Push the connectors into the sockets of the synchronization modules. You should hear the connectors click into place. 4. Repeat steps 1 to 3 for the second H-CPU. Figure 8-12 Connecting redundancy connections (fiber-optic cables) to S7-1500H Uninstalling a synchronization submodule...
Page 284: Connecting The Profinet Ring To S7-1500H
Wiring 8.9 Connecting interfaces for communication with S7-1500H Protecting LC sockets on unused synchronization modules Protect the LC sockets when storing unused synchronization modules: Close off the LC sockets with the blanking plugs to protect them from dirt. The synchronization modules come with blanking plugs inserted. NOTICE Reduced optical performance due to dirt Even a small amount of dirt in the LC socket can affect the quality of the signal transmission.
Page 285 Wiring 8.9 Connecting interfaces for communication with S7-1500H Connecting PROFINET ring with S2 devices Plug the RJ45 connectors of the PROFINET cable of the PROFINET ring respectively into the RJ45 sockets of the PROFINET interfaces X1 P1R/X1 P2R of the two H-CPUs. Figure 8-13 Connecting PROFINET ring with S2 devices S7-1500R/H redundant system...
Page 286 Wiring 8.9 Connecting interfaces for communication with S7-1500H Connecting PROFINET rings with R1 devices Plug the RJ45 connectors of the left PROFINET ring (PROFINET ring 1 with left interface modules) into the RJ45 sockets of the PROFINET interfaces X1 P1R/X1 P2R of the H-CPU with redundancy ID 1.
Page 287: Connecting Line Topology To S7-1500H
Wiring 8.9 Connecting interfaces for communication with S7-1500H 8.9.3 Connecting line topology to S7-1500H Introduction You connect the line topology via the RJ45 sockets of the PROFINET interfaces X1 P1R. Accessories required PROFINET cable for line topology Connecting line topology with S2 devices Plug the RJ45 connectors of the PROFINET cable of the line topology into each of the RJ45 sockets of the PROFINET interfaces X1 P1R of the two H-CPUs.
Page 288 Wiring 8.9 Connecting interfaces for communication with S7-1500H Connecting line topology with R1 devices Connect the devices of the line topology with the PROFINET cables as shown in the following figure: ① H-CPU with redundancy ID 1 ② H-CPU with redundancy ID 2 Figure 8-16 Connect line topology with R1 devices to S7-1500H S7-1500R/H redundant system...
Page 289: Connecting A Communications Processor
You can connect the Industrial Ethernet to the communications processor via an RJ45 interface. Connecting Industrial Ethernet to CP 1543-1 You can find more information on connecting the Industrial Ethernet in the CP 1543-1 (https://support.industry.siemens.com/cs/de/de/view/67700710/en) operating instructions. S7-1500R/H redundant system System Manual, 01/2024, A5E41814787-AF...
Page 290: Configuration
Configuration Requirements Hardware and software requirements You will find the hardware and software requirements for operating S7-1500R/H redundant systems in the section Requirements (Page 129). Note Consistency check If you configure the STEP 7 project as topology, the consistency is then checked by STEP 7. An incorrect configuration is indicated by error messages.
Page 291 Configuration 9.2 Configuring R/H CPUs Result: STEP 7 automatically creates both 1515R-2 PN CPUs for the redundant system. STEP 7 displays both CPUs in the network view graphically. Note Deleting CPUs from the hardware configuration You can only delete the two CPUs as a pair. Figure 9-1 Display of CPUs in the network view 1.
Page 292 Configuration 9.2 Configuring R/H CPUs Redundancy IDs In the STEP 7 project tree, each of the two CPUs is displayed with its own tree in the redundant system: Figure 9-3 Redundant system in the project tree Each CPU of the redundant system has a redundancy ID. The redundancy ID is used to assign a project tree in STEP 7 to the real CPU.
Page 293 You can find more information on the cycle time and recommendations for parameterization of the maximum cycle time and the minimum cycle time in the Cycle and response times function manual (https://support.industry.siemens.com/cs/at/fr/view/59193558). You can find information on system states in the section Operating and system states (Page 380).
Page 294: Basic Procedure For Configuring The Io Devices And The Mrp Roles
Configuration 9.3 Basic procedure for configuring the IO devices and the MRP roles Basic procedure for configuring the IO devices and the MRP roles Introduction The configuration of the IO devices in a S7-1500R/H redundant system is basically the same for S7-1500R and S7-1500H.
Page 295 Configuration 9.3 Basic procedure for configuring the IO devices and the MRP roles Result: The IO devices are connected to the redundant S7-1500R/H system. "Multiple assignment" is displayed for the IO devices. Figure 9-5 IO devices assigned in the network view with system redundancy Note If you have configured modules for the IO devices and compile the project, you receive an error message for the watchdog timer in the Inspector window.
Page 296 Configuration 9.3 Basic procedure for configuring the IO devices and the MRP roles If necessary you have to change the MRP role of the CPUs. To do so, proceed as follows: 1. In the network view of STEP 7, select PROFINET interface X1 of one of the two CPUs of the redundant system.
Page 297 IMs on slot 0 with H-CPU with redundancy ID 1 • IMs on slot 1 with H-CPU with redundancy ID 2 Reference You can find information on the PROFINET topologies of S7-1500R/H redundant systems in the PROFINET Function Manual. (https://support.industry.siemens.com/cs/ww/en/view/49948856) S7-1500R/H redundant system System Manual, 01/2024, A5E41814787-AF...
Page 298: Configuring H-Cpus With Profinet Rings And R1 Devices
Configuration 9.4 Configuring H-CPUs with PROFINET rings and R1 devices Configuring H-CPUs with PROFINET rings and R1 devices Introduction The section below guides you step by step through the configuration of PROFINET rings with R1 devices for an S7-1500H redundant system. The configuration example consists of two R1 devices (ET 200SP IM 155-6 PN R1).
Page 299 Configuration 9.4 Configuring H-CPUs with PROFINET rings and R1 devices Figure 9-8 Create another MRP domain "mrpdomain-2" 2. Creating R1 devices In the example, you add two R1 devices with system redundancy R1 to the H-CPUs. To do so, proceed as follows: 1.
Page 300 Configuration 9.4 Configuring H-CPUs with PROFINET rings and R1 devices 3. Assigning IO devices to the redundant system To assign R1 devices to the redundant S7-1500H system, connect each interface module of the R1 device to each H-CPU. The left interface module of each R1 device must be connected to the left H-CPU in the network view.
Page 301 Configuration 9.4 Configuring H-CPUs with PROFINET rings and R1 devices Note Alternative method for assigning IO devices. For larger projects, we recommend assigning the IO devices as follows: 1. Switch to the network view. 2. Move the cursor over the station you want to assign. 3.
Page 302 Set the MRP role "Client" for devices of the PROFINET rings that are not in STEP 7. Reference You can find information on the PROFINET topologies of S7-1500R/H redundant systems in the PROFINET Function Manual. (https://support.industry.siemens.com/cs/ww/en/view/49948856) S7-1500R/H redundant system System Manual, 01/2024, A5E41814787-AF...
Page 303: Configuring Additional Topologies
Configuration 9.5 Configuring additional topologies Configuring additional topologies Introduction In this section you will find information on configuring other configuration variants of the S7- 500H redundant system. Configuration of PROFINET rings or line topology with R1 devices and Y-switch Reparamaterize operating mode for S2 devices that can only be accessed by an H-CPU If the S2 device is only accessible by one CPU, then the default operating mode IO device (S2) (e.g.
Page 304 CPU. In this case, STEP 7 already outputs an error message when compiling the configuration. Application example with Y-switches and DNA redundancy Under the following link (https://support.industry.siemens.com/cs/ww/de/view/109816704/en), you will find an application example with Y-switches and DNA redundancy, showing scenarios in line and ring topologies. Line topology configuration with R1 devices and switches...
Page 305: Configuring R-Cpus With Communications Processors
CP 1543-1 communications processors. Note Configuring CP 1543-1 communications processors with H-CPUs You can find the procedure for configuring the H-CPUs with the CP 1543-1 in the Active backplane bus (https://support.industry.siemens.com/cs/de/de/view/109778694/en) Equipment Manual. Requirement The configuration detailed assumes that: •...
Page 306 Configuration 9.6 Configuring R-CPUs with communications processors 2. From the hardware catalog, drag the required CP 1543-1 to rail_0 from slot 2. If the power segment overview is negative, then you must additionally drop a PS system power supply onto rail_0. Figure 9-11 Configuring CP 1543-1 Result: The modules are also automatically configured in rail_1.
Page 307: Configuring The System Power Supply
Configuration 9.7 Configuring the system power supply Assigning IP addresses (device addresses)/system IP addresses of the virtual W1 interface of the R/H-CPUs You may assign an IP address/system IP address to the W1 virtual interface of the R/H-CPU. The communication partners that you connected to the CPs then communicate with the R/H-CPU via these IP addresses.
Page 308 Configuration 9.7 Configuring the system power supply Infeed via the R/H-CPU Supply the R/H-CPU with the permissible 24 V DC supply voltage. Follow these steps to set up the infeed via the R/H-CPU: 1. In STEP 7, open the "Properties" tab for the R/H-CPU. Select "System power supply" in the navigation.
Page 309: Configuring The Ie/Pb Link Ha
Configuration 9.8 Configuring the IE/PB LINK HA To set up infeed only via the system power supply, follow these steps: 1. In STEP 7, open the "Properties" tab for the R/H-CPU. Select "System power supply" in the navigation. 2. Select the option "No connection to supply voltage L+". Figure 9-14 No infeed to the backplane bus through the R/H-CPU Note...
Page 310 With simulated PROFINET devices, you need to set the watchdog factor in addition independently of the IE/PB LINK HA. You can find more information on the IE/PB LINK HA in the "Industrial Ethernet / PROFIBUS / IE/PB Link" (https://support.industry.siemens.com/cs/us/en/view/109744280) operating instructions. Loading configuration to the devices The configuration of the IE/PB LINK HA and the connected PROFIBUS DP devices must be loaded directly into the IE/PB LINK HA.
Page 311: Display Of The Io Device Assignments In Step 7
Configuration 9.9 Display of the IO device assignments in STEP 7 Always perform both load operations after configuration changes to the IE/PB LINK HA: First configuration of the R/H-CPUs and then configuration of the IE/PB LINK HA. In this way, you make sure that the configuration data in the IE/PB LINK HA and in the R/H-system are identical.
Page 312 Configuration 9.9 Display of the IO device assignments in STEP 7 Display of the IO device assignments in STEP 7 Regardless of whether an IO device is connected as system redundant or as standard IO device ("switched S1 device") to the redundant S7-1500R/H system, the network view always shows "Multi assigned".
Page 313 If you change the hardware configuration afterwards, you have to recompile the project. After the compile STEP 7 shows valid values again. For more information, refer to the following entry on the Internet (https://support.industry.siemens.com/cs/ww/en/view/93839056) and in the SIMATIC Safety - Configuring and Programming (https://support.industry.siemens.com/cs/ww/en/view/54110126) programming and operating manual.
Page 314: Project Tree
Configuration 9.10 Project tree 9.10 Project tree Structure of the project tree In the project tree, STEP 7 creates the project tree for the CPUs. The project tree has a tree structure and contains all elements and editors of the project. Table 9- 2 Structure of the project tree Below the H system, you will find the device configuration...
Page 315: Parameters
Configuration 9.11 Parameters 9.11 Parameters "Parameter assignment" means setting the module properties. This includes setting addresses, enabling alarms and defining communication properties. You assign the property parameters for the CPUs in the area navigation, in the STEP 7 Inspector window. The CPUs have general parameters and R/H-specific parameters. Some parameters must be identical for both CPUs.
Page 316: Updating Process Image Partitions In The User Program
The CPU automatically updates the TPA 0 (automatic update) at the beginning of each program cycle. You can find additional information in the Cycle and response times (http://support.automation.siemens.com/WW/view/en/59193558) function manual. You can assign other OBs to process image partitions PIP 1 to PIP 31 during configuration of the IO devices.
Page 317 IO devices over the process image or process image partitions. Reference You can find more information on process image partitions in the Cycle and response times (http://support.automation.siemens.com/WW/view/en/59193558) function manual. S7-1500R/H redundant system System Manual, 01/2024, A5E41814787-AF...
Page 318: Basics Of Program Execution
Basics of program execution 10.1 Programming the S7-1500R/H User program for the S7-1500R/H redundant system For the design and programming of the user program, the same rules apply for the redundant S7-1500R/H system as for the S7-1500 automation system. The user program is stored identically in both CPUs in redundant operation. Both CPUs process the user program event-synchronously.
Page 319 Basics of program execution 10.1 Programming the S7-1500R/H As of firmware version V3.1: • Switch R/H-CPU to STOP mode and assign the backup CPU role (Mode 11). With this function, you can switch an R/H-CPU to STOP mode and assign the backup CPU role.
Page 320 Basics of program execution 10.1 Programming the S7-1500R/H • The R/H-system is still in RUN-Redundant system state and the synchronization of the two R/H-CPUs is possible redundantly now or again. • The R/H-system is still in RUN-Redundant system state, but the synchronization of the two R/H-CPUs is no longer possible redundantly.
Page 321 Communication Function Manuals: – Communication (https://support.industry.siemens.com/cs/ww/en/view/59192925) Function Manual: SNMP – PROFINET (https://support.industry.siemens.com/cs/ww/en/view/49948856) Function Manual: Handling timeouts while exchanging data • If you use the instruction WRIT_DBL (SFC84) to write data structures greater than 64 KB into the load memory, the response times in the R/H-CPU user program may increase.
Page 322: Restrictions
You can better maintain and reuse the uniform program code. This allows you to detect or avoid errors early on, for example, through compilers. The programming style guide is available on the Internet (https://support.industry.siemens.com/cs/ww/en/view/109478084). 10.2 Restrictions Supported instructions with restrictions...
Page 323 Basics of program execution 10.2 Restrictions Instruction Description OPC_UA_MethodCall Call method OPC_UA_NodeReleaseHandleList Enable handles for read and write access OPC_UA_MethodReleaseHandleList Enable handles for method calls OPC_UA_Disconnect Close connection OPC_UA_ConnectionGetStatus Read connection status Synchronize user pages S_USSI Initialize USS FTP_CMD Setup of FTP connections from and to an FTP server Extended instructions SET_TIMEZONE Set time zone...
Page 324: Events And Obs
Basics of program execution 10.3 Events and OBs 10.3 Events and OBs Start events The table below gives an overview of the possible event sources for start events and their OBs: Table 10- 3 Start events Event sources Possible priorities (default Possible OB Default system Number of OBs...
Page 325 Basics of program execution 10.3 Events and OBs Response to start events The occurrence of a trigger results in the following response: • If the event comes from an event source to which you have assigned an OB, this event triggers the execution of the assigned OB.
Page 326 Basics of program execution 10.3 Events and OBs OB 86 There are three IO devices in the example. Each failure of one of the three IO devices is followed by recovery of the IO device. Each IO device failure/IO device recovery is signaled. Cyclic program execution is interrupted with an OB 86 call.
Page 327 Basics of program execution 10.3 Events and OBs Behavior of OB 72 and OB 86 for standard IO devices at primary-backup switchover If the primary CPU fails or goes to STOP, the standard IO devices are temporarily separated from the redundant S7-1500R/H system. From the CPU perspective, the standard IO devices fail.
Page 328 Basics of program execution 10.3 Events and OBs Example: OB 72 CPU redundancy failure Automation task You use the S7-1500R redundant system to control a blast furnace. The S7-1500R redundant system controls the blast furnace temperature, volume and pressure parameters. Feature In the event of a loss of redundancy, for example because the primary CPU fails, a signal lamp in the blast furnace control room signals this event.
Page 329 Basics of program execution 10.3 Events and OBs Table 10- 5 Response of S7-1500R/H redundant system when cycle time is exceeded with OB 80 Initial situation 1st time cycle time is ex- 2nd time cycle time is ex- 3rd time cycle time is ex- ceeded ceeded ceeded...
Page 330: Special Instructions For S7-1500R/H Redundant Systems
Basics of program execution 10.4 Special instructions for S7-1500R/H redundant systems *Exception: In the RUN-Redundant system state, a higher-priority OB 83 "Pull/plug modules" does not interrupt the execution of an OB 82 "Diagnostic interrupt". Note Communication Communication (for example test functions with the PG/PC) always operates with a priority of 15.
Page 331 Basics of program execution 10.4 Special instructions for S7-1500R/H redundant systems Example: Disabling/enabling SYNCUP for a baggage handling system Automation task A baggage handling system at an airport is used to distribute pieces of baggage. When a flight lands, all baggage is loaded onto the baggage handling system. The baggage passes through a scanner at high speed.
Page 332 Basics of program execution 10.4 Special instructions for S7-1500R/H redundant systems During SYNCUP, the user program of the primary CPU runs through a cycle with an extended cycle time. In this cycle, there is a delay before the redundant system responds to input signal changes.
Page 333: Determining The Primary Cpu With "Rh_Getprimaryid
Basics of program execution 10.4 Special instructions for S7-1500R/H redundant systems 10.4.2 Determining the primary CPU with "RH_GetPrimaryID" You use the "RH_GetPrimaryID" instruction to read out which CPU is currently the primary CPU. The instruction outputs the redundancy ID of the primary CPU at the Ret_Val block parameter.
Page 334: Asynchronous Instructions
Basics of program execution 10.5 Asynchronous instructions 10.5 Asynchronous instructions Introduction During program execution a distinction is made between synchronous and asynchronous instructions. The "synchronous" and "asynchronous" properties relate to the temporal relationship between the call and execution of the instruction. The following applies to synchronous instructions: When the call of a synchronous instruction is complete, execution of the instruction is also complete.
Page 335 Basics of program execution 10.5 Asynchronous instructions With a synchronous instruction, the instruction is fully executed in each call. ① First call of the asynchronous instruction, start of execution ② Intermediate call of the asynchronous instruction, execution continues. ③ Last call of the asynchronous instruction, completion of execution ④...
Page 336 Basics of program execution 10.5 Asynchronous instructions Parallel processing of asynchronous instruction jobs A CPU can process several asynchronous instruction jobs in parallel. The CPU processes the jobs in parallel under the following conditions: • Jobs for an asynchronous instruction are started while other jobs for that instruction are still running.
Page 337 Basics of program execution 10.5 Asynchronous instructions Assigning calls of an instruction to a job To execute an instruction over multiple calls, the CPU must be able to uniquely relate a subsequent call to a running job of the instruction. To relate a call to a job, the CPU uses one of the following two mechanisms, depending on the type of the instruction: •...
Page 338 Basics of program execution 10.5 Asynchronous instructions Summary The table below provides you with an overview of the relationships described above. It shows in particular the possible values of the output parameters if execution of the instruction is not complete after a call. Note The output parameters of an synchronous instruction can change on every call.
Page 339 Basics of program execution 10.5 Asynchronous instructions Note Lower-level asynchronous instructions Some asynchronous instructions use one or more lower-level asynchronous instructions for their processing. This dependence is shown in the tables below. Please note that each lower-level instruction typically occupies one resource in the instruction's resource pool.
Page 340 Basics of program execution 10.5 Asynchronous instructions Extended instructions 1513R-1 PN 1515R-2 PN 1517H-3 PN 1518HF-4 PN File handling FileReadC FileWriteC FileDelete Reference information ResolveSymbols If you use the instruction WRIT_DBL (SFC84) to write data structures greater than 64 KB into the load memory, the response times in the R/H-CPU user program can increase.
Page 341 Basics of program execution 10.5 Asynchronous instructions Table 10- 10 Lower-level instructions used for asynchronous instructions for communications proces- sors Communications pro- 1513R-1 PN 1515R-2 PN 1517H-3 PN 1518HF-4 PN cessors PtP communication Port_Config uses RDDEC, WRREC Send_Config uses RDDEC, WRREC Receive_Config uses RDDEC, WRREC Send_P2P...
Page 342: Protection
• Do not activate the OPC UA server. You can find more information on the security mechanisms for the OPC UA server in the Communication (https://support.industry.siemens.com/cs/ww/en/view/59192925) Function Manual. • Do not activate time-of-day synchronization over NTP servers. • Do not activate PUT/GET communication.
Page 343: Local User Management
Protection 11.3 Local user management 11.3 Local user management 11.3.1 Useful information on the local user administration and access control As of TIA Portal version V19 and CPU firmware version V3.1, R/H-CPUs feature improved management of users, roles, and CPU function rights (User Management & Access Control, UMAC).
Page 344 Protection 11.3 Local user management Introduction to the local user administration and access control To restrict the PG/HMI access to the CPU at different levels, you configured passwords for the corresponding access levels. With this procedure, for example, HMI accesses could be permitted without restriction, but write accesses could be made dependent on the knowledge of a password.
Page 345 Protection 11.3 Local user management The following figure shows the assignment of the role with full access to a user ("Admin"). Figure 11-2 Assigning a role to a user Requirement CPU parameterization: To make use of users, roles and function rights for a CPU, the "Enable access control"...
Page 346: Advantages Of The Local User Administration And Access Control
Protection 11.3 Local user management 11.3.2 Advantages of the local user administration and access control The advantages of the new local user management for R/H-CPUs and the changes associated with it are described below. Quick activation/deactivation of the local user administration The options for user administration are located in the "Protection &...
Page 347 Protection 11.3 Local user management Loading the user administration during operation As of firmware version V3.1, certain security-relevant configuration data can be loaded both in STOP system state and in RUN-Solo or RUN-Redundant system state. This means that loading the hardware configuration does not necessarily lead to a CPU STOP. You can load the following changes in STOP, RUN-Solo or Run-Redundant system state (Download to device >...
Page 348: From The Access Level To The Function Right Of Users
Protection 11.3 Local user management You can find more information about the API methods in the Web server Function Manual (https://support.industry.siemens.com/cs/de/en/view/59193560). Note Passwords changed at runtime take priority over loaded passwords If you have changed your password during running operation and subsequently load your project, the password assigned during runtime takes precedence over the password set in the project (default setting).
Page 349 Protection 11.3 Local user management Continuing to use access levels Even though the new local user administration replaces the usual access protection via corresponding function rights of individual users, there is still the possibility to continue to use this familiar access protection. This is required, for example, for HMI devices which only support access levels and which do not benefit yet from possibilities of the new user administration.
Page 350 Protection 11.3 Local user management Procedure To activate the "Legacy access control" and set the required access level, follow these steps: 1. In the CPU properties, go to "Protection & Security > Access control". 2. Select the option "Activate access control" and, in addition, select the check box "Use legacy access control via access levels"...
Page 351: Information About Compatibility
Protection 11.4 Configuring access protection for the CPU 11.3.4 Information about compatibility In the following sections, you will find information on the behavior of the CPUs with the local user administration, e.g. when replacing modules in STEP 7 and for further use of projects and programs without local user administration.
Page 352 Protection 11.4 Configuring access protection for the CPU Rules for passwords Ensure that passwords are sufficiently secure. Passwords must not follow a machine- recognizable pattern. Apply the following rules: • Assign a password that is at least 8 characters long. •...
Page 353 Protection 11.4 Configuring access protection for the CPU Communication between the CPUs via the communication functions in the blocks is not restricted by the access level of the CPUs. Entering the correct password enables access to all the functions that are allowed in the given level.
Page 354 For the fail-safe R/H-CPUs up to FW version V3.0, there is an additional access level in addition to the four described access levels. For more information on this access level, refer to the description of the F-system SIMATIC Safety - Configuring and Programming (https://support.industry.siemens.com/cs/ww/en/view/54110126) SIMATIC Safety Programming and Operating Manual. S7-1500R/H redundant system...
Page 355: Using The Display To Set Additional Password Protection
Protection 11.5 Using the display to set additional password protection 11.5 Using the display to set additional password protection Blocking access to a password-protected CPU You can block access to password-protected CPUs (local password block) on the CPU display. The block is effective if the mode selector is set to RUN. The access block requires a configured protection level in STEP 7 and applies regardless of password protection.
Page 356: Know-How Protection
Protection 11.7 Know-how protection 11.7 Know-how protection Application You can use know-how protection to protect one or more OB, FB or FC blocks as well as global data blocks in your program from unauthorized access. To restrict access to a block, assign a password.
Page 357 Protection 11.7 Know-how protection Further actions Further actions that can be carried out with a know-how protected block: • Copying and deleting • Calling in a program • Online/offline comparison • Loading Global data blocks and array data blocks You protect global data blocks (global DBs) from unauthorized write access with know-how protection.
Page 358 Protection 11.7 Know-how protection 5. Click "OK" to confirm your entry. 6. Close the "Know-how protection" dialog by clicking "OK". Result: The blocks selected are know-how-protected. Know-how protected blocks are marked with a padlock in the project tree. The password entered applies to all blocks selected. Note Password provider Alternatively, you can set up know-how protection for blocks with a password provider.
Page 359 Protection 11.7 Know-how protection Removing block know-how protection Proceed as follows to remove block know-how protection: 1. Select the block from which you want to remove know-how protection. The protected block must not be open in the program editor. 2. In the "Edit" menu, select the "Know-how protection" command to open the "Change protection"...
Page 360: Protection By Locking The Cpu
Protection 11.8 Protection by locking the CPU 11.8 Protection by locking the CPU Locking options Provide additional protection for your CPUs from unauthorized access (for example to the SIMATIC memory card) by using a secure front cover. You have the following options, for example: •...
Page 361: Commissioning
Also allow for any possible foreseeable errors in the tests. This prevents you from putting persons or equipment at risk during operation. Software tools for commissioning SIEMENS PRONETA provides commissioning support. You can find more information on SIEMENS PRONETA in the section Software (Page 126). S7-1500R/H redundant system...
Page 362: 12.2 Check Before Powering On For The First Time
Commissioning 12.2 Check before powering on for the first time 12.2 Check before powering on for the first time Before the first power-on, check the installation and the wiring of the S7-1500R/H redundant system. Questions for checking The following questions provide instructions for checking your system in the form of a checklist.
Page 363: Commissioning Procedure
Commissioning 12.3 Commissioning procedure 12.3 Commissioning procedure Requirements • The CPUs are in the "Factory settings" state or have been reset to factory settings. You can find more information in the Resetting CPUs to factory settings (Page 466) section. • The CPUs have the same article numbers. •...
Page 364: Removing/Plugging In Simatic Memory Cards
Administration Editor is assigned to the top CPU in the STEP 7 project tree. You can find more information on commissioning a SIMATIC Safety F-system and the Safety Administration Editor in the SIMATIC Safety – Configuring and Programming (https://support.industry.siemens.com/cs/ww/en/view/54110126) Programming and Operating Manual. 12.3.1...
Page 365 Commissioning 12.3 Commissioning procedure Inserting SIMATIC memory cards Proceed as follows to insert a SIMATIC memory card: 1. Open the front cover of the CPU. 2. Insert the SIMATIC memory card, as shown on the CPU, into the slot for the SIMATIC memory card.
Page 366 Commissioning 12.3 Commissioning procedure Please also note the following FAQs on the Internet (https://support.industry.siemens.com/cs/ww/en/view/59457183) for removal of the SIMATIC memory card. Note If you switch a CPU in redundant mode to the STOP operating state, the S7-1500R/H redundant system switches to the RUN-Solo system state. The other CPU maintains control of the process.
Page 367: First Power-On Of The Cpus
Commissioning 12.3 Commissioning procedure 12.3.2 First power-on of the CPUs Requirements • The SIMATIC S7-1500R/H redundant system has been installed. • The system has been wired. • The SIMATIC memory cards are in the CPUs. Procedure Follow these steps to commission the CPUs: 1.
Page 368 Commissioning 12.3 Commissioning procedure Pairing procedure Proceed as follows to pair two CPUs 1. Create a redundancy connection between two CPUs. Connect the CPUs to the relevant ports of the interfaces (for example for R-CPUs: X1 P2R). 2. POWER ON both CPUs. Loss of pairing If pairing is already established, an invalid configuration variant will lead to the loss of pairing.
Page 369: Redundancy Ids
Commissioning 12.3 Commissioning procedure Primary and backup CPU role assignment The primary CPU and backup CPU roles are assigned by the S7-1500R/H redundant system during pairing. The redundant system always attempts to restore the previous roles of the R/H CP. The following applies here: The CPU that last controlled the process becomes the primary CPU.
Page 370 Commissioning 12.3 Commissioning procedure Redundancy IDs 1 and 2 Redundant operation is only possible if the two CPUs have different redundancy IDs. The redundancy IDs can have values of 1 and 2. The CPUs save the redundancy IDs in their retentive data areas.
Page 371 Commissioning 12.3 Commissioning procedure Automatic assignment Requirement: Both real CPUs of the redundant system have the same redundancy ID (e.g."1"). Options for automatic assignment: • Both CPUs are in STOP. There is pairing between the two CPUs. The ERROR LEDs are flashing red.
Page 372 Commissioning 12.3 Commissioning procedure 4. Download the project and the hardware configuration to the CPU that you want to switch to RUN first. Figure 12-3 Assigning redundancy IDs Reading redundancy IDs from the display As well as assigning redundancy IDs over the display, you can read out the redundancy ID with the menu command "Overview >...
Page 373: Downloading Projects To The Cpus
Commissioning 12.3 Commissioning procedure Proceed as follows to switch the redundancy IDs: 1. Make sure that both CPUs are in STOP operating state: 2. Make sure that the two CPUs are connected to each other. 3. Change the redundancy ID of a CPU using the display. Result: Once the redundancy ID has been changed on one CPU, both CPUs restart and each now has the previous redundancy ID of the other.
Page 374 Loading the safety program with a SIMATIC Safety F-system with the 1518HF-4 PN CPUs You can find the exact procedure in the SIMATIC Safety - Configuring and Programming (https://support.industry.siemens.com/cs/ww/EN/view/54110126) Programming and Operating Manual. Loading project data via communications processor into the redundant S7-1500R/H system As of FW version V3.1, you can also load project data via the communications processor into...
Page 375 Commissioning 12.3 Commissioning procedure Downloading project data to the CPU By default, the project data is downloaded to the primary CPU. Procedure Proceed as follows: 1. Right-click to select the S7-1500R/H system in the project tree. 2. Select the "Download to device" > "Hardware and software (changes only)" command from the shortcut menu.
Page 376 Commissioning 12.3 Commissioning procedure "Load preview" dialog window If necessary, the project data is compiled before the download. You can only load project data that is consistent and has been compiled without errors. The "Load preview" dialog window sets out the key information on the load process to be run: Procedure 1.
Page 377 Commissioning 12.3 Commissioning procedure Note Role change during loading Beware of a possible role change between primary and backup CPU shortly before, during or after loading. A role change can occur during loading if the primary CPU fails (power failure, hardware defect) or is in STOP and: •...
Page 378 Commissioning 12.3 Commissioning procedure Detailed procedure for download to the backup CPU: 1. Right-click to select the S7-1500R/H system in the project tree. 2. Select "Hardware and software (changes only)" under "Download to backup CPU". The backup CPU is now selected instead of the primary CPU in the "Extended download" dialog window.
Page 379 Commissioning 12.3 Commissioning procedure Procedure Proceed as follows to download the user program in RUN: 1. Switch the backup CPU to the STOP operating state. The S7-1500R/H system switches to RUN-Solo system state. 2. Download the modified user program to the primary CPU with "Download to device" > "Software (changes only)".
Page 380 Commissioning 12.3 Commissioning procedure Note Response time when downloading a modified user program into the R/H CPUs in the RUN-Redundant system state During the download process in the RUN-Redundant system state, the response time of the system is restricted compared with the normal redundant mode. The more changes the user program contains, the higher the impact on the response time.
Page 381: Operating And System States
Commissioning 12.4 Operating and system states 12.4 Operating and system states 12.4.1 Overview Operating states Operating states describe the behavior of an individual CPU at a specific time. Knowledge of the operating states of the CPUs is useful for programming startup, testing and error diagnostics.
Page 382 Commissioning 12.4 Operating and system states • Changes to data through communication functions • Access to data that could be different on the different CPUs, for example current time, system time, or runtime messages Synchronization for redundant mode In the SYNCUP system state, the operating system synchronizes the user programs in the two CPUs for redundant operation.
Page 383 Commissioning 12.4 Operating and system states Overview of system and operating states The figure below shows the possible operating states of the CPUs and the resulting system states. In general, the two CPUs have equal priority; each CPU can be either primary or backup. Figure 12-6 System and operating states S7-1500R/H redundant system...
Page 384: Startup Operating State
Commissioning 12.4 Operating and system states The following table provides you with an overview of how the redundant system starts and at the same time runs through the various operating modes and system states. The following initial situation and steps are an example. The operating and system states are described in detail in the following sections.
Page 385 Commissioning 12.4 Operating and system states Points to note • The CPU resets the process image input. • All outputs are disabled or respond as configured for the given module: They provide a configured substitute value or retain the last value output and switch the controlled process to a safe operating state.
Page 386 Commissioning 12.4 Operating and system states Aborting or not running startup If errors occur during startup, the CPU aborts STARTUP and returns to the STOP operating state. The CPU does not perform STARTUP under the following conditions: • You have not inserted a SIMATIC memory card or an invalid one is inserted. •...
Page 387: Stop Operating State
Commissioning 12.4 Operating and system states Note "Comparison preset to actual configuration" parameter for communications processors and active backplane bus The parameter "Comparison preset to actual configuration" can also be set for communications processors and active backplane bus in STEP 7. In addition, you can take over the set "Comparison preset to actual configuration"...
Page 388: Syncup Operating State
Commissioning 12.4 Operating and system states 12.4.4 SYNCUP operating state SYNCUP operating state (only in the backup CPU) In the SYNCUP operating state, the operating system synchronizes the backup CPU with the primary CPU. The primary CPU is in the RUN-Syncup operating state and controls the process. Unlike the primary CPU, the backup CPU and if applicable, central modules, do not go through the STARTUP operating state.
Page 389: Syncup System State
Commissioning 12.4 Operating and system states If the cyclic program exceeds the maximum cycle time, the operating system may start the time error OB (OB 80). You can find additional information in the section Start events (Page 323). Points to note in the RUN operating state In non-redundant operation, the CPUs are independent of each other.
Page 390 Commissioning 12.4 Operating and system states SYNCUP system state Synchronization in the SYNCUP system state ensures that the two CPUs can operate redundantly. With the SYNCUP system state, the redundant system switches from RUN-Solo to the RUN-Redundant system state. Afterwards, both CPUs synchronously process the same user program.
Page 391 Commissioning 12.4 Operating and system states Preparing the SYNCUP system state After SYNCUP starts, the CPUs prepare SYNCUP: • The backup CPU switches to SYNCUP operating state and sends a status message to the primary CPU. • The primary CPU then switches from the RUN operating state to RUN-Syncup. The current operating states are shown on the displays: Table 12- 5 Preparing SYNCUP...
Page 392 Commissioning 12.4 Operating and system states ① Copying the SIMATIC Memory Card The primary CPU copies parts of the load memory to the backup CPU: • User program, system blocks and project data of the CPU from the \SIMATIC.S7S folder Note Overwriting load memory content Copying overwrites the load memory contents on the SIMATIC Memory Card of the backup...
Page 393 Commissioning 12.4 Operating and system states ② Restart of the backup CPU The backup CPU restarts and automatically switches back to the SYNCUP operating state. The display of the backup CPU shows the "Connecting..." state. Table 12- 7 Restart of the backup CPU Primary CPU Backup CPU ③...
Page 394 Commissioning 12.4 Operating and system states The communication connections in the primary CPU are temporarily ended. You can no longer delete, load, generate or compress blocks in the user program. You can no longer run any test or commissioning functions. Table 12- 8 Preparing the copying of the work memory Primary CPU...
Page 395 Commissioning 12.4 Operating and system states The display of the primary CPU indicates the copying progress. Table 12- 9 Copying the work memory Primary CPU Backup CPU The backup CPU is busy accepting the data before it can also process the user program. ⑤...
Page 396 Commissioning 12.4 Operating and system states The display of the primary CPU indicates the lag of the backup CPU. Table 12- 10 Making up backup CPU lag Primary CPU Backup CPU Once the backup CPU has caught up, both CPUs switch to the RUN-Redundant operating state.
Page 397 Commissioning 12.4 Operating and system states Effects of the SYNCUP system state In SYNCUP, there are different effects on the execution of the user program and communication functions. The effects are set out in the table below. Table 12- 11 Properties of SYNCUP Procedure Effects during the SYNCUP system state Processing of the user program on the...
Page 398 Commissioning 12.4 Operating and system states SYNCUP system state aborts Abort is possible in a range of cases even if you have successfully launched the SYNCUP system state: • If one of the two CPUs POWERS OFF. • If you switch the backup CPU to STOP; the primary CPU continues operating in RUN operating state.
Page 399 Commissioning 12.4 Operating and system states You can find a detailed list of causes of errors and solutions in the SYNCUP abort table: Causes and solutions. Figure 12-8 SYNCUP system state aborts Table 12- 12 Sequence of events: SYNCUP aborts No.
Page 400 Memory Card with greater memory capacity. You can find more information in the Structure and use of the CPU memory (https://support.industry.siemens.com/cs/ww/en/view/59193 101) Function Manual. The name of files or directories on the SIMATIC Memory Card Make sure that file and/or directory names do not contain of the backup CPU contains unsupported characters.
Page 401: System And Operating State Transitions
Commissioning 12.4 Operating and system states Cause of SYNCUP abort Solution Primary CPU or backup CPU goes into STOP operating state. Switch the primary CPU or backup CPU into RUN operating state. PROFINET ring interrupted Replace defective PROFINET cables or PROFINET devices in the PROFINET ring.
Page 402 Commissioning 12.4 Operating and system states Operating state transitions Operating state transitions of the redundant system The following figure shows the operating state transitions of the primary and backup CPU. Figure 12-10 Operating state transitions S7-1500R/H redundant system System Manual, 01/2024, A5E41814787-AF...
Page 403 Commissioning 12.4 Operating and system states ① POWER ON → STARTUP, POWER ON → SYNCUP Transition Description Effect System state POWER ON → STARTUP After POWER ON → transition STARTUP, the primary The CPUs implement pairing after switch-on. The redundant system then CPU clears the non- switches to STARTUP if: retentive memory and...
Page 404 Commissioning 12.4 Operating and system states Automatic STARTUP after POWER ON only possible for the primary CPU Note The automatic STARTUP after POWER ON only for the primary CPU prevents a CPU with outdated, retentive data from automatically changing to the RUN operating mode. You can switch the backup CPU manually to RUN, this then automatically becomes the primary CPU and starts with its retentive data.
Page 405 Commissioning 12.4 Operating and system states ② No STARTUP after parameterization "Warm restart - operating mode before POWER OFF" Requirements: • You have parameterized "Warm restart - operating mode before POWER OFF" for both CPUs. • The redundant system is in the RUN-Redundant system state. Procedure: 1.
Page 406 Commissioning 12.4 Operating and system states ③STOP → STARTUP Transition Description Effects System state STOP → STARTUP The primary CPU clears transition the non-retentive The redundant system switches to the STARTUP system state if: memory and resets the • You set a CPU to RUN via the PG/PC or the display and the mode selector is contents of non- retentive data blocks to set to RUN...
Page 407 Commissioning 12.4 Operating and system states ④STARTUP → RUN-Solo, STARTUP → RUN Transition Description Effects System state STARTUP → RUN-Solo The process image is transition updated and pro- The redundant system switches from STARTUP to the RUN-Solo system state if: cessing of the cyclic •...
Page 408 Commissioning 12.4 Operating and system states ⑤RUN-Solo → SYNCUP, RUN → RUN-Syncup, STOP → SYNCUP Transition Description Effects System state RUN-Solo → SYNCUP See section SYNCUP transition system state The primary CPU is in the RUN operating state. The redundant system switch- (Page 388) es from the RUN-Solo system state to the SYNCUP system state if: •...
Page 409 Commissioning 12.4 Operating and system states ⑥SYNCUP → RUN-Redundant, RUN-Syncup → RUN-Redundant Transition Description Effects System state SYNCUP → RUN-Redundant This system state tran- transition sition does not have The redundant system switches from SYNCUP to the RUN-Redundant system any effect on data. state if SYNCUP has successfully run.
Page 410 Commissioning 12.4 Operating and system states ⑧RUN-Redundant → STOP, RUN-Solo → STOP, RUN → STOP Transition Description Effects System state tran- RUN-Redundant → STOP, RUN-Solo → STOP This system state tran- sition sition does not have The redundant system switches from the RUN-Redundant/RUN-Solo system any effect on data.
Page 411 Commissioning 12.4 Operating and system states ⑩SYNCUP → STOP, RUN-Syncup → STOP Transition Description Effects System state SYNCUP → STOP This system state tran- transition sition does not have The redundant system switches from the SYNCUP system state to the STOP any effect on data.
Page 412: Loss Of Redundancy Cpu
Commissioning 12.4 Operating and system states ⑪STARTUP → STOP Transition Description Effects System state STARTUP → STOP This system state tran- transition sition does not have The redundant system switches from the STARTUP system state to the STOP any effect on data. system state if: Primary CPU op- This operating state...
Page 413 Commissioning 12.4 Operating and system states Response Loss of redundancy of CPU means: • The redundant system switches from the RUN-Redundant system state to the RUN-Solo system state. • The primary CPU switches from the RUN-Redundant operating state to RUN (1) •...
Page 414 Commissioning 12.4 Operating and system states (1) Primary CPU switches to the RUN operating state Figure 12-11 Primary CPU switches to the RUN operating state Table 12- 14 Response to loss of redundancy of CPU: Primary CPU switches to RUN No.
Page 415 Commissioning 12.4 Operating and system states (2) Primary-backup switchover Figure 12-12 Primary-backup switchover Table 12- 15 Response to primary CPU error: Backup CPU becomes primary CPU and switches to RUN No. in CPU 1 System state CPU 2 diagram Initial situation: The S7-1500R/H redundant system is in the RUN-Redundant system state. The primary CPU (CPU 1) fails because of a hardware defect.
Page 416: Displaying And Changing The System State
Please note that you can only implement the system states RUN-Redundant and STOP through the displays by switching both CPUs to the operating state RUN or STOP . SIMATIC S7-1500 Display Simulator A simulation of the display of the available menu commands is available in the SIMATIC S7-1500 Display Simulator (https://support.industry.siemens.com/cs/ww/en/view/109761758).
Page 417 Commissioning 12.4 Operating and system states STEP 7 Displaying the system state: The R/H-system operating panel (Online & Diagnostics) displays the system status. Changing the system state: On the R/H system control panel (Online & diagnostics): • STOP system state: Press the STOP R/H-System button. Figure 12-13 STOP system state on the R/H system control panel On the CPU control panels (Online &...
Page 418: Cpu Memory Reset
Commissioning 12.5 CPU memory reset 12.5 CPU memory reset Basics of a memory reset Memory resets can be performed for the primary and for the backup CPU. Memory resets are generally only useful for the primary CPU. Reason: Following a primary CPU memory reset, you need to trigger synchronization for redundant operation.
Page 419: Automatic Memory Reset
CPU. The password is only deleted when the "Delete password for protection of confidential PLC configuration data" option is set. You can find additional information on the password for protection of confidential configuration data in the Communication (https://support.industry.siemens.com/cs/ww/en/view/59192925) function manual. 12.5.1 Automatic memory reset Possible causes of automatic memory reset Proper continuation of work is prevented in the following cases.
Page 420: Manual Memory Reset
Commissioning 12.5 CPU memory reset 12.5.2 Manual memory reset Reason for manual memory reset Memory reset is required to reset the primary or backup CPU to its "initial state". Memory resets can only be run in the STOP operating state of a CPU. CPU memory reset There are three options for performing a CPU memory reset: •...
Page 421 Commissioning 12.5 CPU memory reset Procedure via the operating mode keys (R-CPUs as of article number 6ES7513-1RM03-0AB0, 6ES7515-2RN03-0AB0) Note Memory reset ↔ Reset to factory settings The procedure described below also corresponds to the procedure for resetting to factory settings: •...
Page 422: Backing Up And Restoring The Cpu Configuration
Commissioning 12.6 Backing up and restoring the CPU configuration 12.6 Backing up and restoring the CPU configuration Backup from online device You may make changes in the operation of your plant. For example, you may add new devices, replace existing ones or adapt the user program. If these changes result in undesirable behavior, you can restore the plant to an earlier state.
Page 423 Commissioning 12.6 Backing up and restoring the CPU configuration Backup from Upload from de- Upload device as Snapshot of the online device vice (software) new station actual values Entries in the diagnostics buffer Current time Password for protection of confi- dential configuration data Properties of the type of backup Backup can be edited...
Page 424 If you cannot access the CPU via the IP address, you can set a temporary emergency IP address for the CPU. To the more information on emergency address options, please refer to the Communication (https://support.industry.siemens.com/cs/ww/de/view/59192925/en) function manual. Storage of multilingual project texts Different categories of texts are created when you configure a CPU, for example •...
Page 425 Do not manipulate any contents in the OMSSTORE folder on the SIMATIC Memory Card. You can find information on reading out the memory usage of the CPU and the SIMATIC memory card in the Structure and Use of the CPU Memory (https://support.industry.siemens.com/cs/de/de/view/59193101/en) Function Manual. S7-1500R/H redundant system System Manual, 01/2024, A5E41814787-AF...
Page 426: Time Synchronization
Commissioning 12.7 Time synchronization 12.7 Time synchronization Introduction All S7-1500R/H CPUs have an internal clock. The clock shows: • The time of day with a resolution of 1 millisecond • The date and the day of the week The CPUs take into account the time change caused by daylight saving time. In redundant mode, the two CPUs of the S7-1500R/H redundant system constantly synchronize their internal clocks.
Page 427: Example: Configuring The Ntp Server
Commissioning 12.7 Time synchronization 12.7.1 Example: Configuring the NTP server Configuring time synchronization with your own NTP server Automation task You use your own server in your network. Your own server offers the following advantages: • Protection against unauthorized external accesses •...
Page 428: Identification And Maintenance Data
Commissioning 12.8 Identification and maintenance data 12.8 Identification and maintenance data 12.8.1 Reading out and entering I&M data I&M data Identification and maintenance data (I&M data) is information saved on the module. The data • Read-only (I data) or • Read/write (M data) Identification data (I&M0): Manufacturer information about the module that can only be read.
Page 429 Commissioning 12.8 Identification and maintenance data Reading I&M data over the user program You have the following options for reading module I&M data in the user program: • Using the RDREC instruction The data record structure for centrally inserted modules and for distributed modules accessible over PROFINET IO is described in the section Record structure for I&M data (Page 429).
Page 430: Record Structure For I&M Data
Commissioning 12.8 Identification and maintenance data Enter maintenance data over STEP 7 STEP 7 assigns a default module name. You can enter the following information: • Plant designation (I&M 1) • Location identifier (I&M 1) • Installation date (I&M 2) •...
Page 431 Access Example Explanation Identification data 0: (record index AFF0 VendorIDHigh Read (1 bytes) 0000 Vendor name (002A = SIEMENS AG) VendorIDLow Read (1 bytes) 002A Order_ID Read (20 bytes) 6ES7515-2RM00-0AB0 Article number of module (for example CPU 1515R-1 PN) IM_SERIAL_NUMBER...
Page 432: Example: Read Out Firmware Version Of The Cpu With Get_Im_Data
Commissioning 12.8 Identification and maintenance data 12.8.3 Example: Read out firmware version of the CPU with Get_IM_Data Automation task You want to check whether the modules in your redundant system have the current firmware. The firmware version of the modules can be found in the I&M 0 data. The IM 0 data is the basic information for a device.
Page 433 Commissioning 12.8 Identification and maintenance data Solution Proceed as follows to read out the I&M 0 data of the CPU with the redundancy ID 1: 1. Create a global data block to store the I&M 0 data. 2. Create a structure of the data type "IM0_Data" in the global data block. You can assign any name to the structure ("imData"...
Page 434 Commissioning 12.8 Identification and maintenance data Result The "Get_IM_Data" instruction has stored the I&M 0 data of the CPU with redundancy ID 1 in the data block. You can view the I&M 0 data online in STEP 7, for example with the "Monitor all" button in the data block.
Page 435: Display
Introduction The following section gives an overview of how the R/H-CPU display operates. Detailed information on the individual options, a training course and a simulation of the selectable menu items is available in the SIMATIC S7-1500 Display Simulator (https://support.industry.siemens.com/cs/ww/en/view/109761758). Display The R/H-CPUs have a front cover with a display and operating keys.
Page 436 Display 13.1 CPU display Operating temperature for the display To increase the service life of the display, the display switches off when the permitted operating temperature is exceeded. When the display has cooled down again, it switches back on automatically. When the display is switched off, the LEDs continue to show the status of the CPUs.
Page 437 Display 13.1 CPU display Regarding ①: CPU status information The following table shows the CPU status information that can be retrieved via the display. Table 13- 1 CPU status information Color and icons for the status Meaning data Green • •...
Page 438 Display 13.1 CPU display Regarding ②: Names of the menus The following table shows the available menus of the display. Table 13- 2 Names of the menus Main menu items Meaning Description Overview The "Overview" menu contains information about: • Properties of the local CPU •...
Page 439 Display 13.1 CPU display Menu icons The following table shows the icons that are displayed in the menus. Table 13- 3 Menu icons Icon Meaning Editable menu item. Select the required language. A message is available in the next lower level page. There is an error in the next lower level page.
Page 440 Display 13.1 CPU display Control keys You operate the display using the following keys: • Four arrow keys: "up", "down", "left", "right" If you press and hold an arrow key for 2 seconds, this generates an automatic scroll function. • One ESC key •...
Page 441 Display 13.1 CPU display Tooltips Some of the values shown on the display can exceed the available display width. The values in question include: • Station name • Plant designation • Location identifier • PROFINET device name The available display width is frequently exceeded on CPUs with small displays. If you focus on the relevant value on the display and press the "Left"...
Page 442 Display 13.1 CPU display Uploading image to the display via STEP 7 In the STEP 7 device view, you download an image from your file system to the CPU display with the "Display > User-defined logo" function. Different images can be downloaded to the two R/H-CPUs for clearer differentiation.
Page 443 – To do so, select the "Consistent download" option under "Text libraries" in the "Load preview" dialog (default). Reference Important information/special requirements for the display of HF-CPUs can be found in the Product Information F-CPUs S7-1500 (https://support.industry.siemens.com/cs/ww/de/view/109478599/en). S7-1500R/H redundant system System Manual, 01/2024, A5E41814787-AF...
Page 444: Maintenance
Maintenance 14.1 Replacing components of the S7-1500R/H redundant system 14.1.1 Checking before replacing components Introduction Please observe the following rules if the redundant system is in the RUN-Solo system state: • Do not immediately start replacing components. • Do not immediately switch the failed CPU to the RUN. operating state. First check the pairing status in the RUN-Solo system state.
Page 445 Maintenance 14.1 Replacing components of the S7-1500R/H redundant system Checking pairing state You have the following options for checking the pairing state: • Directly from the display of the backup CPU. In the "Overview > Redundancy > Pairing state" menu: –...
Page 446 Maintenance 14.1 Replacing components of the S7-1500R/H redundant system • In STEP 7 in the diagnostic status (Online & diagnostics) of the S7-1500R/H system: Check the system state in the diagnostic status: – Pairing: "Paired" is shown in the "Pairing state" field. –...
Page 447: Replacing Defective R/H-Cpus
The S7-1500R/H redundant system is in the RUN-Solo system state. Note Replacing defective HF-CPU with safety program You can find the exact procedure in the SIMATIC Safety - Configuring and Programming (https://support.industry.siemens.com/cs/ww/en/view/54110126) programming and operating manual. Note Replacement part case R/H-CPU Replacing a R/H-CPU in the replacement part scenario has an impact on the password for protection of confidential configuration data.
Page 448: Replacing Defective Redundancy Connections
Maintenance 14.1 Replacing components of the S7-1500R/H redundant system Procedure for replacing R/H-CPUs Proceed as follows to replace an R/H-CPU in the redundant system: 1. Switch off the supply voltage to the failed R/H-CPU. 2. Remove the connector for the supply voltage. 3.
Page 449: Replacing Two Defective Profinet Cables With S7-1500R
Maintenance 14.1 Replacing components of the S7-1500R/H redundant system S7-1500H: • Replace a defective redundancy connection with S7-1500H. A fiber-optic cable has been interrupted. • Replace defective synchronization module with S7-1500H. • Replace two defective redundancy connections with S7-1500H. Both fiber-optic cables have been interrupted. Evaluating the diagnostics buffer Detailed diagnostics information is provided in the diagnostics buffer of the R/H-CPU.
Page 450: Replacing A Defective Redundancy Connection With S7-1500H
Maintenance 14.1 Replacing components of the S7-1500R/H redundant system Initial situation: Failure of two PROFINET cables simultaneously Two PROFINET cables in the PROFINET ring have been interrupted at two points simultaneously (≤ 1500 ms apart). Both R-CPUs are primary CPUs. The S7-1500R redundant system is in an undefined system state.
Page 451: Replacing Defective Synchronization Module With S7-1500H
Maintenance 14.1 Replacing components of the S7-1500R/H redundant system 14.1.3.3 Replacing defective synchronization module with S7-1500H Initial situation A synchronization module has failed. The redundant S7-1500H is in the RUN-Redundant system state. Procedure: Replacing the synchronization module Proceed as follows to replace a defective synchronization module: 1.
Page 452: Replacing Defective Profinet Cables
Maintenance 14.1 Replacing components of the S7-1500R/H redundant system Result The defective redundancy connections have been replaced. The redundant system switches to the RUN-Redundant system state. The X3/X4 or X4/X5 LEDs flicker yellow/green. Initial situation: Failure of both redundancy connections simultaneously The two redundancy connections (fiber-optic cables) have been interrupted simultaneously (≤...
Page 453: Replacing A Defective Simatic Memory Card
Note Replacing defective SIMATIC memory card in HF-CPU with safety program You can find the exact procedure in the SIMATIC Safety - Configuring and Programming (https://support.industry.siemens.com/cs/ww/en/view/54110126) programming and operating manual. Requirement • Read the information in the section Checking before replacing components (Page 443).
Page 454: Replacing A Defective System Power/Load Current Supply
You will find the procedure, the response of the redundant system and other information on the SIMATIC memory card in the function manual Structure and use of the CPU memory (https://support.industry.siemens.com/cs/ww/en/view/59193101). 14.1.6 Replacing a defective system power/load current supply Initial situation A system power/load current supply PS/PM has failed.
Page 455: Replacing A Defective Communications Processor
If you have set up the H-system with an active backplane bus, then you can change the CP 1543-1 during operation. You can find more information in the Active backplane bus (https://support.industry.siemens.com/cs/de/de/view/109778694/en) Equipment Manual. Requirement Read the information in the Checking before replacing components (Page 443) section.
Page 456: Replacing Defective Io Devices/Switches
Maintenance 14.1 Replacing components of the S7-1500R/H redundant system 14.1.8 Replacing defective IO devices/switches Initial situation A PROFINET device (IO device/switch) in the PROFINET ring or the line topology has failed, for example because of a defect in the IO device or failure of the power supply. The PROFINET ring or line topology is interrupted.
Page 457: Replacing The Display
Maintenance 14.2 Replacing the display/front cover Result The PROFINET ring or line topology is closed again. The PROFINET device can be accessed again in the S7-1500R/H redundant system. The MAINT and ERROR LEDs on both CPUs are off. 14.2 Replacing the display/front cover Introduction The front cover/display is pluggable.
Page 458 Maintenance 14.2 Replacing the display/front cover The figure below shows an example of the operation at the CPU 1513R-1 PN. Figure 14-2 Remove display S7-1500R/H redundant system System Manual, 01/2024, A5E41814787-AF...
Page 459 Maintenance 14.2 Replacing the display/front cover Replace front cover (R/H-CPUs with article numbers 6ES7513-1RL00-0AB0, 6ES7515-2RM00-0AB0, 6ES7517-3HP00-0AB0, 6ES7518-4JP00-0AB0) To remove the front cover from the CPU, follow these steps: 1. Flip up the front cover until the front cover stands at a 90° angle to the front of the module. 2.
Page 460: Replacing The Coding Element At The Power Connector Of The System Power/Load Current Supply
Maintenance 14.3 Replacing the coding element at the power connector of the system power/load current supply 14.3 Replacing the coding element at the power connector of the system power/load current supply Introduction The coding consists of a 2-part coding element. Ex factory a part of the coding element is inserted into the back side of the power connector.
Page 461 Maintenance 14.3 Replacing the coding element at the power connector of the system power/load current supply Procedure Follow these steps to replace the coding element on the power connector of the system power/load current supply: 1. Orient yourself using the labeling on the power cable connection. Figure 14-4 Labeling on the power connector 2.
Page 462: Firmware Update
However, a downgrade can have effects on the user program if you use new functions in the user program which were not yet supported by the firmware of the CPU. The following entry (https://support.industry.siemens.com/cs/de/en/view/109478459) lists all firmware versions for the CPUs including displays. You will also find a description of the new functions of the respective firmware versions.
Page 463 Maintenance 14.4 Firmware update Requirement You have downloaded the files for the firmware update from Siemens Industry Online Support (https://support.industry.siemens.com/cs/ww/en/ps). On this Web page, select: Automation technology > Automation systems > SIMATIC industrial automation systems > Controllers > Advanced Controller > S7-1500 > CPUs > Redundant CPUs...
Page 464 Maintenance 14.4 Firmware update Procedure: online in STEP 7 via Online & diagnostics Requirements: • There is an online connection between CPU/CP/PROFINET IO device, and PG/PC, and the CPU is configured. • Observe the procedure under "Installation of the firmware update of R/H-CPUs". Proceed as follows to perform a firmware update online via STEP 7: 1.
Page 465 If you perform a firmware update via the SIMATIC memory card, you must use a large enough card. Check the specified file sizes of the update files when downloading them from Siemens Industry Online Support. The file size information is especially important when performing firmware updates not only for the CPU but also for the associated communications modules, for example.
Page 466 Maintenance 14.4 Firmware update Installation of the firmware update of R/H-CPUs For a firmware update of the R/H-CPUs, you must switch both R/H-CPUs to the STOP operating state. A role change between primary and backup CPU can occur during the firmware update. The initial situation is assumed in the following: CPU 1 is the primary CPU.
Page 467: Resetting Cpus To Factory Settings
Maintenance 14.5 Resetting CPUs to factory settings Behavior after the firmware update After the firmware update, check the firmware version of the updated module. Reference You can find more information on firmware updates in the STEP 7 online help. 14.5 Resetting CPUs to factory settings Introduction The CPU can be reset to its as-delivered condition using "Reset to factory settings".
Page 468 Maintenance 14.5 Resetting CPUs to factory settings Restore the factory settings of the CPU as follows: 1. Set the mode selector to the STOP position. Result: The RUN/STOP LED lights up yellow. 2. Remove the SIMATIC memory card from the CPU. Wait until the RUN/STOP LED stops flashing.
Page 469 Maintenance 14.5 Resetting CPUs to factory settings Result: The CPU executes a "Reset to factory settings", during which time the RUN/STOP LED flashes yellow. When the STOP-ACTIVE and RUN/STOP LED light up yellow, then the CPU has been reset to factory settings, and is in the STOP mode. The "Reset to factory settings" event is entered in the diagnostics buffer.
Page 470 Maintenance 14.5 Resetting CPUs to factory settings 4. Click the "Reset" button. 5. Click "OK" in response to the confirmation prompts. Result: The CPU executes a "Reset to factory settings", during which time the RUN/STOP LED flashes yellow. When the RUN/STOP LED lights up in yellow, the CPU has been reset to factory settings and is in STOP.
Page 471: Maintenance And Repair
You can find more information on "Reset to factory settings" in the section on memory areas and retentivity in the function manual Structure and use of the CPU memory (http://support.automation.siemens.com/WW/view/en/59193101), and in the STEP 7 online help. For information on CPU memory resets, please refer to the section CPU memory reset (Page 417).
Page 472: Test And Service Functions
Test and service functions 15.1 Test functions Introduction You have the option of testing the operation of your user program on the CPU. You monitor the signal states and values of tags. You preassign values to tags to allow you to simulate specific situations for program execution.
Page 473 Test and service functions 15.1 Test functions Test options • Testing with program status • Testing with breakpoints (only in the STARTUP (startup OB) or RUN-Solo system state) • Testing with a watch table • Testing with a force table •...
Page 474 Observe the additional information about the errors and effects in the programming and operating manual SIMATIC Safety - Configuring and Programming (https://support.industry.siemens.com/cs/ww/de/view/54110126). Difference between modifying and forcing The fundamental difference between the modifying and forcing functions is the storage behavior: •...
Page 475 Test and service functions 15.1 Test functions Testing with watch tables The following functions are available in the watch table: • Monitoring of tags Using watch tables, you can monitor the actual values of the individual tags of a CPU user program.
Page 476 Test and service functions 15.1 Test functions Testing with a force table The following functions are available in the force table: • Monitoring of tags You use watch tables to monitor the actual values of the individual tags of a CPU user program.
Page 477 – In the "Measurements" system folder, double-click to open the recording to display the measurement. The "Diagram" tab for the measurement opens in the work area. Please also see the FAQs on the Internet (https://support.industry.siemens.com/cs/ww/en/view/102781176) for testing with the trace function. Reference Additional information on the test functions can be found in the STEP 7 online help.
Page 478: Reading Out/Saving Service Data
Test and service functions 15.2 Reading out/saving service data 15.2 Reading out/saving service data Service data In addition to the contents of the diagnostics buffer, the service data contain numerous additional data points about the internal status of the CPU. If a problem occurs with the CPU that you cannot resolve with other methods, send the service data to the Product Support team.
Page 479 Test and service functions 15.2 Reading out/saving service data Procedure using the SIMATIC memory card Use the SIMATIC memory card to save the service data if communication with the CPU is not possible over the Ethernet. In all other cases, save the service data using STEP 7. The procedure using the SIMATIC memory card is more time-consuming than the other options for saving the service data.
Page 480: Technical Specifications
Technical specifications Introduction This chapter lists the technical specifications of the system: • The standards and test values that the modules of the S7-1500R/H redundant system comply with and fulfill. • The test criteria according to which the S7-1500R/H redundant system was tested. Technical specifications for the modules The technical specifications of the individual modules can be found in the manuals of the modules themselves.
Page 481 Technical specifications 16.1 Standards and Approvals Safety information WARNING Personal injury and damage to property may occur In hazardous areas, injury and damage can occur if you disconnect plug-in connections during operation of an S7-1500R/H redundant system. Always switch off the power to the S7-1500R/H redundant system before disconnecting plug-in connections in hazardous areas.
Page 482 DI FA TI COS TT Postfach 1963 D-92209 Amberg The EU declarations of conformity are also available for download from the Siemens Industry Online Support website, under the keyword "Declaration of Conformity". UKCA marking The S7-1500R/H redundant system complies with the designated British Standards (BS) for programmable logic controllers published in the official consolidated list of the British government.
Page 483 Technical specifications 16.1 Standards and Approvals cULus approval Underwriters Laboratories Inc. in accordance with • UL 508 (Industrial Control Equipment) OR UL 61010-1 and UL 61010-2-201 • CAN/C22.2 No. 142 (Process Control Equipment) OR CAN/CSA C22.2 No. 61010-1 and CAN/CSA C22.2 No. 61010-2-201 cULus HAZ.
Page 484 Technical specifications 16.1 Standards and Approvals APPROVED for use in Class I, Division 2, Group A, B, C, D T4; Class I, Zone 2, Group IIC T4 Installation Instructions for FM • WARNING - Explosion Hazard - Do not disconnect while circuit is live unless area is known to be non-hazardous.
Page 485 Technical specifications 16.1 Standards and Approvals UKEX approval According to EN 60079-7 (Explosive atmospheres – Part 7: Equipment protection by increased safety "e") and EN IEC 60079-0 (Explosive atmospheres – Part 0: Equipment - General requirements). Special conditions in explosive atmospheres: 1.
Page 486 Technical specifications 16.1 Standards and Approvals CCCEx approval In accordance with GB/T 3836.8 (Explosive atmospheres - Part 3: Equipment protection by type of protection "n") and GB/T 3836.1 (Explosive atmospheres - Part 1: Equipment - General requirements). Ex nA IIC T4 Gc Special conditions in hazardous areas: •...
Page 487 Technical specifications 16.1 Standards and Approvals PROFINET standard The PROFINET interfaces of the redundant S7-1500R/H system are based on the standard IEC 61158 Type 10. Marine approval Classification societies: • ABS (American Bureau of Shipping) • BV (Bureau Veritas - French marine classification society) •...
Page 488: Electromagnetic Compatibility
(REACH, RoHS), fire load, energy consumption, packaging, and disposal information for your Siemens product. Reference You can search for the current Environmental Product Declarations (EPDs) for Siemens products in Siemens Industry Online Support on the Internet (http://www.siemens.com/automation/service&support) • using the keyword "Environmental Product Declaration".
Page 489 Technical specifications 16.2 Electromagnetic compatibility Pulse-shaped disturbances The table below shows the electromagnetic compatibility of the S7-1500R/H redundant system with regard to pulse-shaped disturbances. Table 16- 1 Pulse-shaped disturbances Pulse-shaped disturbance Test voltage Corresponds with degree of severity Electrostatic discharge in accordance Air discharge: ±8 kV with IEC 61000-4-2.
Page 490 Technical specifications 16.2 Electromagnetic compatibility The following table shows the electromagnetic compatibility of the S7-1500R/H redundant system with respect to sinusoidal disturbances (RF coupling). Table 16- 3 Sinusoidal disturbances with RF coupling RF coupling in accordance with IEC 61000-4-6 Corresponds with de- gree of severity from 10 kHz 10 V...
Page 491: Shipping And Storage Conditions
Technical specifications 16.3 Shipping and storage conditions 16.3 Shipping and storage conditions Introduction The S7-1500R/H redundant system meets the specifications regarding shippings and storage conditions pursuant to IEC 61131-2. The following information applies to modules that are shipped and/or stored in their original packaging. Shipping and storage conditions for modules Table 16- 6 Shipping and storage conditions...
Page 492 Technical specifications 16.4 Mechanical and climatic ambient conditions Test of mechanical ambient conditions The table below provides important information with respect to the type and scope of the test of ambient mechanical conditions. Table 16- 7 Test of mechanical ambient conditions Condition tested Test Standard Comment...
Page 493: Information On Insulation Tests, Protection Class, Degree Of Protection And Rated Voltage
Technical specifications 16.5 Information on insulation tests, protection class, degree of protection and rated voltage Ambient conditions Permissible range Comments Temperature H- Horizontal from 0 to 60 °C CPUs mounting from 0 to 55 °C position with synchronization modules Sync Module 1 GB FO 40 km (6ES7960-1FE00-0AA5) Vertical...
Page 494: Use Of S7-1500R/H In Zone 2 Hazardous Area
IEC 61131-2 or IEC 61010-2-201. 16.6 Use of S7-1500R/H in Zone 2 hazardous area Reference You can find more information in the product information Use of modules in a Zone 2 Hazardous Area (http://support.automation.siemens.com/WW/view/en/19692172). S7-1500R/H redundant system System Manual, 01/2024, A5E41814787-AF...
Page 495: Dimension Drawings
Dimension drawings Mounting rail 160 mm Figure A-1 Mounting rail 160 mm Mounting rail 245 mm Figure A-2 Mounting rail 245 mm S7-1500R/H redundant system System Manual, 01/2024, A5E41814787-AF...
Page 496 Dimension drawings Mounting rail 482.6 mm Figure A-3 Mounting rail 482.6 mm Mounting rail 530 mm Figure A-4 Mounting rail 530 mm S7-1500R/H redundant system System Manual, 01/2024, A5E41814787-AF...
Page 497 Dimension drawings Mounting rail 830 mm Figure A-5 Mounting rail 830 mm Mounting rail 2000 mm Figure A-6 Mounting rail 2000 mm S7-1500R/H redundant system System Manual, 01/2024, A5E41814787-AF...
Page 498: Accessories/Spare Parts
Accessories/spare parts General accessories Table B- 1 General accessories Designation Article number Rail 6ES7590-1AB60-0AA0 • Rail, 160 mm (with drill holes) 6ES7590-1AC40-0AA0 • Rail, 245 mm (with drill holes) 6ES7590-1AE80-0AA0 • Rail, 482 mm (with drill holes) 6ES7590-1AF30-0AA0 • Rail, 530 mm (with drill holes) 6ES7590-1AJ30-0AA0 •...
Page 499 RUGGEDCOM RMC-24-TXFXSM-XX 6GK6001-0AC01-0EA0 Additional media converters On request Online catalog You can find more article numbers for the S7-1500R/H redundant system on the Internet (https://mall.industry.siemens.com) in the online catalog and online ordering system. S7-1500R/H redundant system System Manual, 01/2024, A5E41814787-AF...
Page 500: Use Over 2 000 M Above Sea Level And Extended Temperature Range
Use over 2 000 m above sea level and extended temperature range Ambient temperature and installation altitude Extension of the temperature range and the installation altitude The previously permissible range of ambient temperature of 0 °C to 60 °C for the horizontal mounting position has been extended for the R-CPUs to -30 °C to 60 °C (in each case without condensation or icing).
Page 501 Use over 2 000 m above sea level and extended temperature range C.2 CPUs Below you will find the probability of failure values (PFDavg and PFH values) for the fail-safe CPUs mentioned in the table with a service life of 20 years and with a repair time of 100 hours: Operation in low demand mode in accordance with IEC Operation in high demand or continuous mode in accord-...
Page 502: Restrictions
CPU. • The "Safety-related shutdown of standard modules" function, as described on the Internet (https://support.industry.siemens.com/cs/us/en/view/39198632), is only released up to a maximum of 2 000 m. • The synchronization modules for the CPU 1517H-3 PN and CPU 1518HF-4 PN (sync...
Page 503 2 000 m. The fail-safe components are certified for operation in safety mode up to the specified maximum altitudes (according to "Z10 067803 0020" certificate (https://support.industry.siemens.com/cs/ww/de/view/57141281/en)). Reference You can find more information in the Mechanical and climatic ambient conditions (Page 490) section.
Page 504: Glossary
Glossary The AR (Application Relation) covers all communication relations between IO controller and IO device (for example IO data, data records, interrupts). Automation system Programmable logic controller for the open-loop and closed-loop control of process chains in the process engineering industry and in manufacturing technology. The automation system consists of different components and integrated system functions according to the automation task.
Page 505 Glossary Bus, self-assembling The modules are lined up on the rail. They are mechanically and electrically connected to each other with a U-connector as they are swiveled into position. In this way the bus is extended with each module. Code block In SIMATIC S7, a code block contains part of the STEP 7 user program.
Page 506 Glossary Cycle control point The cycle control point marks the end of a cycle and the start of the next cycle. The cycle time statistics and monitoring of the configured maximum cycle time start at the cycle control point. Once the cycle control point has been reached, the CPU writes the process image output to the output modules, reads the state of the inputs in the input modules and then executes the first program cycle OB.
Page 507 Glossary Diagnostics Monitoring functions include: • Detection, localization and classification of errors, faults and alarms. • Display and further evaluation of errors, faults and alarms. They run automatically while the system is in operation. This increases the availability of systems by reducing commissioning times and downtimes. Diagnostics buffer The diagnostics buffer is a battery-backed memory area in the CPU where diagnostics events are stored in their order of occurrence.
Page 508 Glossary Firmware of the CPU In SIMATIC, a distinction is made between the firmware of the CPU and user programs. The firmware is a software embedded in electronic devices. The firmware is permanently connected to the hardware in functional terms. It is usually saved in a flash memory, such as EPROM, EEPROM or ROM, and cannot be replaced by the user or only with special tools or functions.
Page 509 Glossary GSD file As a Generic Station Description, this file contains all the properties of a PROFINET or PROFIBUS device that are necessary for its configuration. Hardware interrupt You can find more information in the "Interrupt, hardware" glossary entry. H-Sync forwarding H-Sync forwarding enables a PROFINET device with MRP to forward synchronization data (synchronization frames) of a S7-1500R redundant system only within the PROFINET ring.
Page 510 Glossary Interrupt The operating system of the CPU distinguishes between various priority classes that control the execution of the user program. These priority classes include interrupts such as hardware interrupts. When an interrupt occurs, the operating system automatically calls an assigned organization block.
Page 511 Glossary Isolated modules In the case of isolated input/output modules, the reference potentials of the control and load circuits are electrically isolated. Examples are optical isolators, relays or transformers. Input/output circuits can be connected to common potential. Load current supply The load current supply supplies the electric input and output circuits of the module.
Page 512 Glossary Pairing Pairing is the mutual recognition of the CPUs of an S7-1500R/H system within a network. During pairing, the CPUs exchange information for mutual identification. Example: Checking for matching article number and firmware version. Successful pairing of two CPUs is a fundamental requirement for redundant operation.
Page 513 Glossary Process image (I/O) The CPU transfers the values from the input and output modules to this memory area. At the start of the cyclic program, the CPU transfers the process image output as a signal state to the output modules. The CPU then reads the signal states of the input modules into the process image input.
Page 514 Glossary Redundancy connection/redundancy connections The redundancy connection in an S7-1500R system is the PROFINET ring with MRP. The redundancy connection uses part of the bandwidth on the PROFINET cable for the synchronization of the CPUs. This bandwidth is therefore not available for PROFINET IO communication.
Page 515 Glossary Safety class Safety level (Safety Integrity Level) SIL according to IEC 61508. The greater the Safety Integrity Level, the stronger the measures for preventing system errors as well as for control of system errors and hardware failures. With the fail-safe modules, use up to safety class SIL3 is possible. Safety function Mechanism integrated in F-CPU and F-I/O that enables use in the SIMATIC Safety fail-safe system.
Page 516 Glossary A switch thus has the task of regenerating and distributing received signals. The switch "learns" the MAC addresses of a connected PROFINET device or additional switches. The switch only forwards those signals that are intended for the connected PROFINET device or switch.
Page 517 Glossary TIA Portal Totally Integrated Automation Portal The TIA Portal is the key to the full performance capability of Totally Integrated Automation. The software optimizes operating, machine and process sequences. Time-delay interrupt You can find more information in the "Interrupt, time-delay" glossary entry. Time-of-day interrupt You can find more information in the "Interrupt, time-of-day"...
Page 518: Index
Index Check before power-on, 361 First power-on, 366 First power-on, requirements, 366 Identification data, 427, 429 24 V DC supply, 259 Identification data - record structure, 429 Procedure, 362 Removing/plugging in a SIMATIC memory card, 363 Communication, 118 Access control, 343 Communication relations in S7-1500R/H, 97 Access levels Communications processor CP 1543-1, 94, 122...
Page 519 Index Connecting communication interfaces to S7- Languages, 442 1500H, 274 Menu, 437 Connecting communication interfaces to S7- Menu icons, 438 1500R, 271 Password protection, 434 Connecting PROFINET ring Upload image to display, 441 To S7-1500H, 283, 286 Display of the IO device assignments in STEP 7, 311 To S7-1500R, 271 Distribution boxes, 277 Connecting redundancy connections (fiber-optic...
Page 520 Index Grounding, 243 Configuration on grounded reference potential, 260 Know-how protection, 355 Overview of the CPU, 263 Know-how protection for blocks Changing, 357 Removing, 358 Setting up, 356 Hardware Requirements, 129 Restrictions, 132 Hardware restrictions, 132 Languages H-CPU Display, 442 Installing, 254 LED flashing test, 476 Uninstalling, 254...
Page 521 Index Pollution degree, 492 Power segment overview, 234 NTP procedure, 425 Overload, 237 Power supply, 124, 250 Process image Inputs and outputs, 314 OB 70, 319, 326 Process image partition OB 72, 318, 324 Update in the user program, 316 OB 83, 319 PROFIBUS DP, 92 OB 86, 324...
Page 522 Index Assigning, 370 S7-1500H configuration with R1 devices in a line Reading, 371 topology, 162 Replacing, 371 S7-1500H configuration with S2 devices and backbone Redundant system startup, 383 ring, 169 Reference potential of the controller, 261 S7-1500H configuration with S2 devices and switch in a Removing/plugging in a SIMATIC memory card line topology, 151 CPU response after a SIMATIC memory card is...
Page 523 Index SYNCUP in industrial environments, 486 OB behavior, 326 in mixed areas, 486 SYNCUP system state, 389, 399 in residential areas, 486 Cancel, 397 User program, 317 Preparations, 390 Download in the RUN-Redundant system state, 378 Requirements, 388 Download in the RUN-Solo system state, 377 Sequence of events, 390 Using PROFINET devices, 227 System diagnostics, 112...

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