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High-available SIMATIC Automation and Drives Automation and Drives IMATIC S7- 400H S The high-available Automation System
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High-available SIMATIC
Automation and DrivesAutomation and Drives
IMATIC S7-400H
SThe high-available Automation System
Automation and Drives
High-available SIMATIC
Overview
Redundancy features
Configuration
Communication
Redundant I/O
Switchover
Synchronization
Self-test
Programming
CIR
Online repair
A&D AS, 07/2004, Chart 2 © Siemens AG 2004 - Subject to change without prior notice
Benefits
Avoidance of control system failures due to individual faults This is attained primarily through a redundant configuration
High-availability is required in the following cases: When processing valuable materials When downtimes or production failures would be expensive When a control system failure would result in high restart
costs In order to enable operation without supervisory or
maintenance personnel
Overview
Automation and Drives
High-available SIMATIC
Overview
Redundancy features
Configuration
Communication
Redundant I/O
Switchover
Synchronization
Self-test
Programming
CIR
Online repair
A&D AS, 07/2004, Chart 3 © Siemens AG 2004 - Subject to change without prior notice
Industries (1)
Power generation and distribution(oil, gas, electricity) Power plants Pipelines Offshore District heating systems
Chemical, electrochemical, petrochemical and pharmaceutical industries
Mining
Environmental engineering Water treatment Refuse incineration
Pulp and paper
Steel and metal
Overview
Automation and Drives
High-available SIMATIC
Overview
Redundancy features
Configuration
Communication
Redundant I/O
Switchover
Synchronization
Self-test
Programming
CIR
Online repair
A&D AS, 07/2004, Chart 4 © Siemens AG 2004 - Subject to change without prior notice
Industries (2)
Food and beverages
Glass industry
Semiconductor industry (utilities)
Transport Tunnel automation Marine automation
Airports Runway lighting Baggage transport
Overview
Automation and Drives
High-available SIMATIC
Overview
Redundancy features
Configuration
Communication
Redundant I/O
Switchover
Synchronization
Self-test
Programming
CIR
Online repair
A&D AS, 07/2004, Chart 5 © Siemens AG 2004 - Subject to change without prior notice
System architecture
Management level
PC network/terminal bus
Process level
Field level
ET 200M
Ethernet
RedundantIM 153
Redundantpower supply
H CPUsHot stand-by
ClientsParallel redundancy
Server Parallel redundancyWith archive-matching
SW redundancyWarm stand-by
Media redundancy
High-availablecommunication
Overview
RedundantPROFIBUS
Automation and Drives
High-available SIMATIC
Overview
Redundancy features
Configuration
Communication
Redundant I/O
Switchover
Synchronization
Self-test
Programming
CIR
Online repair
A&D AS, 07/2004, Chart 6 © Siemens AG 2004 - Subject to change without prior notice
System integration
Hidden redundancy Transparent programming
(programming same as for non-redundant systems)
Standard system parameterization
Standard handling
All SIMATIC programming languages can be used without restriction
Platform for F andFH systems
Overview
Automation and Drives
High-available SIMATIC
Overview
Redundancy features
Configuration
Communication
Redundant I/O
Switchover
Synchronization
Self-test
Programming
CIR
Online repair
A&D AS, 07/2004, Chart 7 © Siemens AG 2004 - Subject to change without prior notice
Bumpless master-stand-by switchover
Switchover time Switchover time < 100ms Outputs are retained during switchover No information or alarm/interrupt is lost
Switchover criteriaMaster failure Power supply Rack Sync module Sync cable CPUFailure of a DP string or DP slave interface module does not force a switchover
Redundancy features
Switchover
Automation and Drives
High-available SIMATIC
Overview
Redundancy features
Configuration
Communication
Redundant I/O
Switchover
Synchronization
Self-test
Programming
CIR
Online repair
A&D AS, 07/2004, Chart 8 © Siemens AG 2004 - Subject to change without prior notice
Automatic event synchronization
Customer benefits
Transparent programming All standard SIMATIC-S7 programming languages No command restrictions Easy porting of the user program
from standard CPU to high-available CPU
Bumpless switchover No loss of information No loss of alarms/interrupts Because all redundancy-specific functions are handled
by the operating system, the user can feel assured that he/she has done everything right as far as redundancy is concerned
Redundancy features
Synchronization
Automation and Drives
High-available SIMATIC
Overview
Redundancy features
Configuration
Communication
Redundant I/O
Switchover
Synchronization
Self-test
Programming
CIR
Online repair
A&D AS, 07/2004, Chart 9 © Siemens AG 2004 - Subject to change without prior notice
Comprehensive self-test functions
Self-test
Scope: CPU Memory Synchronization link
Organization: Startup self-test
Complete test Self-test in cyclic mode
Executes permanently as background task
Executes in its entirety within a specifiable amount of time (default: 90 minutes)
Redundancy features
Self-test
Automation and Drives
High-available SIMATIC
Overview
Redundancy features
Configuration
Communication
Redundant I/O
Switchover
Synchronization
Self-test
Programming
CIR
Online repair
A&D AS, 07/2004, Chart 10 © Siemens AG 2004 - Subject to change without prior notice
Online programming
Online modifications same as for standard system All modifications are automatically copied to both
CPUs
Connecting a PG At MPI interface Via bus
MPI/DP
PROFIBUS/Ethernet
Redundancy features
Programming
Automation and Drives
High-available SIMATIC
Overview
Redundancy features
Configuration
Communication
Redundant I/O
Switchover
Synchronization
Self-test
Programming
CIR
Online repair
A&D AS, 07/2004, Chart 11 © Siemens AG 2004 - Subject to change without prior notice
Configuration in RUN (CIR)
CPU memory configuration
Adding or removing: Central I/O or CP DP slaves PA interface and PA slaves Y-link and slaves Modules in modular DP slaves
CPU parameter
Redundancy features
CIR
Automation and Drives
High-available SIMATIC
Overview
Redundancy features
Configuration
Communication
Redundant I/O
Switchover
Synchronization
Self-test
Programming
CIR
Online repair
A&D AS, 07/2004, Chart 12 © Siemens AG 2004 - Subject to change without prior notice
Replacing modules in RUN mode
Modules which can be removed and inserted in Run mode I/O and CP Sync module Redundant IM 153-2 Redundant power supplies
Redundant components which can be replaced with the power off: Standard power supplies Central IM CPU
CPU is automatically updated following replacement(program and data)
Redundancy features
Online repair
Automation and Drives
High-available SIMATIC
Overview
Redundancy features
Configuration
Communication
Redundant I/O
Switchover
Synchronization
Self-test
Programming
CIR
Online repair
A&D AS, 07/2004, Chart 13 © Siemens AG 2004 - Subject to change without prior notice
ConfigurationHighlights new CPUs
Performance Increase Average Increase
417-4H appr. x 2,5-3414-4H appr. x 1,2-2,2
More Memeory417-4H from 4 MB to 20MB414-4H from 768KB to 1,4MB
Higher Reliability Memory with automatic Ewrror Detection and
Correction (EDC)
New Feature Distance between the Controller up to 10km (before
500m)
Konfiguration
Automation and Drives
High-available SIMATIC
Overview
Redundancy features
Configuration
Communication
Redundant I/O
Switchover
Synchronization
Self-test
Programming
CIR
Online repair
A&D AS, 07/2004, Chart 14 © Siemens AG 2004 - Subject to change without prior notice
ConfigurationTechnical specifications for the CPUs
Configuration
Two CPU types available CPU 417-4H with
20MB onboard CPU 414-4H with
1,4MB onboard
General technical specifications,e.g. CPU 417-4 or CPU 414-3
4 integrated interfaces Two for the Sync modules One DP interface One MPI/DP interface
Automation and Drives
High-available SIMATIC
Overview
Redundancy features
Configuration
Communication
Redundant I/O
Switchover
Synchronization
Self-test
Programming
CIR
Online repair
A&D AS, 07/2004, Chart 15 © Siemens AG 2004 - Subject to change without prior notice
ConfigurationRedundant link
Fiber-optics (FO)
Fiber-optics (FO)
Replaceable Sync modules
Configuration
Automation and Drives
High-available SIMATIC
Overview
Redundancy features
Configuration
Communication
Redundant I/O
Switchover
Synchronization
Self-test
Programming
CIR
Online repair
A&D AS, 07/2004, Chart 16 © Siemens AG 2004 - Subject to change without prior notice
I/O configurationSwitched I/O: mode of operation
Both DP masters are active and functioning properly
Reading inputs:The inputs are read only from the preferred channelside (active IM)
Writing outputs:The data are accepted by both channels.Only the data in the preferred channel are forwarded to the outputs.
Configuration
Automation and Drives
High-available SIMATIC
Overview
Redundancy features
Configuration
Communication
Redundant I/O
Switchover
Synchronization
Self-test
Programming
CIR
Online repair
A&D AS, 07/2004, Chart 17 © Siemens AG 2004 - Subject to change without prior notice
Redundant I/O
Redundant I/O
New: Redundant IO
Sensor/control element
PR
OFIB
US
DP
Redundant Communication
Redundant Controller
Redundant IM
Redundant
Pro
fibus
Automation and Drives
High-available SIMATIC
Overview
Redundancy features
Configuration
Communication
Redundant I/O
Switchover
Synchronization
Self-test
Programming
CIR
Online repair
A&D AS, 07/2004, Chart 18 © Siemens AG 2004 - Subject to change without prior notice
Redundant I/OPossible redundancy structures (2)
Distributed switchedI/O modules
H-CPU in single mode
Redundant I/O
Automation and Drives
High-available SIMATIC
Overview
Redundancy features
Configuration
Communication
Redundant I/O
Switchover
Synchronization
Self-test
Programming
CIR
Online repair
A&D AS, 07/2004, Chart 19 © Siemens AG 2004 - Subject to change without prior notice
Redundant I/O Wiring digital inputs
With two sensorsWith one sensor
Since the function is not suitable for all module types, the manual or Internet should be consulted to find out which modules can currently be used.
DI DI DI DI
Redundant I/O Redundant
Pro
fibus
Both Inputs are read in parallel.The correct value is selected and processed automatically
DI
DI
Master I/O
Redundant I/O
Automation and Drives
High-available SIMATIC
Overview
Redundancy features
Configuration
Communication
Redundant I/O
Switchover
Synchronization
Self-test
Programming
CIR
Online repair
A&D AS, 07/2004, Chart 20 © Siemens AG 2004 - Subject to change without prior notice
Redundant I/O Wiring analog inputs
With voltage sensor With current sensor With 2 sensors
4-wire transducers only
IR
AE-U AE-U
U
AE-U AE-U
R
I
AE AE
AI-I AI-I
I
With current sensor
Since the function is not suitable for every module type, the manual or Internet should be consulted to find out which modules can currently be used.
Redundant I/O
The CPU reads both inputs. The correct value is selectedand processed automatically
AI
AI
Master I/O
Redundant I/O
Redundant
Pro
fibus
Automation and Drives
High-available SIMATIC
Overview
Redundancy features
Configuration
Communication
Redundant I/O
Switchover
Synchronization
Self-test
Programming
CIR
Online repair
A&D AS, 07/2004, Chart 21 © Siemens AG 2004 - Subject to change without prior notice
Redundant I/O Wiring digital outputs
Without diodes*With diodes *
Since the function is not suitable for every module type, the manual or Internet should be consulted to find out which modules can currently be used.
DQ DQ DQ DQ* Dependant on the
module type
Actuator
Redundant I/O
Both Outputs are set
DO
DO
Master I/O
Redundant I/O
Redundant
Pro
fibus
Automation and Drives
High-available SIMATIC
Overview
Redundancy features
Configuration
Communication
Redundant I/O
Switchover
Synchronization
Self-test
Programming
CIR
Online repair
A&D AS, 07/2004, Chart 22 © Siemens AG 2004 - Subject to change without prior notice
Redundant I/O Wiring analog outputs
Since the function is not suitable for all module types, the manual or Internet should be consulted to find out which modules can currently be used
Actuator
I
Redundant I/O
Each Output outputs half the value.When one of the modules fails, the output that is still intactprovides the full value
Both Outputs are set
AO
AO
Master I/O
Redundant I/O
Redundant
Pro
fibus
Automation and Drives
High-available SIMATIC
Overview
Redundancy features
Configuration
Communication
Redundant I/O
Switchover
Synchronization
Self-test
Programming
CIR
Online repair
A&D AS, 07/2004, Chart 23 © Siemens AG 2004 - Subject to change without prior notice
