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SIMATIC S7-400H
Siemens SIMATIC S7-400H Manuals
Manuals and User Guides for Siemens SIMATIC S7-400H. We have
5
Siemens SIMATIC S7-400H manuals available for free PDF download: System Manual, Manual
Siemens SIMATIC S7-400H Manual (337 pages)
Automation System, Fault-tolerant Systems
Brand:
Siemens
| Category:
Control Unit
| Size: 1.25 MB
Table of Contents
Table of Contents
1
Safety Guidelines
2
Qualified Personnel
2
Correct Usage
2
Warning
2
A5E00068197
3
Changes Compared to the Previous Version
4
Certification
4
Online Help
5
Finding Your Way
5
Training Centers
7
H/F Competence Center
7
Recycling and Disposal
7
A&D Technical Support
8
Service & Support on the Internet
9
Fault-Tolerant Programmable Logic
11
Fault-Tolerant Programmable Logic Controllers
19
Operating Objectives of Redundant Programmable Logic Controllers
20
Redundant Programmable Logic Controllers in the SIMATIC Series
20
Software Redundancy
21
Why Do We Have Fault-Tolerant Programmable Logic Controllers?
21
Graduated Availability by Duplicating Components
22
Increasing System Availability
22
System-Wide Universality
22
Universal Automation Solutions with SIMATIC
22
Example of Redundancy in a 2-Out-Of-2 System with Total Failure
23
Example of Redundancy in a Network Without Malfunction
23
Failure of a Redundant Node (Total Failure)
23
Redundant Nodes
23
S7-400H Installation Options
25
Further Information
26
Overview
26
Redundant PROFIBUS-DP
26
Base System of the S7-400H
27
Central Processing Units
27
Hardware of the S7-400H Base System
27
Fiber-Optic Cables
28
Mounting Rack for S7-400H
28
Power Supply
28
Synchronization Submodules
28
I/O Configuration Versions
29
I/O Modules for S7-400H
29
Communication
30
Communication Availability
30
Programming and Configuration
30
Optional Software
31
Required Software
31
The User Program
31
Tools for Configuration and Programming
31
Specific Blocks for S7-400H
32
User Documentation for Fault-Tolerant Systems
33
Getting Started
33
Getting Started
35
Requirements
36
Configuring Hardware and Starting up the S7-400H
37
Hardware Configuration
37
Installing Hardware
37
Starting up the S7-400H
38
Examples of Fault-Tolerant System Response to Faults
39
Failure of a Central Processing Unit or Power Suppl
39
Failure of a Fiber-Optic Cabl
39
Installation of a CPU 41X-H
41
Controls and Indicators of the Cpus
42
Layout of the Controls and Indicators of the CPU 414-4H/417-4H
42
Operation and Display Elements of the CPU 414-4H/417-4H
42
Leds of the Cpus
43
Operating Mode Selector
43
RAM Cards
43
Slot for Memory Cards
43
Interface for Expanded Memory
44
MPI/DP Interface
44
Profibus-DP Interface
44
Slot for Interface Modules
44
Connecting External Backup Current to the “EXT. BATT.” Socket
45
Monitoring and Error Messages
46
Monitoring Functions of the CPU
46
Leds MSTR, RACK0 and RACK1
48
Leds RUN and STOP
48
Status and Error Leds
48
Leds BUSF1 and BUSF2
49
Leds INTF, EXTF and FRCE
49
Diagnostics Buffer
50
Led Redf
50
Leds IFM1F and IFM2F
50
Function of the Mode Selector
51
Mode Selector
51
Positions
51
Positions of the Mode Selector
51
Positions of the Mode Selector
52
Protection Levels
52
Setting the Protection Levels
52
Cold Restart
53
Operating Sequence for Memory Reset
53
Protection Levels of a S7-400 CPU
53
Operating Sequence at Cold Restart
54
Operation Sequence for Reboot/Warm Start
54
Reboot (Warm Restart)
54
Determining Memory Requirements with the SIMATIC Manager
55
Expanded Memory
55
Generating Block–Specific Messages
56
Design of the Memory Card
57
Expanding Load Memory with Memory Cards
57
Function of the Memory Card
57
Order Numbers
57
Types of Memory Cards
58
Types of Memory Cards for the S7-400
58
What the Memory Card Contains
58
Which Type of Memory Card to Use
58
RAM Card
59
FLASH Card
59
Which Memory Card Capacity to Use
59
Changing Memory Cards
60
Technical Specifications
61
S7-400H
61
Expanding the Working Memory of the CPU 417-4 H with Memory Modules
62
Fitting Memory Cards in the CPU
62
Memory Expansion
62
Fitting Memory Cards in the Cpus
63
Memory Card
63
Communication and Interrupt Response Times
64
Connectable Devices
64
Multipoint Interface (MPI)
64
PG/OP-CPU Communication
64
Connectors
65
PROFIBUS DP Interface
65
Default Values
66
Overview of the Parameters for the S7-400 Cpus
66
Parameter Blocks
66
Changing the Rack Number of an H CPU
67
Parameter Assignment Tool
67
Specially Saved Parameters
67
Changing from Redundant to Single Mode
68
Changing from Single to Redundant Mode, Module Rack Number 0
68
Changing from Single to Redundant Mode, Module Rack Number 1
68
Changing the Operating Mode of an H CPU
68
CPU 41X-H as Profibus DP Master
69
CPU 41X as DP Master
70
Cpus 41X (MPI/DP Interface as Profibus DP)
70
DP Address Areas of the Cpus 41X
70
From en 50170 to DPV1
71
Monitor/Modify, Programming Via PROFIBUS
71
Power-Up of the DP Master System
71
PROFIBUS Address of the DP Master
71
Compatibility between DPV1 and en 50170
72
Components Supporting Profibus DPV1 Features
72
What Are the Operating Modes for DPV1 Components?
72
Overview: System Configuration for Modification
73
System Modifications During Ongoing Operation
73
Hardware Requirements for System Modification During Operation
74
Permitted System Modifications: Overview
74
Software Requirements for System Modification During Operation
74
Diagnostics of the CPU 41X as DP Master
75
Diagnostics Using Leds
75
Meaning of the BUSF Leds of the CPU 41X as DP Master
75
Reading out the Diagnostics Information with STEP 7
76
Diagnostics with CPU 41X
77
Evaluating the Diagnosis in the User Program
77
Diagnostics Addresses for the DP Master and DP Slave
78
Diagnostics Addresses in Connection with DP Slave Functionality
78
Evaluation in the User Program
79
Event Detection of the Cpus 41X as DP Master
79
Consistent Data
80
Consistency for Communication Blocks and Functions
81
Sfc 81 “Ublkmov”
81
Access to the Working Memory of the CPU
82
Consistency Rules for SFB 14 “GET” and Reading Tags
83
Data Transmission Without Data Consistency
83
Consistency Rules for SFB 15 “PUT” or Write Tag
84
Data Transmission Without Data Consistency
84
Upper Limit for the Transmission of Consistent User Data on a DP Slave
86
Consistent Data Access Without the Use of SFC 14 or SFC 15
87
System and Operating Modes of the S7-400H
89
Declaration
90
Master/Standby Assignment
90
What Does Active Redundancy Mean?
90
Continued Operation – Free from Discontinuities
91
Event-Driven Synchronization Procedure
91
Synchronizing the Subsystems
91
Overview of the S7-400H System Modes
92
Self-Test
92
System Modes of the S7-400H
92
Operating Modes from POWER on to Redundant System Mode
93
Operating Modes of the Cpus
93
System and Operating Modes of the Fault-Tolerant System
93
Explanations Relating to Figure 5-2 System and Operating Modes of the Fault-Tolerant System
94
Memory Reset
94
STOP Operating Mode
94
Operating States LINK–UP and UPDATE
95
STARTUP Operating Mode
95
Startup Processing by the Master CPU
95
Causes of Error Leading to the Termination of Redundant System Mode
96
Operating State RUN
96
Redundant Modules
96
Single Mode, Link–Up, Update
96
Operating States HOLD
97
When Is HOLD Mode Possible?
97
TROUBLESHOOTING Operating State
98
Hardware Fault with One-Way ob 121 Call
99
Processing Self-Tests
99
Response to Errors During the Self-Test
99
Checksum Errors
100
RAM/PAA Comparison Error
100
Response to a Recurring Comparison Error
100
Response to Checksum Errors
100
Influencing the Cyclical Self-Test
101
Instruction Run Times
102
Processing I/O Direct Access
102
Reaction Time
102
Time Response
102
Linking and Synchronizing
103
Effects of Link-Up and Update
104
Properties of Link-Up and Update
104
Functional Sequence of Link-Up and Update
105
How to Start Link-Up and Update
105
Functional Sequence of Link-Up and Update
106
Process Diagram for Link-Up and Update
106
Process for Update
107
Minimum Signal Duration of Input Signals During the Update
108
Link-Up to Achieve Redundant System Mode
109
Link-Up with Master/Standby Switch-Over
109
Process of Link-Up
109
Switch to CPU with Expanded Memory Configuration
110
Updating Procedure
111
What Happens During Update?
111
Communication Functions with Derived Jobs
113
Delayed Notification Functions
113
Load Memory
114
Switch to CPU with Modified Configuration
114
Working Memory
114
Block Link-Up and Update
115
Example of a Time-Critical Process
115
Max. Communication Delay
116
Max. Scan-Cycle Time Extension
116
Time Monitoring
116
Minimum I/O Retention Time
117
Significance of the Times Relevant During the Update
117
Response to Time-Out
118
Time Response During Link-Up
118
Determination of the Monitoring Times
119
Determination with STEP7 or Formulas
119
Time Response During the Update
119
Monitoring Time Accuracy
120
Use of Redundant Input and Output Modules
120
Calculating the Minimum I/O Retention Time
121
Configuration of the Monitoring Times
121
Max. Blocking Time for Priority Classes > 15
121
Premium for the Monitoring Times of Redundant I/O
121
Relationship between the Minimum I/O Retention Time and the Maximum Blocking Time for Priority Classes
122
Influences on the Time Response
126
Calculation of the Max. Scan-Cycle Time Extension
126
Calculation of the Max. Communication Delay
126
Deliberate Delaying of the Update
127
Performance Values for Link–Up and Update
127
Peculiarities During Link-Up and Update
129
Requirement of Input Signals During the Update
129
Communication Links and Functions
129
Reset Instruction on Aborting Link-Up
129
Using I/O on the S7-400H
131
Addressing
132
I/O Configuration Types
132
Limits of I/O Configuration
132
Single-Channel, One-Way I/O Configuration
133
Using Single-Channel, One-Sided I/O
133
What Is Single-Channel, One-Way I/O?
133
Failure of the Single-Channel, One-Way I/O
134
Single-Channel, One-Way I/Os and User Program
134
Using Single-Channel, Switched I/O
135
What Is Single-Channel, Switched I/O?
135
Single-Channel, Switched ET 200M Distributed I/O
136
Failure of the Single-Channel, Switched I/O
137
Single-Channel, Switched I/O and User Program
137
Duration of Switch-Over of the Active Channel
138
No Pulses During Switch-Over of the Active Channel
139
Switch-Over of the Active Channel on Link-Up and Update
139
System Configuration and Design
139
Connecting Redundant I/O
140
Redundant I/O in Central- and Expansion Devices
140
Redundant I/O in the One-Way DP Slave
141
Redundant I/O in the Switched DP Slave
142
Block Library “Functional I/O Redundancy”
143
Redundant I/O in Single Mode
143
Hardware Installation and Configuration of the Redundant I/O
144
Signal Modules for Redundancy
145
Which Faults Can be Overcome Using Redundant I/O?
146
Using Digital Input Modules as Redundant I/O
147
Fault-Tolerant Digital Input Module in a 1-Out-Of-2 Configuration
148
Using Digital Input Modules with Non-Redundant Sensor
148
Additional Marginal Conditions for Various Modules
149
Fault-Tolerant Digital Input Modules in a 1-Out-Of-2 Configuration
150
Using Redundant Digital Input Modules with Redundant Sensors
150
Digital Output Module Connected Through/Without Diodes
151
Fault-Tolerant Digital Output Module in a 1-Of-2 Configuration
151
Redundant Digital Output Modules
151
Using Analog Input Modules as Redundant I/O
153
Fault-Tolerant Analog Input Modules in a 1-Out-Of-2 Configuration
154
Redundant Analog Input Modules for Voltage Measurement
154
Redundant Analog Input Modules with Non-Redundant Sensors
154
Redundant Analog Input Modules for Indirect Current Measurement
155
Redundant Analog Input Module for Direct Current Measurements
158
Fault-Tolerant Analog Input Modules in a 1-Out-Of-2 Configuration
160
Redundant Analog Input Modules with Redundant Sensors
160
Analog Input Modules and Sensors
161
Depassivation of Modules
162
Redundant Analog Output Modules in a 1-Of-2 Structure
162
Assignment of the Status Byte
163
Determining the Passivation Status with the Status Byte
163
Determining the Status of the Passivation
163
Assignment of the Status Bytes
164
Other Possibilities for Connecting Redundant I/O
165
Redundant I/O on the User Level
165
Redundant One-Way and Switched I/Os
165
Redundant I/O in the User Program
167
Flowchart for OB1
168
Example of STL
169
Ob 122
170
Communication Functions
171
Fundamentals and Basic Concepts
172
Redundant Communication System
172
Fault-Tolerant Communications
172
Connection (S7 Connection)
173
Fault-Tolerant S7 Connections
173
Example of an S7 Connection
173
Electrical Network
175
Industrial Ethernet
175
Resource Requirements of Fault-Tolerant S7 Connections
175
Suitable Networks
175
Profibus
176
Optical Network
176
Supported Communication Services
178
Communications Via Fault-Tolerant S7 Connections
178
Availability of Communicating Systems
178
Programming
179
Communications between Fault-Tolerant Systems
180
Example of Redundancy with Fault-Tolerant System and Redundant Ring
181
Example of a Fault-Tolerant System with Additional CP Redundancy
181
Response to Failure
182
Redundant S7 Connections
182
Communications between Fault-Tolerant Systems and Pcs
184
Communications Via S7 Connections
185
Communications with Standard Systems
185
Communications Via S7 Connections – One-Sided Mode
186
Two-Fiber Ring and Bus System
187
Communications over Redundant S7 Connections
188
Communications Via a Point-To-Point CP on the ET 200M
189
Connection Via ET 200M
189
Random Connection with Single-Channel Systems
190
Connection Via a PC as Gateway
190
Communication Performance
191
Definition of Communication Load
191
Response Time Via Communication Load (Basic Trend)
192
Data Throughput Via Communication Load (Basic Trend)
192
Work Area
192
Standard and H Systems
193
Which Sizes Influence the Communication Load?
193
General Information on Communication
194
Connecting Standard Systems to H Systems
195
S7 Communication (SFB 12 “BSEND” and SFB 13 “BRCV”)
195
S7 Communication (SFB 8 “USEND” and SFB 9 “URCV”)
195
SIMATIC Ops, SIMATIC Mps
195
OPC Server
196
Advertisement
Siemens SIMATIC S7-400H System Manual (504 pages)
Fault-tolerant systems
Brand:
Siemens
| Category:
Control Systems
| Size: 5.03 MB
Table of Contents
Table of Contents
5
Preface
19
Fault-Tolerant Automation Systems
25
Redundant SIMATIC Automation Systems
25
Figure 2-1 Operating Objectives of Redundant Automation Systems
25
Increasing the Availability of Plants
27
Figure 2-2 Integrated Automation Solutions with SIMATIC
27
Figure 2-3 Example of Redundancy in a Network Without Error
28
Figure 2-4 Example of Redundancy in a 1-Out-Of-2 System with Error
29
Figure 2-5 Example of Redundancy in a 1-Out-Of-2 System with Total Failure
29
S7-400H Setup Options
31
Figure 3-1 Overview
32
Rules for the Assembly of Fault-Tolerant Stations
33
The S7-400H Basic System
34
Figure 3-2 Hardware of the S7-400H Basic System
34
I/O Modules for S7-400H
36
Communication
37
Tools for Configuration and Programming
38
The User Program
39
Documentation
40
Figure 3-3 User Documentation for Fault-Tolerant Systems
40
Getting Started
41
Requirements
41
Hardware Assembly and Commissioning of the S7-400H
42
Figure 4-1 Hardware Assembly
42
Examples of the Response of the Fault-Tolerant System to Faults
44
Special Layout Features of SIMATIC Manager
45
Assembly of a CPU 41X-H
47
Operator Controls and Display Elements of the Cpus
47
Figure 5-1 Arrangement of the Control and Display Elements on CPU 41X-5H PN/DP
47
Table 5- 1 LED Displays on the Cpus
48
Figure 5-2 Jack Connector
50
Monitoring Functions of the CPU
52
Status and Error Displays
55
Table 5- 2 Possible States of the BUS1F, BUS2F and BUS5F Leds
57
Table 5- 3 Possible States of the LINK and RX/TX Leds
58
Mode Switch
60
Function of the Mode Switch
60
Figure 5-3 Mode Switch Positions
60
Table 5- 4 Mode Switch Positions
61
Performing a Memory Reset
62
Cold Restart / Warm Restart
64
Design and Function of the Memory Cards
65
Figure 5-4 Design of the Memory Card
65
Using Memory Cards
67
Table 5- 5 Types of Memory Card
67
Multi Point Interface MPI/DP (X1)
70
PROFIBUS DP Interface (X2, X3)
71
PROFINET Interface (X5)
71
Overview of the Parameters for the S7-400H Cpus
74
Special Functions of a CPU 41X-H
77
Security Levels
77
Table 6- 1 Security Levels of a CPU
77
Encrypting Blocks
79
Resetting the CPU to the Factory State
81
Table 6- 2 CPU Properties in the Factory Settings
81
Table 6- 3 LED Patterns
82
Updating the Firmware Without a Memory Card
83
Firmware Update in RUN Mode
85
Reading Service Data
86
Profibus Dp
87
CPU 41X-H as PROFIBUS DP Master
87
DP Address Ranges of Cpus 41X-H
88
CPU 41Xh as PROFIBUS DP Master
88
Table 7- 1 Cpus 41X, MPI/DP Interface as PROFIBUS DP Interface
88
Diagnostics of a CPU 41Xh Operating as PROFIBUS DP Master
91
Table 7- 2 Meaning of the "BUSF" LED of the CPU 41X Operating as DP Master
91
Table 7- 3 Reading out the Diagnostics Information with STEP 7
91
Figure 7-1 Diagnostics with CPU 41Xh
92
Table 7- 4 Event Detection of the CPU 41Xh as a DP Master
93
Figure 7-2 Diagnostics Addresses for DP Master and DP Slave
93
Profinet
95
Introduction
95
PROFINET IO Systems
97
Blocks in PROFINET IO
99
Table 8- 1 System and Standard Functions that Are New or Have to be Replaced
99
Table 8- 2 System and Standard Functions of PROFIBUS DP that Can be Emulated in PROFINET IO
100
Table 8- 3 Obs in PROFINET IO and PROFIBUS DP
100
System Status Lists for PROFINET IO
101
Table 8- 4 Comparison of the System Status Lists of PROFINET IO and PROFIBUS DP
101
Device Replacement Without Removable Medium/Programming Device
103
Shared Device
103
Media Redundancy
104
Figure 8-1 Configuration Example of System Redundancy with Media Redundancy
105
System Redundancy
106
Figure 8-2 S7-400H System with IO Devices Connected in System Redundancy
106
Figure 8-3 System Redundancy in Different Views
107
Figure 8-4 PN/IO with System Redundancy
109
Figure 8-5 PN/IO with System Redundancy
110
Consistent Data
111
Consistency of Communication Blocks and Functions
112
9.2 Consistency Rules for SFB 14 "GET" or Read Variable, and SFB 15 "PUT" or Write Variable
113
Consistent Reading and Writing of Data from and to DP Standard Slaves/Io Devices
113
Figure 9-1 Properties - DP Slave
116
Memory Concept
117
Overview of the Memory Concept of S7-400H Cpus
117
Figure 10-1 Memory Areas of the S7-400H Cpus
117
Table 10- 1 Memory Requirements
119
System and Operating States of the S7-400H
121
Introduction
121
Figure 11-1 Synchronizing the Subsystems
122
System States of the S7-400H
124
The System States of the S7-400H
124
Table 11- 1 Overview of S7-400H System States
124
Displaying and Changing the System State of a Fault-Tolerant System
125
System Status Change from the STOP System State
126
System Status Change from the Standalone Mode System Status
126
System Status Change from the Redundant System State
127
System Diagnostics of a Fault-Tolerant System
128
The Operating States of the Cpus
130
Figure 11-2 System and Operating States of the Fault-Tolerant System
130
STOP Mode
131
STARTUP Mode
132
LINK-UP and UPDATE Modes
133
RUN Mode
133
Table 11- 2 Causes of Error Leading to Redundancy Loss
133
HOLD Mode
135
ERROR-SEARCH Mode
135
Self-Test
137
Table 11- 3 Response to Errors During the Self-Test
137
Table 11- 4 Response to a Recurring Comparison Error
138
Table 11- 5 Reaction to Checksum Errors
138
Table 11- 6 Hardware Fault with One-Sided Call of ob 121, Checksum Error, Second Occurrence
139
Evaluation of Hardware Interrupts in the S7-400H System
140
Link-Up and Update
141
Effects of Link-Up and Updating
141
Table 12- 1 Properties of Link-Up and Update Functions
141
Conditions for Link-Up and Update
142
Table 12- 2 Conditions for Link-Up and Update
142
Link-Up and Update Sequence
143
Figure 12-1 Sequence of Link-Up and Update
144
Figure 12-2 Update Sequence
145
Figure 12-3 Example of Minimum Signal Duration of an Input Signal During the Update
146
Link-Up Sequence
147
Update Sequence
149
Switch to CPU with Modified Configuration or Expanded Memory Configuration
152
Disabling of Link-Up and Update
154
Time Monitoring
155
Figure 12-4 Meanings of the Times Relevant for Updates
156
Time Response
158
Determining the Monitoring Times
159
Figure 12-5 Correlation between the Minimum I/O Retention Time and the Maximum Inhibit Time for
160
Performance Values for Link-Up and Update
166
Table 12- 3 Typical Values for the User Program Part
166
Influences on Time Response
167
Special Features in Link-Up and Update Operations
168
Using I/Os in S7-400H
169
Introduction
169
Using Single-Channel, One-Sided I/Os
171
Using Single-Channel Switched I/O
173
Table 13- 1 Interfaces for Use of Single-Channel Switched I/O Configuration at the PROFIBUS DP Interface
173
Figure 13-1 Single-Channel Switched Distributed I/O Configuration at the PROFIBUS DP Interface
173
Table 13- 2 Interface for Use of Single-Channel Switched I/O Configuration at the PROFINET Interface
174
Figure 13-2 Single-Channel Switched Distributed I/O Configuration at the PROFINET Interface
174
Connecting Redundant I/O to the PROFIBUS DP Interface
177
Figure 13-3 Redundant I/O in Central and Expansion Devices
178
Figure 13-4 Redundant I/O in the One-Sided DP Slave
179
Figure 13-5 Redundant I/O in the Switched DP Slave
180
Signal Modules for Redundancy
187
Table 13- 3 Signal Modules for Redundancy
187
Table 13- 4 Interconnecting Digital Output Modules With/Without Diodes
197
Table 13- 5 Analog Input Modules and Encoders
203
Evaluating the Passivation Status
206
Other Options for Connecting Redundant I/Os
207
Table 13- 6 Example of Redundant I/O, ob 1 Part
210
Table 13- 7 Example of Redundant I/O, ob 122 Part
211
Table 13- 8 for the Monitoring Times with Redundant I/O
212
Communication
213
Communication Services
213
Overview of Communication Services
213
PG Communication
214
OP Communication
215
S7 Communication
215
S7 Routing
217
Time Synchronization
222
Data Set Routing
224
SNMP Network Protocol
226
Open Communication Via Industrial Ethernet
227
Basics and Terminology of Fault-Tolerant Communication
231
Usable Networks
235
Usable Communication Services
235
Communication Via S7 Connections
236
Communication Via S7 Connections - One-Sided Mode
237
Communication Via Redundant S7 Connections
240
Communication Via Point-To-Point CP on the ET 200M
241
Custom Connection to Single-Channel Systems
243
Communication Via Fault-Tolerant S7 Connections
244
Communication between Fault-Tolerant Systems
247
Communication between Fault-Tolerant Systems and a Fault-Tolerant CPU
250
Communication between Fault-Tolerant Systems and Pcs
251
Communication Performance
254
General Issues Regarding Communication
256
Configuring with STEP 7
259
Rules for Arranging Fault-Tolerant Station Components
260
Configuring Hardware
260
Assigning Parameters to Modules in a Fault-Tolerant Station
261
Recommendations for Setting the CPU Parameters
262
Networking Configuration
263
Programming Device Functions in STEP 7
264
Failure and Replacement of Components During Operation
265
Failure and Replacement of a CPU
266
Failure and Replacement of a Power Supply Module
268
Failure and Replacement of an Input/Output or Function Module
269
Failure and Replacement of a Communication Module
271
Failure and Replacement of a Synchronization Module or Fiber-Optic Cable
272
Failure and Replacement of an IM 460 and IM 461 Interface Module
275
Failure and Replacement of Components of the Distributed I/Os
276
Failure and Replacement of a PROFIBUS DP Master
276
Failure and Replacement of a Redundant PROFIBUS DP Interface Module
277
Failure and Replacement of a PROFIBUS DP Slave
278
Failure and Replacement of PROFIBUS DP Cables
278
System Modifications During Operation
281
Possible Hardware Modifications
282
Adding Components in PCS 7
286
PCS 7, Step 1: Modification of Hardware
287
PCS 7, Step 2: Offline Modification of the Hardware Configuration
288
PCS 7, Step 3: Stopping the Reserve CPU
288
PCS 7, Step 4: Loading a New Hardware Configuration in the Reserve CPU
289
PCS 7, Step 5: Switch to CPU with Modified Configuration
289
PCS 7, Step 6: Transition to Redundant System Mode
291
PCS 7, Step 7: Editing and Downloading the User Program
292
PCS7, Using Free Channels on an Existing Module
293
Adding Interface Modules in PCS 7
294
Removing Components in PCS 7
295
PCS 7, Step 1: Editing the Hardware Configuration Offline
296
PCS 7, Step 2: Editing and Downloading the User Program
297
PCS 7, Step 3: Stopping the Reserve CPU
298
PCS 7, Step 4: Downloading a New Hardware Configuration to the Reserve CPU
298
PCS 7, Step 5: Switching to CPU with Modified Configuration
299
PCS 7, Step 6: Transition to Redundant System Mode
300
Siemens SIMATIC S7-400H System Manual (376 pages)
Fault-tolerant Systems
Brand:
Siemens
| Category:
Controller
| Size: 3.76 MB
Table of Contents
Table of Contents
3
1 Preface
15
2 Fault-Tolerant Automation Systems
21
Redundant Automation Systems in the SIMATIC Series
21
Figure 2-1 Operating Objectives of Redundant Automation Systems
21
Increasing System Availability
23
Figure 2-2 Totally Integrated Automation Solutions with SIMATIC
23
Figure 2-3 Example of Redundancy in a Network Without an Error or Fault
24
Figure 2-4 Example of Redundancy in a 1-Of-2 System with Error/Fault
24
Figure 2-5 Example of Redundancy in a 1-Out-Of-2 System with Total Failure
24
3 S7-400H Installation Options
25
Figure 3-1 Overview
26
Rules for the Assembly of Fault-Tolerant Stations
27
The S7-400H Base System
28
Figure 3-2 Hardware of the S7-400H Base System
28
I/O Modules for S7-400H
30
Communication
31
Tools for Configuration and Programming
31
The User Program
32
Documentation
33
Figure 3-3 User Documentation for Fault-Tolerant Systems
33
4 Getting Started
35
Requirements
35
Hardware Installation and S7-400H Commissioning
36
Figure 4-1 Hardware Installation
36
Examples of the Reaction of the Fault-Tolerant System to Faults
38
5 Installation of a CPU 41X-H
39
Control and Display Elements of the Cpus
39
Figure 5-1 Arrangement of the Operator Controls and Displays on the CPU 412-3H
39
Figure 5-2 Layout of the Control and Display Elements of the CPU 414-4H/417-4H
40
Table 5-1 Leds on the Cpus
41
Figure 5-3 Jack
43
Monitoring Functions of the CPU
44
Status and Error Displays
46
Mode Selector Switch
49
Table 5-2 Mode Selector Switch Settings
49
Figure 5-4 Mode Selector Switch Settings
49
Security Levels
50
Table 5-3 Levels of Protection of a CPU
50
Operating Sequence for Memory Reset
51
Structure and Functions of the Memory Cards
54
Figure 5-5 Design of the Memory Card
54
Table 5-4 Types of Memory Card
55
Multipoint Interface (MPI)
57
PROFIBUS DP Interface
58
Overview of the Parameters for the S7-400H Cpus
59
6 Special Functions of a CPU 41X-H
61
Updating the Firmware Without a Memory Card
61
Firmware Update in RUN Mode
63
Reading Service Data
64
7 S7-400H in PROFIBUS DP Mode
65
CPU 41X-H as PROFIBUS DP Master
65
DP Address Areas of 41Xh Cpus
66
CPU 41Xh as PROFIBUS DP Master
66
Table 7-1 41X Cpus, MPI/DP Interface as PROFIBUS DP
66
Diagnostics of a 41Xh CPU Operating as PROFIBUS DP Master
69
Table 7-2 Meaning of the "BUSF" LED of the 41X CPU Operating as DP Master
69
Table 7-3 Reading out the Diagnostics Information with STEP 7
69
Figure 7-1 Diagnostics with CPU 41Xh
70
Table 7-4 Event Detection of the CPU 41Xh as a DP Master
71
Figure 7-2 Diagnostic Addresses for DP Master and DP Slave
71
Consistent Data
73
Consistency of Communication Blocks and Functions
74
Access to the CPU RAM
74
Consistency Rules for SFB 14 "GET" or Reading Tag and SFB 15 "PUT" or Writing Tag
74
Reading Data Consistently from a DP Standard Slave and Writing Consistently to a DP Standard Slave
75
Consistent Data Access Without Using SFC 14 or SFC 15
76
Figure 7-3 DP Slave Properties
77
8 System and Operating States of the S7-400H
79
Introduction
80
Figure 8-1 Synchronizing the Subsystems
81
The System States of the S7-400H
82
Table 8-1 Overview of S7-400H System States
82
The Operating States of the Cpus
83
Figure 8-2 System and Operating Modes of the Fault-Tolerant System
83
STOP Operating State
84
STARTUP Operating State
85
LINK-UP and UPDATE Operating States
85
RUN Operating State
86
Table 8-2 Causes of Error Leading to Redundancy Loss
86
HOLD Operating State
87
TROUBLESHOOTING Operating State
87
Self-Test
89
Table 8-3 Reaction to Errors During the Self-Test
89
Table 8-4 Reaction to a Recurring Comparison Error
90
Table 8-5 Reaction to Checksum Errors
90
Table 8-6 Hardware Fault with One-Sided Call of ob 121, Checksum Error, Second Occurrence
91
Time-Based Reaction
92
Evaluation of Process Interrupts in the S7-400H System
92
9 Link-Up and Update
93
Effects of Link-Up and Updating
93
Table 9-1 Properties of Link-Up and Update Functions
93
Conditions for Link-Up and Update
94
Table 9-2 Conditions for Link-Up and Update
94
Link-Up and Update
95
Figure 9-1 Sequence of Link-Up and Update
96
Figure 9-2 Update Sequence
97
Figure 9-3 Example of Minimum Signal Duration of an Input Signal During the Update
98
Link-Up Sequence
99
Update Sequence
101
Switch to CPU with Modified Configuration or Expanded Memory Configuration
103
Disabling Link-Up and Update
105
Time Monitoring
106
Time-Based Reaction
108
Determining the Monitoring Times
109
Performance Values for Link-Up and Update
115
Table 9-3 Typical Values for the User Program Part
115
Influences on Time-Based Reaction
116
Special Features in Link-Up and Update Operations
117
10 Using I/Os in S7-400H
119
Introduction
119
Using Single-Channel, One-Sided I/Os
121
Using Single-Channel Switched I/Os
123
Table 10-1 Interfaces for the Use of Single-Channel Switched I/O
123
Connecting Redundant I/Os
127
Table 10-2 Signal Modules for Channel-Oriented Redundancy
133
Table 10-3 Signal Modules for Channel-Oriented Redundancy
134
Table 10-4 Interconnecting Digital Output Modules With/Without Diodes
141
Figure 10-10 Fault-Tolerant Analog Input Modules in 1-Out-Of-2 Structure with Two Encoders
146
Table 10-5 Analog Input Modules and Encoders
146
Figure 10-11 Fault-Tolerant Analog Output Modules in 1-Out-Of-2 Configuration
147
Evaluating the Passivation Status
149
Table 10-6 Assignment of the Status Byte
149
Table 10-7 Assignment of Status Bytes
150
Other Options for Connecting Redundant I/Os
151
Figure 10-13 Flow Chart for ob 1
153
Table 10-8 Example of Redundant I/O, ob 1 Part
154
Table 10-9 Example of Redundant I/O, ob 122 Part
155
Table 10-10 for the Monitoring Times I/O Used Redundantly
155
11 Communication
157
Fundamentals and Basic Concepts
158
Usable Networks
161
Usable Communication Services
161
Communications Via Fault-Tolerant S7 Connections
162
Communication between Fault-Tolerant Systems
163
Communication between Fault-Tolerant Systems and a Fault-Tolerant CPU
166
Communication between Fault-Tolerant Systems and Pcs
167
Communication Via S7 Connections
169
Communication Via S7 Connections - One-Sided Mode
169
Figure 11-10 Example of Linking Standard and Fault-Tolerant Systems to a Redundant Bus System
170
Communication Via Redundant S7 Connections
172
Communication Via a Point-To-Point CP on the ET200M
173
Custom Linking to Single-Channel Systems
174
Communication Performance
175
Figure 11-15 Communication Load as a Function of the Response Time (Basic Profile)
176
General Issues in Communication
177
12 Configuring with STEP 7
179
Rules for the Assembly of Fault-Tolerant Stations
180
Configuring Hardware
180
Assigning Parameters to Modules in a Fault-Tolerant Station
181
Recommendations for Setting the CPU Parameters
182
Configuring Networking
183
Programming Device Functions in STEP 7
184
13 Failure and Replacement of Components During Operation
185
Failure and Replacement of Components During Operation
186
Failure and Replacement of a CPU
186
Failure and Replacement of a Power Supply Module
188
Failure and Replacement of an Input/Output or Function Module
189
Failure and Replacement of a Communication Module
191
Failure and Replacement of a Synchronization Module or Fiber-Optic Cable
192
Failure and Replacement of an IM 460 and IM 461 Interface Module
195
Failure and Replacement of Components of the Distributed I/Os
196
Failure and Replacement of a PROFIBUS-DP Master
196
Failure and Replacement of a Redundant PROFIBUS-DP Interface Module
197
Failure and Replacement of a PROFIBUS-DP Slave
197
Failure and Replacement of PROFIBUS-DP Cables
198
14 System Modifications in Operation
199
Possible Hardware Modifications
200
Adding Components in PCS 7
204
PCS 7, Step 1: Modification of Hardware
205
PCS 7, Step 2: Offline Modification of the Hardware Configuration
205
PCS 7, Step 3: Stopping the Standby CPU
206
PCS 7, Step 4: Loading New Hardware Configuration in the Standby CPU
206
PCS 7, Step 5: Switch to CPU with Modified Configuration
207
PCS 7, Step 6: Transition to Redundant State
208
PCS 7, Step 7: Editing and Downloading the User Program
209
Adding Interface Modules in PCS 7
210
Removing Components in PCS 7
211
PCS 7, Step I: Offline Modification of the Hardware Configuration
212
PCS 7, Step II: Editing and Downloading the User Program
213
PCS 7, Step III: Stopping the Standby CPU
214
PCS 7, Step IV: Loading New Hardware Configuration in the Standby CPU
214
PCS 7, Step V: Switch to CPU with Modified Configuration
215
PCS 7, Step VI: Transition to Redundant State
216
PCS 7, Step VII: Modification of Hardware
217
Removing Interface Modules in PCS 7
218
Adding Components in STEP 7
219
STEP 7, Step 1: Adding Hardware
220
STEP 7, Step 2: Offline Modification of the Hardware Configuration
221
STEP 7, Step 3: Expanding and Downloading Obs
221
STEP 7, Step 4: Stopping the Standby CPU
222
STEP 7, Step 5: Loading New Hardware Configuration in the Standby CPU
222
STEP 7, Step 6: Switch to CPU with Modified Configuration
223
STEP 7, Step 7: Transition to Redundant State
224
STEP 7, Step 8: Editing and Downloading the User Program
225
Adding Interface Modules in STEP 7
226
Removing Components in STEP 7
227
STEP 7, Step I: Offline Modification of the Hardware Configuration
228
STEP 7, Step II: Editing and Downloading the User Program
228
STEP 7, Step III: Stopping the Standby CPU
229
STEP 7, Step IV: Loading New Hardware Configuration in the Standby CPU
229
STEP 7, Step V: Switch to CPU with Modified Configuration
230
STEP 7, Step VI: Transition to Redundant State
231
STEP 7, Step VII: Modification of Hardware
232
STEP 7, Step VIII: Editing and Downloading Organization Blocks
232
Removing Interface Modules in STEP 7
233
Editing CPU Parameters
234
Table 14-1 Modifiable CPU Parameters
234
Step A: Editing CPU Parameters Offline
235
Step B: Stopping the Standby CPU
236
Step C: Loading New Hardware Configuration in the Standby CPU
236
Step D: Switch to CPU with Modified Configuration
237
Step E: Transition to Redundant State
238
Changing the CPU Memory Configuration
239
Expanding Load Memory
239
Changing the Type of Load Memory
240
Reconfiguration of a Module
243
Step A: Editing Parameters Offline
244
Step B: Stopping the Standby CPU
244
Step C: Loading New Hardware Configuration in the Standby CPU
245
Step D: Switch to CPU with Modified Configuration
245
Step E: Transition to Redundant State
247
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Siemens SIMATIC S7-400H Manual (210 pages)
Fault-Tolerant Systems
Brand:
Siemens
| Category:
Controller
| Size: 0.66 MB
Table of Contents
A5E00068197
3
Table of Contents
7
1 Fault-Tolerant Systems in Automation Engineering
11
Redundant Programmable Logic Controllers in the SIMATIC Series
12
Automation Engineering
12
Increasing System Availability
14
2 S7-400H Installation Options
17
Base System of the S7-400H
19
I/O for the S7-400H
21
Communication
22
Configuration and Programming Applications
23
User Program
24
Documentation
25
3 Getting Started
25
Requirements
28
Configuring Hardware and Starting up the S7-400H
29
Examples of Fault-Tolerant System Response in the Event of Faults
31
4 System and Operating Modes of the S7-400H
33
Introduction
34
System Modes of the S7-400H
37
Operating Modes of the Cpus
38
STARTUP Operating Mode
40
LINK-UP and UPDATE Operating Modes
40
RUN Operating Mode
41
HOLD Operating Mode
42
ERROR-SEARCH Operating Mode
43
Time Response
44
5 Link-Up and Update
45
Effects of Link-Up and Update
46
Functional Sequence of Link-Up and Update
47
Process of Link-Up
51
Process of Updating
53
Switch to CPU with Modified Configuration
56
Block Link-Up and Update
57
Time Monitoring
59
Time Behavior
61
Determination of the Monitoring Times
62
Influences on the Time Behavior
70
Performance Values for Link-Up and Update
70
Special Features During Link-Up and Update
72
6 Using I/O on the S7-400H
73
Introduction
74
Using a Single-Channel, One-Sided I/O
75
Using Single-Channel, Switched I/O
77
Connecting a Redundant I/O
82
7 Communications
87
Fundamentals and Basic Concepts
88
Suitable Networks
91
Industrial Ethernet
91
Profibus
92
Supported Communication Services
93
Communications Via Fault-Tolerant S7 Connections
93
Communications between Fault-Tolerant Systems
95
Communications between Fault-Tolerant Systems and a
97
Fault-Tolerant CPU
97
Communications between Fault-Tolerant Systems and Pcs
98
Communications Via S7 Connections
99
Communications Via S7 Connections - One-Sided Mode
99
Communications over Redundant S7 Connections
101
Communications Via a Point-To-Point CP on the ET200M
102
Random Connection with Single-Channel Systems
103
8 Configuring with STEP 7
105
Installing the Options Package
106
Configuring with STEP
107
Rules for H Station Equipment
107
Configuring Hardware
108
Configuring Networks
109
Programming Device Functions in STEP
110
9 Failure and Replacement of Components During Operation
111
Failure and Replacement of Components in Central Racks and Expansion Racks
112
Failure and Replacement of a Central Processing Unit CPU 417-4H
113
Failure and Replacement of a Power Supply Module
115
Failure and Replacement of an Input/Output or Function Module
116
Failure and Replacement of a Communication Processor
117
Fandilure Andnd Replandcement of and Synchronizandtion Submodule or Fiber-Optic Candble
118
Failure and Replacement of Components of the Distributed I/O
122
Failure and Replacement of a Redundant PROFIBUS-DP
124
Interface Module
124
Failure and Replacement of a PROFIBUS-DP Slave
125
Failure and Replacement of PROFIBUS-DP Cables
126
Siemens SIMATIC S7-400H Manual (5 pages)
Fault-tolerant Systems
Brand:
Siemens
| Category:
Industrial Equipment
| Size: 0.06 MB
Table of Contents
Purpose of the Manual
3
Basic Knowledge Required
3
Validity of the Manual
3
Online Help
5
Finding Your Way
5
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