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Siemens SIMATIC S7-400H, System Manual

The Siemens SIMATIC S7-400H is a state-of-the-art programmable logic controller designed for high-performance automation systems. This versatile device ensures seamless integration and efficient control within complex industrial environments. User manuals for the SIMATIC S7-400H are available for free download from manualshive.com, providing detailed instructions for setup and operation.

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Failure and replacement of components during operation 

 

16.2 Failure and replacement of components during operation 

 

S7-400H 

272

 

System Manual, 03/2012, A5E00267695-11 

16.2.5

 

Failure and replacement of a synchronization module or fiber-optic cable 

In this section, you will see three different error scenarios: 
●

 

Failure of a synchronization module or fiber-optic cable 

●

 

Successive failure of both synchronization modules or fiber-optic cables 

●

 

Simultaneous failure of both synchronization modules or fiber-optic cables 

The CPU indicates by means of LEDs and diagnostics whether the lower or upper redundant 

link has failed. After the defective parts (fiber-optic cable or synchronization module) have 

been replaced, LEDs IFM1F and IFM2F must go out.  

Starting situation 

 

Failure 

How does the system react? 

Failure of a fiber-optic cable or synchronization 

module: 
The S7-400H is in redundant system mode and a 

fiber-optic cable or synchronization module fails. 
See also chapter Synchronization modules for 

S7–400H (Page 341).  

 

The master CPU reports the event in the 
diagnostic buffer and with OB 72 of OB 82. 

 

The reserve CPU changes to ERROR-
SEARCH mode for some minutes. If the error 
is eliminated during this time, the reserve 
CPU switches to redundant system mode, 
otherwise it switches to STOP. 

 

The LED Link1 OK or Link2 OK on the 
synchronization module is lit. 

Procedure 

Follow the steps below to replace a synchronization module or fiber-optic cable:    

 

Step 

What has to be done? 

How does the system react? 

1 

First, check the fiber-optic cable. 

– 

2 

Start the reserve CPU (for example, STOP-

RUN or Start using the programming device).

The following responses are possible: 
1.

 

CPU changes to RUN mode. 

2.

 

CPU changes to STOP mode. In this 

case continue at step 3. 

3 

Remove the faulty synchronization module 

from the reserve CPU.  

– 

4 

Insert the new synchronization module in the 

reserve CPU. 

– 

5 

Plug in the fiber-optic cable connections of 

the synchronization modules. 

 

The LED Link1 OK or Link2 OK on the 
synchronization module goes out. 

 

Both CPUs report the event in the 
diagnostic buffer 

Summary of Contents for SIMATIC S7-400H

Page 1: ...__ SIMATIC Fault tolerant systems S7 400H System Manual 03 2012 A5E00267695 11 Preface 1 Fault tolerant automation systems 2 S7 400H setup options 3 Getting Started 4 Assembly of a CPU 41x H 5 Special functions of a CPU 41x H 6 PROFIBUS DP 7 PROFINET 8 Consistent data 9 Memory concept 10 System and operating states of the S7 400H 11 Link up and update 12 Using I Os in S7 400H 13 Communication 14 C...

Page 2: ...Siemens AG Industry Sector Postfach 48 48 90026 NÜRNBERG GERMANY A5E00267695 11 Ⓟ 04 2012 Technical data subject to change Copyright Siemens AG 2012 All rights reserved Legal information ...

Page 3: ...and response times 19 Technical data 20 Characteristic values of redundant automation systems A Stand alone operation B Differences between fault tolerant systems and standard systems C Function modules and communication processors supported by the S7 400H D Connection examples for redundant I Os E ...

Page 4: ...nt documentation in particular its warning notices and safety instructions Qualified personnel are those who based on their training and experience are capable of identifying risks and avoiding potential hazards when working with these products systems Proper use of Siemens products Note the following WARNING Siemens products may only be used for the applications described in the catalog and in th...

Page 5: ...3 6 Tools for configuration and programming 38 3 7 The user program 39 3 8 Documentation 40 4 Getting Started 41 4 1 Getting Started 41 4 2 Requirements 41 4 3 Hardware assembly and commissioning of the S7 400H 42 4 4 Examples of the response of the fault tolerant system to faults 44 4 5 Special layout features of SIMATIC Manager 45 5 Assembly of a CPU 41x H 47 5 1 Operator controls and display el...

Page 6: ...FIBUS DP master 87 7 1 1 DP address ranges of CPUs 41x H 88 7 1 2 CPU 41xH as PROFIBUS DP master 88 7 1 3 Diagnostics of a CPU 41xH operating as PROFIBUS DP master 91 8 PROFINET 95 8 1 Introduction 95 8 2 PROFINET IO systems 97 8 3 Blocks in PROFINET IO 99 8 4 System status lists for PROFINET IO 101 8 5 Device replacement without removable medium programming device 103 8 6 Shared Device 103 8 7 Me...

Page 7: ...uation of hardware interrupts in the S7 400H system 140 12 Link up and update 141 12 1 Effects of link up and updating 141 12 2 Conditions for link up and update 142 12 3 Link up and update sequence 143 12 3 1 Link up sequence 147 12 3 2 Update sequence 149 12 3 3 Switch to CPU with modified configuration or expanded memory configuration 152 12 3 4 Disabling of link up and update 154 12 4 Time mon...

Page 8: ...n via redundant S7 connections 240 14 5 3 Communication via point to point CP on the ET 200M 241 14 5 4 Custom connection to single channel systems 243 14 6 Communication via fault tolerant S7 connections 244 14 6 1 Communication between fault tolerant systems 247 14 6 2 Communication between fault tolerant systems and a fault tolerant CPU 250 14 6 3 Communication between fault tolerant systems an...

Page 9: ... 7 step 4 Loading a new hardware configuration in the reserve CPU 289 17 3 5 PCS 7 step 5 Switch to CPU with modified configuration 289 17 3 6 PCS 7 step 6 Transition to redundant system mode 291 17 3 7 PCS 7 step 7 Editing and downloading the user program 292 17 3 8 PCS7 Using free channels on an existing module 293 17 3 9 Adding interface modules in PCS 7 294 17 4 Removing components in PCS 7 29...

Page 10: ...ep 5 Transition to redundant system mode 328 17 8 Changing the CPU memory configuration 329 17 8 1 Changing the CPU memory configuration 329 17 8 2 Expanding load memory 329 17 8 3 Changing the type of load memory 331 17 9 Re parameterization of a module 334 17 9 1 Re parameterization of a module 334 17 9 2 Step 1 Editing parameters offline 335 17 9 3 Step 2 Stopping the reserve CPU 336 17 9 4 Ste...

Page 11: ...ction modules and communication processors supported by the S7 400H 457 E Connection examples for redundant I Os 461 E 1 SM 321 DI 16 x DC 24 V 6ES7 321 1BH02 0AA0 461 E 2 SM 321 DI 32 x DC 24 V 6ES7 321 1BL00 0AA0 462 E 3 SM 321 DI 16 x AC 120 230V 6ES7 321 1FH00 0AA0 463 E 4 SM 321 DI 8 x AC 120 230 V 6ES7 321 1FF01 0AA0 464 E 5 SM 321 DI 16 x DC 24V 6ES7 321 7BH00 0AB0 465 E 6 SM 321 DI 16 x DC...

Page 12: ... V 0 5 A 6ES7 422 7BL00 0AB0 484 E 25 SM 331 AI 4 x 15 Bit EEx ib 6ES7 331 7RD00 0AB0 485 E 26 SM 331 AI 8 x 12 Bit 6ES7 331 7KF02 0AB0 486 E 27 SM 331 AI 8 x 16 Bit 6ES7 331 7NF00 0AB0 487 E 28 SM 331 AI 8 x 16 Bit 6ES7 331 7NF10 0AB0 488 E 29 AI 6xTC 16Bit iso 6ES7331 7PE10 0AB0 489 E 30 SM331 AI 8 x 0 4 20mA HART 6ES7 331 7TF01 0AB0 490 E 31 SM 332 AO 4 x 12 Bit 6ES7 332 5HD01 0AB0 492 E 32 SM3...

Page 13: ...tatus lists of PROFINET IO and PROFIBUS DP 101 Table 10 1 Memory requirements 119 Table 11 1 Overview of S7 400H system states 124 Table 11 2 Causes of error leading to redundancy loss 133 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 c...

Page 14: ...e CPU 414 5H 360 Table 19 5 Portion of the process image transfer time CPU 416 5H 361 Table 19 6 Portion of the process image transfer time CPU 417 5H 362 Table 19 7 Extending the cycle time 362 Table 19 8 Operating system execution time at the cycle control point 363 Table 19 9 Extended cycle time due to nested interrupts 363 Table 19 10 Direct access of the CPUs to I O modules in the central rac...

Page 15: ...ncy 105 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 Figure 9 1 Properties DP slave 116 Figure 10 1 Memory areas of the S7 400H CPUs 117 Figure 11 1 Synchronizing the subsystems 122 Figure 11 2 System and operating states of the...

Page 16: ...4 8 Example of linking standard and fault tolerant systems in a redundant bus system 238 Figure 14 9 Example of linking of standard and fault tolerant systems in a redundant ring 238 Figure 14 10 Example of redundancy with fault tolerant systems and a redundant bus system with redundant standard connections 240 Figure 14 11 Example of connecting a fault tolerant system to a single channel third pa...

Page 17: ...nection with SM 321 DI 8 x AC 120 230 V 464 Figure E 5 Example of an interconnection with SM 321 DI 16 x DC 24V 465 Figure E 6 Example of an interconnection with SM 321 DI 16 x DC 24V 466 Figure E 7 Example of an interconnection with SM 326 DO 10 x DC 24V 2A 467 Figure E 8 Example of an interconnection with SM 326 DI 8 x NAMUR 468 Figure E 9 Example of an interconnection with SM 326 DI 24 x DC 24 ...

Page 18: ...t EEx ib 485 Figure E 26 Example of an interconnection with SM 331 AI 8 x 12 Bit 486 Figure E 27 Example of an interconnection with SM 331 AI 8 x 16 Bit 487 Figure E 28 Example of an interconnection with SM 331 AI 8 x 16 Bit 488 Figure E 29 Example of an interconnection AI 6xTC 16Bit iso 489 Figure E 30 Interconnection example 1 SM 331 AI 8 x 0 4 20mA HART 490 Figure E 31 Interconnection example 2...

Page 19: ...unication performance Reduction of processing times Adaptation of work memory and additional quantity frameworks to the CPUs 41x 3 PN DP V6 0 Differences in system behavior between versions 4 5 and 6 0 A user program that uses SFC 87 to read out the current connection status and that was written for a H CPU V4 x does not return any data on an H CPU V6 0 The reason is that the quantity Framework ex...

Page 20: ...s basic software This knowledge is provided in the Programming with STEP 7 manual In particular when operating an S7 400H system in potentially explosive atmospheres you should always observe the information on the safety of electronic control systems provided in the appendix of the S7 400 Automation System Installation manual Scope of the manual The manual is relevant to the following components ...

Page 21: ...s also shown for the toolbar buttons when you hold the mouse pointer briefly over a button If you prefer to read the information of the online help in printed form you can print individual topics books or the entire help system Recycling and disposal The S7 400H system contains environmentally compatible materials and can be recycled For ecologically compatible recycling and disposal of your old d...

Page 22: ...IMATIC S7 automation system Please contact your local training center or the central training center Training http www sitrain com index_en html Technical Support For technical support of all Industry Automation products fill in and submit the online Support Request Support Request http www siemens de automation support request Service Support on the Internet In addition to our documentation we of...

Page 23: ...ur products You can find information on this under http support automation siemens com You can register for a product specific newsletter here For the safe operation of a plant machine however it is also necessary to integrate the automation components into an overall IT security concept for the entire plant machine which corresponds to the state of the art IT technology You can find information o...

Page 24: ...Preface 1 1 Preface S7 400H 24 System Manual 03 2012 A5E00267695 11 ...

Page 25: ...SDUDOOHO RSHUDWLRQ RI WZR V VWHPV DLO VDIH RXW RI V VWHPV 2EMHFWLYH 3URWHFW OLIH WKH HQYLURQPHQW DQG LQYHVWPHQWV E VDIHO GLVFRQQHFWLQJ WR D VHFXUH RII SRVLWLRQ Figure 2 1 Operating objectives of redundant automation systems Note the difference between fault tolerant and fail safe systems The S7 400H is a fault tolerant automation system You may only use it to control safety related processes if yo...

Page 26: ...d to use a fault tolerant system The generally higher investment costs of fault tolerant systems are soon recovered since production stops are avoided Redundant I O Input output modules are termed redundant when they exist twice and they are configured and operated as redundant pairs The use of redundant I O provides the highest degree of availability because the system tolerates the failure of a ...

Page 27: ...ring of assemblies and plants System wide integration The S7 400H automation system and all other SIMATIC components such as the SIMATIC PCS7 control system are matched to one another The system wide integration ranging from the control room to the sensors and actuators is implemented as a matter of course and ensures maximum system performance 7 0 7 7 0 7 0 RQWURO URRP XWRPDWLRQ V VWHPV 352 86 3 ...

Page 28: ...tomating Redundancy nodes Redundant nodes represent the fail safety of systems with redundant components A redundant node can be considered as independent when the failure of a component within the node does not result in reliability constraints in other nodes or in the overall system The availability of the overall system can be illustrated simply in a block diagram With a 1 out of 2 system one c...

Page 29: ...em 36 36 38 38 XV XV 0 0 60 36 36 38 38 XV XV 7 7 XV Figure 2 4 Example of redundancy in a 1 out of 2 system with error Failure of a redundancy node total failure The following figure shows that the overall system is no longer operable because both subunits have failed in a 1 out of 2 redundancy node total failure 36 36 38 38 XV XV 0 0 60 5HGXQGDQW QRGHV ZLWK RI UHGXQGDQF Figure 2 5 Example of red...

Page 30: ...Fault tolerant automation systems 2 2 Increasing the availability of plants S7 400H 30 System Manual 03 2012 A5E00267695 11 ...

Page 31: ...iguring and programming the S7 400H Also included is a description of the extensions and functional expansions available for the S7 400 standard system which you need to create your user program to utilize all properties of your S7 400H in order to increase availability Important information on configuration WARNING Open equipment S7 400 modules are classified as open equipment meaning you must in...

Page 32: ... UHGXQGDQW FRPPXQLFDWLRQ QJLQHHULQJ 6 VWHP FRQILJXUDWLRQ DQG FRQWURO ZLWK 67 3 SHUPDQHQWO DVVLJQHG WR D 38 Figure 3 1 Overview Additional information The components of the S7 400 standard system are also used in the fault tolerant S7 400H automation system For a detailed description of all hardware components for S7 400 refer to the Reference Manual S7 400 Automation System Module Specifications T...

Page 33: ...ent of modules in the S7 400 The CPUs have to be inserted in the same slots Redundantly used external DP master interfaces or communication modules must be inserted in the same slots in each case External DP master interfaces for redundant DP master systems must only be inserted in central units rather than in expansion devices Redundantly used modules e g CPU 41x 5H PN DP DP slave interface modul...

Page 34: ...The two CPUs are the heart of the S7 400H Use the switch on the rear of the CPU to set the rack numbers In the following sections we will refer to the CPU in rack 0 as CPU 0 and to the CPU in rack 1 as CPU 1 Rack for S7 400H The UR2 H rack supports the installation of two separate subsystems with nine slots each and is suitable for installation in 19 cabinets You can also set up the S7 400H in two...

Page 35: ...ces up to 10 km between the CPUs A fault tolerant system requires 4 synchronization modules of the same type For more information on synchronization modules refer to section Synchronization modules for S7 400H Page 341 Fiber optic cable The fiber optic cables are used to interconnect the synchronization modules for the redundant link between the two CPUs They interconnect the upper and lower synch...

Page 36: ...onfiguration with standard availability With the single channel one sided design single input output modules are available The I O modules are located in only one subsystem and are only addressed by this subsystem However in redundant mode both CPUs are interconnected via the redundant link and thus execute the user program identically Single channel switched configuration with enhanced availabili...

Page 37: ...undant optical two fiber loop Fault tolerant communication via PROFIBUS or Industrial Ethernet is supported only by the S7 communication functions Programming and configuring Apart from the use of additional hardware components there are basically no differences with regard to configuration and programming compared to standard systems Fault tolerant connections only have to be configured specific ...

Page 38: ... automatically monitors the redundant components and switches over to the standby components when an error occurs You have already configured the relevant information and communicated it to the system in your STEP 7 program Detailed information can be found in the online help section Configuring with STEP 7 Page 259 and Appendix Differences between fault tolerant systems and standard systems Page ...

Page 39: ... S7 400H systems the S7 400H software provides further blocks which you can use to influence the redundancy functions You can react to redundancy errors of the S7 400H using the following organization blocks OB 70 I O redundancy errors OB 72 CPU redundancy errors SFC 90 H_CTRL can be used to influence fault tolerant systems as follows You can disable interfacing in the master CPU You can disable u...

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Page 41: ...s The following requirements must be met A correctly installed and valid version of the STEP 7 basic software on your programming device see section Configuring with STEP 7 Page 259 Any necessary hardware updates are installed The modules required for the hardware setup available An S7 400H automation system consisting of 1 UR2 H rack 2 PS 407 10 A power supply units 2 H CPUs 4 synchronization mod...

Page 42: ...r synchronization modules of the CPUs Route your fiber optic cables so that they are reliably protected against any damage You should also always make sure that the two fiber optic cables are routed separately This increases availability and protects the fiber optic cables from potential double errors caused for example by interrupting both cables at the same time Furthermore always connect at lea...

Page 43: ...am folder is only assigned to CPU0 The user program is executable with the described hardware configuration It activates the LEDs on the digital output module running light 5 Edit the user program as necessary to adapt it to your hardware configuration and then save it 6 Select PLC Download to download the user program to CPU0 7 Start up the S7 400H automation system by setting the mode switch of ...

Page 44: ...ck on Result CPU0 performs an automatic LINK UP and UPDATE CPU0 changes to RUN and now operates as reserve CPU The S7 400H is now in redundant system mode Example 2 Failure of a fiber optic cable Initial situation The S7 400H is in redundant system mode The mode selector switch of each CPU is set to RUN 1 Disconnect one of the fiber optic cables Result The LEDs REDF and IFM1F or IFM2F depending on...

Page 45: ...only under CPU0 No S7 program is visible under CPU1 In the online view the S7 program appears under both CPUs and can be selected in both locations In the online view the CPUs are represented by symbols that reflect the respective operating states of the CPUs For programming device PG functions that set up online connections one of the two CPUs has to be selected even if the function affects the e...

Page 46: ...Getting Started 4 5 Special layout features of SIMATIC Manager S7 400H 46 System Manual 03 2012 A5E00267695 11 ...

Page 47: ... 38 31 3 X 2 3 4 1 1 5 7 5 7 1 2 1 2 0 17 X5 P2 R PSULQW RI PRGXOH GHVLJQDWLRQ SURGXFW YHUVLRQ VKRUW RUGHU QXPEHU DQG ILUPZDUH YHUVLRQ GLVSOD V 17 7 86 0 0 5 0 17 581 6723 0HPRU FDUG VORW 0RGH VZLWFK 6XSSO RI H WHUQDO EDFNXS YROWDJH DW UHDU 5DFN QXPEHU VHOHFWRU VZLWFK 6 QFKURQL DWLRQ PRGXOH LQWHUIDFH 6 QFKURQL DWLRQ PRGXOH LQWHUIDFH GLVSOD V 5 86 86 0675 5 5 03 352 86 3 LQWHUIDFH 6HULDO QXPEHU DWD...

Page 48: ...force request MAINT yellow Maintenance request pending RUN green RUN mode STOP yellow STOP mode REDF red Loss of redundancy Redundancy fault BUS2F red Bus error at the PROFIBUS interface BUS5F red Bus error at the PROFINET interface MSTR yellow CPU controls the process RACK0 yellow CPU in rack 0 RACK1 yellow CPU in rack 1 LINK 1 OK green Connection via synchronization module 1 is active and OK LIN...

Page 49: ...r to section Design and function of the memory cards Page 65 Slot for synchronization modules You can insert one synchronization module into this slot See chapter Synchronization modules Page 341 MPI DP interface You can for example connect the following devices to the MPI of the CPU Programming devices Operator control and monitoring devices For further S7 400 or S7 300 controllers see section Mu...

Page 50: ...located rack number 0 and the partner CPU is assigned rack number 1 The default setting of all CPUs is rack number 0 Connecting an external backup voltage to the EXT BATT socket The S7 400H power supply modules support the use of two backup batteries This allows you to implement the following Back up the user program stored in RAM Retain bit memories timers counters system data and data in variabl...

Page 51: ...umber A5E00728552A Note If you replace a power supply module and want to backup the user program and the data as described above in an RAM while doing so you must connect an auxiliary power supply to the EXT BATT socket Do not interconnect the cables of different CPUs Interconnecting the cables of different CPUs may lead to problems with regard to EMC conditions and different voltage potentials ...

Page 52: ... In SMs Call of OB 122 with direct access call of OB 85 in the event of a process image update Entry in the diagnostic buffer In the case of input modules Entry of null as date in the accumulator or the process image In the case of other modules Call of OB 122 with direct access call of OB 85 in the event of a process image update EXTF Time error The user program execution time OB 1 and all interr...

Page 53: ...ncellation of the update process Comparison error e g RAM PAA Call of OB 72 If the OB is not loaded The CPU remains in RUN EXTF CPU hardware fault A memory error was detected and eliminated In a configuration older than V6 0 Data transmission error at the redundant link Call of OB 84 If the OB is not loaded The CPU remains in RUN INTF Program execution error Priority class is called but the corres...

Page 54: ...depth of block call commands U stack too great Nesting depth of block call commands B stack too great Error during allocation of local data Call of OB 88 If the OB is not loaded CPU changes to STOP mode INTF Programming error User program error BCD conversion error Range length error Range error Alignment error Write error Timer number error Counter number error Block number error Block not loaded...

Page 55: ...ed The cold restart warm start may take a minute or longer depending on the length of the called OB If the CPU still does not change to RUN there might be an error in the system configuration for example Dark Flashes 2 Hz A high quality RAM test self test is executed after POWER ON The self test takes at least 10 minutes Memory is being reset Irrelevant Flashes 0 5 Hz The CPU requests a memory res...

Page 56: ...ontrols switched I O Irrelevant Lit Dark CPU on rack number 0 Irrelevant Dark Lit CPU on rack number 1 INTF EXTF and FRCE LEDs The three LEDs INTF EXTF and FRCE provide information about errors and special events in the user program execution LED Meaning INTF EXTF FRCE Lit Irrelevant Irrelevant An internal error was detected programming or parameter assignment error Irrelevant Lit Irrelevant An ex...

Page 57: ...PROFINET IO system is configured but not connected Irrelevant Irrelevant Flashes One or several devices on the PROFINET IO interface are not responding CPU is DP master One or several slaves at the PROFIBUS DP interface 1 are not responding Flashes Irrelevant Irrelevant CPU is DP slave CPU is not addressed by the DP master CPU is DP master One or several slaves at the PROFIBUS DP interface 2 are n...

Page 58: ...sending data at the PROFINET interface Note The LINK and RX TX LEDs are located directly next to the PROFINET interface sockets They are not labeled REDF LED The REDF LED indicates specific system states and redundancy errors REDF LED System state Basic requirements Flashes 0 5 Hz Link up Flashes 2 Hz Update Dark Redundant CPUs are redundant No redundancy error Lit Redundant CPUs are redundant The...

Page 59: ...h the guidelines in chapter Installation of fiber optic cables Page 346 Check whether the synchronization module works in another CPU Dark The connection is interrupted or there is insufficient light intensity Check the connectors and cables Check whether the fiber optic cables are installed in accordance with the guidelines in chapter Installation of fiber optic cables Page 346 Check whether the ...

Page 60: ...itch Function of the mode switch The mode switch can be used to set the CPU to RUN mode or STOP mode or to reset the CPU memory STEP 7 offers further options of changing the mode Positions The mode switch is designed as toggle switch The following figure shows all possible positions of the mode switch Figure 5 3 Mode switch positions ...

Page 61: ...d programs from the CPU to the programming device CPU Programming device You can download programs from the programming device to the CPU Programming device CPU STOP The CPU does not execute the user program The digital signal modules are disabled The output modules are disabled You can upload programs from the CPU to the programming device CPU Programming device You can download programs from the...

Page 62: ...mory reset requested by system e g after a memory card has been removed or inserted Toggle the switch to MRES and then release it again Result The STOP LED flashes for at least 3 seconds at 2 Hz the memory reset is executed and the LED then remains lit Memory reset process in the CPU During a memory reset the following process occurs on the CPU The CPU deletes the entire user program in the main m...

Page 63: ... MPI DP interface parameters Note the special features shown in the table below MPI address Highest MPI address Baud rate Parameters of the PN interface Note the special features shown in the table below Name NameOfStation IP address of CPU Subnet mask Static SNMP parameters The time of day The status and value of the operating hours counter Special feature A special situation is presented for the...

Page 64: ... valid value The associated startup OB is OB 100 Program execution resumes with OB 1 or with OB 100 if available If the power supply is interrupted the warm restart function is only available in backup mode Note Restart in buffered Power On mode In buffered PowerOn mode of a fault tolerant system with large configurations many CPs and or external DP masters it may take up to 30 seconds until a req...

Page 65: ...HZ 6LGH YLHZ 7 SH SODWH ZLWK VHULDO QXPEHU H J 693 1 DQGOH 1DPH RI WKH PHPRU FDUG 2UGHU QXPEHU Figure 5 4 Design of the memory card Function of the memory card The memory card and an integrated memory area on the CPU together form the load memory of the CPU During operation the load memory contains the complete user program including comments symbols and special additional information that enables...

Page 66: ...number This serial number is listed in INDEX 8 of the SSL Parts List W 16 xy1C The parts list can be read using SFC 51 RDSYSST You can determine the following when you read the serial number in your user program The user program can only be executed when a specific memory card is inserted into the CPU This protects against unauthorized copying of the user program similar to a dongle ...

Page 67: ...p or outside the CPU use a FLASH card RAM card Insert the RAM card to load the user program in the CPU Load the user program in STEP 7 by selecting Target system Download You can load the entire user program or individual elements such as FBs FCs OBs DBs or SDBs in the load memory in STOP or RUN mode When you remove the RAM card from the CPU the information stored on it will be lost The RAM card i...

Page 68: ...tart or cold restart as configured will automatically be carried out after switch on or voltage recovery after power off The user program must be available on the FLASH card and the battery indicator switch on the power supply module may not be set to battery monitoring If battery monitoring is set you must carry out a restart or cold restart either with the mode switch or via a programming device...

Page 69: ...gth of local data in bytes MC7 Length of MC7 code in bytes Length of DB user data Length in load memory of the target system Length in work memory of the target system only if hardware assignment is known The views always show these block data regardless whether it is located in the window of an online view or of an offline view When a block container is opened and View Details is set the project ...

Page 70: ...able of handling several online connections to PGs OPs in parallel By default however one of these connections is always reserved for a PG and one for an OP HMI device CPU CPU communication CPUs exchange data by means of S7 communication For additional information refer to the Programming with STEP 7 manual Connectors Always use bus connectors with an angular cable outlet for PROFIBUS DP or PG cab...

Page 71: ...ct devices to the PROFIBUS DP interface refer to the Installation Manual Redundant mode In redundant mode the PROFIBUS DP interfaces have the same parameters 5 9 PROFINET interface X5 Assigning an IP address You have the following options of assigning an IP address to the Ethernet interface By editing the CPU properties in HW Config Download the modified configuration to the CPU You can also set u...

Page 72: ...munication over TCP UDP ISO on TCP S7 communication PG functions Port statistics of PN IO devices SNMP Detection of the network topology LLDP Media redundancy MRP Time synchronization using the NTP method as a client or the SIMATIC method For more information on the properties of the PROFINET interface refer to the technical specifications of the respective CPU In chapter Technical data Page 383 C...

Page 73: ...e may only be operated at 100 Mbps in full duplex mode Operation at 100 Mbps full duplex is possible if the on board PROFINET interface s of the CPU is are used for Ethernet communication only Half duplex mode is not allowed in any situation Background If a switch that is permanently set to 10 Mbps half duplex is connected to the interface of the CPU the Autonegotiation setting forces the CPU to a...

Page 74: ... g the scan cycle monitoring time Retentivity i e the number of bit memories timers and counters that are retained after restart Memory e g local data Note If you change the work memory allocation by modifying parameters this work memory is reorganized when you download system data to the CPU As a consequence the data blocks generated by means of SFC are deleted and the remaining data blocks are i...

Page 75: ...he local data Number of diagnostic buffer entries Communication resources This involves the following initialization actions Data blocks are initialized with the load values Bit memories timers counters inputs and outputs are deleted regardless of their retentivity setting 0 DBs generated by SFC will be deleted Permanently configured basic communication connections are shut down All run levels are...

Page 76: ...Assembly of a CPU 41x H 5 10 Overview of the parameters for the S7 400H CPUs S7 400H 76 System Manual 03 2012 A5E00267695 11 ...

Page 77: ... Access granted Access granted Access granted Monitor variables Access granted Access granted Access granted Module status STACKS Access granted Access granted Access granted Operator control and monitoring functions Access granted Access granted Access granted S7 communication Access granted Access granted Access granted Reading the time Access granted Access granted Access granted Setting the ti...

Page 78: ...2 Setting of security level 3 without password legitimization This means you cannot cancel the write and read protection set with SFC 109 even if you know the valid password If a legitimate connection exists when you call SFC 109 with MODE 12 the SFC 109 call has no effect on this connection Note Setting a lower security level You can use SFC 109 PROTECT to set a lower security level than the one ...

Page 79: ... kept in a safe place The loading of encrypted blocks is only supported on CPUs as of V6 0 If your project contains sources you can use these to restore the encrypted blocks by means of compilation The S7 Block Privacy sources can be removed from the project General procedure To encrypt the blocks follow these steps 1 In STEP 7 right click the block container and select Block protection If you hav...

Page 80: ... on the loading time of blocks and the startup after a system modification at runtime may be significantly prolonged Operation with FlashCard can significantly prolong the time for memory reset To optimize additional time requirements it is best practice to encrypt one large block instead of many small blocks If you have many encrypted blocks and change one of the following parameters the error Un...

Page 81: ...3 Hold the toggle switch in the MRES setting and switch the mains voltage on again 4 Wait until LED pattern 1 from the following overview is displayed 5 Release the toggle switch set it back to MRES within 3 seconds and hold it in this position After approx 4 seconds all the LEDs light up 6 Wait until LED pattern 2 from the following overview is displayed This LED pattern lights up for approximate...

Page 82: ...PU to its factory settings the LEDs light up consecutively in the following LED patterns Table 6 3 LED patterns LED LED pattern 1 LED pattern 2 LED pattern 3 INTF Flashes at 0 5 Hz Flashes at 0 5 Hz Lit EXTF Dark Dark Dark BUSxF Dark Dark Dark FORCE Flashes at 0 5 Hz Dark Dark MAINT Dark Dark Dark IFMxF Dark Dark Dark RUN Flashes at 0 5 Hz Dark Dark STOP Flashes at 0 5 Hz Dark Dark ...

Page 83: ...ou require the password to update the firmware Note You can update the firmware of the fault tolerant CPUs via Industrial Ethernet Updating the firmware over a MPI can take a long time if the transfer rate is low e g approximately 10 minutes at 187 5 Kbit s Procedure in HW Config Proceed as follows to update the firmware of a CPU 1 Open the station containing the CPU you want to update in HW Confi...

Page 84: ...ifies that the module supports this function Note Update security For reasons of firmware security the CPU validates a digital signature before it runs the firmware update If it detects an error it retains the current firmware version and rejects the new one Values retained after a firmware update The following values are retained after a CPU memory reset Parameters of the MPI MPI address and high...

Page 85: ... in HW Config or in SIMATIC Manager in your STEP 7 project 3 Select the PLC Update Firmware menu command The Update Firmware dialog box opens Select the firmware file from which the current firmware will be downloaded to the selected CPU 4 In SIMATIC Manager or HW Config select the PLC Operating Mode Switch to CPU 41x H and select the with altered operating system check box The fault tolerant syst...

Page 86: ...e service data Select the PLC Save service data command to read this information and save the data to two files You can then send these to Customer Support Note the following If possible save the service data immediately after the CPU goes into STOP or the synchronization of a fault tolerant system has been lost Always save the service data of both CPUs in an H system Procedure 1 Select the PLC Sa...

Page 87: ...xchange Further references The STEP 7 Online Help provides descriptions and information on the following topics Planning of a PROFIBUS subnet Configuration of a PROFIBUS subnet Diagnostics in the PROFIBUS subnet Additional information Details and information on migrating from PROFIBUS DP to PROFIBUS DPV1 is available under entry ID 7027576 at the Internet address http support automation siemens co...

Page 88: ...nostics addresses when you configure the project data If you do not specify any DP diagnostics addresses STEP 7 automatically assigns the addresses as DP diagnostics addresses in descending order starting at the highest byte address In DPV1 mode of the master the slaves are usually assigned 2 diagnostics addresses 7 1 2 CPU 41xH as PROFIBUS DP master Requirement You have to configure the relevant ...

Page 89: ...ed I Os has been enhanced The enhancements were incorporated into IEC 61158 IEC 61784 1 2002 Ed1 CP 3 1 The SIMATIC documentation uses the term DPV1 in this context The new version features various expansions and simplifications SIEMENS automation components feature DPV1 functionality In order to be able to use these new features you first have to make some modifications to your system A full desc...

Page 90: ...n this case they behave like conventional slaves SIEMENS DPV1 slaves can be operated in S7 compatible mode To integrate DPV1 slaves from other manufacturers you need a GSD file complying with IEC 61158 earlier than revision 3 Determining the bus topology in a DP master system using SFC 103 DP_TOPOL A diagnostic repeater is available to make it easier to localize disrupted modules or DP cable break...

Page 91: ...luate the diagnosis of the DP slaves Check whether the bus cable has a short circuit or a break Reading out the diagnostics information with STEP 7 Table 7 3 Reading out the diagnostics information with STEP 7 DP master Block or tab in STEP 7 Application See CPU 41x DP slave diagnostics tab Display the slave diagnosis as plain text on the STEP 7 user interface See Hardware diagnostics in the STEP ...

Page 92: ...ed interrupt OB Evaluating diagnostics data in the user program The figure below shows how to evaluate the diagnostics data in the user program 38 LDJQRVWLFV HYHQW 2 LV FDOOHG 5HDG 2 B0 B 5 DQG 2 B 2B 2 PRGXOH LGHQWLILHU QWHU ELW RI WKH 2 B 2B DV ELW LQ 2 B0 B 5 5HVXOW LDJQRVWLFV DGGUHVV 2 B0 B 5 RU WKH GLDJQRVLV RI WKH DIIHFWHG FRPSRQHQW DOO 6 LQ 39 HQYLURQPHQW LDJQRVWLF GDWD DUH HQWHUHG LQ SDUDP...

Page 93: ... SURMHFW RI WKH 3 VODYH 7KLV GLDJQRVWLF DGGUHVV LV LGHQWLILHG DV DVVLJQHG WR WKH 3 VODYH EHORZ 7KLV GLDJQRVWLF DGGUHVV LV XVHG E WKH 3 VODYH WR REWDLQ LQIRUPDWLRQ DERXW WKH VWDWXV RI WKH 3 PDVWHU RU DERXW EXV LQWHUUXSWLRQV Figure 7 2 Diagnostics addresses for DP master and DP slave Event detection The following table shows how the CPU 41xH in DP master mode detects operating state changes on a DP ...

Page 94: ...ress in master system 1022 Example of diagnostics addresses Slave diagnostics address 422 Master diagnostics address irrelevant The CPU calls OB 82 with the following information for example OB 82_MDL_ADDR 1022 OB82_EV_CLASS B 16 39 As incoming event OB82_MDL_DEFECT module error The CPU diagnostic buffer also contains this information Your user program should also be set up to read the diagnostic ...

Page 95: ...lows all stations to access the network at any time In this way the network can be used much more efficiently through the simultaneous data transfer of several nodes Simultaneous sending and receiving is enabled through the full duplex operation of Switched Ethernet PROFINET IO is based on Switched Ethernet full duplex operation and a bandwidth of 100 Mbit s In PROFINET IO communication a slice of...

Page 96: ...tion about PROFINET http www profibus com is available on the Internet Also observe the following documents Installation guideline Assembly guideline PROFINET_Guideline_Assembly Additional information on the use of PROFINET in automation engineering is available at the following Internet address http www siemens com profinet ...

Page 97: ...3 3 6ZLWFK 3 3 38 31 3 5DFN 2 FRQWUROOHU 3 PDVWHU 3 3 3 3 6ZLWFK 3 3 3 3 38 31 3 5DFN 2 FRQWUROOHU 3 PDVWHU 3 3 7 2 GHYLFH 3 3 7 2 GHYLFH 3 3 7 2 GHYLFH 3 3 3 3 6ZLWFK 3 3 PDVWHU 3 3 3 3 OLQN 7 6 3 VODYH 3 3 7 2 GHYLFH 3 3 38 31 3 3 PDVWHU HYLFH 2 3 4 5 6 7 8 9 10 352 1 7 2 V VWHP DXOW WROHUDQW V VWHP 2QH VLGHG 2 6 VWHP UHGXQGDQF 352 1 7 2 V VWHP ZLWK V VWHP UHGXQGDQF DQG 053 053 3 38 31 3 2 FRQWU...

Page 98: ... 3 and for the intelligent device CPU 317 2 PN DP The CPU 41x 5H PN DP is also the master for the DP slave via the IE PB Link The fault tolerant system consisting of CPU 41x 5H PN DP sets up the PROFINET system 2 as IO controller A one sided IO device is operated in system redundancy in addition to IO devices at this IO controller The fault tolerant system consisting of CPU 41x 5H PN DP sets up PR...

Page 99: ...o replace when migrating from PROFIBUS DP to PROFINET IO New system and standard functions Table 8 1 System and standard functions that are new or have to be replaced Blocks PROFINET IO PROFIBUS DP SFC 13 DPNRM_DG Reading diagnostics data of a DP slave No Replacement Event related SFB 54 Status related SFB 52 Yes SFC 58 WR_REC SFC 59 RD_REC Write read record in the I O devices No Replacement SFB 5...

Page 100: ...ynamic parameters No Emulation by means of SFB 53 Yes SFC 56 WR_DPARM Writing predefined parameters No Emulation by means of SFB 81 and SFB 53 Yes SFC 57 PARM_MOD Assigning module parameters No Emulation by means of SFB 81 and SFB 53 Yes The following SIMATIC system function is not supported for PROFINET IO SFC 103 DP_TOPOL Determine the bus typology in a DP master Comparison of the Organization B...

Page 101: ...gurations are now possible with PROFINET You can also use these new system status lists with PROFIBUS You can continue to use a known PROFIBUS system status list that is also supported by PROFINET If you use a system status list in PROFINET that PROFINET does not support an error code is returned in RET_VAL 8083 Index wrong or not permitted Comparison of the system status lists of PROFINET IO and ...

Page 102: ...ation status between the fault tolerant system and a switched DP slave PN device W 16 0C96 Yes internal interface No external interface Yes internal interface No external interface Module status information of a submodule using the logical address of this submodule W 16 xy92 No Replacement SSL ID W 16 0x94 Yes Rack stations status information Replace this system status list with the system status ...

Page 103: ...nal information refer to the STEP 7 Online Help and to the PROFINET System Description http support automation siemens com WW view en 19292127 manual 8 6 Shared Device The Shared Device functionality facilitates distribution of the submodules of an IO device to different IO controllers An intelligent IO device can also be operated as shared device Prerequisite for using the Shared Device function ...

Page 104: ...l MRP for IO devices switches and CPUs with PROFINET interface V6 0 or higher MRP is a component of PROFINET standardization to IEC 61158 Installing a ring topology To set up a ring topology with media redundancy you must join both free ends of a line network topology in the same device You join the line topology to form a ring via two ports ring ports port ID R of a device connected to the ring S...

Page 105: ...tion is interrupted station failure if the reconfiguration time of the ring is greater than the selected response monitoring time of the IO device This means that you should select a response monitoring time of the IO device of sufficient length The same applies to IO devices configured with MRP outside the ring Additional information For additional information refer to the STEP 7 Online Help and ...

Page 106: ...ndicate if an IO device is integrated in system redundancy Contrary to a one sided connection of IO devices the failure of a CPU does not result in the failure of the IO devices connected with this CPU Requirement You need the following component versions to set up a fault tolerant system with system redundant I Os CPU 41x 5H PN DP as of version 6 0 IM 153 4BA00 as of version 4 0 STEP7 as of V5 5 ...

Page 107: ... devices that were redundant until now will continue operating as one sided IO devices The figure below shows the view in STEP7 the logical view and the physical view of the configuration with two integrated IO devices in system redundancy Note that the view in STEP7 does not exactly match the physical view 38D 38D 2 HYLFH 2 HYLFH 38 D 38 D DXOW WROHUDQW V VWHP 2 HYLFH XV DXOW WROHUDQW V VWHP ORFN...

Page 108: ...t tolerant system to STOP on both sides 2 Reset the standby CPU memory 3 Download the new project to the master CPU 4 Start the fault tolerant system Note Using the topology editor Use the topology editor in HW Config Maximum number of IO devices You can connect up to 256 IO devices to both integrated PROFINET interfaces These can be configured for one sided or redundant mode The station numbers m...

Page 109: ...with system redundancy The figure below shows the system redundant connection of three IO devices using one switch Two additional IO devices are also connected in system redundancy 2 GHYLFHV LQ V VWHP UHGXQGDQF 6ZLWFK 2 GHYLFHV LQ V VWHP UHGXQGDQF Figure 8 4 PN IO with system redundancy ...

Page 110: ...lows you to arrange IO devices in several cabinets 6ZLWFK Figure 8 5 PN IO with system redundancy Note Logical structure and topology The topology itself does not determine if IO devices are connected one sided or in a configuration with system redundancy This is determined in thje course of configuration You can configure the IO devices in the first figure as one sided instead of the system redun...

Page 111: ...hen a communication block such as SFB 14 GET or SFB 15 PUT is interrupted by a process alarm OB of higher priority If the user program modifies any data of this process alarm OB which in part have already been processed by the communication block certain parts of the transferred data will have retained their original status which was valid prior to process alarm processing while others represent d...

Page 112: ...1 byte 1 word 2 bytes or 1 double word 4 bytes cannot be interrupted If the user program calls communication blocks such as SFB 12 BSEND and SFB 13 BRCV which are only used in pairs and access shared data access to this data area can be coordinated by the user by means of the DONE parameter for example The consistency of data transmitted locally with these communication blocks can thus be ensured ...

Page 113: ...tion is not completed until the status parameter DONE assumes value 1 9 3 Consistent reading and writing of data from and to DP standard slaves IO devices Reading data consistently from a DP standard slave using SFC 14 DPRD_DAT Using SFC14 DPRD_DAT read consistent data of a DP standard slave you can consistently read the data of a DP standard slave of IO device The data read is entered into the de...

Page 114: ...on In the special identification format SIF you can define a maximum length of consistent data of 64 words 128 bytes 128 bytes for inputs and 128 bytes for outputs A greater length is not possible This upper limit applies only to pure user data Diagnostics and parameter data are grouped to form complete data records and are thus always transferred consistently In the general identification format ...

Page 115: ...ient integration and parameterization of for example drives or other DP slaves is made possible Any direct access to a consistently configured data area e g L PEW or T PAW does not result in an I O area access error Important aspects in the conversion from the SFC14 15 solution to the process image solution are SFC 50 RD_LGADR outputs different address areas with the SFC 14 15 method as with the p...

Page 116: ...image was previously updated by means of SFC 26 27 call or the update of the process image was linked to an OB PIP 3 at output Those 50 bytes are stored consistently in process image partition 3 drop down list box Consistent over Total length and can thus be read by means of standard Load input xy commands Selecting Process image under Input in the drop down list box means no storage in a process ...

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Page 118: ...HW Config you can influence the work memory available to the runtime relevant blocks NOTICE Please note the following if you expand the process image of a CPU Reconfigure the modules whose addresses have to be above the highest address of the process image so that the new addresses are still above the highest address of the expanded process image Important note for CPUs after the parameter setting...

Page 119: ...b Code memory Size of the diagnostics buffer 32 bytes per entry in the diagnostics buffer Code memory Quantity of local data 1 byte per byte of local data Data memory Flexible memory space Work memory The capacity of the work memory is determined by selecting the appropriate CPU from the graded range of CPUs Load memory The integrated load memory is sufficient for small and medium sized programs T...

Page 120: ...Memory concept 10 1 Overview of the memory concept of S7 400H CPUs S7 400H 120 System Manual 03 2012 A5E00267695 11 ...

Page 121: ...f two redundantly configured subsystems that are synchronized via fiber optic cables Both subsystems create a fault tolerant automation system operating with a two channel 1 out of 2 structure based on the active redundancy principle What does active redundancy mean Active redundancy means that all redundant resources are constantly in operation and simultaneously involved in the execution of the ...

Page 122: ...ed by fiber optic cables Both CPUs maintain event synchronous program execution via this connection 6XEV VWHP 38 6 QFKURQL DWLRQ 6XEV VWHP 38 Figure 11 1 Synchronizing the subsystems Synchronization is performed automatically by the operating system and has no effect on the user program You create your program in the same way as for standard S7 400 CPUs Event driven synchronization procedure The e...

Page 123: ...tions or errors must be detected localized and reported as quickly as possible Consequently extensive self test functions have been implemented in the S7 400H that run automatically and entirely in the background The following components and functions are tested Coupling of the central racks Processor Internal memory of the CPU I O bus If the self test detects an error the fault tolerant system tr...

Page 124: ... CPU is in RUN and the reserve CPU is in LINK UP mode we say the S7 400H system is in link up mode Overview of system states The table below provides an overview of the possible states of the S7 400H system Table 11 1 Overview of S7 400H system states System states of the S7 400H Operating states of the two CPUs Master Reserve Stop STOP STOP power off DEFECTIVE Start up STARTUP STOP power off DEFE...

Page 125: ... PLC Operating mode menu command Result The Operating mode dialog shows the current system state of the fault tolerant system the operating states of the individual CPUs as well as the current position of the mode switches on the modules The CPU that was selected in SIMATIC Manager when the menu command was executed is the first one displayed in the table Changing the system state The options of c...

Page 126: ... up and will become the standby CPU after link up and update operations Changing to standalone mode starting only one CPU 1 In the table select the CPU you want to start up 2 Select the Restart warm restart button 11 2 4 System status change from the standalone mode system status Requirements You have opened the Operating state dialog using the PLC Operating state menu command in SIMATIC Manager T...

Page 127: ...erating state menu command in SIMATIC Manager Changing to STOP system state stopping the fault tolerant system 1 Select the fault tolerant system in the table 2 Select the Stop button Changing to standalone mode stop of one CPU 1 In the table select the CPU that you want to stop 2 Select the Stop button Result The selected CPU goes into the STOP state while the other CPU remains in RUN state the f...

Page 128: ...ct the CPU and confirm with OK Result The operating state of the selected CPU can be identified based on the display of the selected CPU in the Diagnose hardware dialog CPU icon Operating state of the respective CPU Master CPU is in RUN state Standby CPU is in RUN state Master CPU is in STOP state Standby CPU is in STOP state Master CPU is in STARTUP state Standby CPU is in LINK IN or UPDATE state...

Page 129: ...03 2012 A5E00267695 11 129 CPU icon Operating state of the respective CPU Maintenance required on standby CPU Maintenance request on master CPU Maintenance request on standby CPU NOTICE The view is not updated automatically in the Online view Use the F5 function key to view the current operating mode ...

Page 130: ... the master or the standby CPU For reasons of legibility the illustration presumes that the master CPU CPU 0 is started up before the standby CPU CPU 1 is switched on The following figure shows the operating states of the two CPUs from POWER ON to redundant system state The HOLD HOLD mode Page 135 and ERROR SEARCH ERROR SEARCH mode Page 135 states are a special feature and are not shown 67 5783 32...

Page 131: ...nputs outputs timers counters bit memories and data blocks Following the update the memories of both CPUs have the same content see also section LINK UP and UPDATE modes Page 133 6 The master and standby CPUs are in RUN after the update Both CPUs process the user program in synchronous mode Exception Master standby changeover for configuration program modifications The redundant system state is on...

Page 132: ...ne sided I O devices Startup of the standby CPU The standby CPU startup routine does not call an OB 100 or OB 102 The standby CPU checks and parameterizes the following its assigned one sided I O devices Special features at startup If the master CPU returns to STOP immediately after transition to RUN during startup of a fault tolerant system the standby CPU takes over the master role and continues...

Page 133: ...t of standard S7 400 CPUs The user program is executed by at least one CPU in the following system states Single mode Link up update Redundant Single mode link up update In the system states standalone mode link up and update the master CPU is in RUN and executes the user program in standalone mode Redundant system mode The master CPU and standby CPU are always in RUN when operating in redundant s...

Page 134: ... 03 2012 A5E00267695 11 Redundant use of modules The following rule applies to the redundant system mode Modules interconnected in redundant mode e g DP slave interface module IM 153 2 must be in identical pairs i e the two redundant linked modules have the same order number and product or firmware version ...

Page 135: ...ndant system mode is exited the other CPU can become master and continue to work in standalone mode Note If the master CPU changes to STOP during troubleshooting the troubleshooting is continued on the standby CPU However once troubleshooting is completed the standby CPU does not start up again The following events will trigger ERROR SEARCH mode 1 If a one sided call of OB 121 on only one CPU occu...

Page 136: ...dalone mode The purpose of ERROR SEARCH mode is to find a faulty CPU The standby CPU runs the full self test while the master CPU remains in RUN If a hardware fault is detected the CPU changes to DEFECTIVE state If no fault is detected the CPU is linked up again The fault tolerant system resumes the redundant system state An automatic master standby changeover then takes place This ensures that wh...

Page 137: ... can be modified in the configuration Response to errors during the self test If the self test returns an error the following happens Table 11 3 Response to errors during the self test Type of error System response Hardware fault without one sided call of OB 121 The faulty CPU enters the DEFECTIVE state The fault tolerant system switches to standalone mode The cause of the error is written to the ...

Page 138: ...witches to standalone mode Checksum errors When a checksum error occurs for the first time after the last POWER ON without backup the system reacts as follows Table 11 5 Reaction to checksum errors Time of detection System response During the startup test after POWER ON The faulty CPU enters the DEFECTIVE state The fault tolerant system switches to standalone mode In the cyclic self test STOP or s...

Page 139: ... in single stand alone mode after twice the test cycle time has expired the CPU reacts as it did on the first occurrence of the error If a second error hardware fault with one sided call of OB 121 checksum error occurs in redundant mode when troubleshooting is finished the CPU reacts as it did on the first occurrence of the error Multiple bit errors The CPU changes to ERROR SEARCH mode when a mult...

Page 140: ...ss do not match the process values valid at the time of the interrupt Evaluate the temporary variables start information in the hardware interrupt OB instead When using the process interrupt triggering module SM 321 7BH00 it is not advisable to have different responses to rising or falling edges at the same input because this would require direct access to the I O If you want to respond differentl...

Page 141: ... are inhibited Blocks cannot be deleted loaded created or compressed Execution of communication functions PG operation Communication functions are executed Execution of the functions is restricted section by section and delayed All the delayed functions are caught up with after the update For details refer to the sections below CPU self test Not performed Not performed Test and commissioning funct...

Page 142: ...y in the master and reserve CPUs FW version in the master and reserve CPUs Available sync connections Hardware version on master and reserve CPU Restart of the reserve Are identical Are identical 2 Are identical Switch to CPU with modified configuration RAM and EPROM mixed Are identical 2 Are identical Switchover to CPU with expanded memory configuration Size of load memory in the reserve CPU is l...

Page 143: ...mal link up and update operation must be performed subsequently How to start the link up and update operation Initial situation Single mode i e only one of the CPUs of a fault tolerant system connected via fiber optic cables is in RUN To establish system redundancy initiate the link up and update operation as follows Toggle the mode selector switch of the standby CPU from STOP to RUN POWER ON the ...

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Page 146: ...ime required for I O update DP and PNIO only call interval of the priority class program execution time of the priority class update time execution time for programs of higher priority classes Example Minimum signal duration of an input signal that is evaluated in a priority class 15 e g OB 40 0LQLPXP VLJQDO GXUDWLRQ DOO LQWHUYDO RI SULRULW FODVV H J 2 8SGDWH WLPH PV PV SHU IRU PRGLILHG GDWD EORFN...

Page 147: ...copies the user program from its load memory in RAM to the reserve CPU The user program stored in load memory on the FLASH card is not transferred It must be identical before initiating link up Link up with master reserve changeover In STEP 7 you can select one of the following options Switch to CPU with modified configuration Switchover to CPU with expanded memory configuration Switchover to CPU ...

Page 148: ... The contents of FLASH cards must be identical During the link up the user program blocks OBs FCs FBs DBs SDBs of the master are transferred from the load memory and work memory to the reserve Exception If the load memory modules are FLASH cards the system only transfers the blocks from work memory For information on changing the type of memory or on load memory expansions refer to section Changin...

Page 149: ...as a result no new request errors occur The system waits until the update is completed and then generates and processes a maximum of one request per cyclic interrupt OB The time stamp of delayed cyclic interrupts cannot be evaluated 4 Transfer of all data block contents modified since link up 5 The following communication jobs are acknowledged negatively Reading writing of data records using HMI f...

Page 150: ...terrupts 10 Cancel all restrictions Delayed interrupts and communication functions are executed All OBs are executed again A constant bus cycle time compared with previous calls can no longer be guaranteed for delayed cyclic interrupt OBs Note Process interrupts and diagnostic interrupts are stored by the I O devices Such interrupt requests issued by distributed I O modules are executed when the b...

Page 151: ...disable messages by SFC 9 EN_MSG and SFC 10 DIS_MSG are rejected with a negative return value Communication functions and resulting jobs After it has received one of the jobs specified below the CPU must in turn generate communication jobs and output them to other modules These include for example jobs for reading or writing parameterization data records from to distributed I O modules These jobs ...

Page 152: ...connections using NETPRO you can no longer change the memory type of the load memory from RAM to FLASH When you initiate a link up and update operation with the Switch to CPU with modified configuration option in STEP 7 the system reacts as follows with respect to handling of the memory contents Load memory The contents of the load memory are not copied from the master to the reserve CPU Work memo...

Page 153: ...ns to STOP and writes a corresponding message to the diagnostic buffer Assuming you have not expanded load memory on the reserve CPU this CPU does not go into RUN but rather returns to STOP and writes a corresponding message to the diagnostic buffer The system does not perform a master reserve changeover and the previous master CPU remains in RUN For information on changing the type of memory or o...

Page 154: ...oes not perform a self test during link up and updating If you use a fail safe user program you should avoid any excessive delay for the update operation For more details refer to the S7 400F and S7 400FH Automation Systems manual Example of a time critical process A slide block with a 50 mm cam moves on an axis at a constant velocity v 10 km h 2 78 m s 2 78 mm ms A switch is located on the axis S...

Page 155: ...te is cancelled the fault tolerant system switches to standalone mode The previous master CPU remains in RUN and the standby CPU goes into STOP You can either configure all the monitoring times or none at all You made allowances for the technological requirements in your configuration of monitoring times The monitoring times are described in detail below Maximum cycle time extension Cycle time ext...

Page 156: ...hen the system performs an update with master standby changeover The minimum I O retention time is of particular importance when updating with master standby changeover If you set the minimum I O retention time to 0 the outputs could possibly shut down when you modify the system during operation The monitoring start times are indicated in the highlighted boxes in Figure 12 2 These times expire whe...

Page 157: ...B 72 with corresponding start information The standby CPU then reevaluates its system data blocks Then but after at least one minute the CPU tries again to perform the link up and update If still unsuccessful after a total of 10 retries the CPU abandons the attempt You yourself will then need to start the link up and update again A monitoring timeout can be caused by High interrupt load e g from I...

Page 158: ...mation system Link up runtime size of load memory and work memory in MB 1 s base load The base load is a few seconds Whenever your automation system is subject to high load the memory specific share may increase up to 1 minute per MB Time response during updating The update transfer time is determined by the number and overall length of modified data blocks rather than by the modified volume of da...

Page 159: ...fig Monitoring time accuracy Note The monitoring times determined by STEP 7 or by using formulas merely represent recommended values These times are based on a fault tolerant system with two communication peers and an average communication load Your system profile may differ considerably from those scenarios therefore the following rules must be observed The cycle time extension factor may increas...

Page 160: ...x maximum target rotation time of all DP master systems of the fault tolerant station For distributed I O PROFINET IO TPH Twd_max with Twd_max maximum cyclic interrupt time product of WD factor and update time of a switched device in all IO subsystems of the fault tolerant station When using central and distributed I Os the resultant minimum I O retention time is TPH MAX 30 ms 3 x TTRmax Twd_max T...

Page 161: ...e active communication channel on the switched DP slaves and switched IO devices on completion of the update This operation prolongs the time within which valid values can neither be read nor output How long this process takes is determined by your hardware configuration The technological conditions in your process also decide how long an I O update can be delayed This is particularly important in...

Page 162: ...of all TP15 DP master system values This time is then known as TP15_HW 10 Define the share of the maximum inhibit time for I O classes 15 determined by the minimum I O retention time TP15_OD TP15_OD 50 ms min I O retention time 2 NOTICE If TP15_OD TP15_HW stop the calculation here Possible remedies are shown below the following example calculation Make appropriate changes and then restart the calc...

Page 163: ...ted Ethernet interface 1 Based on the bus parameters in STEP 7 TTR_1 25 ms TTR_2 30 ms TDP_UM_1 100 ms TDP_UM_2 80 ms 2 Based on the configuration in STEP 7 Tmax_Akt 8 ms TPN_UM 110 ms 3 Based on the technical data of the DP slaves used TSLAVE_UM_1 30 ms TSLAVE_UM_2 50 ms 4 Based on the technical specifications of the PN devices used TDevice_UM 20 ms 5 Based on the technological settings of your s...

Page 164: ...e of the configured cyclic interrupt If TTR times are particularly high distribute the slaves across several DP master systems If possible reduce the maximum update time of switched devices on the IO subsystem Increase the baud rate on the affected DP master systems Configure the DP PA links and Y links in separate DP master systems If there is a great difference in changeover times on the DP slav...

Page 165: ...ur system This can be understood as the absolute load or as the load relative to the size of your user program You may have to adjust this time Calculation of the maximum cycle time extension Use the following formula Maximum cycle time extension 10 x maximum inhibit time for priority classes 15 Decisive factors for determining this time are the process status and the communication load in your sy...

Page 166: ...alues for the user program part Work memory data TP15_AWP 500 KB 220 ms 1 MB 400 ms 2 MB 0 8 s 5 MB 1 8 s 10 MB 3 6 s The following assumptions were made for this formula 80 of the data blocks are modified prior to delaying the interrupts of priority classes 15 In particular for fail safe systems this calculated value must be more precise to avoid any timeout of driver blocks see section Determini...

Page 167: ...ith PROFIBUS DP a lower baud rate and higher number of slaves increases the time it takes for I O updates Expansion of distributed I Os with PROFINET IO a higher update time and higher number of devices increases the time it takes for I O updates In the worst case this period is extended by the following amounts Maximum cyclic interrupt used Duration of all cyclic interrupt OBs Duration of high pr...

Page 168: ...reater than the required update period Communication links and functions Connections on the master CPU are not be shut down However associated communication jobs are not executed during updates They are queued for execution as soon as one of the following cases occurs The update is completed and the system is in the redundant state The update and master reserve changeover are completed the system ...

Page 169: ...high availability in the user program see section Other options for connecting redundant I Os Page 207 Addressing No matter whether you are using a single channel one sided or switched I O you always access the I O via the same address Limits of I O configuration If there are insufficient slots in the central racks you can add up to 20 expansion units to the S7 400H configuration Module racks with...

Page 170: ...ices to both integrated PROFINET interfaces Note PROFIBUS DP and PROFINET IO in combination You can operate PROFINET IO devices as well as PROFIBUS DP stations on a fault tolerant CPU Distributed I O over PNIO You can also operate distributed I O on the integrated PROFINET interface See chapter System redundancy Page 106 ...

Page 171: ...nly addressed by this subsystem A single channel one sided I O configuration is possible in the following devices Central and expansion devices Distributed I O devices at the PROFIBUS DP interface Distributed I O devices at the PROFINET interface A configuration with single channel one sided I O is useful for single I O channels up to system components which only require standard availability VLQJ...

Page 172: ... single channel one sided I O that can only be executed conditionally This ensures that specific I O access functions are only called in redundant system mode and when the relevant subsystem is in standalone mode NOTICE The user program also has to update the process image for single channel one sided output modules when the system is in standalone mode direct access for example If you use process...

Page 173: ... containing an ET 200M distributed I O module with active backplane bus and a redundant PROFIBUS DP slave interface module 6 DXWRPDWLRQ V VWHP 7b 0 LVWULEXWHG 2 5DFN 5DFN Figure 13 1 Single channel switched distributed I O configuration at the PROFIBUS DP interface You can use the following interfaces for the I O configuration at the PROFIBUS DP interface Table 13 1 Interfaces for use of single ch...

Page 174: ...olerate the failure of individual modules within the ET 200M Single channel switched I O configuration at the PROFIBUS DP interface The system supports single channel switched I O configurations containing an ET 200M distributed I O module with active backplane bus and a redundant PROFINET interface 6 DXWRPDWLRQ V VWHP 7b 0 LVWULEXWHG 2 5DFN 5DFN Figure 13 2 Single channel switched distributed I O...

Page 175: ... interrupt processing and the exchange of data records Failure of the single channel switched I O The fault tolerant system with single channel switched I O responds to errors as follows The I O is no longer available after it fails In certain failure situations such as the failure of a subsystem DP master system or DP slave interface module IM153 2 or IM 157 see section Communication Page 213 the...

Page 176: ...t system If you ignore this rule you risk failure of the fail safe modules during the changeover of the active channel NOTICE The above calculation also includes the processing time in OB 70 or OB 86 Make sure that the processing time for a DP or PNIO station is no longer than 1 ms In situations requiring extensive processing exclude this processing from direct execution of the OBs mentioned Note ...

Page 177: ...em Provided the minimum I O retention time is set correctly see section Time monitoring Page 155 no interrupts or data records will be lost due to a changeover There is an automatic repetition when necessary System configuration and project engineering You should allocate switched I O with different changeover times to separate chains This for example simplifies the calculation of monitoring times...

Page 178: ...rations are supported 1 Redundant signal modules in the central and expansion devices For this purpose the signal modules are installed in pairs in the CPU 0 and CPU 1 subsystems Redundant I O in central and expansion devices 5HGXQGDQW PRGXOH SDLU HQWUDO GHYLFH HQWUDO GHYLFH 5HGXQGDQW PRGXOH SDLU SDQVLRQ XQLW SDQVLRQ XQLW Figure 13 3 Redundant I O in central and expansion devices ...

Page 179: ...S7 400H System Manual 03 2012 A5E00267695 11 179 2 Redundant I O in the one sided DP slave To achieve this the signal modules are installed in pairs in ET 200M distributed I O devices with active backplane bus 5HGXQGDQW PRGXOH SDLU Figure 13 4 Redundant I O in the one sided DP slave ...

Page 180: ... S7 400H 180 System Manual 03 2012 A5E00267695 11 3 Redundant I O in the switched DP slave To achieve this the signal modules are installed in pairs in ET 200M distributed I O devices with active backplane bus 5HGXQGDQW PRGXOH SDLU Figure 13 5 Redundant I O in the switched DP slave ...

Page 181: ...ted Depassivation depassivates all affected channels as well as the modules passivated due to module errors Channel group specific passivation significantly increases availability in the following situations Relatively frequent encoder failures Repairs that take a long time Multiple channel errors on one module Note Channel and channel group Depending on the module a channel group contains a singl...

Page 182: ...IO MGP V30 library Module specific redundancy is a special form of redundant module operation see above Note Operating redundant modules When you are operating signal modules for the first time use channel group specific redundancy with the blocks in the Redundant IO CGP V50 library This ensures maximum flexibility when using redundant modules The Functional I O redundancy block libraries that sup...

Page 183: ...t first of all edit your user program accordingly Refer to the context sensitive block help or the STEP 7 Readme for more information Switching to channel group specific redundancy To activate channel group specific passivation you have to stop the automation system memory reset and reload user program in STOP Observe the following Mixing blocks from various libraries in one CPU is not permitted a...

Page 184: ...r OB 30 to 38 cyclic interrupt You must also call FC 451 conditionally in OB1 or OB 30 to 38 after having eliminated the malfunction for example with a user acknowledgment The FC 451 only depassivates modules in the corresponding process image partition Depassivation is delayed by 10 seconds with Version 3 5 or higher of FB 450 RED_IN in the library Redundant IO MGP and Version 5 8 or higher of FB...

Page 185: ...ogram are always located at the lower address of both redundant modules This means that only the lower address can be used for the application the values of the higher address are not relevant for the application Note Use of FB 450 RED_IN and 451 RED_OUT when using process image partitions For each priority class used OB 1 OB 30 OB 38 you must use a separate process image partition ...

Page 186: ...e PROFIBUS address in the partner DP subsystem is proposed provided the DP master system is redundant Distributed configuration in a switched DP slave stand alone mode If the module in the slave with a DP address is inserted in slot X the module in the slave with the next PROFIBUS address at slot X is proposed 3 Enter the remaining redundancy parameters for the input modules Note System modificati...

Page 187: ... at two inputs in parallel You achieve this by connecting a resistor via the encoder Its value depends on the type of switch and usually ranges between 6800 and 8200 ohms for contacts For BEROS calculate the resistance based on this formula 30 V 4 9 mA I_R_Bero R 20 V 2 4 mA I_R_Bero X X DI 32xDC 24V 6ES7 421 1BL0x 0AA0 X X DI 32xUC 120V 6ES7 421 1EL00 0AA0 Distributed Redundant DI dual channel X ...

Page 188: ...nt only preferably encoder negative When selecting encoders compare their properties with the specified input characteristics Remember that this function must always be available regardless of whether you are using one or two inputs Example of valid values for NAMUR encoders for 0 current 0 2 mA for 1 current 4 2 mA DI 16xNamur 6ES7321 7TH00 0AB0 X X Use with non redundant encoder Equipotential bo...

Page 189: ... V 10 mA EEx ib 6ES7322 5SD00 0AB0 X X You cannot use the module for applications in hazardous areas in redundant mode DO 4x24 V 10 mA EEx ib 6ES7322 5RD00 0AB0 X X You cannot use the module for applications in hazardous areas in redundant mode DO 16xDC 24 V 0 5 A 6ES7322 8BH01 0AB0 X X X The equipotential bonding of the load circuit should always take place from one point only preferably load min...

Page 190: ...e 10 9 The tolerance of the resistor must be added on to the module error Use in direct current measurement Suitable Zener diode BZX85C6v2 Load capability of 4 wire transmitters RB 325 ohms determined for worst case 1 input 1 Zener diode at an S7 overload value 24 mA to RB RE Imax Uz max Imax Input voltage in the circuit when operating with a 2 wire transmitter Ue 2w 8 V determined for worst case ...

Page 191: ...ted in parallel The wire break diagnostics function in HW Config must not be activated neither when operating the modules with transmitters nor when thermocouples are connected Use a 50 ohm resistor measuring range 1 V or 250 ohm resistor measuring range 1 5 V to map the current on a voltage see figure 10 9 The tolerance of the resistor must be added on to the module error This module is not suita...

Page 192: ...pprox 0 1 Load capability of 4 wire transmitters RB 610 ohms determined for worst case scenario 1 input 1 Zener diode at an S7 overload value 24 mA to RB RE Imax Uz max Imax Input voltage in the circuit when operating with a 2 wire transmitter Ue 2w 15 V determined for worst case 1 input 1 Zener diode at an S7 overshoot value 24 mA to Ue 2w RE Imax Uz max AI 8x16Bit 6ES7 331 7NF10 0AB0 X X Use in ...

Page 193: ...imum voltage range 1 V the indirect current measurement can be carried out exclusively via a 50 ohm resistor Mapping that conforms to the system is only possible for the area 20 mA AI 4x15Bit EEx ib 6ES7331 7RD00 0AB0 X X You cannot use the module for applications in hazardous areas in redundant mode It is not suitable for indirect current measurement Use in direct current measurement Suitable Zen...

Page 194: ...of the channels Using digital input modules as redundant I O The following parameters were set to configure digital input modules for redundant operation Discrepancy time maximum permitted time in which the redundant input signals may differ The configured discrepancy time must be a multiple of the update time of the process image and therefore also the basic conversion time of the channels When t...

Page 195: ...etc Redundant input signals can therefore be different for a longer period than the configured discrepancy time Modules with diagnostics capability are also passivated by calling OB 82 Using redundant digital input modules with non redundant encoders With non redundant encoders you use digital input modules in a 1 out of 2 configuration LJLWDO LQSXW PRGXOHV Figure 13 7 Fault tolerant digital input...

Page 196: ...ired current per input Using redundant digital input modules with redundant encoders With redundant encoders you use digital input modules in a 1 out of 2 configuration LJLWDO LQSXW PRGXOHV Figure 13 8 Fault tolerant digital input modules in 1 out of 2 configuration with two encoders The use of redundant encoders also increases their availability A discrepancy analysis detects all errors except fo...

Page 197: ...on The digital output modules must be connected to a common load voltage supply You will find connection examples in Appendix Connection examples for redundant I Os Page 461 Interconnection using external diodes without external diodes The table below lists the redundant digital output modules which in redundant mode you should interconnect using external diodes Table 13 4 Interconnecting digital ...

Page 198: ...ut modules the default value for the discrepancy time is usually sufficient If you use different sensors in particular temperature sensors you will have to increase the discrepancy time Applied value The applied value represents the value of the two analog input values that is accepted in the user program The system verifies that the two read in analog values are within the configured tolerance wi...

Page 199: ... Measurement type parameter Redundant analog input modules with non redundant encoder With non redundant encoders analog input modules are used in a 1 out of 2 configuration 5 8 QDORJ LQSXW PRGXOHV QDORJ LQSXW PRGXOHV QDORJ LQSXW PRGXOHV 9ROWDJH PHDVXUHPHQW QGLUHFW FXUUHQW PHDVXUHPHQW LUHFW FXUUHQW PHDVXUHPHQW Figure 13 10 Fault tolerant analog input modules in 1 out of 2 configuration with one en...

Page 200: ...re also possible Note however that such combinations may lead to loss of the number format diagnostics function and resolution The measurement error also depends largely on the size of the measure resistance of certain modules Use a measure resistance with a tolerance of 0 1 and TC 15 ppm Additional conditions for specific modules AI 8x12bit 6ES7 331 7K 02 0AB0 Use a 50 ohm or 250 ohm resistor to ...

Page 201: ... format x Circuit specific measuring error 2 parallel inputs 1 input Wire break diagnostics x Load for 4 wire transmitters 250 ohms Input voltage for 2 wire transmitters 6 V It may be possible to use the freely connectable internal 250 ohm resistors of the module AI 16x16bit 6ES7 431 7QH00 0AB0 Use a 50 ohm or 250 ohm resistor to map the current on a voltage Resistor 50 ohms 250 ohms Current measu...

Page 202: ...be listed in the constraints The errors specified in the manual must be added to these errors for all modules The 4 wire transmitters used must be capable of driving the load resulting from the circuit above You will find details in the technical specifications of the individual modules When connecting up 2 wire transmitters note that the Zener diode circuit weighs heavily in the power budget of t...

Page 203: ...Redundant analog output modules You implement fault tolerant control of a final controlling element by wiring two outputs of two analog output modules in parallel 1 out of 2 structure QDORJ RXWSXW PRGXOHV FWXDWRU Figure 13 12 Fault tolerant analog output modules in 1 out of 2 configuration The following applies to the wiring of analog output modules Wire the ground connections in a star structure ...

Page 204: ...A for HART analog output modules i e a total of approximately 240 2000 µA or 480 2000 μA for HART analog output modules Considering the tolerance this means that the output value is always positive A configured substitute value of 0 mA will produce at least these output values In redundant mode in the event of a CPU STOP the response of the current outputs is automatically set to zero current and ...

Page 205: ...to redundant mode After system modifications during operation If you call FC 451 RED_DEPA and at least one redundant channel or module is passivated The depassivation is executed in FB 450 RED IN after one of these events has occurred Completion of the depassivation of all modules is logged in the diagnostic buffer Note When a redundant module is assigned a process image partition and the correspo...

Page 206: ...n status using the status byte The status word FB_RED_IN STATUS_CONTROL_W is located in the instance DB of FB 450 RED_IN The status byte returns information on the status of the redundant I Os The assignment of the status byte is described in the online help for the respective block library Evaluating the passivation status of individual module pairs by means of MODUL_STATUS_WORD MODUL_STATUS_WORD...

Page 207: ...redundant I O at the user level Configurations The following redundant I O configurations are supported 1 Redundant configuration with one sided central and or distributed I O For this purpose one signal module each is inserted into the CPU 0 and CPU 1 subsystems 2 Redundant configuration with switched I O One signal module each is inserted into two ET 200M distributed I O devices with active back...

Page 208: ...ut modules when the system is in single mode direct access for example If you use process image partitions the user program must update them SFC 27 UPDAT_PO in OB 72 recovery of redundancy The system would otherwise first output old values on the single channel one sided output modules of the reserve CPU when the system changes to redundant mode Redundant I O in the user program The sample program...

Page 209: ... until an access error occurs on module B NOTICE The MODA and IOAE_BIT variables must also be valid outside OB 1 and OB 122 The ATTEMPT2 variable however is used only in OB 1 5HWU DOVH 5HDG PRGXOH ILUVW HV 1R HV HV HV HV 1R 1R 1R 1R FFHVV WR PRGXOH 2 DFFHVV HUURU FFHVV WR PRGXOH 2 DFFHVV HUURU b R QRW UHDG PRGXOH ILUVW DQ PRUH LQ IXWXUH 5HWU 758 b R QRW UHDG PRGXOH ILUVW DQ PRUH LQ IXWXUH 5HWU 758...

Page 210: ...E bit L PID 8 Read from CPU 0 A IOAE_BIT Was IOAE detected in OB 122 JCN IOOK If not process access OK A ATTEMPT2 Was this access the second attempt JC CMO0 If yes use substitute value SET R MODA Do not read module A first any more in future S ATTEMPT2 CMOB SET R IOAE_BIT Delete IOAE bit L PID 12 Read from CPU 1 A IOAE_BIT Was IOAE detected in OB 122 JCN IOOK If not process access OK A ATTEMPT2 Wa...

Page 211: ...odule A cause IOAE L OB122_MEM_ADDR Relevant logical base address L W 16 8 I Module A JCN M01 If not continue with M01 IOAE during access to module A SET IOAE_BIT Set IOAE bit JU CONT Does module B cause an IOAE M01 NOP 0 L OB122_MEM_ADDR Relevant logical start address L W 16 C I Module B JCN CONT If not continue with CONT IOAE during access to module B SET IOAE_BIT Set IOAE bit CONT NOP 0 ...

Page 212: ...erties CPU H Parameter An overhead is only required if you operate modules from the following table as redundant modules Table 13 8 For the monitoring times with redundant I O Module type Overhead in ms ET200M Standard output modules 2 ET200M HART output modules 10 ET200M F output modules 50 ET200L SC with analog outputs 80 ET200S with analog outputs or technology modules 20 Follow the steps below...

Page 213: ...s Yes Yes Yes Yes PROFIBUS DP Data exchange between master and slave No No Yes No PROFINET IO Data exchange between I O controllers and I O devices No No No Yes SNMP Simple Network Management Protocol Standard protocol for network diagnostics and parameterization No No No Yes Open communication over TCP IP Data exchange over Industrial Ethernet with TCP IP protocol with loadable FBs Yes No No Yes ...

Page 214: ... is specified for communication services using S7 connection resources Reliable operation of those communication services at a low baud rate via PROFIBUS DP interface can be ensured in configurations with a Ttr Target Rotation Time 20 s 14 1 2 PG communication Properties Programming device communication is used to exchange data between engineering stations PG PC for example and SIMATIC modules whi...

Page 215: ...PU can always act as a server or client in S7 Communication A connection is configured permanently The following connections are possible One sided configured connections for PUT GET only Two side configured connections for USEND URCV BSEND BRCV PUT GET You can use S7 communication via integral interfaces MPI DP PROFIBUS DP PROFINET and if necessary via additional communication processors CP443 1 ...

Page 216: ...f the S7 400 CPUs Table 14 3 SFBs for S7 Communication Block Block name Brief description SFB 8 SFB 9 USEND URCV Send data to a remote partner SFB with the type URCV Receive asynchronous data from a remote partner SFB with the type USEND SFB 12 SFB 13 BSEND BRCV Send data to a remote partner SFB with the type BRCV Receive asynchronous data from a remote partner SFB with the type BSEND With this da...

Page 217: ...rmation refer to the Programming with STEP 7 manual or directly to the STEP 7 Online Help Requirements The network configuration does not exceed project limits The modules have loaded the configuration data containing the latest knowledge of the entire network configuration of the project Reason All modules connected to the network gateway must receive routing information which defines the paths t...

Page 218: ...ateways MPI to DP Gateways between subnets are routed in a SIMATIC station that is equipped with interfaces to the respective subnets The following figure shows CPU 1 DP master acting as router for subnets 1 and 2 3 6XEQHW 03 IRU H DPSOH 6XEQHW 352 86 3 IRU H DPSOH 3 PDVWHU 3 VODYH Figure 14 1 S7 routing ...

Page 219: ...FINET The following figure shows access from MPI to PROFINET via PROFIBUS CPU 1 for example 416 3 is the router for subnet 1 and 2 CPU 2 is the router for subnet 2 and 3 38 H J 31 2 6XEQHW 352 1 7 6XEQHW 352 86 3 0DVWHU 6XEQHW 03 03 3 VODYH DFWLYH 38 31 3 38 31 3 31 31 3 03 Figure 14 2 S7 routing gateways MPI DP PROFINET ...

Page 220: ...e of an S7 station using a PG The connection to other subnets is set up via modem The bottom of the figure shows how this can be configured in STEP 7 3 3 3 PDVWHU 3 VODYH 0RGHP 6XEQHW 03 IRU H DPSOH 6XEQHW 352 86 3 IRU H DPSOH 6XEQHW 03 IRU H DPSOH 6XEQHW 352 86 3 IRU H DPSOH 7HOH6HUYLFH DGDSWHU 3 PDVWHU 3 VODYH 0RGHP RQILJXUDWLRQ LQ 67 3 5HDO VWUXFWXUH Figure 14 3 S7 routing TeleService applicati...

Page 221: ...n the Communication with SIMATIC http support automation siemens com WW view en 25074283 manual For more information about the TeleService adapter refer to the manual TS Adapter http support automation siemens com WW view en 20983182 For additional information about SFCs refer to the Instructions list http support automation siemens com WW view en 44395684 For more information refer to the STEP 7 ...

Page 222: ...figure the CPU as a time master or a time slave CPU as a time master If you configure the CPU as a time master you must specify a synchronization interval You can select any interval between 1 second and 24 hours If the CPU time master is on the S7 400 backplane bus you should select a synchronization interval of 10 seconds The time master sends its first message frame once the time has been set f...

Page 223: ... an interval of 90 minutes the PROFINET CPU requests an NTP at cyclic intervals of 90 minutes If synchronizing the PROFINET CPU based on the NTP method you should configure the PROFINET CPU as the time master for the synchronization method in the S7 400 Select a synchronization interval of 10 seconds Use FB LT_BT or FB BT_LT from the STEP 7 standard library to make allowances for a time zone or da...

Page 224: ... receiver across several networks Data set routing is an expansion of S7 routing and is used for example in SIMATIC PDM The data sent through data record routing include the parameter assignments of the participating communication devices and device specific information for example setpoint values limit values etc The structure of the destination address for data set routing depends on the data co...

Page 225: ...ield devices The engineering station is connected to the CPU via Industrial Ethernet in this scenario The CPU communicates with the field devices via the PROFIBUS P 57 3 3 OLQN 352 86 3 352 86 3 QGXVWULDO WKHUQHW 6 02 2 7 0 QJLQHHULQJ 6WDWLRQ ZLWK 6 0 7 3 0 7 L63 Figure 14 4 Data set routing See also For more information on SIMATIC PDM refer to the The Process Device Manager manual ...

Page 226: ...M PC included on the SIMATIC NET CD All Ethernet devices can be detected by means of their IP address and or the SNMP protocol SNMP V1 and transferred to the configuration Use the profile MIB_II_V10 Applications based on SNMP can be operated on the same network at the same time as applications with PROFINET Note MAC addresses During SNMP diagnostics the following MAC addresses are shown for the if...

Page 227: ... cable can generally accommodate several logical connections The maximum job length is 32 KB The following connection oriented protocols are supported for the FBs for open IE communication TCP to RFC 793 ISO on TCP according to RFC 1006 Note ISOonTCP For data communication with third party systems via RFC1006 the connection partner must adhere to the maximum TPDU size TPDU Transfer Protocol Data U...

Page 228: ...eterization Data blocks for parametzerizing TCP and ISO on TCP connections To be able to parameterize your connection at TCP and ISO on TCP you must create a DB that contains the data structure of UDT 65 TCON_PAR This data structure contains all parameters you need to set up the connection Such a data structure which you can group within a global data range is required for every connection Connect...

Page 229: ...tors and holds the active connection If the connection is broken for example by line interruption or by the remote communication partner the active partner tries to reestablish the connection You do not have to call FB 65 TCON again FB 66 TDISCON disconnects the CPU from a communication partner as does STOP mode To reestablish the connection to have to call FB65 TCON again Use with UDP Both commun...

Page 230: ... Program cancellation of the communication connection with FB 66 TDISCON The CPU state changes from RUN to STOP At POWER OFF POWER ON Connection diagnostics In Step7 you can read detailed information on the configured connections by selecting Module state Communication Open communication over Industrial Ethernet Reference For detailed information on the blocks described above refer to the STEP 7 O...

Page 231: ...nchronization mechanisms ensure that the communication functions are taken over by the reserve components during operation A redundant communication system is essential if you want to use fault tolerant S7 connections Fault tolerant communication Fault tolerant communication is the deployment of S7 communication SFBs over fault tolerant S7 connections Fault tolerant S7 connections need a redundant...

Page 232: ... S7 connection For other types of connection please refer to the SIMATIC NET NCM S7 for PROFIBUS and SIMATIC NET NCM S7 for Industrial Ethernet manuals Fault tolerant S7 connections The requirement for higher availability with communication components for example CPs and buses means that redundant communication connections are necessary between the systems involved Unlike an S7 connection a fault ...

Page 233: ...ks are not supported in STEP 7 38 D 38 E 38 D 38 E 38 D 38 E 38 D 38 E 38 D 38 D 38 E 38 E 3 E 3 D 3 E 3 D 38 E 3 D 38 D 38 D 38 E 3 E 3 E 38 E 38 D 3 D 3 D 38 E 3 D 38 D 3 E 3 E 1 UHG 260 260 260 260 38 D 38 E 38 D 38 E 5HGXQGDQW FRQQHFWLRQ DXOW WROHUDQW V VWHP D DXOW WROHUDQW V VWHP E DXOW WROHUDQW V VWHP D DXOW WROHUDQW V VWHP E 5HVXOWLQJ VXEFRQQHFWLRQV XV XV XV XV 6 VWHP EXV DV GXSOH ILEHU RSW...

Page 234: ...CPU subconnections do not need any additional connection resources On the CP on the other hand each subconnection needs a connection resource NOTICE If you have configured several fault tolerant S7 connections for a fault tolerant station establishing them may take a considerable time If the configured maximum communication delay is set too short link up and updating is canceled and the redundant ...

Page 235: ... communication via fault tolerant S7 connections via PROFIBUS Industrial Ethernet ISO S7 fault tolerant connections are only possible between SIMATIC S7 400H stations or SIMATIC S7 400 stations with CPU41x 5H Fault tolerant communication with PC stations is only possible over Industrial Ethernet with ISO protocol and with ISO on TCP as of version 8 1 2 Via integrated PROFINET interface ISOonTCP Op...

Page 236: ...ns are configured in STEP 7 Programming All communication functions are supported for S7 communication on a fault tolerant system The communication SFBs are used in STEP 7 to program communication Note The START and STOP communication functions act on exactly one CPU or on all CPUs of the fault tolerant system for more details refer to the System Software for S7 300 400 System and Standard Functio...

Page 237: ...anced by using a redundant plant bus instead of a simple bus see image below for communication between a fault tolerant system and a standard system 3 E 38 E 38D 38D 3D 3E 38E 3 D 38 D 3 D 3D DXOW WROHUDQW V VWHP 6WDQGDUG V VWHP XV 6WDQGDUG V VWHP DXOW WROHUDQW V VWHP ORFN GLDJUDP RQQHFWLRQ XV RQQHFWLRQ Figure 14 7 Example of linking standard and fault tolerant systems in a simple bus system ...

Page 238: ... E 38 E 38D 38D 3D 3D 3E 3E 38E DXOW WROHUDQW V VWHP 6WDQGDUG V VWHP XV XV 6WDQGDUG V VWHP DXOW WROHUDQW V VWHP ORFN GLDJUDP RQQHFWLRQ RQQHFWLRQ XV XV Figure 14 8 Example of linking standard and fault tolerant systems in a redundant bus system On a plant bus configured as duplex fiber optic ring communication between the partner systems is maintained if the duplex fiber optic cable breaks The syst...

Page 239: ...k S7H4_BSR You can link a fault tolerant system to an S7 400 S7 300 using the S7H4_BSR driver block For more information contact Siemens by e mail function blocks industry siemens com Alternative SFB 15 PUT and SFB 14 GET in the fault tolerant system As an alternative use two SFB 15 PUT blocks over two standard connections First call the first block If there was no error message when the block exe...

Page 240: ... the implementation of monitoring functions in order to allow the detection of failures and to change over to the standby connection The following figure shows such a configuration 38 D 38 E 3 D 3 E 3 E 38D 38D 3D 3D 3E 3E 38E XV XV DXOW WROHUDQW DXOW WROHUDQW 6WDQGDUG V VWHP 6WDQGDUG V VWHP ORFN GLDJUDP XV XV Figure 14 10 Example of redundancy with fault tolerant systems and a redundant bus syste...

Page 241: ...le channel system available to CPUs of the fault tolerant system as well the point to point CP CP 341 must be installed in a distributed rack along with two IM 153 2 modules Configuring connections Redundant connections between the point to point CP and the fault tolerant system are not necessary 38D 38D 0D 0D 38 D 3 W 0 3 3W3 7 0 38 3 3 3W3 38 3 3W3 V VWHP D V VWHP D 6LQJOH FKDQQHO WKLUG SDUW V V...

Page 242: ...12 Example of connecting a fault tolerant system to a single channel third party system using PROFINET IO with system redundancy Response to failure Double errors in the fault tolerant system i e CPUa1 and IM153 and single errors in the third party system lead to a total failure of communication between the systems involved see previous figure The point to point CP can also be inserted centrally i...

Page 243: ...el systems to be linked to a fault tolerant system Configuring connections Redundant connections between the gateway CP and the single channel system are not required The gateway CP is located on a PC system which has fault tolerant connections to the fault tolerant system To configure fault tolerant S7 connections between fault tolerant system A and the gateway you first need to install S7 REDCON...

Page 244: ... and fail safe communication see Appendix Function modules and communication processors supported by the S7 400H Page 457 Only Industrial Ethernet with the ISO protocol or PROFIBUS without distributed I O and ISO on TCP as of version 6 0 is supported Fault tolerant S7 connections via Industrial Ethernet with ISO on TCP are supported by the integrated PN interface and corresponding CPs You require ...

Page 245: ...41xH V4 5 CPU 41xH V4 0 CPU 41xH V3 0 S7 fault tolerant connection via ISO PC station with Simatic Net CD CP1623 up to V7 x ISO ISO ISO ISO CP443 1 EX11 20 CP443 1 EX11 20 CP443 1 EX11 CP443 1 EX11 ISO ISO ISO ISO CPU 41xH V6 CPU 41xH V4 5 CPU 41xH V4 0 CPU 41xH V3 0 S7 fault tolerant connection via ISO Configuration The availability of the system including the communication is set during configur...

Page 246: ...subnets Industrial Ethernet PROFIBUS The standard communication SFBs integrated into the operating system offer you the option of acknowledged data transfer In addition to data transfer you can also use other communication functions for controlling and monitoring the communication peer User programs written for S7 connections can also be run for fault tolerant S7 connections without program modifi...

Page 247: ...forms a 1 out of 2 redundancy node A fiber optic network can be set up as a line or star topology However the line topology does not permit cable redundancy If one electrical cable segment fails communication between the participating systems is also upheld 1 out of 2 redundancy The examples below illustrate the differences between the two variants Note The number of connection resources required ...

Page 248: ... VWHP E DXOW WROHUDQW V VWHP E 5HGXQGDQF EORFN GLDJUDP Figure 14 15 Example of redundancy with fault tolerant system and redundant bus system Configuration view Physical view 38 D 3 E 3 E 3 D 3 D 38 D 38D 38D 38E 38E 3E 3E 3E 3E 3D 3D 3D 3D 38 D 38 E 3 E 3 D 3 E 3 D DXOW WROHUDQW V VWHP D DXOW WROHUDQW V VWHP D DXOW WROHUDQW V VWHP E DXOW WROHUDQW V VWHP E XV XV 5HGXQGDQF EORFN GLDJUDP XV XV Figur...

Page 249: ...double error within a fault tolerant system e g CPUa1 and CPa2 in one system leads to total failure of communication between the systems involved see first figure If a double error e g CPUa1 and CPb2 occurs in the first case of a redundant electrical bus system see second figure this results in a total failure of communication between the systems involved In the case of a redundant electrical bus ...

Page 250: ...on resources on CP b1 for the redundant connections One connection resource each is occupied on CP a1 and CP a2 respectively In this case the use of further CPs in the standard system only serves to increase the resources 38 D 38 E 3 D 3 E 38D 38E 3D 3E 38D 3D 260 260 260 V VWHP D V VWHP D 5HGXQGDQF EORFN GLDJUDP 6WDQGDUG V VWHP ZLWK 38 6WDQGDUG V VWHP ZLWK 38 3ODQW EXV DV RSWLFDO WZR ILEHU ULQJ X...

Page 251: ...s data management is ensured by means of suitable software such as WinCC Redundancy Communication takes place via fault tolerant S7 connections The S7 REDCONNECT software package is required for fault tolerant communication on a PC It supports the connection of a PC to a fiber optic network with one CP or to a redundant bus system with 2 CPs Always use the latest version of this software Only Indu...

Page 252: ...ntegrate fault tolerant S7 communication for a PC into your OS system in the WinCC documentation 38D 3 3D 3 38D 3D 3 38 D 3 D 3 260 260 260 V VWHP D V VWHP D 5HGXQGDQF EORFN GLDJUDP 3ODQW EXV DV RSWLFDO WZR ILEHU ULQJ RXW RI UHGXQGDQF XV D XV E LQ 6HUYHU Figure 14 18 Example of redundancy with fault tolerant system and redundant bus system 38D 3 3D 3 38D 3D 3 38 D 3 D 3 260 260 260 3 260 3 V VWHP ...

Page 253: ... result in a total failure of communication between the systems involved see previous figures PC PG as Engineering System ES To be able to use a PC as Engineering System you need to configure it under its name as a PC station in HW Config The ES is assigned to a CPU and is capable of executing STEP 7 functions on that CPU If the CPU fails communication between the ES and the fault tolerant system ...

Page 254: ... CPU Higher communication load increases the response time of the CPU meaning the CPU takes more time to respond to a request such as a read job or to output requests and messages Operating range In every automation system there is a linear operating range in which an increase in communication load will also lead to an increase in data throughput This then results in reasonable response times whic...

Page 255: ...dundant fault tolerant system is not operating at its performance limits the performance benchmark compared to the single mode will be lower by the factor 2 to 3 Communication statistics You can determine the distribution of the communication load across all connections of a CPU or the redundant fault tolerant system via STEP 7 Module state Communication statistics Which variables influence commun...

Page 256: ...want to transfer any user data A significant increase in communication performance between S7 components is achieved by using S7 communication functions rather than S5 compatible communication functions As S5 compatible communication functions FB AG_SEND FB AG_RECV AP_RED generate a significantly higher communication load you should only deploy these for the communication of S7 components with non...

Page 257: ... that all screen tags are requested within the same cycle time in order to form an optimized group for read jobs OPC servers When OPC is used to connect several HMI devices for your visualization tasks to a fault tolerant system you should keep the number of OPC servers accessing the fault tolerant system as low as possible OPC clients should address a shared OPC server which then fetches the data...

Page 258: ...Communication 14 8 General issues regarding communication S7 400H 258 System Manual 03 2012 A5E00267695 11 ...

Page 259: ...d stations Configuring hardware and networking Loading system data onto the target system Even the individual steps that are required for this are identical for the most part to those familiar from the S7 400 NOTICE OBs required Always download these error OBs to the S7 400H CPU OB 70 OB 72 OB 80 OB 82 OB 83 OB 85 OB 86 OB 87 OB 88 OB 121 and OB 122 If you do not download these OBs the fault toler...

Page 260: ...rack 1 Modules with communication bus interface can be operated only in racks 0 through 6 Communication bus capable modules are not permissible in switched I O Pay attention to the rack numbers for operation of CPs for fault tolerant communication in expansion devices The numbers must be directly sequential and begin with the even number e g rack numbers 2 and 3 but not rack numbers 3 and 4 A rack...

Page 261: ...or CPU1 Parameters of the MPI DP interface X1 Parameters of the DP interface X2 Addresses of sync modules Parameters of the PROFINET interface Configuring modules addressed in the I O address space Always configure a module that is addressed in the I O address space so that it is located either entirely in the process image or entirely outside Otherwise consistency cannot be guaranteed and the dat...

Page 262: ...ese parameters are packed in system data blocks The transmission time of the parameters depends on the following factors Baud rate of the bus system high baud rate short transmission time Size of the parameters and the system data blocks long parameter long transmission time Load on the bus system many slaves long transmission time Note The bus load is at its peak during restart of the DP master f...

Page 263: ...0 fault tolerant station with 2 fault tolerant CPUs When this connection type is configured the application automatically determines the number of possible connecting paths If two independent but identical subnets are available and they are suitable for an S7 connection DP master systems two connecting paths are used In practice they are usually electrical power systems one CP in each subnet If on...

Page 264: ...under both CPUs and can be selected in both locations Communication functions For programming device PG functions that establish online connections e g downloading and deleting blocks one of the two CPUs has to be selected even if the function affects the entire system over the redundant link Data which is modified in one of the central processing units in redundant operation affect the other CPUs...

Page 265: ...w you in the following sections how simple and fast it can be to repair and replace components in the S7 400H Also refer to the tips in the corresponding sections of the manual S7 400 Automation Systems Installation 16 2 Failure and replacement of components during operation Which components can be replaced The following components can be replaced during operation Central processing units e g CPU ...

Page 266: ...th the same load memory as the failed CPU NOTICE New CPUs are always shipped with the latest operating system version If this differs from the version of the operating system of the remaining CPU you will have to equip the new CPU with the same version of the operating system Either create an operating system update card for the new CPU and use this to load the operating system on the CPU or load ...

Page 267: ...he reserve CPU Starting situation for replacement of the load memory Failure How does the system react The S7 400H is in redundant system mode and a load memory access error occurs The relevant CPU changes to STOP and requests a memory reset The partner CPU switches to single mode Procedure Follow the steps below to replace the load memory Step What has to be done How does the system react 1 Repla...

Page 268: ... The entire subsystem is switched off system operates in single mode 2 Replace the module 3 Switch the power supply module on again The CPU executes the self tests The CPU performs an automatic LINK UP and UPDATE The CPU changes to RUN redundant system mode and operates as reserve CPU Note Redundant power supply If you use a redundant power supply PS 407 10A R two power supply modules are assigned...

Page 269: ...e S7 300 and S7 400 Use the correct procedure when replacing a module The correct procedure is described below for the S7 300 and the S7 400 To replace signal and function modules of an S7 300 perform the following steps Step What has to be done How does the system react 1 Disconnect the module from its peripheral power supply if necessary 2 Remove the failed module in RUN mode Both CPUs process t...

Page 270: ...he configuration Call OB 122 if you are accessing the module by direct access Call OB 85 if you are accessing the module using the process image 3 Remove the failed module in RUN mode Both CPUs process the swapping interrupt OB 83 synchronized with each other 4 Insert the new module Both CPUs process the swapping interrupt OB 83 synchronized with each other Parameters are assigned automatically to...

Page 271: ...nication via standard connections Connection failed In communication via redundant connections Communication is maintained without interruption over an alternate channel Procedure If you want to use a communication module that is already being used by another system you have to ensure that there are no parameter data saved in the module s integrated FLASH EPROM before you swap it Proceed as follow...

Page 272: ...ronization module fails See also chapter Synchronization modules for S7 400H Page 341 The master CPU reports the event in the diagnostic buffer and with OB 72 of OB 82 The reserve CPU changes to ERROR SEARCH mode for some minutes If the error is eliminated during this time the reserve CPU switches to redundant system mode otherwise it switches to STOP The LED Link1 OK or Link2 OK on the synchroniz...

Page 273: ...iting state 9 Plug in the fiber optic cable connections of the synchronization modules 10 Start the reserve CPU for example STOP RUN or Start using the programming device The CPU performs an automatic LINK UP and UPDATE The CPU changes to RUN redundant system mode and operates as reserve CPU Note If both fiber optic cables or synchronization modules are damaged or replaced one after the other the ...

Page 274: ...is event proceed as follows Step What has to be done How does the system react 1 Switch off one subsystem 2 Replace the faulty components 3 Turn the subsystem back on LEDs IFM1F and IFMF2F go off The LED MSTR of the switched on subsystem goes out 4 Start the CPU for example Start from programming device or STOP RUN The CPU performs an automatic LINK UP and UPDATE The CPU changes to RUN redundant s...

Page 275: ...the diagnostic buffer and via OB 86 Procedure Follow the steps below to replace an interface module Step What has to be done How does the system react 1 Turn off the power supply of the central rack The partner CPU switches to single mode 2 Turn off the power supply of the expansion unit in which you want to replace the interface module 3 Remove the interface module 4 Insert the new interface modu...

Page 276: ...P interface module IM 153 2 or IM 157 PROFIBUS DP slave PROFIBUS DP cable Note Replacing I O and function modules located in a distributed station is described in section Failure and replacement of an input output or function module Page 269 16 3 1 Failure and replacement of a PROFIBUS DP master Starting situation Failure How does the system react The S7 400H is in redundant system mode and a DP m...

Page 277: ...and operates as the reserve CPU 16 3 2 Failure and replacement of a redundant PROFIBUS DP interface module Starting situation Failure How does the system react The S7 400H is in redundant system mode and a PROFIBUS DP interface module IM 153 2 IM 157 fails Both CPUs report the event in the diagnostic buffer and via OB 70 Replacement procedure Proceed as follows to replace the PROFIBUS DP interface...

Page 278: ...ly for the DP slave 2 Remove the bus connector 3 Replace the DP slave 4 Plug the bus connector back in and turn the power supply back on The CPUs process the rack failure OB 86 synchronized with each other outgoing event The associated DP master can address the DP slave 16 3 4 Failure and replacement of PROFIBUS DP cables Starting situation Failure How does the system react The S7 400H is in redun...

Page 279: ...o be done How does the system react 1 Check the cabling and localize the interrupted PROFIBUS DP cable 2 Replace the defective cable 3 Switch the failed modules to RUN mode The CPUs process the error OBs synchronized with each other With one sided I O Rack failure OB 86 outgoing event The DP slaves can be addressed via the DP master system With switched I O I O redundancy error OB 70 outgoing even...

Page 280: ...Failure and replacement of components during operation 16 3 Failure and replacement of components of the distributed I Os S7 400H 280 System Manual 03 2012 A5E00267695 11 ...

Page 281: ...ee section The system states of the S7 400H Page 124 with the aim of returning to this mode when the procedures are completed NOTICE Keep strictly to the rules described in this section with regard to modifications of the system in runtime If you contravene one or more rules the response of the fault tolerant system can result in its availability being restricted or even failure of the entire auto...

Page 282: ...h CPUs must be updated several times in the process It is therefore advisable to expand the integrated load memory with a RAM card at least temporarily You may only change the FLASH card to a RAM card as required for this if the FLASH card has as much maximum storage space as the largest RAM card available If you cannot obtain a RAM card with a capacity to match the FLASH card memory space split t...

Page 283: ...es with a redundant interface module e g ET 200M DP PA link or Y link One sided DP slaves in any DP master system Modules in modular DP slaves DP PA links PA devices Changing specific CPU parameters Changing the CPU memory configuration Re parameterization of a module Assigning a module to another process image partition Upgrading the CPU version Changing the master with only one available redunda...

Page 284: ...ot be installed and removed during operation Always terminate both ends of PROFIBUS DP and PROFIBUS PA bus cables using active bus terminating elements in order to ensure proper termination of the cables while you are reconfiguring the system PROFIBUS PA bus systems should be built up using components from the SpliTConnect product range see interactive catalog CA01 so that separation of the lines ...

Page 285: ...Page 207 Due to the link up and update process carried out after a system modification the I O data of the previous master CPU may be temporarily deleted from the process image until all changed I Os of the new master CPU are written to the process image During the first update of the process image after a system modification you may incorrectly have the impression that the redundant I O has faile...

Page 286: ...rdware configuration in the reserve CPU PCS 7 step 4 Loading a new hardware configuration in the reserve CPU Page 289 5 Switching to CPU with modified configuration PCS 7 step 5 Switch to CPU with modified configuration Page 289 6 Transition to redundant system mode PCS 7 step 6 Transition to redundant system mode Page 291 7 Editing and downloading the user program PCS 7 step 7 Editing and downloa...

Page 287: ...Plug new module into existing modular DP stations Add new DP stations to existing DP master systems NOTICE With switched I O Always complete all changes on one segment of the redundant DP master system before you modify the next segment 2 Connect the required sensors and actuators to the new components Result The insertion of non configured modules will have no effect on the user program The same ...

Page 288: ...nt system mode Configuring connections The interconnections with added CPs must be configured on both connection partners after you complete the HW modification 17 3 3 PCS 7 step 3 Stopping the reserve CPU Starting situation The fault tolerant system is operating in redundant system mode Procedure 1 In SIMATIC Manager select a CPU of the fault tolerant system then choose PLC Operating Mode from th...

Page 289: ...n ongoing operation 17 3 5 PCS 7 step 5 Switch to CPU with modified configuration Starting situation The modified hardware configuration is downloaded to the reserve CPU Procedure 1 In SIMATIC Manager select a CPU of the fault tolerant system then choose PLC Operating Mode from the menu 2 In the Operating Mode dialog box click the Switch to button In the Switch dialog box select the with altered c...

Page 290: ...figured substitute or holding values are given new parameter settings1 and updated by the CPU continue operation without interruption Added DP stations are not addressed by the CPU as for added I O modules see above 1 The central modules are first reset Output modules briefly output 0 during this time instead of the configured substitute or hold values Reaction to monitoring timeout The update is ...

Page 291: ...parameter settings and updated by the CPU Driver blocks are not yet present Any interrupts occurring are not reported are updated by the CPU Driver blocks are not yet present Process or diagnostic interrupts are detected but are not reported I O modules still present are given new parameter settings1 and updated by the CPU continue operation without interruption Added DP stations as for added I O ...

Page 292: ... to the block parameters could be lost You will find more detailed information on this topic in the CFC for S7 Continuous Function Chart manual Procedure 1 Adapt the program to the new hardware configuration You can add the following components CFCs and SFCs Blocks in existing charts Connections and parameter settings 2 Assign parameters for the added channel drivers and interconnect them with the...

Page 293: ...y output 0 during this time instead of the configured substitute or hold values Modules in switched DP stations are not reconfigured when you switch over to the CPU with the modified configuration Proceed as follows to change the channel use In steps 1 to 5 you completely remove the respective module from the hardware configuration and the user program But it can remain inserted in the DP station ...

Page 294: ...erve CPU Switch off the power supply of the reserve subsystem Insert the new IM460 into the central unit then establish the link to a new expansion unit or Add a new expansion unit to an existing chain or Plug in the new external DP master interface and set up a new DP master system Switch on the power supply of the reserve subsystem again 5 Switch to CPU with altered configuration see section PCS...

Page 295: ...nloading the user program Page 297 3 Stopping the reserve CPU PCS 7 step 3 Stopping the reserve CPU Page 298 4 Loading a new hardware configuration in the reserve CPU PCS 7 step 4 Downloading a new hardware configuration to the reserve CPU Page 298 5 Switch to CPU with modified configuration PCS 7 step 5 Switching to CPU with modified configuration Page 299 6 Transition to redundant system mode PC...

Page 296: ...ing in redundant system mode Procedure 1 Perform offline only the configuration modifications relating to the hardware being removed As you do delete the icons to the channels that are no longer used 2 Compile the new hardware configuration but do not load it into the target system just yet Result The modified hardware configuration is in the PG ES The target system continues operation with the ol...

Page 297: ...ock parameters could be lost You will find more detailed information on this topic in the CFC for S7 Continuous Function Chart manual Procedure 1 Edit only the program elements related to the hardware removal You can delete the following components CFCs and SFCs Blocks in existing charts Channel drivers interconnections and parameter settings 2 In SIMATIC Manager select the charts folder and choos...

Page 298: ...log box select the reserve CPU then click Stop Result The reserve CPU switches to STOP mode the master CPU remains in RUN mode the fault tolerant system works in single mode The one sided I O of the reserve CPU is no longer addressed 17 4 4 PCS 7 step 4 Downloading a new hardware configuration to the reserve CPU Starting situation The fault tolerant system is operating in single mode Procedure Loa...

Page 299: ...ype of I O One sided I O of previous master CPU One sided I O of new master CPU Switched I O I O modules to be removed1 are no longer addressed by the CPU Driver blocks are no longer present I O modules still present are no longer addressed by the CPU Output modules output the configured substitute or holding values are given new parameter settings2 and updated by the CPU continue operation withou...

Page 300: ...serve CPU One sided I O of master CPU Switched I O I O modules to be removed1 are no longer addressed by the CPU Driver blocks are no longer present I O modules still present are given new parameter settings2 and updated by the CPU continue operation without interruption DP stations to be removed as for I O modules to be removed see above 1 No longer included in the hardware configuration but stil...

Page 301: ...remove 2 Unplug modules of the one sided I Os that are no longer required from the racks 3 Unplug components that are no longer required from the modular DP stations 4 Remove DP stations that are no longer required from the DP master systems NOTICE With switched I O Always complete all changes on one segment of the redundant DP master system before you modify the next segment Result The removal of...

Page 302: ...to the reserve CPU see section PCS 7 step 4 Downloading a new hardware configuration to the reserve CPU Page 298 5 Follow the steps below to remove an interface module from the subsystem of the reserve CPU Switch off the power supply of the reserve subsystem Remove an IM460 from the central unit or Remove an expansion unit from an existing chain or Remove an external DP master interface module Swi...

Page 303: ...n 1 Modification of hardware STEP 7 step 1 Adding hardware Page 304 2 Editing the hardware configuration offline STEP 7 step 2 Offline modification of the hardware configuration Page 305 3 Expanding and downloading OBs STEP 7 step 3 Expanding and downloading OBs Page 305 4 Stopping the reserve CPU STEP 7 step 4 Stopping the reserve CPU Page 306 5 Downloading a new hardware configuration to the res...

Page 304: ...u will find more information in the HW Config online help Download to module Download station configuration in RUN mode 17 5 1 STEP 7 step 1 Adding hardware Starting situation The fault tolerant system is operating in redundant system mode Procedure 1 Add the new components to the system Plug new central modules into the racks Plug new module into existing modular DP stations Add new DP stations t...

Page 305: ...et Result The modified hardware configuration is in the PG The target system continues operation with the old configuration in redundant system mode Configuring connections The interconnections with added CPs must be configured on both connection partners after you complete the HW modification 17 5 3 STEP 7 step 3 Expanding and downloading OBs Starting situation The fault tolerant system is operat...

Page 306: ...TOP mode the master CPU remains in RUN mode the fault tolerant system works in single mode The one sided I O of the reserve CPU is no longer addressed OB 70 I O redundancy loss is not called due to the higher priority CPU redundancy loss OB72 17 5 5 STEP 7 step 5 Loading a new hardware configuration in the reserve CPU Starting situation The fault tolerant system is operating in single mode Procedu...

Page 307: ...vious master CPU One sided I O of new master CPU Switched I O Added I O modules are not addressed by the CPU are given new parameter settings and updated by the CPU The output modules temporarily output the configured substitution values I O modules still present are no longer addressed by the CPU Output modules output the configured substitute or holding values are given new parameter settings1 a...

Page 308: ...ched I O Added I O modules are given new parameter settings and updated by the CPU The output modules temporarily output the configured substitution values are updated by the CPU are updated by the CPU Generate insertion interrupt must be ignored in OB 83 I O modules still present are given new parameter settings1 and updated by the CPU continue operation without interruption Added DP stations as ...

Page 309: ...stem mode will lead to stop system mode both CPUs in STOP mode Procedure 1 Adapt the program to the new hardware configuration You can add edit or remove OBs FBs FCs and DBs 2 Download only the program changes to the target system 3 Configure the interconnections for the new CPs on both communication partners and download them to the target system NOTICE Until an FC is called the first time the va...

Page 310: ... is no longer possible One sided output modules briefly output 0 during this time instead of the configured substitute or hold values Modules in switched DP stations are not reconfigured when you switch over to the CPU with the modified configuration Proceed as follows to change the channel use In steps 1 to 5 you completely remove the respective module from the hardware configuration and the user...

Page 311: ... reserve CPU see section STEP 7 step 5 Loading a new hardware configuration in the reserve CPU Page 306 5 Proceed as follows to expand the subsystem of the present reserve CPU Switch off the power supply of the reserve subsystem Insert the new IM460 into the central unit then establish the link to a new expansion unit or Add a new expansion unit to an existing chain or Plug in the new external DP ...

Page 312: ...7 S7 400H 312 System Manual 03 2012 A5E00267695 11 8 Change to redundant system mode see section STEP 7 step 7 Transition to redundant system mode Page 308 9 Modify and download the user program see section STEP 7 step 8 Editing and downloading the user program Page 309 ...

Page 313: ... described in a subsection Step What to do See section 1 Editing the hardware configuration offline STEP 7 step 1 Editing the hardware configuration offline Page 314 2 Editing and downloading the user program STEP 7 step 2 Editing and downloading the user program Page 315 3 Stopping the reserve CPU STEP 7 step 3 Stopping the reserve CPU Page 315 4 Downloading a new hardware configuration to the re...

Page 314: ...tep 6 Transition to redundant system mode Page 318 The system behavior remains as described You will find more information in the HW Config online help Download to module Download station configuration in RUN mode 17 6 1 STEP 7 step 1 Editing the hardware configuration offline Starting situation The fault tolerant system is operating in redundant system mode Procedure 1 Perform all the modificatio...

Page 315: ... the program changes to the target system Result The fault tolerant system continues to operate in redundant system mode The modified user program will no longer attempt to access the hardware being removed 17 6 3 STEP 7 step 3 Stopping the reserve CPU Starting situation The fault tolerant system is operating in redundant system mode The user program will no longer attempt to access the hardware b...

Page 316: ...ion to the reserve CPU Starting situation The fault tolerant system is operating in single mode Procedure Load the compiled hardware configuration in the reserve CPU that is in STOP mode NOTICE The user program and connection configuration cannot be downloaded in single mode Result The new hardware configuration of the reserve CPU does not yet have an effect on ongoing operation ...

Page 317: ... I O Type of I O One sided I O of previous master CPU One sided I O of new master CPU Switched I O I O modules to be removed1 are no longer addressed by the CPU I O modules still present are no longer addressed by the CPU Output modules output the configured substitute or holding values are given new parameter settings2 and updated by the CPU continue operation without interruption DP stations to ...

Page 318: ...O of reserve CPU One sided I O of master CPU Switched I O I O modules to be removed1 are no longer addressed by the CPU I O modules still present are given new parameter settings2 and updated by the CPU continue operation without interruption DP stations to be removed as for I O modules to be removed see above 1 No longer included in the hardware configuration but still plugged in 2 Central module...

Page 319: ...om the components you want to remove 2 Remove the relevant components from the system Remove the central modules from the rack Remove the modules from modular DP stations Remove DP stations from DP master systems NOTICE With switched I O Always complete all changes on one segment of the redundant DP master system before you modify the next segment Result The removal of non configured modules does ...

Page 320: ...anization blocks Starting situation The fault tolerant system is operating in redundant system mode Procedure 1 Make sure that the interrupt OBs 4x and 82 no longer contain any interrupts of the removed components 2 Download the modified OBs and the corresponding program elements to the target system Result The fault tolerant system is operating in redundant system mode ...

Page 321: ...U Page 315 4 Download the new hardware configuration to the reserve CPU see section STEP 7 step 4 Downloading a new hardware configuration to the reserve CPU Page 316 5 Follow the steps below to remove an interface module from the subsystem of the reserve CPU Switch off the power supply of the reserve subsystem Remove an IM460 from the central unit or Remove an expansion unit from an existing chai...

Page 322: ...00H 322 System Manual 03 2012 A5E00267695 11 8 Change to redundant system mode see section STEP 7 step 6 Transition to redundant system mode Page 318 9 Modify and download the user organization blocks see section STEP 7 step 8 Editing and downloading organization blocks Page 320 ...

Page 323: ...e 17 1 Modifiable CPU parameters Tab Editable parameter Start up Monitoring time for signaling readiness by modules Monitoring time for transferring parameters to modules Cycle clock memory Scan cycle monitoring time Cycle load due to communication Size of the process image of inputs Size of the process image of outputs Memory Local data for the various priority classes Communication resources Max...

Page 324: ...eters to the reserve CPU Step 3 Downloading a new hardware configuration to the reserve CPU Page 326 4 Switching to CPU with modified configuration Step 4 Switching to CPU with modified configuration Page 326 5 Transition to redundant system mode Step 5 Transition to redundant system mode Page 328 Note After changing the hardware configuration download takes place practically automatically This me...

Page 325: ...dware configuration is in the PG ES The target system continues operation with the old configuration in redundant system mode 17 7 3 Step 2 Stopping the reserve CPU Starting situation The fault tolerant system is operating in redundant system mode Procedure 1 In SIMATIC Manager select a CPU of the fault tolerant system then choose PLC Operating Mode from the menu 2 In the Operating Mode dialog box...

Page 326: ...f the standby CPU do not yet have an effect on ongoing operation 17 7 5 Step 4 Switching to CPU with modified configuration Starting situation The modified hardware configuration is downloaded to the reserve CPU Procedure 1 In SIMATIC Manager select a CPU of the fault tolerant system then choose PLC Operating Mode from the menu 2 In the Operating Mode dialog box click the Switch to button 3 In the...

Page 327: ...ithout interruption 1 Central modules are first reset Output modules briefly output 0 during this time instead of the configured substitute or hold values Reaction to monitoring timeout The update is canceled and no change of master takes place if one of the monitored times exceeds the configured maximum The fault tolerant system remains in single mode with the previous master CPU and assuming cer...

Page 328: ...e Reaction of the I O Type of I O One sided I O of reserve CPU One sided I O of master CPU Switched I O I O modules are given new parameter settings1 and updated by the CPU continue operation without interruption 1 Central modules are first reset Output modules briefly output 0 during this time instead of the configured substitute or hold values Reaction to monitoring timeout If one of the monitor...

Page 329: ...ble Upgrade the load memory by inserting a memory card with more memory space Upgrade the load memory by inserting a RAM card if no memory card was previously inserted If you change memory in this way the entire user program is copied from the master CPU to the reserve CPU during the link up process see section Update sequence Page 149 Restrictions Memory should preferably be expanded using RAM ca...

Page 330: ... reset 3 Reset the reserve CPU using the programming device 4 Start the reserve CPU with the menu command PLC Mode Switch to CPU with expanded memory configuration The reserve CPU links up is updated and becomes the master Previous master CPU changes to STOP System operates in single mode 5 Turn off power to the second CPU The subsystem is disabled 6 Modify the memory configuration of the second C...

Page 331: ...he user program see section Switch to CPU with modified configuration or expanded memory configuration Page 152 It is your responsibility to download the entire user program to the new load memory Note After reloading connections gateways it is no longer possible to change from a RAM card to a FLASH card Starting situation The fault tolerant system is operating in redundant system mode The current...

Page 332: ...ges to STOP System operates in single mode 6 Modify the memory configuration of the second CPU as you did for the first CPU in step 2 7 Download the user program and the hardware configuration to the second CPU 8 Start the second CPU from the PG The second CPU is linked up and updated The system is now operating again in redundant system mode NOTICE If you want to change to FLASH Cards you can loa...

Page 333: ...Card command Note Select the correct CPU from the selection dialog 7 Execute a warm restart of the reserve CPU using the Operating Mode dialog The system status now changes to Redundant mode Removing the FLASH card The online and offline data consistency described earlier also applies when you remove FLASH Cards from a fault tolerant system In addition the available RAM size must not be less than ...

Page 334: ... the wrongly changed parameters in the parameter configuration to their last valid values The selected new values must match the current and the planned user program Starting situation The fault tolerant system is operating in redundant system mode Procedure To edit the parameters of modules in a fault tolerant system perform the steps outlined below Details of each step are described in a subsect...

Page 335: ...39 The system behavior remains as described You will find more information in the HW Config online help Download to module Download station configuration in RUN mode 17 9 2 Step 1 Editing parameters offline Starting situation The fault tolerant system is operating in redundant system mode Procedure 1 Edit the module parameters offline in HW Config 2 Compile the new hardware configuration but do no...

Page 336: ...sult The reserve CPU switches to STOP mode the master CPU remains in RUN mode the fault tolerant system works in single mode The one sided I O of the reserve CPU is no longer addressed 17 9 4 Step 3 Downloading a new hardware configuration to the reserve CPU Starting situation The fault tolerant system is operating in single mode Procedure Load the compiled hardware configuration in the reserve CP...

Page 337: ...operating in single mode Reaction of the I O Type of I O One sided I O of previous master CPU One sided I O of new master CPU Switched I O I O modules are no longer addressed by the CPU Output modules output the configured substitute or holding values are given new parameter settings1 and updated by the CPU continue operation without interruption 1 Central modules are first reset Output modules br...

Page 338: ...3_MDL_ADDR and the module type OB83_MDL_TYPE From now on the input and or output data of the module might no longer be correct and no SFCs that send data records to this module may be active 2 After termination of OB 83 the parameters of the module are reset 3 After termination of the parameter reset operation the OB 83 is started again trigger event W 16 3267 if the parameterization was successfu...

Page 339: ...stem mode Reaction of the I O Type of I O One sided I O of reserve CPU One sided I O of master CPU Switched I O I O modules are given new parameter settings1 and updated by the CPU continue operation without interruption 1 Central modules are first reset Output modules briefly output 0 during this time instead of the configured substitute or hold values Reaction to monitoring timeout If one of the...

Page 340: ...System modifications during operation 17 9 Re parameterization of a module S7 400H 340 System Manual 03 2012 A5E00267695 11 ...

Page 341: ...OFINET If you remove a synchronization module in redundant system mode there is a loss of synchronization The reserve CPU changes to ERROR SEARCH mode for some minutes If the new synchronization module is inserted and the redundant link is reestablished during this time the reserve CPU switches to redundant system mode otherwise it switches to STOP Once you have inserted the new synchronization mo...

Page 342: ...chronization module CAUTION Risk of injury The synchronization module is equipped with a laser system and is classified as a CLASS 1 LASER PRODUCT according to IEC 60825 1 Avoid direct contact with the laser beam Do not open the housing Always observe the information provided in this manual and keep the manual to hand as a reference 66 6 5 352 8 7 6 5 66 352 8 7 72 1 ...

Page 343: ...tate If OB 82 was called you can only determine the cause later if the data were read out with SFB 52 or SFB 54 Diagnostics of the synchronization module If you have configured a CPU 41x 5H PN DP as V6 0 you can display the following channel specific diagnostic data in the tab dialog module state for the selected synchronization module Overtemperature The synchronization module is too hot Fiber op...

Page 344: ...U with the IF2 interface of the second CPU NOTICE Wiring synchronization modules crosswise If you wire synchronization modules crosswise i e the IF1 interface of the first CPU with the IF2 interface of the second CPU and vice versa the two CPUs take over the master role and the system will now function properly The LEDs IFM 1 and IFM 2 are lit on both CPUs Make sure that you connect the IF1 interf...

Page 345: ... Power supply 3 3 V supplied by the CPU 3 3 V supplied by the CPU Current consumption 220 mA 240 mA Power loss Wavelength of the optical transceiver 0 77 W 850 nm 0 83 W 1310 nm Maximal permitted attenuation of the fiber optic cable 7 5 dB 9 5 dB Maximum permitted difference in cable lengths 9 m 50 m Dimensions W x H x D mm 13 x 14 x 58 13 x 14 x 58 Weight 0 014 kg 0 014 kg See also Installation o...

Page 346: ... when laying the cable Next to connector 55 mm During installation 60 mm repeated After installation 40 mm one time Points to observe when installing the fiber optic cables for the S7 400H synchronization link Always route the two fiber optic cables separately This increases availability and protects the fiber optic cables from potential double errors caused for example by interrupting both cables...

Page 347: ... cable when you fasten it see Pressure Always deburr or round the edges of the breakthrough before you install the fiber optic cable in order to prevent damage to the sheathing when you pull in and fasten the cable The bending radii must not be smaller than the value specified in the manufacturer s data sheet The branching radii of the cable ducts must correspond to the specified bending radius of...

Page 348: ...he cable for example by the inappropriate use of clamps cable quick mount or cable ties Your installation should also prevent anyone from stepping onto the cable Influence of heat Fiber optic cables are highly sensitive to direct heat which means the cables must not be worked on using hot air guns or gas burners as used in heat shrink tubing technology ...

Page 349: ...ber optic cable need to be water proof Which temperatures influence the installed fiber optic cable Cable length up to 10 m The synchronization module 6ES7 960 1AA06 0XA0 can be operated in pairs with fiber optic cables up to a length of 10 m Select cables with the following specification for lengths up to 10 m Multimode fiber 50 125 µ or 62 5 125 µ Patch cable for indoor applications 2 x duplex c...

Page 350: ... Note Cable up to 10 m lenght on the synchronization module 6ES7 960 1AB06 0XA0 Cables up to a length of 10 m are available on order as accessories If you use one of these cables on the synchronization module 6ES7 960 1AB06 0XA0 you may see the error message Optical perforrmance too high at the call of OB 82 The table below shows the further specifications based on your application Table 18 2 Spec...

Page 351: ...ricated cables with pulling protection aids in whiplash or breakout design including measuring log The entire cabling is routed within a building No cable junction is required between the indoor and outdoor area The necessary cable length is available in one piece There is no need to connect several cable segments by means of distribution boxes Convenient and complete installation using patch cabl...

Page 352: ...ainst rodents Water proofing Suitable for direct underground installation Suitable for the given temperature ranges Avoid splicing cables in the field Use prefabricated cables with pulling protection aids in whiplash design including measuring log including patch cables for indoor applications as required 1 cable with 4 cores per fault tolerant system Both interfaces in one cable 1 or 2 cables wit...

Page 353: ...r example Check the cross over installation when you wire the CPUs Connector type ST or SC for example to match other components 6 ZLWK 38 UDFN 6 ZLWK 38 UDFN XUWKHU GLVWULEXWLRQ ER HV IRU H DPSOH ZLWK 6 RU 67 SOXJ DQG VRFNHW FRQQHFWRUV LQ RUGHU WR LQFUHDVH WRWDO OHQJWKV E LQWHUFRQ QHFWLQJ WKH VLQJOH VHJPHQWV 3DWFK FDEOH GXSOH H J 6 67 3DWFK FDEOH GXSOH H J 6 67 LVWULEXWLRQ ER H J ZLWK 6 RU 67 SOX...

Page 354: ...Synchronization modules 18 3 Selecting fiber optic cables S7 400H 354 System Manual 03 2012 A5E00267695 11 ...

Page 355: ...t of a process is its response time How to calculate this factor is described in detail in this section When operating a CPU 41x H as master on the PROFIBUS DP network you also need to include the additional DP cycle times in your calculation see section Response time Page 369 Additional information For more detailed information on the following execution times refer to the S7 400H instruction lis...

Page 356: ...gram execution Subsequently during program processing the CPU does not access the signal modules directly when addressing the input I and output O address areas but rather it accesses the CPU s internal memory area containing the I O process image Sequence of cyclic program processing The table below shows the various phases in cyclic program execution Table 19 1 Cyclic program processing Step Seq...

Page 357: ...1 357 Elements of the cycle time 3 2 3 3 2 3URFHVV LPDJH RI RXWSXWV 3 3URFHVV LPDJH RI WKH LQSXWV 6 66FDQ F FOH FKHFNSRLQW 26 2SHUDWLQJ V VWHP 7LPH VOLFHV PV HDFK 7LPH VOLFH PV 8VHU SURJUDP 6 26 8VHU SURJUDP RPPXQLFDWLRQ 2SHUDWLQJ V VWHP Figure 19 1 Elements and composition of the cycle time ...

Page 358: ...block status Transfer and deletion of blocks compressing of the user program memory Runtime of signals using the synchronization cable Influencing factors The table below shows the factors influencing the cycle time Table 19 2 Factors influencing cycle time Factors Remark Transfer time for the process output image POI and process input image PII See tables from 19 3 onwards User program execution ...

Page 359: ...te of consistent data for the integrated PROFINET interface from row G Transfer time for process image update The tables below show the various portions of the transfer time for a process image update process image transfer time The specified times only represent ideal values and may be extended accordingly by any interrupts or communication of the CPU Table 19 3 Portion of the process image trans...

Page 360: ...s B In the expansion unit with local link Read write byte word double word 23 µs 40 µs C In the expansion unit with remote link Read write byte word double word 47 µs 64 µs D1 In the DP area for the integrated DP interface Read byte word double word 0 5 µs 21 5 µs D2 In the DP area for the external DP interfaces Read write byte word double word 5 2 µs 24 6 µs E1 Consistent data in the process imag...

Page 361: ...uble word 5 1 µs 20 µs E1 Consistent data in the process image for the integrated DP interface Read write data 12 µs 35 µs E2 Consistent data in the process image for the external DP interface CP 443 5 extended Read write 127 µs 60 µs 141 µs 80 µs F In the PNIO area for the integrated PROFINET interface Read write for each byte word double word 2 5 µs 20 µs G Per submodule with 32 bytes of consist...

Page 362: ...O area for the integrated PROFINET interface Read write for each byte word double word 2 µs 15 µs G Per submodule with 32 bytes of consistent data for the integrated PROFINET interface 8 µs 30 µs In the case of I O inserted into the central controller or expansion device the specified value contains the execution time of the I O module The module data is updated with the minimum number of accesses...

Page 363: ...sted interrupts CPU Hardware interrupt Diagnostic interrupt Time of day interrupt Delay interrupt Cyclic inter rupt Programming error I O access error Asyn chronous error CPU 412 5H stand alone mode 240 µs 240 µs 230 µs 150 µs 150 µs 80 µs 80 µs 180 µs CPU 412 5H redundant 680 µs 550 µs 700 µs 580 µs 450 µs 350 µs 179 µs 550 µs CPU 414 5H stand alone mode 160 µs 120 µs 150 µs 100 µs 100 µs 60 µs 6...

Page 364: ...GDWH 3 Figure 19 2 Different cycle times Fluctuation of the block processing time e g OB 1 may also be a factor causing cycle time fluctuation due to conditional instructions conditional block calls different program paths loops etc Maximum cycle time In STEP 7 you can modify the default maximum cycle time scan cycle monitoring time OB 80 is called when this time expires In this block you can spec...

Page 365: ...ould be updated more often than necessary 2 2 2 2 6 3 3 3 XUUHQW F FOH 1H W F FOH 6WDQGE 3URFHVV LPDJH XSGDWH RI RXWSXWV 3URFHVV LPDJH XSGDWH RI RXWSXWV 3URFHVV LPDJH XSGDWH RI LQSXWV 3 3 7PLQ FRQILJXUDEOH PLQLPXP F FOH WLPH 7PD FRQILJXUDEOH PD LPXP F FOH WLPH 7F F WKH F FOH WLPH 7ZDLW GLIIHUHQFH EHWZHHQ 7PLQ DQG WKH DFWXDO F FOH WLPH LWKLQ WKLV WLPH RX FDQ SURFHVV LQWHUUXSW HYHQWV RU 6 WDVNV 3 3U...

Page 366: ... describes the influence of communication load on the cycle time FWXDO F FOH WLPH FOH WLPH RQILJXUHG FRPPXQLFDWLRQ ORDG LQ 5RXQG WKH UHVXOW XS WR WKH QH W KLJKHVW LQWHJHU Figure 19 4 Formula Influence of communication load Data consistency The user program is interrupted to process communications This interruption can be triggered after any statement These communication jobs may lead to a change i...

Page 367: ...ear amount of 2 ms but by 3 ms Example 50 communication load In the hardware configuration you have set a communication load of 50 The calculated cycle time is 10 ms This means that 500 µs remain in each time slice for the cycle So the CPU requires 10 ms 500 µs 20 time slices to execute one cycle This means the physical cycle time is 20 ms if the CPU fully utilizes the configured communication loa...

Page 368: ... times due to communication load leads to more asynchronous events occurring within an OB 1 cycle for example interrupts This further extends the OB 1 cycle How much it is extended depends on the number of events per OB 1 cycle and the time required for processing these events Remarks Change the value of the communication load parameter to check the effects on the cycle time during system runtime ...

Page 369: ...esponse times Factors The response time depends on the cycle time and the following factors Delay of the inputs and outputs Additional DP cycle times on the PROFIBUS DP network Execution in the user program Delay of the I Os Make allowances for the following module specific delay times For digital inputs the input delay time For digital inputs with interrupt function the input delay time internal ...

Page 370: ...ameters section The figure below provides an overview of the DP cycle time In this example we assume an average value for each DP slave of 4 bytes of data PV PV PV PV PV PV PV PV XV UXQWLPH 0LQ VODYH LQWHUYDO 1XPEHU RI 3 VODYHV DXG UDWH 0ESV DXG UDWH 0ESV Figure 19 7 DP cycle times on the PROFIBUS DP network If you are operating a PROFIBUS DP network with more than one master you will need to take...

Page 371: ...VHG KHUH E WKH XVHU SURJUDP 7KH UHDFWLRQ RI WKH XVHU SURJUDP WR WKH FKDQJH RI WKH LQSXW VLJQDO LV RXWSXWWHG KHUH WR WKH RXWSXWV Figure 19 8 Shortest response time Calculation The shortest response time is calculated as follows 1 x process image transfer time of the inputs 1 x process image transfer time of the outputs 1 x program processing time 1 x operating system processing time at the SCCP Del...

Page 372: ... OORZDQFHV DUH PDGH KHUH LQ WKH 3 IRU LQSXW VLJQDO WUDQVLWLRQV 7KH FKDQJH RI LQSXW VLJQDO LV SURFHVVHG KHUH E WKH XVHU SURJUDP 7KH UHDFWLRQ RI WKH XVHU SURJUDP WR WKH FKDQJH RI LQSXW VLJQDO LV SDVVHG KHUH WR WKH RXWSXWV Figure 19 9 Longest response time Calculation The longest response time is calculated as follows 2 x process image transfer time of the inputs 2 x process image transfer time of th...

Page 373: ...ution times of direct access by the CPU to I O modules The specified times are pure CPU processing times and do not include the processing times of the signal modules Table 19 10 Direct access of the CPUs to I O modules in the central rack Access mode 412 5H stand alone mode 412 5H redundant 414 5H stand alone mode 414 5H redundant 416 5H stand alone mode 416 5H redundant 417 5H stand alone mode 4...

Page 374: ...s 19 9 µs 5 3 µs 10 2 µs 19 8 µs 13 4 µs 18 6 µs 28 7 µs 13 4 µs 18 3 µs 28 0 µs Table 19 12 Direct access of the CPUs to I O modules in the expansion unit with remote link setting 100 m Access mode 412 5H stand alone mode 412 5H redundant 414 5H stand alone mode 414 5H redundant 416 5H stand alone mode 416 5H redundant 417 5H Einzel betrieb 417 5H redundant Read byte Read word Read double word Wr...

Page 375: ...ed communication load in 2 Using the instruction list calculate the runtime of the program elements processing the interrupts To do so add the relevant value from Table 16 9 Multiply this value by the factor from step 4 Add this value to the theoretical cycle time as often as the interrupt is triggered or is expected to be triggered during the cycle time The result is an approximated actual cycle ...

Page 376: ...fic factor is 1 2 the user program execution time is approx 18 0 ms Process image transfer time 4 double word accesses Process image 9 µs 4 25 µs approx 0 109 ms OS execution time at the scan cycle checkpoint approx 0 31 ms The total of the listed times is equivalent to the cycle time Cycle time 18 0 ms 0 109 ms 0 31 ms 18 419 ms Calculation of the actual cycle time Allowance for communication loa...

Page 377: ...he theoretical cycle time for the example is derived from the following times As the CPU specific factor is 1 2 the user program execution time is approx 12 0 ms Process image transfer time 4 x double word access and 3 x word access Process image 9 µs 7 25 µs approx 0 184 ms Operating system runtime at scan cycle checkpoint approx 0 31 ms The total of the listed times is equivalent to the cycle ti...

Page 378: ...are active a cycle time of the analog input module of 200 ms results Analog output module SM 432 AO 8 13Bit was parameterized for operation in the measuring range 0 10 V This results in a conversion time of 0 3 ms per channel Since 8 channels are active the result is a cycle time of 2 4 ms The transient time of a resistive load of 0 1 ms must be added to this The result is an analog output respons...

Page 379: ...e of the CPU minimum interrupt response time of the signal modules PROFIBUS DP cycle time on PROFINET Shortest interrupt response time Minimum interrupt response time of the CPU maximum interrupt response time of the signal modules 2 cycle time on PROFIBUS DP or PROFINET Longest interrupt response time Process and diagnostic interrupt response times of the CPUs Table 19 14 Process and interrupt re...

Page 380: ...put modules Process interrupt response time internal interrupt processing time conversion time The internal interrupt processing time for analog input modules can be neglected The conversion times can be found in the data sheet for the individual analog input modules The diagnostic interrupt response time of the signal modules is the time from detection of a diagnostic event by the signal module t...

Page 381: ... 0 5 ms for the digital input modules No activities are required at the scan cycle checkpoint You have set a cycle load of 20 due to communication Calculation In this example the process interrupt response time is based on following time factors Process interrupt response time of CPU 417 5H Approx 0 3 ms mean value in redundant system mode Extension due to communication according to the descriptio...

Page 382: ...lity The following table contains the reproducibility of time delay and cyclic interrupts of the CPUs Table 19 15 Reproducibility of time delay and cyclic interrupts of the CPUs Reproducibility Module Time delay interrupt Cyclic interrupt CPU 412 5H stand alone mode 230 µs 250 µs CPU 412 5H redundant 430 µs 520 µs CPU 414 5H stand alone mode 160 µs 240 µs CPU 414 5H redundant 280 µs 280 µs CPU 416...

Page 383: ...ated 512 KB for code 512 KB for data Load memory integrated 512 KB RAM Expandable FEPROM With memory card FLASH up to 64 MB Expandable RAM With memory card RAM up to 64 MB Battery backup Yes all data Typical execution times Execution times of Bit instructions 31 25 ns Word instructions 31 25 ns Fixed point arithmetic 31 25 ns Floating point arithmetic 62 5 ns Timers counters and their retentivity ...

Page 384: ...te Data blocks Maximum 6000 DB 0 reserved Number range 1 16000 Size Maximum 64 KB Local data configurable Maximum 16 KB Default 8 KB Blocks OBs See Instruction List Size Maximum 64 KB Number of free cycle OBs OB 1 Number of time of day interrupt OBs OB 10 11 12 13 Number of time delay interrupt OBs OB 20 21 22 23 Number of cyclic interrupts OB 32 33 34 35 Number of process interrupt OBs OB 40 41 4...

Page 385: ...via PROFIBUS Via integrated PROFINET interface Max 244 bytes Max 1024 bytes Digital channels Maximum 65536 maximum 65536 of those central Maximum 65536 maximum 65536 Analog channels Maximum 4096 maximum 4096 of those central Maximum 4096 maximum 4096 Configuration Central controllers expansion units Maximum 2 20 Multicomputing No Number of plug in IMs total Maximum 6 IM 460 Maximum 6 IM 463 2 Maxi...

Page 386: ...AS on MPI DP and Ethernet MMS As master or slave On Ethernet over NTP As client Time difference in the system with synchronization via MPI Max 200 ms Time difference in the system with synchronization via Ethernet Max 10 ms S7 alarm functions Number of stations that can be logged on For block related alarms with SFC Alarm_S SQ and or Alarm_D DQ 47 For block related alarms with SFB Notify Notify_8 ...

Page 387: ...f breakpoints Maximum 16 Diagnostic buffer Yes Number of entries Maximum 3200 configurable Default 120 Communication PG OP communication Yes Routing Yes S7 communication Yes User data per job Maximum 64 KB of which consistent 1 tag 462 bytes S7 basic communication No Global data communication No S5 compatible communication Using FC AG_SEND and AG_RECV max via 10 CPs 443 1 or 443 5 User data per jo...

Page 388: ... integrated PROFINET interface and loadable FBs Maximum number of connections 46 Data length max 32 KB ISO on TCP Yes via integrated PROFINET interface or CP 443 1 EX20 GX 20 and loadable FBs Maximum number of connections 46 Maximum data length via integrated PROFINET interface 32 KB Maximum data length via CP 443 1 1452 bytes UDP Yes via integrated PROFINET interface and loadable blocks Maximum n...

Page 389: ... No S7 basic communication No Constant bus cycle time No Isochronous mode No SYNC FREEZE No Enable disable DP slaves No Direct data exchange cross traffic No Transmission rates Maximum 12 Mbps Number of DP slaves Maximum 32 Number of slots per interface Maximum 544 Address range Maximum 2 KB inputs 2 KB outputs User data per DP slave Maximum 244 Maximum 244 bytes inputs Maximum 244 bytes outputs M...

Page 390: ...ta communication No S7 basic communication No Constant bus cycle time No SYNC FREEZE No Enable disable DP slaves No Direct data exchange cross traffic No Transmission rates Up to 12 Mbps Number of DP slaves Maximum 64 Number of slots per interface Maximum 1088 Address range Maximum 4 KB inputs 4 KB outputs User data per DP slave Maximum 244 bytes Maximum 244 bytes inputs Maximum 244 bytes outputs ...

Page 391: ... Changeover time on line interruption typical 200 ms PROFINET MRP Number of nodes on the ring max 50 Change of the IP address at runtime supported No Keep Alive function supported Yes Functionality PROFINET Yes Utilities PG communication Yes OP communication Yes S7 communication Maximum number of configurable connections Maximum number of instances Yes 48 one of each reserved for programming devic...

Page 392: ...µs 1 ms 2 ms 4 ms Update Time 250 μs 0 5 ms 1 ms 2 ms 4 ms 8 ms 16 ms 32 ms 64 ms 128 ms 256 ms and 512 ms The minimum value depends on the communication slice set for PROFINET IO the number of IO devices and the amount of configured user data Maximum user data length 1024 bytes per address range Maximum consistency of user data 1024 bytes per address range S7 protocol functions PG functions Yes O...

Page 393: ...YSST 8 SFC 103 DP_TOPOL 1 The total number of active SFCs on all external segments may be four times more than on one single segment System function blocks SFB See instruction list Number of simultaneously active SFBs per segment SFB 52 RDREC 8 SFB 53 WRREC 8 The total number of active SFBs on all external segments may be four times more than on one single segment User program protection Password ...

Page 394: ...nsume any current at 24 V it mderely makes this voltage available on the MPI DP interface Total current consumption of the components connected to the MPI DP interfaces however with a maximum of 150 mA per interface Current output to DP interface 5 V DC Max 90 mA Backup current Typically 180 µA up to 40 C Maximum 1000 µA Maximum backup time See Module Specifications Reference Manual Section 3 3 Fe...

Page 395: ...oad memory integrated 512 KB RAM Expandable FEPROM With memory card FLASH 1 MB to 64 MB Expandable RAM With memory card RAM 256 KB to 64 MB Battery backup Yes all data Typical execution times Execution times of Bit instructions 18 75 ns Word instructions 18 75 ns Fixed point arithmetic 18 75 ns Floating point arithmetic 37 5 ns Timers counters and their retentivity S7 counters 2048 Retentivity con...

Page 396: ... Maximum 16 KB Default 8 KB Blocks OBs See instruction list Size Maximum 64 KB Number of free cycle OBs OB 1 Number of time of day interrupt OBs OB 10 11 12 13 Number of time delay interrupt OBs OB 20 21 22 23 Number of cyclic interrupts OB 32 33 34 35 Number of process interrupt OBs OB 40 41 42 43 Number of DPV1 interrupt OBs OB 55 56 57 Number of redundancy error OBs OB70 72 Number of asynchrono...

Page 397: ...Maximum 65536 of those central Maximum 65536 Maximum 65536 Analog channels Maximum 4096 Maximum 4096 of those central Maximum 4096 Maximum 4096 Configuration Central controllers expansion units Maximum 2 20 Multicomputing No Number of plug in IMs total Maximum 6 IM 460 Maximum 6 IM 463 2 Maximum 4 in stand alone mode only Number of DP masters integrated 2 Via CP 443 5 Ext Maximum 10 Number of plug...

Page 398: ...in the system with synchronization via MPI Max 200 ms Time difference in the system with synchronization via Ethernet Max 10 ms S7 alarm functions Number of stations that can be logged on For block related alarms with SFC Alarm_S SQ and or Alarm_D DQ 63 For block related alarms with SFB Notify Notify_8 Alarm Alarm_8 Alarm 8P 8 Block related alarms with SFC Yes Simultaneously active Alarm_S SQ bloc...

Page 399: ...of breakpoints Maximum 16 Diagnostic buffer Yes Number of entries Maximum 3200 configurable Default 120 Communication PG OP communication Yes Routing Yes S7 communication Yes User data per job Maximum 64 KB of which consistent 1 tag 462 bytes S7 basic communication No Global data communication No S5 compatible communication Using FC AG_SEND and AG_RECV max via 10 CPs 443 1 or 443 5 User data per j...

Page 400: ...integrated PROFINET interface and loadable FBs Maximum number of connections 62 Data length max 32767 bytes ISO on TCP Yes via integrated PROFINET interface or CP 443 1 EX20 GX 20 and loadable FBs Maximum number of connections 62 Maximum data length via integrated PROFINET interface 32767 bytes Maximum data length via CP 443 1 1452 bytes UDP Yes via integrated PROFINET interface and loadable block...

Page 401: ...ication No S7 basic communication No Constant bus cycle time No SYNC FREEZE No Enable disable DP slaves No Direct data exchange cross traffic No Transmission rates Maximum 12 Mbps Number of DP slaves Maximum 32 Number of slots per interface Maximum 544 Address range Maximum 2 KB inputs 2 KB outputs User data per DP slave Maximum 244 bytes Maximum 244 bytes inputs Maximum 244 bytes outputs Maximum ...

Page 402: ...ta communication No S7 basic communication No Constant bus cycle time No SYNC FREEZE No Enable disable DP slaves No Direct data exchange cross traffic No Transmission rates Up to 12 Mbps Number of DP slaves Maximum 96 Number of slots per interface Maximum 1632 Address range Maximum 6 KB inputs 6 KB outputs User data per DP slave Maximum 244 bytes Maximum 244 bytes inputs Maximum 244 bytes outputs ...

Page 403: ... Changeover time on line interruption typical 200 ms PROFINET MRP Number of nodes on the ring max 50 Change of the IP address at runtime supported No Keep Alive function supported Yes Functionality PROFINET Yes Utilities PG communication Yes OP communication Yes S7 communication Maximum number of configurable connections Maximum number of instances Yes 64 one of each reserved for programming devic...

Page 404: ...data qualifiers 1024 bytes Send clock cycles 250 µs 500 µs 1 ms 2 ms 4 ms Update Time 250 μs 0 5 ms 1 ms 2 ms 4 ms 8 ms 16 ms 32 ms 64 ms 128 ms 256 ms and 512 ms The minimum value depends on the communication slice set for PROFINET IO the number of IO devices and the amount of configured user data IRT Isochronous Real Time No S7 protocol functions PG functions Yes OP functions Yes Prioritized sta...

Page 405: ...SYSST 8 SFC 103 DP_TOPOL 1 The total number of active SFCs on all external segments may be four times more than on one single segment System function blocks SFB See instruction list Number of simultaneously active SFBs per segment SFB 52 RDREC 8 SFB 53 WRREC 8 The total number of active SFBs on all external segments may be four times more than on one single segment User program protection Password...

Page 406: ...U does not consume any current at 24 V it only makes this voltage available on the MPI DP interface Total current consumption of the components connected to the MPI DP interfaces but maximum 150 mA per interface Current output to DP interface 5 V DC Max 90 mA Backup current Typically 180 µA up to 40 C Maximum 1000 µA Maximum backup time See Module Specifications Reference Manual Section 3 3 Feed o...

Page 407: ...ta Load memory integrated 1 MB RAM Expandable FEPROM With memory card FLASH 1 MB to 64 MB Expandable RAM With memory card RAM 256 KB to 64 MB Battery backup Yes all data Typical execution times Execution times of Bit instructions 12 5 ns Word instructions 12 5 ns Fixed point arithmetic 12 5 ns Floating point arithmetic 25 ns Timers counters and their retentivity S7 counters 2048 Retentivity config...

Page 408: ...ult 32 KB Blocks OBs See instruction list Size Maximum 64 KB Number of free cycle OBs OB 1 Number of time of day interrupt OBs OB 10 11 12 13 14 15 16 17 Number of time delay interrupt OBs OB 20 21 22 23 Number of cyclic interrupts OB 30 31 32 33 34 35 36 37 38 Number of process interrupt OBs OB 40 41 42 43 44 45 46 47 Number of DPV1 interrupt OBs OB 55 56 57 Number of redundancy error OBs OB70 72...

Page 409: ...2 of those central Maximum 131072 maximum 131072 Analog channels Maximum 8192 maximum 8192 of those central Maximum 8192 maximum 8192 Configuration Central controllers expansion units Maximum 2 20 Multicomputing No Number of plug in IMs total Maximum 6 IM 460 Maximum 6 IM 463 2 Maximum 4 in stand alone mode only Number of DP masters integrated 2 Via CP 443 5 Ext Maximum 10 Number of plug in S5 mod...

Page 410: ... the system with synchronization via MPI Max 200 ms Time difference in the system with synchronization via Ethernet Max 10 ms S7 alarm functions Number of stations that can be logged on For block related alarms with SFC Alarm_S SQ and or Alarm_D DQ 95 For block related alarms with SFB Notify Notify_8 Alarm Alarm_8 Alarm 8P 16 Block related alarms with SFC Yes Simultaneously active Alarm_S SQ block...

Page 411: ...um 16 Diagnostic buffer Yes Number of entries Maximum 3200 configurable Default 120 Communication PG OP communication Yes Routing Yes S7 communication Yes User data per job Maximum 64 KB of which consistent 1 tag 462 bytes S7 basic communication No Global data communication No S5 compatible communication Using FC AG_SEND and AG_RECV max via 10 CPs 443 1 or 443 5 User data per job Maximum 8 KB of w...

Page 412: ...integrated PROFINET interface and loadable FBs Maximum number of connections 94 Data length max 32767 bytes ISO on TCP Yes via integrated PROFINET interface or CP 443 1 EX20 GX 20 and loadable FBs Maximum number of connections 94 Maximum data length via integrated PROFINET interface 32767 bytes Maximum data length via CP 443 1 1452 bytes UDP Yes via integrated PROFINET interface and loadable block...

Page 413: ...ication No S7 basic communication No Constant bus cycle time No SYNC FREEZE No Enable disable DP slaves No Direct data exchange cross traffic No Transmission rates Maximum 12 Mbps Number of DP slaves Maximum 32 Number of slots per interface Maximum 544 Address range Maximum 2 KB inputs 2 KB outputs User data per DP slave Maximum 244 bytes Maximum 244 bytes inputs Maximum 244 bytes outputs Maximum ...

Page 414: ...a communication No S7 basic communication No Constant bus cycle time No SYNC FREEZE No Enable disable DP slaves No Direct data exchange cross traffic No Transmission rates Up to 12 Mbps Number of DP slaves Maximum 125 Number of slots per interface Maximum 2173 Address range Maximum 8 KB inputs 8 KB outputs User data per DP slave Maximum 244 bytes Maximum 244 bytes inputs Maximum 244 bytes outputs ...

Page 415: ...Changeover time on line interruption typical 200 ms PROFINET MRP Number of nodes on the ring max 50 Change of the IP address at runtime supported No Keep Alive function supported Yes Functionality PROFINET Yes Utilities PG communication Yes OP communication Yes S7 communication Maximum number of configurable connections Maximum number of instances Yes 96 one of each reserved for programming device...

Page 416: ...data qualifiers 1024 bytes Send clock cycles 250 µs 500 µs 1 ms 2 ms 4 ms Update Time 250 μs 0 5 ms 1 ms 2 ms 4 ms 8 ms 16 ms 32 ms 64 ms 128 ms 256 ms and 512 ms The minimum value depends on the communication slice set for PROFINET IO the number of IO devices and the amount of configured user data S7 protocol functions PG functions Yes OP functions Yes IRT Isochronous Real Time No Prioritized sta...

Page 417: ...SYSST 8 SFC 103 DP_TOPOL 1 The total number of active SFCs on all external segments may be four times more than on one single segment System function blocks SFB See instruction list Number of simultaneously active SFBs per segment SFB 52 RDREC 8 SFB 53 WRREC 8 The total number of active SFBs on all external segments may be four times more than on one single segment User program protection Password...

Page 418: ...U does not consume any current at 24 V it only makes this voltage available on the MPI DP interface Total current consumption of the components connected to the MPI DP interfaces but maximum 150 mA per interface Current output to DP interface 5 V DC Max 90 mA Backup current Typically 180 µA up to 40 C Maximum 1000 µA Maximum backup time See Module Specifications Reference Manual Section 3 3 Feed o...

Page 419: ...data Load memory integrated 1 MB RAM Expandable FEPROM With memory card FLASH 1 MB to 64 MB Expandable RAM With memory card RAM 256 KB to 64 MB Battery backup Yes all data Typical execution times Execution times of Bit instructions 7 5 ns Word instructions 7 5 ns Fixed point arithmetic 7 5 ns Floating point arithmetic 15 ns Timers counters and their retentivity S7 counters 2048 Retentivity configu...

Page 420: ... 32 KB Blocks OBs See instruction list Size Maximum 64 KB Number of free cycle OBs OB 1 Number of time of day interrupt OBs OB 10 11 12 13 14 15 16 17 Number of time delay interrupt OBs OB 20 21 22 23 Number of cyclic interrupts OB 30 31 32 33 34 35 36 37 38 Number of process interrupt OBs OB 40 41 42 43 44 45 46 47 Number of DPV1 interrupt OBs OB 55 56 57 Number of asynchronous error OBs OB 80 81...

Page 421: ...2 of those central Maximum 131072 Maximum 131072 Analog channels Maximum 8192 Maximum 8192 of those central Maximum 8192 Maximum 8192 Configuration Central controllers expansion units Maximum 2 20 Multicomputing No Number of plug in IMs total Maximum 6 IM 460 Maximum 6 IM 463 2 Maximum 4 in stand alone mode only Number of DP masters integrated 2 Via CP 443 5 Ext Maximum 10 Number of plug in S5 mod...

Page 422: ...rence in the system with synchronization via MPI Max 200 ms Time difference in the system with synchronization via Ethernet Max 10 ms S7 alarm functions Number of stations that can be logged on For block related alarms with SFC Alarm_S SQ and or Alarm_D DQ 119 For block related alarms with SFB Notify Notify_8 Alarm Alarm_8 Alarm 8P 16 Block related alarms with SFC Yes Simultaneously active Alarm_S...

Page 423: ...ication PG OP communication Yes Routing Yes Number of connection resources for S7 connections across all interfaces and CPs 120 incl one each reserved for programming device and OP 62 reserved for fault tolerant connections S7 communication Yes User data per job Maximum 64 KB of which consistent 1 tag 462 bytes Global data communication No S7 basic communication No S5 compatible communication Usin...

Page 424: ... via integrated PROFINET interface and loadable FBs Maximum number of connections 118 Data length max 32 KB ISO on TCP Yes via integrated PROFINET interface or CP 443 1 EX20 GX 20 and loadable FBs Maximum number of connections 118 Maximum data length via integrated PROFINET interface 32 KB Maximum data length via CP 443 1 1452 bytes UDP Yes via integrated PROFINET interface and loadable blocks Max...

Page 425: ...ication No S7 basic communication No Constant bus cycle time No SYNC FREEZE No Enable disable DP slaves No Direct data exchange cross traffic No Transmission rates Maximum 12 Mbps Number of DP slaves Maximum 32 Number of slots per interface Maximum 544 Address range Maximum 2 KB inputs 2 KB outputs User data per DP slave Maximum 244 bytes Maximum 244 bytes inputs Maximum 244 bytes outputs Maximum ...

Page 426: ...outing Yes S7 communication Yes Global data communication No S7 basic communication No Constant bus cycle time No SYNC FREEZE No Enable disable DP slaves No Direct data exchange cross traffic No Transmission rates Maximum 12 Mbps Number of DP slaves Maximum 125 Number of slots per interface Maximum 2173 Address range Maximum 8 KB inputs 8 KB outputs User data per DP slave Maximum 244 bytes Maximum...

Page 427: ...Changeover time on line interruption typical 200 ms PROFINET MRP Number of nodes on the ring max 50 Change of the IP address at runtime supported No Keep Alive function supported Yes Functionality PROFINET Yes Utilities PG communication Yes OP communication Yes S7 communication Maximum number of configurable connections Maximum number of instances Yes 120 one of each reserved for programming devic...

Page 428: ...data qualifiers 1024 bytes Send clock cycles 250 µs 500 µs 1 ms 2 ms 4 ms Update Time 250 μs 0 5 ms 1 ms 2 ms 4 ms 8 ms 16 ms 32 ms 64 ms 128 ms 256 ms and 512 ms The minimum value depends on the communication slice set for PROFINET IO the number of IO devices and the amount of configured user data S7 protocol functions PG functions Yes OP functions Yes IRT Isochronous Real Time No Prioritized sta...

Page 429: ...SYSST 8 SFC 103 DP_TOPOL 1 The total number of active SFCs on all external segments may be four times more than on one single segment System function blocks SFB See instruction list Number of simultaneously active SFBs per segment SFB 52 RDREC 8 SFB 53 WRREC 8 The total number of active SFBs on all external segments may be four times more than on one single segment User program protection Password...

Page 430: ...U does not consume any current at 24 V it only makes this voltage available on the MPI DP interface Total current consumption of the components connected to the MPI DP interfaces but maximum 150 mA per interface Current output to DP interface 5 V DC Max 90 mA Backup current Typically 180 µA up to 40 C Maximum 1000 µA Maximum backup time See Module Specifications Reference Manual Section 3 3 Feed o...

Page 431: ... 0AA0 typ 45 mA max 100 mA typ 5 µA max 60 µA MC 952 16 MB RAM 6ES7952 1AS00 0AA0 typ 100 mA max 150 mA typ 50 µA max 125 µA MC 952 64 MB RAM 6ES7952 1AY00 0AA0 typ 100 mA max 150 mA typ 100 µA max 500 µA MC 952 1 MB 5 V FLASH 6ES7952 1KK00 0AA0 typ 40 mA max 90 mA MC 952 2 MB 5 V FLASH 6ES7952 1KL00 0AA0 typ 50 mA max 100 mA MC 952 4 MB 5 V FLASH 6ES7952 1KM00 0AA0 typ 40 mA max 90 mA MC 952 8 MB...

Page 432: ...tion may increase the runtime of the FB RED_IN by 0 4 8 ms An 8 ms increase can be expected in redundant operation of modules totaling more than 370 pairs of modules at a sequence level 1000 μs 70 μs module pair of the current TPA The specification for a module pair is a mean value The runtime may be additionally increased if discrepancies occur resulting in passivation and logging to the diagnost...

Page 433: ...redundant I O FB 453 RED_STATUS 160 μs 4 μs configured module pairs number of module pairs The runtime depends on the random position of the module being searched for in the working DB When a module address is not redundant the entire working DB is searched This results in the longest runtime of FB RED_STATUS The number of module pairs is based either on all inputs DI AI or all outputs DO AO 350 μ...

Page 434: ...Technical data 20 6 Runtimes of the FCs and FBs for redundant I Os S7 400H 434 System Manual 03 2012 A5E00267695 11 ...

Page 435: ... Mean Time Between Failure This can be analyzed statistically based on the parameters of running systems or by calculating the failure rates of the components used Reliability of modules The reliability of SIMATIC components is extremely high as a consequence of extensive quality assurance measures in design and production Reliability of automation systems The use of redundant modules considerably...

Page 436: ...tem components The structure in which the components make up the system also forms part of the calculation Correlation between MDT and MTBF MDT MTBF The MDT value is of the highest significance for the quality of system maintenance The most important factors are Qualified personnel Efficient logistics High performance tools for diagnostics and error recognition A sound repair strategy The figure b...

Page 437: ...n average temperature of 40 C The system installation and configuration is free of errors All replacement parts are available locally in order to prevent extended repair times due to missing spare parts This keeps the component MDT down to a minimum The MDT of individual components is 4 h The system s MDT is calculated based on the MDT of the individual components plus the system structure The MTB...

Page 438: ...containing different components Within the range stipulated in IEC 61508 a CCF factor between 0 02 and 5 is used to calculate the MTBF UURU RQ FKDQQHO UURU RQ FKDQQHO DIIHFWV ERWK FKDQQHOV Figure A 3 Common Cause Failure CCF Reliability of an S7 400H The use of redundant modules prolongs the system MTBF by a large factor The integrated high grade self test and the test message functions of the S7 ...

Page 439: ... same sampling point Redundant components are arranged such that system operability is not affected by the failure of a single component Here again an important element of availability is a detailed diagnostics display The availability of a system is expressed as a percentage It is defined by the mean time between failure MTBF and the mean time to repair MTTR MDT The availability of a two channel ...

Page 440: ...ature 40 degrees Buffer voltage is safeguarded A 2 1 System configurations with redundant CPU 417 5H The following system with one CPU e g 417 5H operating in stand alone mode forms the basis for calculation of a reference factor which defines the multiple of the system MTBF of other systems with centralized I Os compared to the base line Fault tolerant CPU in stand alone mode Fault tolerant CPU i...

Page 441: ...nt automation systems A 2 Comparison of MTBF for selected configurations S7 400H System Manual 03 2012 A5E00267695 11 441 Redundant CPU 417 5H in two separate racks CCF 1 Factor ILEHU RSWLF FDEOHV 5DFN 85 5DFN 85 36 38 36 38 approx 38 ...

Page 442: ...a basis for calculating a reference factor which specifies the multiple of the availability of the other systems with distributed I Os compared with the base line You can find the order numbers of the IMs in chapter Using single channel one sided I Os Page 171 Redundant CPUs with single channel one sided or switched I Os One sided distributed I Os Base line ILEHU RSWLF FDEOHV 7 0 36 38 36 0 38 1 S...

Page 443: ...mparison of MTBF for selected configurations S7 400H System Manual 03 2012 A5E00267695 11 443 Switched distributed I O PROFINET CCF 2 Factor ILEHU RSWLF FDEOHV 7 0 352 1 7 36 38 36 0 38 approx 10 The estimate applies if the process allows for any device to fail ...

Page 444: ...TBF for selected configurations S7 400H 444 System Manual 03 2012 A5E00267695 11 Redundant CPUs with redundant I Os The comparison only took account of the I O modules Single channel one sided I O MTBF factor 7 0 0 1 Redundant I O MTBF factor 0 0 3 3 0 0 See following table ...

Page 445: ...tributed AI 6x13Bit 6ES7 336 1HE00 0AB0 approx 5 AI8x12Bit 6ES7 331 7KF02 0AB0 approx 5 Digital output modules distributed DO 10xDC24V 2A 6ES7 326 2BF00 0AB0 approx 5 DO8xDC24V 2A 6ES7 322 1BF01 0AA0 approx 3 DO32xDC24V 0 5A 6ES7 322 1BL00 0AA0 approx 3 Summary There are now several thousand applications of redundant automation systems in the field in various configurations To calculate the MTBF w...

Page 446: ... standard and fault tolerant communication for a configuration consisting of a fault tolerant system a fault tolerant CPU operating in stand alone mode and a single channel OS The comparison only took account of the CP and cable communication components Systems with standard and fault tolerant communication Standard communication Base line 26 ZRUNVWDWLRQ 6 V VWHP 6 ZLWK IDXOW WROHUDQW 38 1 Fault t...

Page 447: ...ing and programming the fault tolerant CPU are given in appendix Differences between fault tolerant systems and standard systems Page 453 Definition By stand alone operation we mean the use of a fault tolerant CPU in a standard SIMATIC 400 station Reasons for stand alone operation The applications outlined below are only possible when using a fault tolerant CPU so they are not possible with standa...

Page 448: ...olerant CPU in stand alone mode and in redundant mode Table B 1 Differences between stand alone mode and redundant mode Function Fault tolerant CPU in stand alone mode Fault tolerant CPU in redundant system mode Connection of S5 modules via IM or adapter casing via IM 463 2 No Redundancy error OBs OB 70 OB 72 Yes but no calls Yes CPU hardware fault OB 84 after the detection and elimination of memo...

Page 449: ...SIMATIC Manager 3 Parameterize the fault tolerant CPU Use the default values or customize the necessary parameters 4 Configure the necessary networks and connections For stand alone operation you can configure fault tolerant S7 connections For help on procedure refer to the Help topics in SIMATIC Manager Expansion to a fault tolerant system WARNING You can only expand your system to a fault tolera...

Page 450: ...configured for the CPU Changing from redundant to stand alone mode 1 Remove the synchronization modules 2 Remove the CPU 3 Set rack number 0 on the CPU 4 Install the CPU 5 Download a project with the stand alone configuration to the CPU Changing from stand alone mode to redundant mode rack number 0 1 Insert the synchronization modules into the CPU 2 Run an unbuffered power cycle for example by rem...

Page 451: ...stems in particular this has virtually no effect on the process See also the Modifying the System during Operation via CiR manual System modifications during operation are only supported with distributed I O They require a configuration as shown in the figure below To give you a clear overview this shows only one DP master system and one PA master system 03 3 LQWHUIDFH RI D 38 RU 3 LQWHUIDFH RI D ...

Page 452: ...those that do not Depending on your selected configuration there may be restrictions affecting the components on which you can make system modifications during operation Software requirements for system modifications during operation To make modifications during operation the user program must be written so that station failures or module faults for example do not lead to a CPU STOP Permitted syst...

Page 453: ... redundancy error OB OB 70 CPU redundancy error OB OB 72 For detailed information refer to the System and Standard Functions Reference Manual CPU hardware fault Depending on the configuration OB 82 or OB 84 is also called if the performance of the redundant link between the two CPUs is reduced Additional information in OB start information and in diagnostic buffer entries The rack number and the C...

Page 454: ...s from the partial list with SSL ID W 16 0174 The partial list with the SSL ID W 16 xy75 provides information on the status of the communication between the fault tolerant system and switched DP slaves Update monitoring The operating system monitors the following four configurable timers Maximum cycle time extension Maximum communication delay Maximum inhibit time for priority classes 15 Minimum I...

Page 455: ...ecution time for a CPU 41x 5H is slightly higher compared to the corresponding standard CPU see S7 400 Instruction List and S7 400H Instruction List This must be taken into account for all time critical applications You may need to increase the scan cycle monitoring time DP cycle time A CPU 41x 5H has a slightly longer DP cycle time compared to the corresponding standard CPU Delays and inhibits Du...

Page 456: ... the active channel If there is no active channel the function outputs the ID of the DP master system belonging to the master CPU Call of SFC 51 RDSYSST with SSL_ID W 16 xy91 The data records of the SSL partial lists shown below cannot be read with SFC 51 RDSYSST SSL_ID W 16 0091 SSL_ID W 16 0191 SSL_ID W 16 0291 SSL_ID W 16 0391 SSL_ID W 16 0991 SSL_ID W 16 0E91 Web server Not integrated PROFINET...

Page 457: ...firmware V1 0 0 6ES7 441 2AA02 0AE0 As of product version 2 6ES7 441 2AA03 0AE0 As of product version 1 as of firmware V1 0 0 6ES7 441 2AA04 0AE0 As of product version 1 as of firmware V1 0 0 Yes No Communication processor CP 441 2 point to point link 6ES7 441 2AA03 0AE0 As of product version 1 as of firmware V1 0 0 Yes No 6GK7 443 1EX10 0XE0 As of product version 1 as of firmware V2 7 3 Yes Yes C...

Page 458: ...ed for the ET 200M with the S7 400H in distributed and one sided mode FMs and CPs usable for distributed switched use Module Order No Release Communication processor CP 341 1 point to point link 6ES7 341 1AH00 0AE0 6ES7 341 1BH00 0AE0 6ES7 341 1CH00 0AE0 As of product version 3 6ES7 341 1AH01 0AE0 6ES7 341 1BH01 0AE0 6ES7 341 1CH01 0AE0 As of product version 1 as of firmware V1 0 0 6ES7 341 1AH02 ...

Page 459: ...H00 0AE0 As of product version 1 as of firmware V1 0 0 Control module FM 355 2 S 6ES7 355 0SH00 0AE0 As of product version 1 as of firmware V1 0 0 NOTICE One sided or switched function and communication modules are not synchronized in the fault tolerant system if they are in pairs e g two identical FM 450 modules operating in one sided mode do not synchronize their counter states ...

Page 460: ...Function modules and communication processors supported by the S7 400H S7 400H 460 System Manual 03 2012 A5E00267695 11 ...

Page 461: ... redundant I Os E E 1 SM 321 DI 16 x DC 24 V 6ES7 321 1BH02 0AA0 The diagram below shows the connection of two redundant encoders to two SM 321 DI 16 x DC 24 V The encoders are connected to channel 0 1 1 9 Figure E 1 Example of an interconnection with SM 321 DI 16 x DC 24 V ...

Page 462: ...2012 A5E00267695 11 E 2 SM 321 DI 32 x DC 24 V 6ES7 321 1BL00 0AA0 The diagram below shows the connection of two redundant encoder pairs to two redundant SM 321 DI 32 x DC 24 V The encoders are connected to channel 0 and channel 16 respectively 9 9 Figure E 2 Example of an interconnection with SM 321 DI 32 x DC 24 V ...

Page 463: ... Manual 03 2012 A5E00267695 11 463 E 3 SM 321 DI 16 x AC 120 230V 6ES7 321 1FH00 0AA0 The diagram below shows the connection of two redundant encoders to two SM 321 DI 16 x AC 120 230 V The encoders are connected to channel 0 1 1 9 Figure E 3 Example of an interconnection with SM 321 DI 16 x AC 120 230 V ...

Page 464: ...System Manual 03 2012 A5E00267695 11 E 4 SM 321 DI 8 x AC 120 230 V 6ES7 321 1FF01 0AA0 The diagram below shows the connection of two redundant encoders to two SM 321 DI 8 AC 120 230 V The encoders are connected to channel 0 1 1 9 Figure E 4 Example of an interconnection with SM 321 DI 8 x AC 120 230 V ...

Page 465: ...al 03 2012 A5E00267695 11 465 E 5 SM 321 DI 16 x DC 24V 6ES7 321 7BH00 0AB0 The diagram below shows the connection of two redundant encoder pairs to two SM 321 DI 16 x DC 24V The encoders are connected to channels 0 and 8 9 9V 9V 9V 9V 0 Figure E 5 Example of an interconnection with SM 321 DI 16 x DC 24V ...

Page 466: ...Manual 03 2012 A5E00267695 11 E 6 SM 321 DI 16 x DC 24V 6ES7 321 7BH01 0AB0 The diagram below shows the connection of two redundant encoder pairs to two SM 321 DI 16 x DC 24V The encoders are connected to channels 0 and 8 9 9V 9V 9V 9V 0 Figure E 6 Example of an interconnection with SM 321 DI 16 x DC 24V ...

Page 467: ...m Manual 03 2012 A5E00267695 11 467 E 7 SM 326 DO 10 x DC 24V 2A 6ES7 326 2BF01 0AB0 The diagram below shows the connection of an actuator to two redundant SM 326 DO 10 x DC 24V 2A The actuator is connected to channel 1 9 9 9 9 9 9 Figure E 7 Example of an interconnection with SM 326 DO 10 x DC 24V 2A ...

Page 468: ...8 System Manual 03 2012 A5E00267695 11 E 8 SM 326 DI 8 x NAMUR 6ES7 326 1RF00 0AB0 The diagram below shows the connection of two redundant encoders to two redundant SM 326 DI 8 x NAMUR The encoders are connected to channel 4 9 9 Figure E 8 Example of an interconnection with SM 326 DI 8 x NAMUR ...

Page 469: ...ystem Manual 03 2012 A5E00267695 11 469 E 9 SM 326 DI 24 x DC 24 V 6ES7 326 1BK00 0AB0 The diagram below shows the connection of one encoder to two redundant SM 326 DI 24 x DC 24 V The encoder is connected to channel 13 9 9 9 9 Figure E 9 Example of an interconnection with SM 326 DI 24 x DC 24 V ...

Page 470: ...6ES7 421 1EL00 0AA0 The diagram below shows the connection of a redundant encoder to two SM 421 DI 32 x UC 120 V The encoder is connected to channel 0 1 R R R R R R R R 1 R R R R R R R R 1 R R R R R R R R 1 R R R R R R R R 1 R R R R R R R R 1 R R R R R R R R 1 R R R R R R R R 1 R R R R R R R R 98 Figure E 10 Example of an interconnection with SM 421 DI 32 x UC 120 V ...

Page 471: ...E00267695 11 471 E 11 SM 421 DI 16 x DC 24 V 6ES7 421 7BH01 0AB0 The diagram below shows the connection of two redundant encoders pairs to two SM 421 D1 16 x 24 V The encoders are connected to channel 0 and 8 R R R R R R R R R R R R R R R R R R R R R R 9 Figure E 11 Example of an interconnection with SM 421 DI 16 x 24 V ...

Page 472: ...2 System Manual 03 2012 A5E00267695 11 E 12 SM 421 DI 32 x DC 24 V 6ES7 421 1BL00 0AB0 The diagram below shows the connection of two redundant encoders to two SM 421 D1 32 x 24 V The encoders are connected to channel 0 R R R R R R 9 Figure E 12 Example of an interconnection with SM 421 DI 32 x 24 V ...

Page 473: ...System Manual 03 2012 A5E00267695 11 473 E 13 SM 421 DI 32 x DC 24 V 6ES7 421 1BL01 0AB0 The diagram below shows the connection of two redundant encoders to two SM 421 D1 32 x 24 V The encoders are connected to channel 0 R R R R 9 Figure E 13 Example of an interconnection with SM 421 DI 32 x 24 V ...

Page 474: ...00267695 11 E 14 SM 322 DO 8 x DC 24 V 2 A 6ES7 322 1BF01 0AA0 The diagram below shows the connection of an actuator to two redundant SM 322 DO 8 x DC 24 V The actuator is connected to channel 0 Types with U_r 200 V and I_F 2 A are suitable as diodes 9 0 0 Figure E 14 Example of an interconnection with SM 322 DO 8 x DC 24 V 2 A ...

Page 475: ...4 V 0 5 A 6ES7 322 1BL00 0AA0 The diagram below shows the connection of an actuator to two redundant SM 322 DO 32 x DC 24 V The actuator is connected to channel 1 Suitable diodes are for example those of the series 1N4003 1N4007 or any other diode with U_r 200 V and I_F 1 A 0 0 9 H J 1 H J 1 Figure E 15 Example of an interconnection with SM 322 DO 32 x DC 24 V 0 5 A ...

Page 476: ... 476 System Manual 03 2012 A5E00267695 11 E 16 SM 322 DO 8 x AC 230 V 2 A 6ES7 322 1FF01 0AA0 The diagram below shows the connection of an actuator to two SM 322 DO 8 x AC 230 V 2 A The actuator is connected to channel 0 9 1 1 Figure E 16 Example of an interconnection with SM 322 DO 8 x AC 230 V 2 A ...

Page 477: ...0 mA EEx ib 6ES7 322 5SD00 0AB0 The diagram below shows the connection of an actuator to two SM 322 DO 16 x DC 24 V 10 mA EEx ib The actuator is connected to channel 0 Suitable diodes are for example those of the series 1N4003 1N4007 or any other diode with U_r 200 V and I_F 1 A 9 1 H J 1 H J 1 Figure E 17 Example of an interconnection with SM 322 DO 16 x DC 24 V 10 mA EEx ib ...

Page 478: ... ib 6ES7 322 5RD00 0AB0 The diagram below shows the connection of an actuator to two SM 322 DO 16 x DC 15 V 20 mA EEx ib The actuator is connected to channel 0 Suitable diodes are for example those of the series 1N4003 1N4007 or any other diode with U_r 200 V and I_F 1 A 9 1 1 IRU H DPSOH 1 IRU H DPSOH Figure E 18 Example of an interconnection with SM 322 DO 16 x DC 15 V 20 mA EEx ib ...

Page 479: ...m Manual 03 2012 A5E00267695 11 479 E 19 SM 322 DO 8 x DC 24 V 0 5 A 6ES7 322 8BF00 0AB0 The diagram below shows the connection of an actuator to two redundant SM 322 DO 8 x DC 24 V 0 5 A The actuator is connected to channel 0 9 0 0 Figure E 19 Example of an interconnection with SM 322 DO 8 x DC 24 V 0 5 A ...

Page 480: ...nual 03 2012 A5E00267695 11 E 20 SM 322 DO 16 x DC 24 V 0 5 A 6ES7 322 8BH01 0AB0 The diagram below shows the connection of an actuator to two redundant SM 322 DO 16 x DC 24 V 0 5 A The actuator is connected to channel 8 9 9 0 0 0 0 0 0 0 0 Figure E 20 Example of an interconnection with SM 322 DO 16 x DC 24 V 0 5 A ...

Page 481: ...12 Bit 6ES7 332 5HF00 0AB0 The diagram below shows the connection of two actuators to two redundant SM 332 AO 8 x 12 Bit The actuators are connected to channels 0 and 4 Suitable diodes are for example those of the series 1N4003 1N4007 or any other diode with U_r 200 V and I_F 1 A 9 0 0 Figure E 21 Example of an interconnection with SM 332 AO 8 x 12 Bit ...

Page 482: ... 0 4 20 mA EEx ib 6ES7 332 5RD00 0AB0 The diagram below shows the connection of an actuator to two SM 332 AO 4 x 0 4 20 mA EEx ib The actuator is connected to channel 0 Suitable diodes are for example types from the series 1N4003 1N4007 or any other diode with U_r 200 V and I_F 1 A 9 1 Figure E 22 Example of an interconnection with SM 332 AO 4 x 0 4 20 mA EEx ib ...

Page 483: ...E 23 SM 422 DO 16 x AC 120 230 V 2 A 6ES7 422 1FH00 0AA0 The diagram below shows the connection of an actuator to two SM 422 DO 16 x 120 230 V 2 A The actuator is connected to channel 0 1 R R R R 1 R R R R 1 R R R R 1 R R R R O 1 R R R R 1 R R R R 1 R R R R 1 R R R R O 9 Figure E 23 Example of an interconnection with SM 422 DO 16 x 120 230 V 2 A ...

Page 484: ...0AB0 The diagram below shows the connection of an actuator to two SM 422 DO 32 x 24 V 0 5 A The actuator is connected to channel 0 Suitable diodes are for example those of the series 1N4003 1N4007 or any other diode with U_r 200 V and I_F 1 A R R R R R R R R R R R R R R R R R R R R R R R R R R R R R R 9 H J 1 H J 1 Figure E 24 Example of an interconnection with SM 422 DO 32 x DC 24 V 0 5 A ...

Page 485: ...695 11 485 E 25 SM 331 AI 4 x 15 Bit EEx ib 6ES7 331 7RD00 0AB0 The diagram below shows the connection of a 2 wire transmitter to two SM 331 AI 4 x 15 Bit EEx ib The transmitter is connected to channel 1 Suitable Zener diode BZX85C6v2 9 0 ZLUH WUDQVGXFHU P Figure E 25 Example of an interconnection with SM 331 AI 4 x 15 Bit EEx ib ...

Page 486: ...86 System Manual 03 2012 A5E00267695 11 E 26 SM 331 AI 8 x 12 Bit 6ES7 331 7KF02 0AB0 The diagram below shows the connection of a transmitter to two SM 331 AI 8 x 12 Bit The transmitter is connected to channel 0 0 9 9 7UDQVGXFHU Figure E 26 Example of an interconnection with SM 331 AI 8 x 12 Bit ...

Page 487: ...00267695 11 487 E 27 SM 331 AI 8 x 16 Bit 6ES7 331 7NF00 0AB0 The figure below shows the connection of a transmitter to two redundant SM 331 AI 8 x 16 Bit The transmitter is connected to channel 0 and 7 respectively 8 9 9 9 8 7UDQVGXFHU ZLUH WUDQVGXFHU Figure E 27 Example of an interconnection with SM 331 AI 8 x 16 Bit ...

Page 488: ...A5E00267695 11 E 28 SM 331 AI 8 x 16 Bit 6ES7 331 7NF10 0AB0 The figure below shows the connection of a transmitter to two redundant SM 331 AI 8 x 16 Bit The transmitter is connected to channel 0 and 3 respectively 8 8 9 9 9 9 7UDQVGXFHU ZLUH WUDQVGXFHU Figure E 28 Example of an interconnection with SM 331 AI 8 x 16 Bit ...

Page 489: ... 7PE10 0AB0 S7 400H System Manual 03 2012 A5E00267695 11 489 E 29 AI 6xTC 16Bit iso 6ES7331 7PE10 0AB0 The figure below shows the connection of a thermocouple to two redundant SM 331 AI 6xTC 16Bit iso 9 7 F 7 F Figure E 29 Example of an interconnection AI 6xTC 16Bit iso ...

Page 490: ...em Manual 03 2012 A5E00267695 11 E 30 SM331 AI 8 x 0 4 20mA HART 6ES7 331 7TF01 0AB0 The diagram below shows the connection of a 4 wire transmitter to two redundant SM 331 AI 8 x 0 4 20mA HART 8 8 0 0 0 0 0 0 9 9 9 IRU H DPSOH ZLUH WUDQVGXFHU Figure E 30 Interconnection example 1 SM 331 AI 8 x 0 4 20mA HART ...

Page 491: ... 7TF01 0AB0 S7 400H System Manual 03 2012 A5E00267695 11 491 The diagram below shows the connection of a 2 wire transmitter to two redundant SM 331 AI 8 x 0 4 20mA HART 0 0 0 0 0 0 9 9 9 IRU H DPSOH ZLUH WUDQVGXFHU Figure E 31 Interconnection example 2 SM 331 AI 8 x 0 4 20mA HART ...

Page 492: ... AO 4 x 12 Bit 6ES7 332 5HD01 0AB0 The diagram below shows the connection of an actuator to two SM 332 AO 4 x 12 Bit The actuator is connected to channel 0 Suitable diodes are for example those of the series 1N4003 1N4007 or any other diode with U_r 200 V and I_F 1 A 0 0 0 DQD 9 Figure E 32 Example of an interconnection with SM 332 AO 4 x 12 Bit ...

Page 493: ...8TF01 0AB0 S7 400H System Manual 03 2012 A5E00267695 11 493 E 32 SM332 AO 8 x 0 4 20mA HART 6ES7 332 8TF01 0AB0 The diagram below shows the connection of an actuator to two SM 332 AO 8 x 0 4 20 mA HART K K K 0 0 K 9 Figure E 33 Interconnection example 3 SM 332 AO 8 x 0 4 20mA HART ...

Page 494: ...5 11 E 33 SM 431 AI 16 x 16 Bit 6ES7 431 7QH00 0AB0 The diagram below shows the connection of a sensor to two SM 431 AI 16 x 16 Bit Suitable Zener diode BZX85C6v2 R R 9 R R R R R R R R R R R 9 P R 9 9 R ZLUH WUDQVGXFHU 7UDQVGXFHU 8 LW 8 LW വ ZLUH WUDQVGXFHU R R R Figure E 34 Example of an interconnection with SM 431 AI 16 x 16 Bit ...

Page 495: ...ur they remain in a safe state or go directly to another safe state Fault tolerant station A fault tolerant station containing two central processing units master and reserve Fault tolerant system A fault tolerant system consists of at least two central processing units master and reserve The user program is processed identically in both the master and reserve CPUs Fault tolerant systems Fault tol...

Page 496: ...master CPU and the reserve CPU compare the memory configuration and the contents of the load memory If they establish differences in the user program the master CPU updates the user program of the reserve CPU Master CPU The central processing unit that is the first redundant central processing unit to start up It continues to operate as the master when the redundancy connection is lost The user pr...

Page 497: ... of the program is not interrupted Reserve CPU The redundant central processing unit of a fault tolerant system that is linked to the master CPU It goes to STOP mode when the redundancy connection is lost The user program is processed identically in both the master and reserve CPUs Self test In the case of fault tolerant CPUs defined self tests are executed during startup cyclical processing and w...

Page 498: ... 03 2012 A5E00267695 11 Synchronization module An interface module for the redundant link in a fault tolerant system Update In the update system mode of a fault tolerant system the master CPU updates the dynamic data of the reserve CPU ...

Page 499: ...unication blocks Consistency 112 Communication functions 151 Communication processors 457 Communication services Overview 213 S7 communication 215 Communication via MPI and communication bus Cycle load 358 Comparison error 138 Components Basic system 34 Duplicating 28 Configuration 37 Configuration 37 Configuring 259 Connecting with diodes 203 Connection Fault tolerant S7 232 S7 232 Connection res...

Page 500: ...PUs 56 CPU 412 5H 58 CPU 414 5H 58 CPU 416 5H 58 CPU 417 5H 58 Error messages 52 Execution time Cycle control 363 Operating system 363 Process image update 359 User program 358 Expanded memory configuration 148 Expanding the load memory 65 External backup voltage 50 External diodes 197 EXTF 56 F Factory settings 81 Fail safe 25 Failure of a CPU 44 Failure of a fiber optic cable 44 Failure of a pow...

Page 501: ...Effects 141 Sequence 143 Starting 143 Link up with master reserve changeover 147 Link up update 133 Load memory 152 Loss of redundancy 123 M Manual Purpose 19 Scope of validity 20 Master CPU 121 Master reserve assignment 122 Maximum communication delay Calculation 165 Definition 155 Maximum cycle time extension Calculation 165 Definition 155 Maximum inhibit time for priority classes 15 Calculation...

Page 502: ...0 of the CPUs 379 380 PROFIBUS address 89 PROFIBUS DP Diagnostic address 93 Organization blocks 100 System and standard functions 99 System status list 101 PROFIBUS DP interface 49 PROFINET 71 95 Device replacement without removable medium 103 Media redundancy 104 Shared Device 103 PROFINET interface 50 Properties 72 PROFINET IO Organization blocks Overview of functions 97 System and standard func...

Page 503: ...REDCONNECT 243 244 Save service data 86 Scope of validity of the manual 20 Security level 77 Setting 77 Self test 123 137 Serial number 66 Setup 31 SFB 14 113 SFB 15 113 SFB 52 RDREC SFB 53 WRREC SFB 54 RALRM SFB 81 RD_DPAR SFBs S7 communication 216 SFC 103 DP_TOPOL SFC 103 DP_TOPOL 90 SFC 109 PROTECT 78 SFC 13 DPNRM_DG SFC 14 DPRD_DAT 113 SFC 15 DPWR_DAT 114 SFC 49 LGC_GADR SFC 5 GADR_LGC SFC 54 ...

Page 504: ...d standard functions 99 100 System modifications during operation Hardware requirements 452 Software requirements 452 Stand alone operation 451 System redundancy 106 System states 124 System status list Compatibility 101 T Technical data Memory cards 431 Technical Support 22 Time monitoring 155 Time response 167 Time out 157 Toggle switch 60 Tolerance window 198 Tools 38 U Update 141 142 143 154 1...

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