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Automation and Drives

SIMATIC S7-400H
Fault Tolerant Automation System

Automation and Drives

Motivation for the use of H-PLC Systems


SIMATIC S7-400H
Application fields Overview Redundany Features Configuration Communication

Expensive downtimes or processing of valuable material High restart costs after control failure Operation without monitoring or maintenance personal

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SIMATIC S7-400H

Automation and Drives

AUTOMATE S7-400H Domaines dapplication


SIMATIC S7-400H

Energie
Pipeline, Offshore et Central Thermique

Chimie, Petrochimie, Pharmacie Industrie minire Environnement


Traitement des eaux, Incinration des dchets

Transport
Gestion Tunnel Construction naval

Industrie du verre Industrie alimentaire

SIMATIC S7-400H

Automation and Drives

High Availability Overview


SIMATIC S7-400H
Application fields Overview Redundany Features Configuration Communication

Supervisiory level
PC-Network/Terminalbus

Clients Parallel Redundancy

Server Parallel Redundancy High available Communication Re d. PS MediumRedundancy SW-Redundanz Warm-Standby

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Process level S7-400H

PROFIBUS / Ethernet

H-CPUs Hot-Standby

Field level

ET 200M

Red. IM 157

Red. DPBus

Red. IM 153

Red. IM 153
SIMATIC S7-400H

Red. DP-Bus

Automation and Drives

Definitions
SIMATIC S7-400H

Terminologie Disponibilit

Buts quelque soit l lment qui tombe en dfaut.

Raction Dans le cas d un dfaut sur le systme actif, celui-ci va basculer automatiquement sur le second systme

H (High availability) Eviter les arrts de production

F (Failsafe)
Scurit

Eviter les dgats, corporels, sur le matriel ou l environnement Eviter les arrts de production Et viter les dgats, corporels, sur le matriel ou l environnement

Dans le cas d un dfaut le systme se place en tat de scurit Dans le cas d un dfaut dans la partie dite de scurit le systme se place en tat de scurit pour cette partie l, le reste de l installation continue de fonctionner

FH

ou

HF

Scurit ET Disponibilit

SIMATIC S7-400H

Automation and Drives

Redundancy Principles
SIMATIC S7-400H
Application fields Overview Redundany Features Configuration Communication

Redundancy with
identical components (homogenous redundancy)

different components (Diversified redundancy) Not used with SIMATIC redundancyprinciple S7-400H B

majority redundancy
m-v-n

passive redundancy
1-v-2

active redundancy R
1-v-2 2oo2

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2oo2

Hot-Standby =
automatic switch in ms-range

High availability

Warm-Standby = m-from-n high availability and fail-safe


HW or SW Voting

automatic switch in second range 1-v-2 2oo2

2-v-2

1oo2

Fail-safe

Cold-stand-by = manuel switch


SIMATIC S7-400H

Automation and Drives

Architecture
SIMATIC S7-400H
Application fields Overview Redundany Features Configuration Communication

P C B D A AC S P I O I OP U

Synchronisation, Data and State Exchange

P C B B A AC S P I O I OP U

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I I B B A A F M M I O I O M

Process
SIMATIC S7-400H

Automation and Drives

Highlights S7-400H: Complete SIMATIC System Integration


SIMATIC S7-400H
Application fields Overview Redundany Features Configuration Communication

User hidden redundancy


Transparent

programming (programming same as nonredundant systems) Easy system parameterisation with option package Handling like non-redundant systems

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All standard programming languages can be used without limitation Use of standard components (I/O, CP, FM)

Hardware platform for F/FH systems

SIMATIC S7-400H

Automation and Drives

Synchronisation Principle
SIMATIC S7-400H
Application fields Overview Redundany Features Configuration Communication

EventSynchronisation
Without
Synchronisation

CycleSynchronisation

TimeSynchronisation

ClockSynchronisation

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CPU B

CPU A

CPU B

CPU A

SIMATIC S7-400H

CPU A

CPU B

CPU A

CPU B

Automation and Drives

Principe de la synchronisation vnementielle


SIMATIC S7-400H

Cette fonction est prise en charge par le firmware des CPUs Points de synchronisation

Mise jour de la MIE Accs direct la priphrie Interruptions,alarmes Evaluation des temporisations Echanges des donnes lors de fonctions de communications

SIMATIC S7-400H

Partial PLC A

B B Teil-AG Partial PLC

Dfinition Les CPUs se synchronisent sur toute instruction dont lexcution pourrait conduire des branches de programmes diffrentes dans chaque CPU

Synchronisation vnementiell (Brevet Siemens)

Automation and Drives

Synchronisation vnementielle Exemple de droulement de fonctionnement


SIMATIC S7-400H

P C S P U

Synchronization, Information and Status Exchange

P C S P U A S I 10.0 O 8.0 PEW100 Synchronisation

: : L

A S

I 10.0 O 8.0 PEW100


Value Acknowledge

: : L

DW 10

L +

DW 10 F PAW130 Synchronisation DW 12 F

T L +

SIMATIC S7-400H

Automation and Drives

Event Synchronisation Cycle


SIMATIC S7-400H
CPU 0 CPU 1 Self test PII Exchange PII switched and one-sided

Application fields Overview Redundany Features Configuration Communication Alarms, Diagnostic OB

Self test PII switched and one-sided

Alarms, Diagnostic OB
OB 1 synch. 1 2 synch. synch. 1 2

synch. synch. synch. User program

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synch.
synch. User program

PIQ Comparison PIQ switched, one-sided PIQ switched and one-sided

SIMATIC S7-400H

Automation and Drives

Event Synchronisation Customer Advantages


SIMATIC S7-400H
Application fields Overview Redundany Features Configuration Communication

Transparent Programming
All

command from standard can be used User program directly portable from standard CPU to H CPU and back All standard SIMATIC S7 programming languages can be used

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Guaranteed bumpless Switch-Over


Quick

Switch-Over time No loss of information No loss of alarms

SIMATIC S7-400H

Automation and Drives

Self Test
SIMATIC S7-400H
Application fields Overview Redundany Features Configuration Communication

What is tested
CPU

(Processor, ASIC)

Memory Synchronisation

connection

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SIMATIC S7-400H

Automation and Drives

Self test Organization


SIMATIC S7-400H
Application fields Overview Redundany Features Configuration Communication

Start-up self test


Complete

test When errors occur, the CPU goes to the state defect

Self test in cycle operation


Runs

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in background The entire test is distributed over multiple cycles Runs completely through during a time that can be parameterized (default value 90mn)

SIMATIC S7-400H

Automation and Drives

Automate H : 1 seul point dentre


SIMATIC S7-400H

MPI/DP

PG/PC pour configuration chargement de programme modification en ligne , etc...

SIMATIC S7-400H

Automation and Drives

Programming Connection Examples


SIMATIC S7-400H
Application fields Overview Redundany Features Configuration Communication MPI/DP Profibus/Ethernet

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MPI

SIMATIC S7-400H

Automation and Drives

Programming Online Program Corrections


SIMATIC S7-400H
Application fields Overview Redundany Features Configuration Communication

Fully online programming through a CPU


the

program is automatically copied to the redundant CPU

Ordering

SIMATIC S7-400H

Automation and Drives

Online Repair
SIMATIC S7-400H
Application fields Overview Redundany Features Configuration Communication

S7-400 Components
I/O

and CP can be exchanged in RUN mode

IM

and CPU via Power off

exchanged CPU is automatically updated after power ON

Sync-Modules

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PS

Standard PV via power off Redundant PS in RUN mode

DP Components
IM I/O

153-2 in RUN mode modules can be exchanged in RUN mode

SIMATIC S7-400H

Automation and Drives

AUTOMATE S7-400H Configuration de base


SIMATIC S7-400H

Alimentation Redondante

2 Chssis Standard UR1/UR2

P P C SV S S P U P-Bus
K-Bus

P P C SV S S P U P-Bus
K-Bus

Alimentation Redondante

Chssis de base divis UR2-H

P P C SV S S P U P-Bus
K-Bus

P P C SV S S P U P-Bus
K-Bus

SIMATIC S7-400H

Automation and Drives

AUTOMATE S7-400H CPU Redondantes


SIMATIC S7-400H CPU 417-H/414-H avec 4 interfaces integrs: 2 Modules de synchro 1 Interface DP 1 Interface MPI/DP

CPU 417H

CPU 417H

X2 34

X2 34

Sync-Module

Liaison FO Haute vitesse


Redundancy Module Redundancy Module

X2 34

X2 34

Redundancy Module

X2 34

X2 34

SIMATIC S7-400H

Redundancy Module

Automation and Drives

Configuration CPU
SIMATIC S7-400H
Application fields Overview Redundany Features Configuration Communication

CPUs
High

end: CPU 417H (4MB expandable to 20MB)

Mid

mrange: CPU 414H (768KB)


CPU 417H

4 integrated interfaces
Sync-Module

Ordering

Sync-Module
DP MPI/DP

X2 34

X2 34

X2 34

SIMATIC S7-400H

Sync-Module

Sync-Module

Automation and Drives

Redondance des Entres,Sorties


SIMATIC S7-400H

Entres/Sorties

1 canal

2 canaux

Monovoie

Commute

Redondante

standard

Disponibilit

Haute Disponibilit
(en prparation)

SIMATIC S7-400H

Automation and Drives

I/O Configuration Redundant PROFIBUS


SIMATIC S7-400H
Application fields Overview Redundany Features Configuration Profibus-DP Communication

Redundant IM 153-2

Ordering

L+ L+

ET 200M with active backplane bus


Special bus module (BM)

Available as separate components IM: 6ES7 153-2AA02-0XB0 BM: 6ES7 195-7HD00-0XA0


or as Bundle (2 x IM + 1 BM) 6ES7 153-2AR00-0XA0

IM
Active backplane bus

IM

SIMATIC S7-400H

Automation and Drives

Fonctionnement dun API H Rseaux redondants,priphrie commune


SIMATIC S7-400H

Les deux CPUs sont actives


Lecture

des entres Les deux CPUs lisent les entres et la MIE est constitue partir des coupleurs actifs Ecriture des sorties - Les deux CPUs transfrent la MIS sur les coupleurs. - Les coupleurs actifs transmettent la MIS sur les sorties.

SIMATIC S7-400H

Automation and Drives

I/O Configuration Connection of PROFIBUS PA via DP/PA Link


SIMATIC S7-400H
Application fields Overview Redundany Features Configuration Communication

Profibus-DP
IM 157 (DP PA Link) DP PA Coupler

Ordering

SIMATIC S7-400H

Automation and Drives

I/O Configuration Connection of single DP slaves via Y Link


SIMATIC S7-400H
Application fields Overview Redundany Features Configuration Communication

Ordering

2xIM 157 Y-Link

SIMATIC S7-400H

Automation and Drives

Communication Configuration of single Communication


SIMATIC S7-400H
Application fields Overview Redundany Features Configuration Communication

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Profibus-DP PzP Kommunikation

CP 341

Single controller

SIMATIC S7-400H

Automation and Drives

High Available Communication Principle


SIMATIC S7-400H
Application fields Overview Redundany Features Configuration Communication

The communication switches automatically from the active to the reserve connection after a fault

Active + Reserve Connection = H Connection

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Active Connection

Reserve Connection

SIMATIC S7-400H

Automation and Drives

High Available Communication Configuration of the connections


SIMATIC S7-400H
Application fields Overview Redundany Features Configuration Communication

Active and reserve connections are automatically offered by the HW configuration tool H connections can be created between H stations, one-channel H-CPUs and PC stations (on PC Redconnect package required).

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SIMATIC S7-400H

Automation and Drives

AUTOMATE S7-400H Configuration :CPU et rseaux redondants


SIMATIC S7-400H Superviseur avec Soft de Redondance S7 Red-Connect

Communication Haute disponibilit

API S7-400H avec CPU 417H dans un chassis UR2-H avec liaison redondante

PROFIBUS-DP Priphrie commute/ Redondante

Peripherie IM153-2 avec

chssis Actif ! chssis Actif !

Peripherie IM153-2 avec

SIMATIC S7-400H

Automation and Drives

High Available Communication Configuration with redundant Bus


SIMATIC S7-400H
Application fields Overview Ethernet Redundany Features Configuration Communication

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H-CPU im Single Mode

Redundancy Diagram

PS

CPU

CP

Bus

CP

CPU

PS

PS

CPU

CP

Bus

CP

CPU

PS

SIMATIC S7-400H

Automation and Drives

High Available Communication - Configuration with redundant Bus and redundant CP


SIMATIC S7-400H
Application fields Overview Redundany Features Configuration Communication Ethernet

Ordering

H-CPU in Single Mode

Redundancy Diagram

PS PS

CPU CPU

CP CP CP CP

Bus

CP CP CP CP

CPU CPU

PS PS

Bus

SIMATIC S7-400H

Automation and Drives

High Available Communication Configuration with single Bus


SIMATIC S7-400H
Application fields Overview Redundany Features Configuration Communication Ethernet

S7-400H

S7-400H

Ordering

H-CPU in Single Mode

Redundancy Diagram:

PS PS

CPU CPU

CP Bus CP

CP CP

CPU CPU

PS PS

SIMATIC S7-400H

Automation and Drives

High Available Communication Configuration with optical Ringbus


SIMATIC S7-400H
Application fields Overview Redundany Features Configuration Communication Redundant optical Ringbus

S7-400H

S7-400H

Ordering

H-CPU im Single Mode

Redundancy Diagram

PS

CPU

CP

Bus

CP

CPU

PS

PS
SIMATIC S7-400H

CPU

CP

Bus

CP

CPU

PS

Automation and Drives

Haute Disponibilit Automate Redondant


SIMATIC S7-400H

Prix + lev que Api standard.


Hautes performances, Solution Haute disponibilit (Hot stand-by) avec Firmware H. Utilisation de priphrie dcentralise standard. Pas de programme applicatif (firmware uniquement) Fonctions transparentes (on-line). Redondance :
temps de basculement Matre-Rserve de lordre de la ms, Alimentations, Units centrales, Priphrie dentres/sorties, coupleurs

rseaux, modules technologiques.

SIMATIC S7-400H

Automation and Drives

Automatisation
SIMATIC S7-400H

Totally Integrated Automation avec

SIMATIC S7- 400H


SIMATIC S7-400H