In many areas of automation technology, there is a continually increasing demand for the availability and thus the fail-safety of the automation systems. There are areas where a plant standstill can result in extremely high costs. Here, only redundant systems can do justice to the availability requirements.
The high-availability SIMATIC S7-400H meets these requirements. It continues to operate even when parts of the controller have failed due to one or more faults. The availability thus achieved makes the SIMATIC S7-400H especially suitable for the following application areas:
Ordering data
The ordering data of the components for the S7-400H can be found with the relevant modules under "S7-400/S7-400H/S7-400F/FH".
You can also find information about SIMATIC S7-400 in Catalog ST 70:
http://www.automation.siemens.com/salesmaterial-as/catalog/en/simatic-st70-chap06-english-2015.pdf
The SIMATIC S7-400H consists of the following components:
Central functions are always redundant in design.
I/O can be configured with normal availability or switched.
In a one-sided configuration, I/O modules are single-channel in design and are addressed by only one of the two central controllers. One-sided I/O modules can be plugged into
.
Information read in on one side is always available to both central controllers, provided the device addressing the I/O is working correctly. In the event of a fault, the I/O modules of the affected central controller are out of service.
One-sided configuration is used:
In a switched configuration, I/O modules are single-channel in design but they are addressed via a redundant PROFIBUS DP by both central controllers. Switched I/O modules can only be plugged into
.
The redundancy of the I/O is supported in operating system version 3.1 or higher.
Redundant I/O modules are configured redundantly in pairs. The use of redundant I/O offers maximum availability because in this way, the failure of a CPU, a PROFIBUS or a signal module is tolerated.
The redundant I/O on the system side is only supported if it is connected via PROFIBUS DP. If I/O modules that are connected to PROFINET are to be operated, this is can done via the user program.
Configuration options
The following configurations are possible:
Suitable I/O modules
The mutually redundant modules must be of the same type and design (e.g. both centralized or both distributed). The slots are not stipulated. However, use in different stations is recommended for availability reasons. Please refer to Customer Support or the manual to see which modules can be used.
Function modules (FMs) and communications processors (CPs) can be used redundantly in two different configurations:
The redundancy of the modules is achieved in different ways here:
With high-availability communication SIMATIC offers a type of communication with the following features:
High-availability communication is currently supported by the S7-400H (redundant and non-redundant configuration) and by PCs. On PCs, the Redconnect program package is required (see "SIMATIC NET communication systems").
Depending on availability requirements, different configuration options can be used:
The operating system of the CPU 417-5H, CPU 416-5H, CPU 414-5H and CPU 412-5H executes all the necessary additional functions of the S7-400H autonomously:
Redundancy principle
The S7-400H works according to the principle of active redundancy in "hot standby" mode (reaction-free automatic switchover in the event of a fault). According to this principle, both subunits are active during fault-free operation. In the event of a fault, the intact device assumes control of the process alone.
To guarantee this transfer bumplessly, fast and reliable data exchange via the central controller link is required.
In the course of the failover, the devices automatically retain
This means both devices are always completely up-to-date and can continue control alone in the event of a fault.
For redundant operation of the I/O this results in the following:
Synchronization
For reaction-free switchover, synchronization of both subunits is necessary.
The S7-400H works with "event-driven synchronization".
This involves a synchronization operation whenever events could result in different internal states in the subunits, e.g. in the case of
The synchronization takes place automatically by means of the operating system and can be ignored at the programming stage.
Self-test
The S7-400H executes extensive self-tests. This involves testing the following:
Every detected fault is reported.
Self-test at startup
At startup, each subunit executes all self-test functions completely.
Self-test in cyclic operation
The complete self-test is spread over several cycles. A short section of the self-test is executed per cycle so that the load on the actual controller is insignificant.
The S7-400H is programmed like an S7-400. All the STEP 7 functions available there can be used.
Programming the S7-400H with PROFINET requires STEP 7 V5.5 with SP2.
Configuring of I/O modules
When configuring the hardware, users must specify via HW Config which modules are mutually redundant. This only requires the specification of the modules to be operated in redundant mode and the second module that is to be the "redundancy partner". In the user program, the module with the lowest address is to be accessed. The second address remains hidden from the user and programming of the control section with redundant and non-redundant I/O is identical. The only difference with regard non-redundant I/O are two FBs (RED_IN and RED_OUT) from the block library that are to be called at the start and at the end of the user program.
In STEP 7 V5.3 or higher, the library is integrated as standard into STEP 7.