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I/O configuration variants

4.2 Fail-safe operation

CPU 410-5H Process Automation
System Manual, 09/2014, A5E31622160-AB

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Safety-related communication with PROFIsafe profile
PROFIsafe was the first communication standard according to the IEC 61508 safety

standard that permits both standard and safety-related communication on one bus line. This

not only results in an enormous savings potential with regard to cabling and part variety, but

also the advantage of retrofit ability.

Figure 4-3

Safety-related communication

Safety-related and standard data are transmitted with PROFIsafe over the same bus line.

Black channel means that collision-free communication via a bus system with media-

independent network components (also wireless) is possible.
PROFIsafe is an open solution for safety-related communication via standard fieldbuses.

Numerous manufacturers of safety components and end users of safety technology have

helped to develop this vendor-neutral and open standard for PROFIBUS International (PI).
The PROFIsafe profile supports safe communication for the open PROFIBUS and

PROFINET standard buses. An IE/PB Link ensures integrated, safety-related communication

between PROFIBUS DP and PROFINET IO.
PROFIsafe is is certified to IEC 61784-3 and meets the highest requirements for the

manufacturing and process industry.
PROFIBUS is the global standard for fieldbuses with approximately 13 million installed

nodes. Its market acceptance is so high because a large number of manufacturers offer

many products for PROFIBUS. With the PA transmission variant (IEC 1158-2), PROFIBUS

extends the unified system concept of distributed automation to the process world.

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Summary of Contents for SIMATIC PCS 7 CPU 410-5H

Page 1: ...31622160 AB Preface 1 Introduction to CPU 410 5H 2 Structure of the CPU 410 5H 3 I O configuration variants 4 PROFIBUS DP 5 PROFINET IO 6 Operator controls and operating modes of the CPU 410 5H 7 Link up and update 8 Special functions of the CPU 410 5H 9 System modifications during redundant operation 10 Failure and replacement of components during redundant operation 11 Synchronization modules 12...

Page 2: ...y personnel qualified for the specific task in accordance with the relevant 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...

Page 3: ...ng STEP 7 HW Config PCS 7 30 2 9 PCS 7 project 31 2 10 Scaling and licensing scaling concept 32 3 Structure of the CPU 410 5H 35 3 1 Operator controls and display elements on the CPU 410 5H 35 3 2 Monitoring functions of the CPU 410 5H 39 3 3 Status and error displays 41 3 4 PROFIBUS DP interface X1 45 3 5 PROFINET IO interfaces X5 X8 45 3 6 Overview of the parameters for the CPU 410 5H 48 4 I O c...

Page 4: ... 1 3 STARTUP mode 102 7 1 4 HOLD mode 103 7 1 5 LINK UP and UPDATE modes 104 7 1 6 ERROR SEARCH mode 104 7 1 7 DEFECTIVE state 105 7 2 System states of the redundant CPU 410 5H 106 7 2 1 Introduction 106 7 2 2 The system states of the fault tolerant system 109 7 2 3 Displaying and changing the system state of a fault tolerant system 110 7 2 4 System status change from the STOP system state 111 7 2...

Page 5: ... Step 5 Switch to CPU with modified configuration 160 10 3 6 Step 6 Transition to redundant system state 161 10 3 7 Step 7 Modify and download the user program 163 10 3 8 Use of free channels on an existing module 164 10 3 9 Addition of interface modules 165 10 4 Removal of components 166 10 4 1 Step 1 Modify the hardware configuration offline 167 10 4 2 Step 2 Modify and download the user program...

Page 6: ...2 1 Failure and replacement of a PROFIBUS DP master 195 11 2 2 Failure and replacement of a redundant PROFIBUS DP interface module 196 11 2 3 Failure and replacement of a PROFIBUS DP slave 197 11 2 4 Failure and replacement of PROFIBUS DP cables 198 11 3 Failure and replacement of components of PROFINET IO 199 11 3 1 Failure and replacement of a PROFINET IO device 199 11 3 2 Failure and replacemen...

Page 7: ... and a fault tolerant CPU 275 15 10 3 Communication between fault tolerant systems and PCs 276 15 11 Consistent data 279 15 11 1 Consistency of communication blocks and functions 279 15 11 2 Consistency rules for SFB 14 GET or read variable and SFB 15 PUT or write variable 280 15 11 3 Consistent reading and writing of data from and to DP standard slaves IO devices 280 15 12 Link up and update sequ...

Page 8: ...0 V 6ES7 321 1FF01 0AA0 344 C 9 SM 321 DI 16 x DC 24V 6ES7 321 7BH00 0AB0 345 C 10 SM 321 DI 16 x DC 24V 6ES7 321 7BH01 0AB0 346 C 11 SM 326 DO 10 x DC 24V 2A 6ES7 326 2BF01 0AB0 347 C 12 SM 326 DI 8 x NAMUR 6ES7 326 1RF00 0AB0 348 C 13 SM 326 DI 24 x DC 24 V 6ES7 326 1BK00 0AB0 349 C 14 SM 421 DI 32 x UC 120 V 6ES7 421 1EL00 0AA0 350 C 15 SM 421 DI 16 x DC 24 V 6ES7 421 7BH01 0AB0 351 C 16 SM 421...

Page 9: ...odules for use of single channel switched I O configuration at the PROFIBUS DP interface 64 Table 4 4 Bus modules for hot swapping 64 Table 4 5 Interface module for use of single channel switched I O configuration at the PROFINET IO interface 66 Table 4 6 Signal modules for redundancy 76 Table 5 1 CPU 410 5H 91 Table 5 2 Meaning of the BUSF LED of the CPU 410 5H as DP master 92 Table 7 1 Causes of...

Page 10: ... O 297 Table 15 9 Cyclic program processing 298 Table 15 10 Factors influencing cycle time 300 Table 15 11 Portion of the process image transfer time CPU 410 5H 301 Table 15 12 Extending the cycle time 302 Table 15 13 Operating system execution time at the cycle control point 302 Table 15 14 Extended cycle time due to nested interrupts 303 Table 15 15 Direct access of the CPUs to I O modules in th...

Page 11: ...cted in system redundancy 70 Figure 4 12 System redundancy in different views 71 Figure 4 13 PN IO with system redundancy 72 Figure 4 14 PN IO with system redundancy 73 Figure 4 15 Configuration example of media redundancy 75 Figure 4 16 Fault tolerant digital input module in 1 out of 2 configuration with one encoder 82 Figure 4 17 Fault tolerant digital input modules in 1 out of 2 configuration w...

Page 12: ...y 267 Figure 15 15 Example of linking a fault tolerant system to a single channel third party system 268 Figure 15 16 Example of redundancy with fault tolerant system and redundant ring 272 Figure 15 17 Example of redundancy with fault tolerant system and redundant bus system 273 Figure 15 18 Example of fault tolerant system with additional CP redundancy 273 Figure 15 19 Example of redundancy with...

Page 13: ... interconnection with SM 421 DI 32 x 24 V 353 Figure C 16 Example of an interconnection with SM 322 DO 8 x DC 24 V 2 A 354 Figure C 17 Example of an interconnection with SM 322 DO 32 x DC 24 V 0 5 A 355 Figure C 18 Example of an interconnection with SM 322 DO 8 x AC 230 V 2 A 356 Figure C 19 Example of an interconnection with SM 322 DO 16 x DC 24 V 10 mA EEx ib 357 Figure C 20 Example of an interc...

Page 14: ...nts CPU 410 5H Process Automation 14 System Manual 09 2014 A5E31622160 AB Figure C 34 Example of an interconnection with SM 332 AO 4 x 12 Bit 372 Figure C 35 Interconnection example 3 SM 332 AO 8 x 0 4 20mA HART 373 ...

Page 15: ...Windows XP Windows Server or Windows 7 operating system The PCS7 Readme includes information on which operating system is suitable for your PCS7 configuration The CPU 410 5H is configured using the PCS 7 software and you should thus be familiar in the handling of this software In particular when operating a CPU 410 5H system in potentially explosive atmospheres you should always observe the inform...

Page 16: ...ommand A short info text is 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 CPU 410 5H contains environmentally compatible materials and can be recycled For ecologically compatible recycling and ...

Page 17: ...et started with the SIMATIC 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 ou...

Page 18: ...s undergo continuous development Siemens recommends strongly that you regularly check for product updates For the secure operation of Siemens products and solutions it is necessary to take suitable preventive action e g cell protection concept and integrate each component into a holistic state of the art industrial security concept Third party products that may be in use should also be considered ...

Page 19: ...Link http support automation siemens com WW view en 1142696 Configuring commissioning and operation of a PROFINET IO system PROFINET IO System De scription PROFINET system description http support automation siemens com WW view en 19292127 Fail safe systems Configuring and programming of fail safe systems Working with S7 F Systems V 6 1 S7 F FH Systems SIMATIC Industrial Software S7 F FH Systems C...

Page 20: ...Preface 1 3 Documentation CPU 410 5H Process Automation 20 System Manual 09 2014 A5E31622160 AB ...

Page 21: ...ly designed for the SIMATIC PCS 7 control system As with previous controllers of the SIMATIC PCS 7 system the CPU 410 5H Process Automation can be used in all Process Automation industries The very flexible scalability based on PCS 7 process objects makes it possible to cover the entire performance range from the smallest to the largest controller in standard fault tolerant and fail safe applicati...

Page 22: ...a Important information on configuration WARNING Open equipment Risk of death or serious injury S7 400 modules are classified as open equipment meaning you must install the S7 400 in an enclosure cabinet or switch room that can only be accessed by means of a key or tool Only instructed or authorized personnel are permitted to access these enclosures cabinets or switch rooms Additional information ...

Page 23: ...l the S7 400 in an enclosure cabinet or switch room that can only be accessed by means of a key or tool Only instructed or authorized personnel are permitted to access these enclosures cabinets or switch rooms The following figure shows an example of an S7 400H configuration with shared distributed I O and connection to a redundant plant bus The next pages deal with the hardware and software compo...

Page 24: ...al 09 2014 A5E31622160 AB Additional information The components of the S7 400 standard system are also used in connection with the CPU 410 5H Process Automation For a detailed description of all hardware components for S7 400 refer to Reference Manual S7 400 Automation System Module Specifications ...

Page 25: ...ed for a controller The following figure shows the components in the configuration The basic system can be expanded with standard modules of the S7 400 There are restrictions for the function modules and communication processors See Appendix Function and communication modules that can be used in a redundant configuration Page 335 Figure 2 2 Hardware of the S7 400H basic system Central controller a...

Page 26: ...can also use two redundant power supplies In this case you use the power supply modules PS 405 R PS 407 R A combination of these can also be used in redundant configurations PS 405 R with PS 407 R Operation The operation of a CPU 410 5H requires a system expansion card The system expansion card specifies the maximum number of process objects that can be loaded to the CPU and saves the license info...

Page 27: ...odules and communication processors See Appendix Function and communication modules that can be used in a redundant configuration Page 335 Figure 2 3 Hardware of the S7 400H basic system Central processing units 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...

Page 28: ...nchronization modules for synchronization cables up to 10 kilometers long You must use 4 synchronization modules of the same type in a fault tolerant system For a description of the synchronization modules refer to the section Synchronization modules for the CPU 410 5H Page 201 Fiber optic cable The fiber optic cables are used to interconnect the synchronization modules for the redundant link betw...

Page 29: ...they must have the same article number product version and firmware version It is not the marking on the front side that is decisive for the product version but the revision of the Hardware component Module status dialog mask to be read using STEP 7 Redundantly used other modules must be identical i e they must have the same article number product version and if available firmware version Two CPUs...

Page 30: ...channel switched configuration with enhanced availability In the single channel switched distributed configuration there is a single set of the I O modules but they can be addressed by both subsystems In redundant operation two channel redundant configuration with maximum availability In the two channel redundant configuration there are two sets of the I O modules that can be addressed by both sub...

Page 31: ...ontinuous Function Chart CFC The CFC editor is the tool for graphical configuration and commissioning You use the CFC editor to place and interconnect instances of function block types and assign their parameters In addition the CFC editor is the tool for loading user programs The CFC editor supports the following types of standardized software modules Function block type Process tag type Control ...

Page 32: ...ication You need a number of runtime licenses AS TR POs which cover the required number of POs for productive operation of the PCS 7 application The system expansion card of the associated CPU 410 5H must also always have the same number of POs or a higher number of POs The CPU is scaled by means of the system expansion card which means the system expansion card determines the maximum quantity of ...

Page 33: ... deletion of the user program on the CPU You must replace both SECs for redundant operation The new SECs must have the same number of POs Expanding the number of POs without replacing the SEC You can expand the number of POs in four steps without replacing the SEC Step 1 Order the number CPU 410 expansion packs you need using the regular ordering process You can order expansions for 100 POs and 50...

Page 34: ...Introduction to CPU 410 5H 2 10 Scaling and licensing scaling concept CPU 410 5H Process Automation 34 System Manual 09 2014 A5E31622160 AB ...

Page 35: ...2014 A5E31622160 AB 35 Structure of the CPU 410 5H 3 3 1 Operator controls and display elements on the CPU 410 5H Arrangement of the control and display elements on CPU 410 5H Figure 3 1 Arrangement of the control and display elements on CPU 410 5H ...

Page 36: ...nchronization module 1 IFM2F red Error in synchronization module 2 MAINT yellow Maintenance request pending RUN green RUN mode STOP yellow STOP mode Bottom bar MSTR yellow CPU controls the process RACK0 yellow CPU in rack 0 RACK1 yellow CPU in rack 1 For the interfaces LINK green Connection at the PROFINET IO interface is active RX TX orange Receiving or sending data at the PROFINET IO interface L...

Page 37: ...ace The PROFINET IO interfaces establish the connection to Industrial Ethernet The PROFINET IO interfaces also serve as the access point for the engineering system The PROFINET IO interfaces feature two switched ports with external connectors RJ 45 You will find additional information about PROFINET IO in the sections PROFINET IO systems Page 97 NOTICE Connecting only to Ethernet LAN These interfa...

Page 38: ... 0 Slot for system expansion card The back of the CPU has a slot in which you insert the system expansion card SEC before commissioning the CPU The SEC contains information that specifies the performance class of the CPU in terms of the amount of POs it supports The SEC is an essential part of the CPU hardware The CPU cannot be operated without an SEC If an SEC is not detected the corresponding CP...

Page 39: ...ailure In the central or S7 400 expansion rack at least one backup battery of the power supply module is com pletely discharged the backup battery voltage is missing the 24 V supply to the power supply module has failed EXTF Diagnostic interrupt An I O module with interrupt capability reports a diagnostic interrupt The synchronization module signals a diagnostic interrupt see Chapter Synchronizati...

Page 40: ...ng levels too great Nesting depth of master control relay too great Nesting depth of synchronization errors too great Nesting 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 Such errors cannot occur with blocks from a PCS 7 library INTF Missing license for Runtime software The Runtime software could not be ...

Page 41: ...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 15 minutes CPU memory reset is active Dark Flashes 0 5 Hz The CPU requests a memory reset Flashes 0 5 Hz Flashes 0 5 Hz Troubleshooting mode Startup POWER ON of a CPU on which a large numb...

Page 42: ...8F Lit Irrelevant Irrelevant An error was detected at the PROFIBUS DP interface Irrelevant Lit Irrelevant An error was detected at the first PROFINET IO interface A PROFINET IO system is configured but not connected Irrelevant Irrelevant Lit An error was detected at the second PROFINET IO interface A PROFINET IO system is configured but not connected Irrelevant Flashes Irrelevant One or several de...

Page 43: ...nd RX TX LEDs are located directly next to the sockets of the PROFINET IO interfaces 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 There is an I O redundancy error Failure of a ...

Page 44: ...rk The connection is interrupted or there is insufficient light intensity Check the connectors and cables Ensure that the fiber optic cables are installed in accordance with the guidelines in Chapter Installation of fiber optic cables Page 206 Check whether the synchronization module works in another CPU If necessary replace the synchronization module in the other CPU LED MAINT This LED indicates ...

Page 45: ...interface is non isolated Connectors Always use bus connectors for PROFIBUS DP and PROFIBUS cables to connect devices to the PROFIBUS DP interface refer to the Installation Manual Redundant operation In redundant operation the PROFIBUS DP interfaces have the same baud rate 3 5 PROFINET IO interfaces X5 X8 Assigning an IP address You have the following options of assigning an IP address to an Ether...

Page 46: ...block communication 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 IO interfaces refer to the technical specifications of the respective CPU In Chapter Technical da...

Page 47: ...n operation of the PROFINET IO interface is permissible only in 100 Mbps full duplex mode If an PROFINET IO interface of the CPU is used for Ethernet communication only 100 Mbps full duplex mode is possible Background If a switch that is permanently set to 10 Mbps half duplex is connected to an interface of the CPU the Autonegotiation setting forces the CPU to adapt itself to the settings of the p...

Page 48: ...ify these default setting by editing the parameters in the hardware configuration The list below provides an overview of the assignable system properties of the CPUs General properties such as the CPU name Watchdog interrupts e g priority interval duration Diagnostics clock e g time of day synchronization Security levels H parameters e g duration of a test cycle Startup for example times for compl...

Page 49: ...n stand alone operation how to configure stand alone operation of a CPU 410 5H how you can expand a CPU 410 5H to form a fault tolerant system which system modifications are possible during stand alone operation and which hardware requirements must be met Definition Stand alone operation is the use of a CPU 410 5H in a standard SIMATIC 400 station Reasons for stand alone operation No requirements ...

Page 50: ...cement of compo nents during redundant operation Page 185 for redundant operation Fault tolerance specific LEDs The REDF IFM1F IFM2F MSTR RACK0 and RACK1 LEDs show the reaction specified in the table below in stand alone operation LED Behavior REDF Dark IFM1F Dark IFM2F Dark MSTR Lit RACK0 Lit RACK1 Dark Configuring stand alone operation Requirement No synchronization module may be inserted in the...

Page 51: ...refer to the Online Help Changing the operating mode of a CPU 410 5H The procedure for changing the operating mode of a CPU 410 5H differs depending on the operating mode you want to switch to and the rack number configured for the CPU Change from stand alone to redundant operation rack number 0 1 Insert the synchronization modules into the CPU 2 Insert the synchronization cables into the synchron...

Page 52: ...quire 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 Figure 4 1 Overview System structure for system modifications during operation Hardware requirements for system modifications during operation To modify a system during operation the following hardware requirements must be met at the commissioning stage CPU ...

Page 53: ...ermitted system modifications Overview During operation you can make the following system modifications Add modules or submodules with the modular DP slaves ET 200M or ET 200iS Use of previously unused channels in a module or submodule of the modular slaves ET 200M or ET 200iS Add DP slaves to an existing DP master system Add PA slaves field devices to an existing PA master system Add DP PA couple...

Page 54: ...A fail safe CPU has the following functions Comprehensive self tests and self diagnostics check the fail safe state of the CPU Simultaneous execution of standard and safety programs on one CPU When there are changes to the standard user program there are no unwanted effects on the safety program S7 F FH Systems The S7 F Systems optional package extends the CPU 410 5H by the safety functions The st...

Page 55: ...reless is possible PROFIsafe is an open solution for safety related communication via standard fieldbuses Numerous manufacturers of safety components and end users of safety technology have helped to develop this vendor neutral and open standard for PROFIBUS International PI The PROFIsafe profile supports safe communication for the open PROFIBUS and PROFINET standard buses An IE PB Link ensures in...

Page 56: ...ange both user data as well as status and control information no additional hardware is required for this PROFIsafe takes the following measures to counteract the various possible errors when transferring messages Table 4 2 Measures in PROFIsafe for error avoidance Measure Error Consecutive number Time expectation with acknowledgment Identifier for sender and receiver Data backup CRC Repetition Lo...

Page 57: ...H is a fault tolerant automation system You may only use the S7 400H to control safety related processes if you have programmed it and assigned its parameters in accordance with the rules for F systems You can find details in the following manual SIMATIC Industrial Software S7 F FH Systems http support automation siemens com WW view en 2201072 Why fault tolerant automation systems The purpose of u...

Page 58: ...60 AB 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 CPU or of a signal module See also Connecting redundant I O to the PROFIBUS DP interface Page 76 ...

Page 59: ...e CPU 410 and all other SIMATIC components such as the SIMATIC PCS 7 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 Figure 4 5 Integrated automation solutions with SIMATIC Graduated availability by duplicating components The redundant structu...

Page 60: ...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 component of the redundant node may fail without impairing the operability of the overall system The weakest link in the chain of redundant nodes determines the ...

Page 61: ...ponent may fail without impairing the functionality of the overall system Figure 4 7 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 Figure 4 8 Example of redundancy in a 1 out of 2 system with to...

Page 62: ... are insufficient slots in the central controllers you can expand the installation of a fault tolerant system with expansion units You can assign racks with even numbers only to central controller 0 and racks with odd numbers only to central controller 1 For use of distributed I O you can connect a DP master system in each of the two subsystems Connect a DP master to the integrated interface of th...

Page 63: ...lways address all switched I Os in contrast to one sided I O The single channel switched I O configuration is recommended for system components which tolerate the failure of individual modules within the ET 200M or ET 200iSP 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 mod...

Page 64: ...153 2BA82 0XB0 6ES7 153 2BA81 0XB0 6ES7 153 2BA02 0XB0 6ES7 153 2BA01 0XB0 6ES7 153 2BA00 0XB0 Each S7 400H subsystem is interconnected with one of the two DP slave interfaces of the ET 200M via a DP master interface Bus modules for hot swapping You can use the following bus modules for hot swapping a variety of components Table 4 4 Bus modules for hot swapping Bus module Article No BM PS IM for l...

Page 65: ...A01 0XB0 Y Link The Y Link consists of two IM 153 2 interface modules and one Y coupler that are connected with one another by bus modules The Y Link creates a gateway from the redundant DP master system of an S7 400H to a non redundant DP master system This means that devices with only one PROFIBUS DP interface can be connected to a S7 400H as switched I Os A single channel DP master system can b...

Page 66: ...IO interface Interface module Article No IM 153 4 PN V4 0 and higher 6ES7153 4BA00 0XB0 Single channel switched I O and user program In redundant operation in principle any subsystem can access single channel switched I O The data is automatically transferred via the synchronization link and compared An identical value is available to the two subsystems at all times owing to the synchronized acces...

Page 67: ... master interface or at the PNIO interface shutdown of the DP master system e g RUN STOP transition on a CP 443 5 and a short circuit at the cable harness of a DP master system or PNIO system The following applies to each station affected by a failure If both DP slave interfaces or PNIO connections are currently functional and the active channel fails the previously passive channel automatically b...

Page 68: ...te that the CPU can only detect a signal change if the signal duration is greater than the specified changeover time When there is a changeover of the entire DP master system the changeover time of the slowest DP component applies to all DP components A DP PA link or Y link usually determines the changeover time and the associated minimum signal duration We therefore recommend that you connect DP ...

Page 69: ...ess Automation System Manual 09 2014 A5E31622160 AB 69 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 See also Time monitoring Page 123 ...

Page 70: ... alone does not indicate 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 Configuration The figure below shows a configuration with two IO devices connected in system redundancy Figure 4 11 S7 400H system with IO devices connected in system redundancy Thi...

Page 71: ...edundancy Note that the view in STEP 7 does not exactly match the physical view Figure 4 12 System redundancy in different views Commissioning a system redundant configuration It is imperative that you assign unique names during commissioning Proceed as follows when you change or reload a project 1 Set the fault tolerant system to STOP on both sides 2 Reset the standby CPU memory 3 Download the ne...

Page 72: ...he IO devices can be configured as one sided or redundant The station numbers must be unique across both PROFINET IO interfaces and between 1 and 256 PN IO 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 Figure 4 13 PN IO with system redundancy ...

Page 73: ...es This configuration for example allows you to arrange IO devices in several cabinets Figure 4 14 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 the course of configuration You can configure the IO devices in the first figure for example...

Page 74: ... 0 or higher in STEP 7 HW Config MRP is a component of the PROFINET IO standardization according to IEC 61158 In media redundancy with MRP one device is the media redundancy manager MRM and all other devices are redundancy clients 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 t...

Page 75: ...ion of your project to the individual devices RT communication real time communication Note RT communication is interrupted station failure if the reconfiguration time of the ring is greater than the selected response monitoring time of the IO device The same applies to IO devices configured with MRP outside the ring Additional information For additional information refer to the STEP 7 Online Help...

Page 76: ...FINET interface is not possible A complete list of all modules approved for PCS 7 V8 1 is available in the technical documentation of SIMATIC PCS 7 see Technical documentation Table 4 6 Signal modules for redundancy Module Article No Redundant DI dual channel DI16xDC 24 V interrupt 6ES7 321 7BH00 0AB0 DI16xDC 24 V 6ES7 321 7BH01 0AB0 In the event of an error on one channel the entire group 2 chann...

Page 77: ...UR encoders for 0 current 0 2 mA for 1 current 4 2 mA DI 16xNamur 6ES7321 7TH00 0AB0 Use with non redundant encoder Equipotential bonding of the encoder circuit should always be at one point only preferably encoder negative Operate the two redundant modules on a common load power supply When selecting encoders compare their properties with the specified input characteristics Remember that this fun...

Page 78: ... Use of redundant encoders You can use a redundant encoder with the following voltage settings 80 mV only without wire break monitoring 250 mV only without wire break monitoring 500 mV wire break monitoring not configurable 1 V wire break monitoring not configurable 2 5 V wire break monitoring not configurable 5 V wire break monitoring not configurable 10 V wire break monitoring not configurable 1...

Page 79: ...27 C is checked if 1 is entered or a tolerance of 138 C is checked if 5 is entered A firmware update is not possible in redundant operation Online calibration is not possible in redundant operation Use in voltage measurement The wire break diagnostics function in HW Config must not be activated when operating the modules with thermo couples Use in indirect current measurement Due to the maximum vo...

Page 80: ...onfiguration Pack http support automation siemens com WW view en 15208817 Quality levels in the redundant configuration of signal modules The availability of modules in the case of an error depends on their diagnostics possibilities and the fine granularity of the channels Using digital input modules as redundant I O The following parameters were set to configure digital input modules for redundan...

Page 81: ...gnal change occurred is the intact channel and the other channel is passivated Note The time that the system actually needs to determine a discrepancy depends on various factors bus runtimes cycle and call times of the user program conversion times etc Redundant input signals can therefore be different for a longer period than the configured discrepancy time Modules with diagnostics capability are...

Page 82: ...put a Continuous 0 error means that the input is not energized This can be caused for example by a short circuit to L or M The current flow over the chassis ground connection between the modules and the encoder should be the minimum possible When connecting an encoder to several digital input modules the redundant modules must operate at the same reference potential If you want to replace a module...

Page 83: ...f a non redundant load voltage supply You can enhance availability by installing redundant load power supplies You will find interconnection examples in Appendix Connection examples for redundant I Os Page 337 Redundant digital output modules Fault tolerant control of a final controlling element can be achieved by connecting two outputs of two digital output modules or fail safe digital output mod...

Page 84: ...lue is written to the lower data memory area of the process input image If there is a discrepancy and it is the first it is marked accordingly and the discrepancy time is started When the discrepancy time is running the most recent valid value is written to the process image of the module with the lower address and made available to the current process If the discrepancy time expires the channel w...

Page 85: ...Connection examples for redundant I Os Page 337 Redundant analog input modules for indirect current measurement The following applies to the wiring of analog input modules Suitable encoders for this circuit are active transmitters with voltage output and thermocouples The wire break diagnostics function in HW Config must not be activated neither when operating the modules with transmitters nor whe...

Page 86: ...d value 7FFF in the event of wire break The listed measuring error results solely from the interconnection of one or two voltage inputs with a measure resistance Allowance has neither been made here for the tolerance nor for the basic operational limits of the modules The measuring error for one or two inputs shows the difference in the measurement result depending on whether two inputs or in case...

Page 87: ...n additional error which may 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 hea...

Page 88: ...undantly The output value is divided by 2 and each of the two modules outputs half If one of the modules fails the failure is detected and the remaining module outputs the full value As a result the surge at the output module in the event of an error is not as high Note The output value drops briefly to half and after the reaction in the program it is returned to the proper value The duration of t...

Page 89: ... both storage locations in the process image of outputs If one channel is depassivated then the full value is output on the available channel If this is not required a substitute value must be written to the lower channels of both modules prior to executing FB 451 RED_OUT Depassivation of modules Passivated modules are depassivated by the following events When the fault tolerant system starts up W...

Page 90: ...e passivation 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...

Page 91: ... SMART the maximum output or input data length you can use is 242 bytes For each ET 200PA SMART you are using in a DP line the total number of user data of this DP line is reduced by one output word and one input word 5 2 DP address ranges of the CPU 410 5H Address ranges of the CPU 410 5H Table 5 1 CPU 410 5H Address range CPU 410 5H DP interface as PROFIBUS DP both inputs and outputs bytes 6144 ...

Page 92: ... are addressable Lit Bus fault physical fault Check whether the bus cable has a short circuit or a break DP interface fault Different baud rates in multi DP master operation only in stand alone operation Analyze the diagnostic data Reconfigure or correct the configuration Flashes Station failure At least one of the assigned slaves cannot be addressed Check whether the bus cable is connected to the...

Page 93: ...ve Specify 2 diagnostic addresses when configuring Diagnostic address Diagnostic address During configuration of the DP master specify in the associated project of the DP master a diagnostic address for the DP slave This diagnostic address is used by DP master to obtain information about the status of DP slave or a bus interruption During configuration of the I slave also specify in the associated...

Page 94: ...PROFIBUS DP 5 3 Diagnostics of the CPU 410 5H as PROFIBUS DP master CPU 410 5H Process Automation 94 System Manual 09 2014 A5E31622160 AB ...

Page 95: ...that allows all stations to access the network at any time In this way the network can be used much more efficiently through simultaneous data transmission of multiple 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 ...

Page 96: ...al time automatically includes an increase in priority with PROFINET compared to UDP IP frames This is necessary to prioritize the transmission of data in the switches so that RT frames are not delayed by UDP IP frames RT communication is interrupted station failure if the reconfiguration time of the ring is greater than the selected response monitoring time of the IO device The same applies to IO...

Page 97: ...ths The connection of company network and field level You can access devices at the field level from PCs in your company network Example PC Firewall Switch 1 Router Switch 2 CPU 410 5H Connections between the automation system and field level You can also access other areas on the Industrial Ethernet from a programming device at the field level Example Programming device integrated Switch 3 Switch...

Page 98: ...stem is the IO controller for both system redundant IO devices ET 200 as well as the one sided IO device Further information You will find further information about PROFINET IO in the documents listed below In manual PROFINET system description http support automation siemens com WW view en 19292127 In Programming Manual Migration from PROFIBUS DP to PROFINET IO http support automation siemens com...

Page 99: ...ogram or remains idle The I O can be accessed You can upload 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 The user program is executed by at least one CPU in the following system states Stand alone operation Single mode Link up update Redundant Single mode link up update In the system ...

Page 100: ...n and firmware version Redundancy will be lost if one of the errors listed in the following table occurs Table 7 1 Causes of error leading to redundancy loss Cause of error Reaction Failure of one CPU Failure and replacement of a CPU during redun dant operation Page 185 Failure of the redundant link synchronization module or fiber optic cable Failure and replacement of a synchronization module or ...

Page 101: ...edundant mode When you download a configuration to one of the CPUs while both are in STOP operating state observe the points below Start the CPU to which you downloaded the configuration first in order to set it up for master mode If the system startup is requested from the ES the CPU to which an active connection exists is started first regardless of the master or standby status Then the second C...

Page 102: ... Retain attribute are reset to the downloaded values The other data blocks retain their last valid value The associated startup OB is OB 100 Program execution is restarted from the beginning OB 100 or OB 1 If the power supply is interrupted the warm restart function is only available in backup mode Special features in redundant mode The special features described below apply to startup when you op...

Page 103: ...light up 2 The STOP LED flashes as it does during a memory reset 3 The RUN and STOP LEDs are flashing 4 The RUN LED flashes briefly 2 to 3 times 5 The STOP LED lights up 6 The RUN LED starts flashing again This begins the start up Additional information For detailed information on STARTUP operating state refer to Manual Programming with STEP 7 7 1 4 HOLD mode The HOLD mode is for test purposes You...

Page 104: ...kes place This ensures that when the next error is detected in error search mode the hardware of the previous master CPU is tested No communication is possible e g by means of access from a programming device while the CPU is in ERROR SEARCH operating state The ERROR SEARCH operating state is indicated by the flashing RUN and STOP LEDs see Chapter Status and error displays Page 41 Note If the mast...

Page 105: ...CPU enters the DEFECTIVE state when an error occurred that cannot be automatically eliminated by the operating system Reaction of the CPU The reaction of the CPU in the DEFECTIVE state is intended to leave this state if possible and to restart The CPU reacts as follows in DEFECTIVE state 1 The CPU writes the cause of the defect into the diagnostic buffer 2 The CPU generates the current service dat...

Page 106: ...this description However the standby runs event synchronized with the master at all times and not just when an error occurs The differentiation between the master and standard CPUs is primarily important for ensuring reproducible fault reactions The standby goes into troubleshooting mode when RAM PIQ errors are detected for example while the master CPU remains in RUN Master standby assignment When...

Page 107: ...ct on the user program You create your program in the same way as for standard S7 400 CPUs Event driven synchronization procedure The event driven synchronization procedure patented by Siemens was used for the S7 400H Event driven synchronization means that the master and standby always synchronize their data when an event occurs which may lead to different internal states of the subsystems Such e...

Page 108: ...nternal memory of the CPU I O bus If the self test detects an error the fault tolerant system tries to eliminate it or to suppress its effects A description of the self test is available in Chapter Self test Page 116 System operation without STOP To best meet the requirements of the process industry for system operation without STOP PCS 7 intercepts as many possible STOP causes as possible The CPU...

Page 109: ...U is in RUN and the standby CPU is in LINK UP mode we say the fault tolerant system is in link up mode Overview of system states The table below provides an overview of the possible states of the fault tolerant system Table 7 2 Overview of system states of the fault tolerant system System states of the fault tolerant system Operating states of the two CPUs Master Reserve STOP STOP STOP power off D...

Page 110: ...stics Setting Operating state Note STOP is only possible with authorization in projects with password protection Result The Operating state dialog box shows the current system state of the fault tolerant system and the operating states of the individual central processing units The CPU that was selected in SIMATIC Manager when the menu command was executed is the first one displayed in the table C...

Page 111: ...g box using the PLC Diagnostics Setting Operating state menu command Changing to redundant system mode starting the fault tolerant system 1 Select the fault tolerant system in the table 2 Select the Restart button warm restart Result The CPU displayed first in the table starts up as master CPU Then the second CPU starts up and will become the standby CPU after link up and update operations Changin...

Page 112: ...rating state menu command in SIMATIC Manager The standby CPU is not in ERROR SEARCH operating state Changing to redundant system state starting the standby CPU 1 In the table select the CPU that is in STOP or the fault tolerant system 2 Select the Restart button warm restart Changing to system status STOP stopping the running CPU 1 In the table select the CPU that is in RUN or the fault tolerant s...

Page 113: ...IC 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 Result Both CPUs switch to STOP 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 faul...

Page 114: ...dware 3 In the Select CPU dialog select 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 operating state Standby CPU is in RUN operating state Master CPU is in STOP operating state Standby CPU is in STOP operating s...

Page 115: ...U 410 5H Process Automation System Manual 09 2014 A5E31622160 AB 115 CPU icon Operating state of the respective CPU Maintenance request on master CPU Maintenance request on standby CPU Note The view is not updated automatically in the Online view Use the F5 function key to view the current operating state ...

Page 116: ... interval in which a possible error is detected Response to errors during the self test If the self test returns an error the following happens Table 7 3 Response to errors during the self test Type of error System response Hardware fault The faulty CPU switches to DEFECTIVE state The fault tolerant system switches to single mode The cause of the error is written to the diagnostics buffer Hardware...

Page 117: ...lf test cycles after trouble shooting The fault tolerant system switches to single mode Standby CPU switches to ERROR SEARCH Checksum errors When a checksum error occurs for the first time since the last POWER ON without battery backup the system reacts as follows Table 7 5 Reaction to checksum errors Time of detection System response During the startup test after POWER ON The faulty CPU switches ...

Page 118: ... event occurs in ERROR SEARCH mode If a second checksum error occurs in solo or stand alone operation 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 operation when troubleshooting is finished the CPU reacts as it did on the first occurrence of...

Page 119: ...and execution of the cyclic self test For example you can remove various test components from the overall test and re introduce them In addition you can explicitly call and process specific test components For detailed information on SFC 90 H_CTRL refer to Manual System Software for S7 300 400 System and Standard Functions Note In a fail safe system you are not allowed to disable and then re enabl...

Page 120: ...memories and timers but not the time of day The CPU tests its hardware The CPU sets its parameters to default settings The LEDs behave as following during the memory reset 1 The STOP LED flashes for about 1 2 seconds at 2 Hz 2 All LEDs light up for approximately 10 seconds 3 The STOP LED flashes for about 40 seconds at 2 Hz 4 The STOP LED lights up permanently Data retained after a memory reset Th...

Page 121: ...deleted loaded created or compressed Execution of communication functions PG operation Communication functions are executed Execution of the functions is restrict ed section by section and delayed All the delayed functions are caught up with after the update For details refer to the sections be low CPU self test Not performed Not performed Test and commissioning functions such as Monitor and modif...

Page 122: ...dware version on master and standby CPU Number of POs on system expansion cards Restart of the standby Are identical 2 Are identical Are identical Switching to a partner CPU with modified configura tion Are identical 2 Are identical Are identical Switching to a partner CPU with modified operating system Are different 2 Are identical Are identical Switching to a partner CPU with modified hardware p...

Page 123: ...pdate during which no communication functions are processed Note The master CPU however maintains all existing communication links Maximum communication delay The maximum permissible communication delay configured by the user Maximum inhibit time for priority classes 15 Inhibit time for priority classes 15 The time span during an update during which no OBs and thus no user program are executed nor...

Page 124: ...3 Cause of cancelation is entered in diagnostic buffer 4 Call OB 72 with corresponding start information The standby CPU then reevaluates its system data blocks Following this 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...

Page 125: ...for link up is in particular determined by the communication load the cycle time Link up takes about 2 minutes for automation systems without load It can take more than one hour when there is a high load on your automation system Time response during updating The transmission time during updating depends on the current changes of the process values and the communication load As a simple approximat...

Page 126: ... H Parameters in HW Config 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 A high communication...

Page 127: ... 30 ms For distributed I O PROFIBUS DP TPH 3 x TTRmax Where TTRmax 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 O the resultant ...

Page 128: ... see section Link up sequence Page 287 you also need to changeover the 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 ho...

Page 129: ...lculation Make appropriate changes and then restart the calculation at 1 9 Select the minimum of all TP15 DP master system IO subsystem values This time is referred to below as TP15_HW 10 Determine the share of the maximum inhibit time for I O classes 15 that is required by the minimum I O retention time TP15_OD TP15_OD 50 ms min I O retention time 2 Note If TP15_OD TP15_HW stop the calculation he...

Page 130: ...interface The IO subsystem is connected via the integrated 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_U...

Page 131: ...ce TP15_OD 140 ms TP15_HW 660 ms continue with 1 Based on section Performance values for link up and update Page 133 with 170 KB of user program data TP15_AWP 194 ms Check Since TP15_AWP 194 ms TP15_HW 660 ms continue with 1 Based on formula 3 we obtain the recommended max inhibit time for priority classes 15 TP15 MAX 194 ms 140 ms TP15 194 ms This means that by setting a maximum inhibit time of 1...

Page 132: ... a station failure in the distributed I O The time value TP15_AWP represents a guideline and depends on your program structure You can reduce it by taking the following measures for example Save data that changes often in different DBs than data that does not change as often Specify a smaller DB sizes in the work memory If you reduce the time TP15_AWP without taking the measures described you run ...

Page 133: ...Typical values 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 ...

Page 134: ...SFBs for generating block specific messages System modifications during operation Expansion of distributed I Os with 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 extende...

Page 135: ...ways greater 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 standby changeover are completed the s...

Page 136: ...Link up and update 8 4 Special features in link up and update operations CPU 410 5H Process Automation 136 System Manual 09 2014 A5E31622160 AB ...

Page 137: ...ontrol and monitoring functions Access granted Access granted Access granted S7 communication Access granted Access granted Access granted Read time of day Access granted Access granted Access granted Set time of day Access granted Access granted Access granted Block status Access granted Access granted Password required Load in PG Access granted Access granted Password required Controlling select...

Page 138: ...109 call with MODE 1 Setting of protection level 2 with password legitimization This means you can cancel the write protection set with SFC 109 if you know the valid password The SFC 109 call with MODE 1 overrides any existing lock of password legitimization SFC 109 call with MODE 12 Setting of protection level 3 without password legitimization This means you cannot cancel the write and read prote...

Page 139: ...s transferred from the master to the standby during link up update operations The set protection levels of both fault tolerant CPUs are retained if you make modifications to the plant during operation The protection level is transferred to the target CPU in the following cases Switch to CPU with modified configuration Switching to a CPU with modified PO limit Switching to a CPU with modified opera...

Page 140: ...diting if you have the correct key and the corresponding decompilation information included in your package Make sure that the key is always kept in a safe place If your project contains sources you can use these to restore the protected blocks by means of compilation The S7 Block Privacy sources can be removed from the project Note Memory requirements Each protected block with decompilation infor...

Page 141: ...time 01 01 94 00 00 00 without battery backup Procedure Proceed as follows to reset a CPU to its factory settings 1 Switch off the line voltage 2 Switch on the line voltage while pressing and holding down the Reset button 3 Wait until LED lamp image 1 from the subsequent overview is displayed In this lamp pattern INTF flashes at 0 5 Hz EXTF BUSxF MAINT IFMxF RUN and STOP remain unlit 4 Wait until ...

Page 142: ...14 A5E31622160 AB LED patterns during CPU reset While you are resetting the CPU to its factory settings the LEDs light up consecutively in the following LED patterns Table 9 3 LED patterns LED LED pattern 1 LED pattern 2 INTF Flashes at 0 5 Hz Lit EXTF Dark Dark BUSxF Dark Dark MAINT Dark Dark IFMxF Dark Dark RUN Dark Dark STOP Dark Dark ...

Page 143: ...he current service data and writes the event W 16 4308 Memory reset started by switch operation to the diagnostics buffer 2 The CPU performs a memory reset and then switches to STOP or links up Reset in stand alone operation with restart Note During Power On with battery backup of a fault tolerant system with large configurations many CPs and or external DP masters it may take up to 30 seconds unt...

Page 144: ...PU you want to update in HW Config 2 Select the CPU 3 Select the PLC Update Firmware menu command 4 In the Update Firmware dialog select the path to the firmware update files UPD using the Browse button After you have selected a file the information in the bottom boxes of the Update Firmware dialog box indicate the modules for which the file is suitable and from which firmware version 5 Click on R...

Page 145: ...are CPU 410 5H Process Automation System Manual 09 2014 A5E31622160 AB 145 Values retained after a firmware update The following values are retained after a CPU memory reset IP address of the CPU Device name NameOfStation Subnet mask Static SNMP parameters ...

Page 146: ... Project or HW Config Do not use the Accessible nodes menu command in SIMATIC Manager 3 Select the PLC Update Firmware menu command A wizard is started that can automatically update the firmware on both CPUs Alternative procedure for progressive firmware update Follow the steps below to update the firmware of the CPUs of a fault tolerant system in RUN 1 For CPU access protection with password In S...

Page 147: ...rating state Note Only the third number of the firmware versions of the master and standby CPU may differ by 1 You can only update to the newer version The constraints described in Chapter Operator controls and operating modes of the CPU 410 5H Page 99 also apply to a firmware update in RUN Any set up access right is not canceled until you stop the SIMATIC Manager You should reset the access right...

Page 148: ...h and the file names 2 Save the files 3 Forward these files to Customer Support on request 9 8 Response to fault detection Response to fault detection In order to ensure a high level of reliability in particular of the fault tolerant system the CPU 410 has many self diagnostics Faults can thus be detected and eliminated at an early stage In the rare instance that a fault occurs that cannot be elim...

Page 149: ...e Time synchronization via the PROFINET IO interface With the PROFINET IO interface time synchronization is possible using the NTP method and the SIMATIC method The PROFINET IO CPU is a client in this process You may configure up to four NTP servers You can set the update interval between 10 seconds and 1 day For times greater than 90 minutes an NTP request of the PROFINET IO CPU always occurs eve...

Page 150: ...C 100 SET_CLKS or an interface as time slave NTP client slave Reference Information about time synchronization for PCS 7 is available in the Time Synchronization manual of the SIMATIC PCS 7 technical documentation at the following address SIMATIC Process Control System PCS 7 time synchronization V8 0 http support automation siemens com WW view en 61189664 9 10 Type update with interface change in ...

Page 151: ...dant mode Detailed information is available in the chapters below The procedures described below for making changes during operation are each created in such a way that they start from the redundant system state see Chapter The system states of the fault tolerant system Page 109 and have as their objective a return to redundant system state Note Keep strictly to the rules described in this section...

Page 152: ...ssible because the bus modules cannot be installed and removed during operation The removal of the terminal modules with the ET200iSP should have sufficient reserves and be fitted with unconfigured reserve modules 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...

Page 153: ...t tolerant system to stop In solo operation the process is then controlled by only one CPU while the desired configuration changes are made to the other CPU Note During a hardware modification you can either remove or add modules If you want to alter your fault tolerant system such that you remove modules and add others you have to make two hardware changes Note Always download configuration chang...

Page 154: ...substitute values in a central controller There is always a gap of 3 to 50 ms Adding or removing components of the distributed I O such as DP slaves with a redundant interface module e g ET 200M ET200iSP DP PA link or Y Link One sided DP slaves in any DP master system Modules in modular DP slaves ET200M and ET200iSP DP PA couplers PA devices Changing specific CPU parameters Reassigning the module ...

Page 155: ...dification 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 failed completely or that a redundant I O exists So correct evaluation of the red...

Page 156: ...ion to the standby CPU Step 4 Download new hardware configuration to the standby CPU Page 159 5 Switch to CPU with modified configuration Step 5 Switch to CPU with modified configuration Page 160 6 Transition to redundant system state Step 6 Transition to redundant system state Page 161 7 Modify and download the user program Step 7 Modify and download the user program Page 163 Exceptions This over...

Page 157: ...acks Plug new module into existing modular DP stations Add new DP stations to existing DP master systems Note 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 sa...

Page 158: ...ations to the hardware configuration relating to the added hardware offline Assign appropriate icons to the new channels to be 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 old configuration in redundant system mode Configuring connections The...

Page 159: ...click Stop Result The standby 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 standby CPU is no longer addressed Although I O access errors of the one sided I O will result in OB 85 being called due to the higher priority CPU redundancy loss OB 72 they will not be reported OB 70 I O redundancy loss is not called 1...

Page 160: ...of previ ous master CPU One sided I O of new master CPU Switched I O Added I O mod ules are not addressed by the CPU are given new parameter settings and updated by the CPU Driver blocks are not yet present Process or diag nostic interrupts are detected but are not reported I O modules still present are no longer addressed by the CPU Output modules output the configured substitute or holding value...

Page 161: ...uld reset the access right once again to prevent unauthorized access You reset the access right in the SIMATIC Manager with the menu command PLC Access Rights Cancel Reaction of the I O Type of I O One sided I O of the standby CPU One sided I O of the master CPU Switched I O Added I O mod ules are given new parameter settings and updated by the CPU Driver blocks are not yet present Any interrupts ...

Page 162: ...B Reaction to monitoring timeout If one of the monitored times exceeds the configured maximum the update is canceled The fault tolerant system remains in single mode with the previous master CPU and assuming certain conditions are met attempts the link up and update later For additional information refer to section Time monitoring Page 123 ...

Page 163: ... modifications 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...

Page 164: ...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 program But it can remain inserted in t...

Page 165: ... 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 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...

Page 166: ...g the user program Step 2 Modify and download the user program Page 168 3 Stopping the reserve CPU Step 3 Stop the standby CPU Page 169 4 Loading a new hardware configuration in the reserve CPU Step 4 Download new hardware configuration to the standby CPU Page 169 5 Switch to CPU with modified configuration Step 5 Switch to CPU with modified configuration Page 170 6 Transition to redundant system ...

Page 167: ...is operating 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 wi...

Page 168: ...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 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 ...

Page 169: ... CPU of the fault tolerant system then select PLC Operating Mode from the menu 3 In the Operating Mode dialog box select the standby CPU and click Stop Result The standby 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 standby CPU is no longer addressed 10 4 4 Step 4 Download new hardware configuration to the stan...

Page 170: ...e I O Type of I O One sided I O of previ ous 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 operatio...

Page 171: ...ccess right in the SIMATIC Manager with the menu command PLC Access Rights Cancel Reaction of the I O Type of I O One sided I O of the standby CPU One sided I O of the 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 ...

Page 172: ...nt to 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 Note 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 remova...

Page 173: ...uration to the reserve CPU see section Step 4 Download new hardware configuration to the standby CPU Page 169 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 Switch...

Page 174: ...ve to restore the wrongly changed parameters in the parameter configuration to their last valid values Table 10 1 Modifiable CPU parameters Tab Editable parameter Startup Monitoring time for signaling readiness by modules Monitoring time for transferring parameters to modules Cycle clock memory Cycle load due to communication Memory Local data for the individual priority classes Time of day interr...

Page 175: ...tep 3 Downloading a new hardware configura tion to the reserve CPU Page 177 4 Switch to CPU with modified configuration Step 4 Switching to CPU with modified configura tion Page 177 5 Transition to redundant system mode Step 5 Transition to redundant system mode Page 179 Note After changing the hardware configuration download takes place practically automatically You then no longer have to perform...

Page 176: ...ith the old configuration in redundant system mode 10 5 3 Step 2 Stopping the reserve CPU Starting situation The fault tolerant system is operating in redundant system mode Procedure 1 For CPU access protection with password In SIMATIC Manager select a CPU of the fault tolerant system then select PLC Access Rights Setup from the menu Enter the CPU access password 2 In SIMATIC Manager select a CPU ...

Page 177: ...configuration of the standby CPU do not yet have an effect on ongoing operation 10 5 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 ...

Page 178: ...inue 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 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 ...

Page 179: ...nce again to prevent unauthorized access You reset the access right in the SIMATIC Manager with the menu command PLC Access Rights Cancel Reaction of the I O Type of I O One sided I O of the standby CPU One sided I O of the master CPU Switched I O I O modules are given new parameter set tings1 and updated by the CPU continue operation without interruption 1 Central modules are also reset first Out...

Page 180: ...t 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 subsection Step What to do See section 1 Editing parameters offline Step 1 Editing parameters offline Page 181 2 Stopping the reserve CPU Step 2 Stopping the reserve CPU Page 181 3 Downloading modified CPU par...

Page 181: ...th the old configuration in redundant system mode 10 6 3 Step 2 Stopping the reserve CPU Starting situation The fault tolerant system is operating in redundant system mode Procedure 1 For CPU access protection with password In SIMATIC Manager select a CPU of the fault tolerant system then select PLC Access Rights Setup from the menu Enter the CPU access password 2 In SIMATIC Manager select a CPU o...

Page 182: ...ation 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 Note The user program and connection configuration cannot be downloaded in single mode Result The modified parameters in the new hardware configuration of the reserve CPU do not yet have an effect on ongoing ope...

Page 183: ...em continues 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 set tings1 and updated by the CPU continue operation without interruption 1 Central modules are also reset firs...

Page 184: ... once again to prevent unauthorized access You reset the access right in the SIMATIC Manager with the menu command PLC Access Rights Cancel Reaction of the I O Type of I O One sided I O of the standby CPU One sided I O of the master CPU Switched I O I O modules are given new parameter set tings1 and updated by the CPU continue operation without interruption 1 Central modules are also reset first O...

Page 185: ...es to single mode The partner CPU reports the event in the diagnostic buffer and in OB 72 Requirements for replacement The module replacement described below is possible only if the new CPU has the same operating system version as the failed CPU and if it is equipped with the same system expansion card as the failed CPU Note New CPUs are always shipped with the latest operating system version If t...

Page 186: ...e connections of the synchronization modules 5 Switch the power supply module on again CPU runs the self tests and changes to STOP 6 Perform a CPU memory reset on the re placed CPU 7 Start the replaced CPU for example STOP RUN or Start using the PG The CPU performs an automatic LINK UP and UPDATE The CPU changes to RUN and operates as the reserve CPU Note Wiring synchronization modules crosswise I...

Page 187: ...07 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 with two PS 407 10A R or PS 405 10A R two power ...

Page 188: ...S7 400 Use the correct procedure when replacing a module The correct procedure is described below for the S7 300 in Chapter Failure and replacement of components of the distributed I Os Page 194 To replace signal and function modules of an S7 400 perform the following steps Step What to do How does the system react 1 Disconnect the module from its peripheral power supply if necessary 2 Disconnect ...

Page 189: ... new module Both CPUs generate a remove insert interrupt and enter the event in the di agnostic buffer and the system status list Parameters are assigned automatically to the module by the CPU concerned and the module is addressed again 5 Plug the front connector into the new mod ule If the affected module can generate diagnostic interrupts and if diagnostic in terrupts are enabled as per configur...

Page 190: ... In communication via standard connections Connection failed In communication via redundant connections Communication is maintained without inter ruption 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...

Page 191: ...e intact redundancy link option in the Switch STEP 7 dialog box 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 the CPU 410 5H Page 201 The master CPU reports the event in the diagnostic buffer and...

Page 192: ...es to Redun dant mode Starting situation Failure How does the system react Simultaneous failure of both fiber optic cables The S7 400H is in redundant system mode and both fiber optic cables fail Both CPUs report the event in the diagnostic buffer and via OB 72 Both CPUs become the master CPU and remain in RUN mode The LEDs IFM1F and IFM2F are lit on both CPUs Procedure The described double fault ...

Page 193: ...e event in 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 inter face module 3 Remove the interface module 4 Insert the new in...

Page 194: ...or function module differs for modules of the S7 300 and S7 400 Use the correct procedure when replacing a module The correct procedure is described below for the S7 400 in Chapter Failure and replacement of an input output or function module Page 188 To replace signal and function modules of an S7 300 perform the following steps Step What to do How does the system react 1 Disconnect the module fr...

Page 195: ...ngle mode 2 Unplug the Profibus DP cable of the affect ed DP master module 3 Replace the module 4 Plug the Profibus DP back in 5 Turn on the power supply of the central rack The CPU performs an automatic LINK UP and UPDATE The CPU changes to RUN and operates as the reserve CPU Exchanging a CP 443 5 in case of spare part requirement If a CP 443 5 is replaced by a successor module with a new article...

Page 196: ...k in 12 Turn on the power supply of the second central rack again 13 Perform a Warm restart CPU performs a link up and update and operates as stand by CPU see chapter Step 6 Transition to redundant system state Page 161 11 2 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 PROFIB...

Page 197: ... and via a corresponding OB 86 Procedure Proceed as follows to replace a DP slave Step What to do How does the system react 1 Turn off the supply for the DP slave With one sided I O OB 86 and OB85 are called for access errors during the PA up date With switched I O OB70 is called incoming event the LED REDF lights up 2 Remove the bus connector 3 Replace the DP slave 4 Plug the bus connector back i...

Page 198: ...ED BUS1F flashes With switched I O I O redundancy error OB OB 70 is started incoming event DP slaves are addressed via the DP master of the partner The LED BUS1F and the LED REDF are flashing Replacement procedure Proceed as follows to replace PROFIBUS DP cables Step What to do How does the system react 1 Check the cabling and localize the interrupted PROFIBUS DP cable 2 Replace the defective cabl...

Page 199: ...system state and an IO device fails Both CPUs signal the event in the diagnostics buffer and via a corresponding OB Procedure Proceed as follows to replace an IO device Step What to do How does the system react 1 Switch off the power supply for the IO de vice OB 86 and OB85 are called the LED REDF lights up the corresponding LED BUSxF flashes 2 Remove the bus connector 3 Replace the IO device 4 Pl...

Page 200: ... LED BUS5F lF or BUS8F IF is flashing With switched I O I O redundancy error OB OB 70 is started incoming event The IO devices are ad dressed via the IO controller of the partner The LED BUS5F lF or BUS8F IF and the LED REDF are flashing Replacement procedure Proceed as follows to replace PROFINET IO cables Step What to do How does the system react 1 Check the cabling and localize the interrupted ...

Page 201: ...ule in redundant system mode there is a loss of synchronization The standby CPU switches to ERROR SEARCH operating state for a few minutes If the new synchronization module is inserted and the redundant link is reestablished during this time the standby CPU then switches to redundant system mode otherwise it switches to STOP Once you have inserted the new synchronization module and reestablished t...

Page 202: ...ion Dummy plugs Figure 12 1 Synchronization 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 ...

Page 203: ...y link between the CPUs transmission distance including synchronization modules and fiber optic cables is reduced so that transmission errors are occurring frequently In redundant mode the OB82 is also called at Power Off On or at a firmware update of the partner CPU This does not indicate any problem with the synchronization link but is instead due to the fact that the synchronization modules are...

Page 204: ... of the first CPU with the IF2 interface of the second CPU Note 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 ...

Page 205: ...mum distance between the CPUs 10 m 10 km Supply voltage 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 transceivers 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 Weigh...

Page 206: ...epeated After installation 59 mm one time Permitted bending radii for prefabricated cables When you install self assembled cables make sure to comply with the bending radii specified by the manufacturer Note that approx 50 mm of space is available for the connector and the fiber optic cable under the front cover of the CPU and that no tight bending radius of a fiber optic cable is therefore possib...

Page 207: ...n slight amounts of dirt at the end of a fiber optic cable will adversely affect its optical performance and thus the quality of the signal transmission This can lead to synchronization losses during operation Protect the ends of the fiber optic cables against dirt during storing and installation If the ends of the fiber optic cable are covered when delivered do not remove these covers Open instal...

Page 208: ...se a cable pulling sleeve to pull in the fiber optic cable Always observe the specified bending radii Do not use any grease or oil based lubricants You may use the lubricants listed below to support the pulling in of fiber optic cables Yellow compound Wire Pulling lubricant from Klein Tools 51000 Soft soap Dishwashing liquid Talcum powder Detergent Pressure Do not exert any pressure on the cable f...

Page 209: ...p 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 cables per fault tolerant system cross over Connector type LC LC Such cables are available in the following length as accessories for fault tolerant systems Table 12 1 Accessory fiber optic cable Length Article No 1 m 6ES7...

Page 210: ...06 0XA0 you may see the error message Optical performance too high at the call of OB 82 The table below shows the further specifications based on your application Table 12 2 Specification of fiber optic cables for indoor applications Cabling Components required Specification The entire cabling is routed within a building No cable junction is required between the indoor and outdoor area The necessa...

Page 211: ...e installation of the interfaces in order to increase availability reduction of common cause factor Connector type ST or SC for example to match other components see below Further specifications you may need to observe for your plant UL approval Halogen free materials Avoid splicing cables in the field Use prefabri cated cables with pulling protection aids in whip lash or breakout design including...

Page 212: ... need to observe for your plant Protection against increased mechanical stress Protection against 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...

Page 213: ...en the indoor and out door area see Figure 12 2 One distribution junction box per branch Installation and patch cables are connected via the distribution box Either ST or SC plug in connec tions can be used for example Check the cross over installation when you wire the CPUs Connector type ST or SC for example to match other components Figure 12 2 Fiber optic cables installation using distribution...

Page 214: ...Synchronization modules 12 3 Selecting fiber optic cables CPU 410 5H Process Automation 214 System Manual 09 2014 A5E31622160 AB ...

Page 215: ...e process objects More detailed information about the scaling concept can be found in the section Scaling and licensing scaling concept Page 32 The CPU cannot be operated without the SEC SECs are available with the following number of POs 0 You must store the required number of POs on this SEC before the first use 100 500 1000 1600 2k unlimited You can expand the number of POs without replacing th...

Page 216: ...System expansion card 13 1 Variants of the system expansion card CPU 410 5H Process Automation 216 System Manual 09 2014 A5E31622160 AB ...

Page 217: ...ng package SIMATIC PCS 7 V8 1 or higher CiR Configuration in RUN CiR synchronization time base load 60 ms CiR synchronization time time per I O slave 0 µs Design mounting Rack mounting possible Yes Front installation possible Yes Rail mounting possible No Supply voltage Type of supply voltage System power supply Input current From backplane bus 5 V DC typ 2 0 A From backplane bus 5 V DC max 2 4 A ...

Page 218: ... the Module Data manual Feed of external backup voltage to the CPU No CPU processing times For bit operations typ 7 5 ns For word operations typ 7 5 ns For integer math typ 7 5 ns For floating point math typ 15 ns Processing time for 1000 binary instructions 7 5 µs CPU speed 450 MHz multiprocessor system PCS 7 process objects 100 approx 2600 can be set with system expansion card Average processing...

Page 219: ...0 47 Number of DPV1 interrupt OBs 3 OB 55 57 Number of restart OBs 2 OB 100 102 Number of asynchronous error OBs 9 OB 80 88 Number of synchronous error OBs 2 OB 121 122 Nesting depth Per priority class 24 Additionally within an error OB 2 Counters timers and their retentivity S7 counters Quantity 2048 Retentivity Can be set Yes Counting range Lower limit 0 Upper limit 999 IEC counter Available Yes...

Page 220: ... O address range Inputs 16 Kbyte up to 7 500 IO Outputs 16 Kbyte up to 7 500 IO of those distributed DP interface inputs 6 Kbyte up to 2 800 IO channels DP interface outputs 6 Kbyte up to 2 800 IO channels PN interface inputs 8 Kbyte up to 3 800 IO channels PN interface outputs 8 Kbyte up to 3 800 IO channels Process image Inputs can be set 16 KB Outputs can be set 16 KB Inputs preset 16 KB Output...

Page 221: ...460s max 6 Number of plug in IM 463s max 4 only in stand alone operation Number of DP masters integrated 1 Via CP 10 CP 443 5 Extended Number of IO controllers integrated 2 Via CP 0 Number of usable FMs and CPs recommendation PROFIBUS and Ethernet CPs 11 max 10 CPs as DP masters Slots Slots required 2 Time Clock Hardware clock real time clock Yes With battery backup can be synchronized Yes Resolut...

Page 222: ...on PROFINET IO Number of PROFINET interfaces 2 1 Interface Interface type integrated Physics RS 485 PROFIBUS Electrically isolated Yes Power supply at interface 15 to 30 V DC max 150 mA Number of connection resources 16 Functionality DP master Yes DP slave No DP master Number of connections max 16 Transmission rate max 12 Mbps Number of DP slaves max 96 Number of slots per interface max 1632 Servi...

Page 223: ...es Outputs max 244 bytes Slots max 244 Per slot max 128 bytes 2 Interface Interface type PROFINET Physics Ethernet RJ45 Electrically isolated Yes Integrated switch Yes Number of ports 2 Automatic determination of transmission rate Yes Autosensing Autonegotiation Yes Autocrossing Yes Change of the IP address at runtime supported No Number of connection resources 120 Media redundancy Supported Yes C...

Page 224: ...ends on the amount of configured user data and the configured operating mode or redundancy mode Services PG OP communication Yes S7 routing Yes S7 communication Yes Open IE communication Yes Address range Inputs max 8 Kbyte up to 3 800 IO channels Outputs max 8 Kbyte up to 3 800 IO channels User data consistency max 1024 bytes Open IE communication Open IE communication supported Yes Number of con...

Page 225: ...7 framework Prioritized startup supported No Enabling disabling of IO devices No Hot swapping of IO devices partner ports supported No Device replacement without removable medium Yes Send clocks 250 µs 500 µs 1 ms 2 ms 4 ms Update time 250 µs to 512 ms minimum value depends on the amount of configured user data and the configured operating mode or redundancy mode Services PG OP communication Yes S...

Page 226: ...TCP IP Yes Other protocols AS i Yes via add on MODBUS Yes via add on Foundation Fieldbus Yes via DP FF link Communication functions PG OP communication Yes Number of connectable OPs without message processing 119 Number of connectable OPs with message processing 119 when using Alarm_S SQ and Alarm_D DQ Data record routing Yes S7 routing Yes S7 communication Supported Yes As server Yes As client Ye...

Page 227: ...connections max 118 Data length max 1472 bytes Number of connections Total 120 Suitable for PG communication Reserved for PG communication 1 Usable for OP communication Reserved for OP communication 1 S7 message functions Number of stations that can be logged on for message func tions max 119 max 119 with Alarm_S and Alarm_D OPs max 12 wit Alarm_8 and Alarm_P e g WinCC Symbol related messages No S...

Page 228: ... of tags max 70 Diagnostics buffer Available Yes Number of entries max Can be set No Default 3200 Service data Readable Yes EMC Emission of radio interference according to EN 55 011 Limit class A for use in industrial areas Yes Limit class B for use in residential areas No Configuration Programming Instruction set See instruction list Nesting levels 7 Access to consistent data in the process image...

Page 229: ... 5HX08 0AB0 Number of simultaneously active SFCs RD_REC 8 WR_REC 8 WR_PARM 8 PARM_MOD 1 WR_DPARM 2 DPNRM_DG 8 RDSYSST 8 DP_TOPOL 1 Number of simultaneously active SFBs RD_REC 8 WR_REC 8 Know how protection User program password security Yes Block encryption Yes using S7 Block Privacy Dimensions Width 50 mm Height 290 mm Depth 219 mm Weights Weight approx 1 1 kg ...

Page 230: ...Technical data 14 1 Technical specifications of the CPU 410 5H 6ES7 410 5HX08 0AB0 CPU 410 5H Process Automation 230 System Manual 09 2014 A5E31622160 AB ...

Page 231: ...y it You use SFC 103 DP_TOPOL to trigger the identification of the bus topology of a DP master system by the diagnostic repeater For information on SFC 103 refer to the related online help and to Manual System and Standard Functions The diagnostic repeater is described in the Diagnostic Repeater for PROFIBUS DP manual article number 6ES7972 0AB00 8BA0 Adding modules with ET 200M at a later time If...

Page 232: ...ve diagnostics data i e save them to the data area of the user program It is possible that the busy bit will not be set to 0 if an error occurs while SFC 13 is being processed You should there fore check the RET_VAL pa rameter after every execution of SFC 13 see System and Standard Functions reference manual For the structure of other slaves refer to their descriptions SFC 59 RD_REC Read data reco...

Page 233: ... of CPU 410 5H as PROFIBUS DP master CPU 410 5H Process Automation System Manual 09 2014 A5E31622160 AB 233 Evaluating diagnostics data in the user program The figure below shows how to evaluate the diagnostics data in the user program Figure 15 1 Diagnostics with CPU 410 ...

Page 234: ...ble OB82_MDL_STOP 1 DP slave STOP RUN OB 82 is called with the message Module OK as incoming event diagnostic address of the DP slave assigned to the DP master variable OB82_MDL_STOP 0 Evaluation in the user program The table below shows you how to evaluate RUN STOP changes of the DP slave on the DP master Also refer to the previous table On the DP master On the DP slave CPU 41x Example of diagnos...

Page 235: ...ET IO configuration sizes and can also be used for PROFIBUS You can use a previously known PROFIBUS system status list that is also supported by PROFINET IO as usual If you use a system status list in PROFINET IO that PROFINET IO 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 PROFIBUS DP Table 15 3 Co...

Page 236: ...rface Yes internal interface No external interface Rack station status information W 16 0C96 Yes internal interface No external interface Yes internal interface No external interface Module status information of a submod ule using the logical address of this sub module W 16 0591 Yes Parameter adr1 changed Yes Module status information for the inter faces of a module W 16 0696 Yes internal interfac...

Page 237: ...sive for the product version but the revision of the Hardware component Module status dialog mask to be read using STEP 7 Redundantly used other modules must be identical which means they must have the same article number product version and if available firmware version Layout rules A fault tolerant station may contain up to 20 expansion units Assign racks with even numbers only to central contro...

Page 238: ...the subsequent dialogs Special features in presenting the hardware configuration In order to enable quick recognition of a redundant DP master system or PN IO system each of them is represented by two parallel cables 15 4 3 Assigning parameters to modules in a fault tolerant station Procedure Assign all parameters of the redundant components identically with the exception of communication addresse...

Page 239: ...ud 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 slow transmission rate Note The bus load is at its peak during restart of the DP master for example following Power OFF ON Recommended setting default setting of the CPU 410 600 corresponds to 60 s Note The fault...

Page 240: ...ion automatically determines the number of possible subconnections If two independent but identical subnets are available and they are suitable for a fault tolerant S7 connection two subconnections are used In practice they are usually electrical networks one network connection in each subnet If only one subnet is available four subconnectors are used for a connection between two fault tolerant st...

Page 241: ...S7 program appears under both CPUs and can be selected in both locations Communication functions For programming device PG functions that establish online connections e g downloading charts 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 othe...

Page 242: ...slave No Yes No PROFINET IO Data exchange between I O controllers and I O devices No No Yes SNMP Simple Network Manage ment Protocol Standard protocol for network diagnos tics and parameter assignment No No Yes Open communication over TCP IP Data exchange over Industrial Ethernet with TCP IP protocol with loadable FBs Yes No Yes Open communication over ISO on TCP Data exchange over Industrial Ethe...

Page 243: ... you operate those communication services via a PROFIBUS DP interface at a low baud rate operation in configurations with a Ttr Target Rotation Time 20 s is ensured 15 6 2 PG communication Properties Programming device communication is used to exchange data between engineering stations PG PC for example and SIMATIC modules which are capable of communication This service is available via PROFIBUS a...

Page 244: ...onfigured connections for USEND URCV BSEND BRCV PUT GET You can use the S7 communication via integrated PROFIBUS DP or PROFINET IO interfaces If required S7 communication can be used via additional communication processors CP 443 1 for Industrial Ethernet or CP 443 5 for PROFIBUS The S7 400 features integrated S7 communication services that allow the user program in the controller to initiate read...

Page 245: ...te partner SFB of type URCV Receive asynchronous data from a remote partner SFB of type USEND SFB 12 SFB 13 BSEND BRCV Send data to a remote partner SFB of type BRCV Receive data from a remote partner SFB of type BSEND With this data transfer a larger amount of data can be transported between the communication partners than is possible with all other communications SFBs for the configured S7 conne...

Page 246: ...aded 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 to other subnets In your network configuration the PG PC you want to use to set up a connection via gateway must be assigned to the network to which it is physically connected The ...

Page 247: ... A5E31622160 AB 247 S7 routing gateways PROFINET IO DP PROFINET IO The following figure shows the access from PROFINET IO to PROFIBUS to PROFINET IO CPU 1 is the router between subnet 1 and subnet 2 CPU 2 is the router between subnet 2 and subnet 3 Figure 15 3 S7 routing gateways PROFINET IO DP PROFINET IO ...

Page 248: ...AB S7 routing TeleService application example The following figure shows an application example of the remote maintenance 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 Figure 15 4 S7 routing TeleService application example ...

Page 249: ...detailed description refer to the STEP 7 online help or Manual System and Standard Functions http support automation siemens com WW view de 44240604 0 en 15 6 6 Data set routing Routing and data set routing Routing is the transfer of data beyond network boundaries You can send information from a transmitter to a receiver across several networks Data set routing is an expansion of S7 routing and is...

Page 250: ...ollowing figure shows the engineering station accessing a variety of field 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 Figure 15 5 Data set routing See also For more information on SIMATIC PDM refer to Manual The Process Device Manager ...

Page 251: ...vices 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 SNMP based applications can be operated on the same network parallel to applications with PROFINET IO Note MAC addresses During SNMP diagnostics the following MAC addresses are shown for the ifPhysAddress parameter Interface 1 PN interface MAC address ...

Page 252: ... 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 Unit negotiated in the ISOonTCP connection establishment Connectionless protocols Connecti...

Page 253: ...meter assignment Data blocks for parameter assignment of communication connections for TCP and ISO on TCP In order to assign parameters for the communication connections for TCP and ISO on TCP you must create a DB that contains the data structure from UDT 65 TCON_PAR This data structure contains all parameters you need to set up the connection For each connection you need this type of data structu...

Page 254: ...s 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 When FB 66 TDISCON is called or the CPU is in STOP operating state an existing connection will be terminated To reestablish the connection you must call FB65 TCON again U...

Page 255: ...ication connections You program the termination of the communication connection with FB 66 TDISCON The CPU state changes from RUN to STOP At POWER OFF POWER ON Connection diagnostics In Step 7 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 ...

Page 256: ...the various monitoring and synchronization mechanisms ensure that the communication functions are taken over by the standby 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...

Page 257: ...on For other types of connection refer to Manuals SIMATIC NET NCM S7 for PROFIBUS and SIMATIC NET NCM S7 for Industrial Ethernet 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 tolerant S7 connection ...

Page 258: ... The following examples and the possible configurations in STEP 7 are based on a maximum of two subnets and a maximum of 4 CPs in the redundant fault tolerant system Configurations with a higher number of CPs or networks are not supported in STEP 7 Figure 15 7 Example that shows that the number of resulting partial connections depends on the configuration ...

Page 259: ...fault tolerant S7 connections see technical specifications Each connection needs a connection resource on the CPU subconnections do not need any additional connection resources On the CP on the other hand each subconnection needs a connection resource Note If you have configured several fault tolerant S7 connections for a fault tolerant station establishing them may take a considerable time If the...

Page 260: ...lt tolerant communication between a fault tolerant system and a standard CPU The following examples illustrate the actual availability of the communicating systems Configuration S7 connections are configured in STEP 7 Programming If S7 communication is used on a fault tolerant system all communication functions can be used for this The communication SFBs are used in STEP 7 to program communication...

Page 261: ...1 15 9 1 Communication via S7 connections one sided mode Availability Availability for communication between a fault tolerant system and a standard system is also increased by using a redundant plant bus instead of a single bus see figure below Figure 15 8 Example of linking standard and fault tolerant systems in a simple bus system ...

Page 262: ...m via bus1 This applies no matter which CPU is the master CPU For linked fault tolerant and standard systems the availability of communication cannot be improved by means of a dual electrical bus system To be able to use the second bus system as redundancy a second S7 connection must be used and managed accordingly in the user program see next figure Figure 15 9 Example of linking standard and fau...

Page 263: ... of the communication between the two systems involved This can be seen in the preceding figures There are no bus system specific differences in the response to failure Linking standard and fault tolerant systems Driver block 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 siem...

Page 264: ...em bus and two separate CPs in a standard system Figure 15 11 Example of linking standard and fault tolerant systems in a single bus system Redundant communication can also be operated with standard connections For this two separate S7 connections must be configured in the program in order to implement connection redundancy In the user program both connections require the implementation of monitor...

Page 265: ...Figure 15 12 Example of redundancy with fault tolerant systems and a redundant bus system with redundant standard connections Response to failure Double errors in the fault tolerant system i e CPUa1 and CPa 2 or in the standard system CPb1 and CPb2 and single errors in the standard system CPUb1 lead to a total failure of communication between the systems involved see previous figure ...

Page 266: ...nt connections as many systems offer no other connection options In order to make the data of a single channel system available to CPUs of the fault tolerant system as well the point to point CP i e 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 necessar...

Page 267: ...th system redundancy Response to failure Double errors in the fault tolerant system i e CPUa1 and IM 153 and a single fault in the third party system lead to a total failure of communication between the systems involved This can be seen in the previous figure The point to point CP can also be inserted centrally in Fault tolerant system a However in this configuration even the failure of the CPU fo...

Page 268: ...oftware instance in the gateway implements the single channel transition to the fault tolerant systems and so allows any single channel 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 ...

Page 269: ...be used for fault tolerant and fail safe communication see Appendix Function and communication modules that can be used in a redundant configuration Page 335 Industrial Ethernet with ISO protocol or PROFIBUS without distributed I O and ISO on TCP is supported Fault tolerant S7 connections via Industrial Ethernet with ISO on TCP are supported by the integrated PN interfaces and corresponding CPs Yo...

Page 270: ...lerant connection via ISO PC station with Simatic Net CD CP1623 up to V7 x ISO CP443 1 ISO CPU 41xH CPU 410 S7 fault tolerant connection via ISO Configuration The availability of the system including the communication is set during configuration Refer to the STEP 7 documentation to find out how to configure connections Only S7 communication is used for fault tolerant S7 connections To set this up ...

Page 271: ...ets Industrial Ethernet PROFIBUS The communication SFBs integrated in the operating system enable an acknowledged data transmission 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 used for fault tolerant S7 connections without program modification Cable and connect...

Page 272: ...f they were connected to a bus system line A ring topology basically contains two redundant components and automatically forms a 1 out of 2 redundancy node The fiber optic network can also be set up in star topology as redundant bus If one electrical cable segment fails communication between the participating systems is also upheld 1 out of 2 redundancy The following examples illustrate the differ...

Page 273: ...H Process Automation System Manual 09 2014 A5E31622160 AB 273 Configuration view Physical view Figure 15 17 Example of redundancy with fault tolerant system and redundant bus system Configuration view Physical view Figure 15 18 Example of fault tolerant system with additional CP redundancy ...

Page 274: ...h a duplex optic fiber ring only a 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 Figure 11 14 If a double error e g CPUa1 and CPb2 occurs in the first case of a redundant electrical bus system see Figure 11 15 this results in a total failure of communication between the systems involved In the c...

Page 275: ...igured in contrast to systems with a standard CPU Note Fault tolerant connections use two connection 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 Figure 15 19 Example of redundancy with fault tolerant system and fault tolerant...

Page 276: ...e package is required for fault tolerant communication on a PC S7 REDCONNECT is used to connect a PC to a redundant bus system using one or two CPs The second CP is merely used to redundantly connect the PC to the bus system and does not increase the availability of the PC Always use the latest version of this software Only Industrial Ethernet is supported for connecting PC systems The SIMATIC Net...

Page 277: ...lerant communication is not necessary at the PC end The connection configuration is uploaded from the STEP 7 project to the PC station You can find out how to use STEP 7 to integrate fault tolerant S7 communication for a PC into your OS system in the WinCC documentation Figure 15 20 Example of redundancy with fault tolerant system and redundant bus system Figure 15 21 Example of redundancy with a ...

Page 278: ...re of the PC station 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 this CPU fails communication between the ES and the f...

Page 279: ...a 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 in the user program In contrast S7 communication functions do not require a block such as SFB 14 GET SFB 15 PUT in the user program of the target device Here you must make allowance for the volume of consistent data in the ...

Page 280: ...d until the status parameter DONE assumes value 1 15 11 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 SFC 14 DPRD_DAT read consistent data of a DP standard slave you can consistently read the data of a DP standard slave of IO device if no error occurred during the data transmission t...

Page 281: ...dentification 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 GIF you can define ...

Page 282: ... Device The length of consistent user data that you can transmit to an IO device is limited to 1025 bytes 1024 bytes user data 1 byte secondary value Irrespective of whether you can transmit more than 1024 bytes to an IO device the transmission of consistent data is still limited to 1024 bytes When operating in PN IO mode the length of data transmission via CP 443 1 is limited to 240 bytes ...

Page 283: ... system state a normal link up and update operation must be performed subsequently How to start the link up and update operation Initial situation Solo operation i e only one of the CPUs of a fault tolerant system connected via fiber optic cables is in RUN operating state You can initiate the link up and update operation for achieving the redundant system state as follows POWER ON the standby if p...

Page 284: ...update In the initial situation the master is in solo operation In the figure CPU 0 is assumed to be the master CPU Figure 15 22 Sequence of link up and update If the Switchover to CPU with modified configuration option is set the content of the load memory is not copied what is copied from the user program blocks of the work memory OBs FCs FBs DBs SDBs of the master CPU is listed in Chapter Switc...

Page 285: ...Supplementary information 15 12 Link up and update sequence CPU 410 5H Process Automation System Manual 09 2014 A5E31622160 AB 285 Figure 15 23 Update sequence ...

Page 286: ... can reliably detect changes to input signals during the update the following condition must be satisfied Minimum signal duration 2 time required for I O update DP and PNIO only call interval of the priority class execution time for the program of the priority class update time execution time for programs of higher priority classes Example Minimum signal duration of an input signal that is evaluat...

Page 287: ...from the master CPU to the standby CPU Link up with master standby changeover In STEP 7 you can select one of the following options Switch to CPU with modified configuration Switchover to CPU with modified operating system Switchover to CPU with modified hardware version Switchover to CPU via only one intact redundant link Switching to a CPU with modified PO limit Switch to CPU with modified confi...

Page 288: ... are stored and 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 rec...

Page 289: ...etween cyclic and time of day interrupts 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...

Page 290: ... to enable and 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 modu...

Page 291: ...on option 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 standby CPU Work memory The following components are transferred from the work memory of the master CPU to the standby CPU Contents of all data blocks assigned the same interface time stamp in both load memories and whose attribute...

Page 292: ...90 H_CTRL The CPU does 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 Manual S7 400F and S7 400FH Automation Systems 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 locate...

Page 293: ...he extension of cycle times due to updates Specific blocks for S7 400H In addition to the blocks that can be used both in S7 400 and in S7 400H there are additional blocks for S7 400H You can use these blocks to influence 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_CT...

Page 294: ...ponents you can also implement the use of 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 200...

Page 295: ...nt one sided output modules even in solo operation e g direct accesses 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 to the single channel one sided output modules of the standby CPU on the transition to redundant system state Redundant I O in the user program The sample progr...

Page 296: ...sed on the fact that following an access error on module A and its replacement module B is always processed first in OB 1 Module A is not processed first again in OB 1 until an access error occurs on module B Note 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 Figure 15 26 Flow chart for OB 1 ...

Page 297: ...that no bumps occur at output modules in HW Config Properties CPU H Parameter An overhead is only required if you operate modules from the following table as redundant modules Table 15 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 Follow the steps below Calculate the overhead from t...

Page 298: ... process signals To ensure this the process signals are read written prior to program execution During the subsequent program execution the CPU does not access the signal modules directly when addressing the input I and output O address areas It accesses the CPU s system memory area containing the image of the inputs and outputs Sequence of cyclic program processing The table below shows the vario...

Page 299: ... information 15 15 Cycle and response times of the CPU 410 5H CPU 410 5H Process Automation System Manual 09 2014 A5E31622160 AB 299 Elements of the cycle time Figure 15 27 Elements and composition of the cycle time ...

Page 300: ...r the 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 15 10 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 exe...

Page 301: ...ted PROFINET IO 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 15 11 Portion of the process image transfer time CPU 410 5H Portions CPU ...

Page 302: ...3 and IM461 3 at a link length of 100 m Measured with modules with 1 byte of user data e g DI 16 Extending the cycle time The calculated cycle time of a S7 400H CPU must be multiplied by a CPU specific factor The table below lists these factors Table 15 12 Extending the cycle time Startup CPU 410 5H stand alone mode CPU 410 5H redundant Factor 1 05 1 2 Long synchronization cables may increase cycl...

Page 303: ...CPU Hardware interrupt Diagnostic interrupt Time of day inter rupt Delay interrupt Cyclic inter rupt Programming error I O access error Asyn chronous error CPU 410 5H stand alone mode 75 µs 40 µs 50 µs 40 µs 40 µs 20 µs 20 µs 55 µs CPU 410 5H redundant 180 µs 70 µs 200 µs 120 µs 120 µs 90 µs 45 µs 130 µs The program runtime at interrupt level must be added to this time extension If several interru...

Page 304: ...ercentage is to be interpreted as a mean value i e within one time slice the communication portion may be significantly greater than 20 On the other hand communication load in the next time slice is very small or not present The formula below describes the influence of communication load on the cycle time Figure 15 28 Formula Influence of communication load Data consistency The user program is int...

Page 305: ...cle by a linear amount of 2 ms but by 3 ms Example 50 communication load You configured a communication load of 50 in the hardware configuration The calculated cycle time is 10 ms This means that 500 µs remain in each time slice for the cycle Therefore 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 configu...

Page 306: ...nication load Further effects on the actual cycle time Seen statistically the extension of cycle 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 o...

Page 307: ...of the response time 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 inputs outputs Make allowances for the following module specific delay times For digital inputs the input delay time For interrupt capable digital inputs the input delay time in...

Page 308: ...hen view the DP cycle time of your configuration on the PG in the bus parameters 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 Figure 15 31 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 the DP cycle time into acc...

Page 309: ...ulation 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 Delay of the inputs and outputs The result is equivalent to the sum of the cycle time plus the I O delay times Note If the CPU and signal module are not in the central co...

Page 310: ...3 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 the outputs 2 x operating system processing time 2 x program processing time 2 x delay of the DP slave frame including processing in the DP master Delay of the inputs and outputs This is equivalent to the sum of twice the cycle time...

Page 311: ...untime of DP The following table lists the execution 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 15 15 Direct access of the CPUs to I O modules in the central controller Access type CPU 410 5H stand alone mode CPU 410 5H redundant Read byte Read word Read double word Write byt...

Page 312: ...the expansion unit with remote link setting 100 m Access type CPU 410 5H stand alone mode CPU 410 5H redundant Read byte Read word Read double word Write byte Write word Write double word 11 3 µs 22 8 µs 44 1 µs 10 8 µs 21 9 µs 44 0 µs 16 6 µs 28 1 µs 49 8 µs 16 2 µs 27 3 µs 49 4 ms Note You can also achieve fast response times by using hardware interrupts see Chapter Interrupt response time Page ...

Page 313: ...00 100 configured 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 approximate...

Page 314: ...specific 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 communicatio...

Page 315: ... time The 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 c...

Page 316: ...As 8 channels are active a cycle time of the analog input module of 200 ms results Analog output module SM 432 AO 8 13Bit was assigned for 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 for a resistive load of 0 1 ms must be added to this The result is an analog output response time ...

Page 317: ...e CPU minimum interrupt response time of the signal modules cycle time on PROFIBUS DP or PROFINET IO 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 IO Longest interrupt response time Hardware and diagnostic interrupt response times of the CPUs Table 15 19 Hardware and interrup...

Page 318: ...g 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 to the triggering of the diagnostic interrupt by the signal module This short time can be neglected Hardware interrupt processing Hardware inter...

Page 319: ... 0 5 ms for the digital input modules No activities are required at the scan cycle checkpoint You have set the communication load of the cycle as 20 Calculation In this example the hardware interrupt response time is based on following time factors Process interrupt response time of CPU 410 5H Approx 0 3 ms mean value in redundant operation Extension due to communication according to the descripti...

Page 320: ...e interval between two successive calls measured between the respective initial operations of the interrupt OB Reproducibility The following table contains the reproducibility of time delay and cyclic interrupts of the CPUs Table 15 20 Reproducibility of time delay and cyclic interrupts of the CPUs Module Reproducibility Time delay interrupt Cyclic interrupt CPU 410 5H stand alone mode 120 µs 160 ...

Page 321: ...vel the depassivation may increase the runtime of the FB RED_IN by 0 4 8 ms An 8 ms increase can be expected in redun dant 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 loggi...

Page 322: ...ng to the redun dant I O FB 453 RED_STATUS 160 μs 4 μs configured module pairs num ber of module pairs The runtime depends on the random position of the module being searched for in the work ing 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 output...

Page 323: ...ommonly used measure for reliability is the MTBF 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 s...

Page 324: ...m The system MDT is calculated based on the MDT of the individual system 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 d...

Page 325: ...tion 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 MTBF of the components meets the following standards...

Page 326: ...nts and between 1 and 0 1 in a system containing different components Within the range stipulated in IEC 61508 a CCF factor between 0 02 and 5 is used to calculate the MTBF 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 400H CPUs enable...

Page 327: ...or multiple encoders at the 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 ava...

Page 328: ...rk conditions are set for the calculation MDT Mean Down Time 4 hours Ambient temperature 40 degrees Buffer voltage is safeguarded A 2 1 System configurations with redundant CPU 410 5H The following system with one CPU e g CPU 410 5H PN DP in stand alone operation serves as the basis for calculating a reference factor that defines the multiple of the system MTBF of other systems with centralized I ...

Page 329: ...n of MTBF for selected configurations CPU 410 5H Process Automation System Manual 09 2014 A5E31622160 AB 329 Redundant CPUs in different racks Redundant CPU 410 5H in divided rack CCF 2 Factor approx 20 Redundant CPU 410 5H in two separate racks CCF 1 Factor approx 38 ...

Page 330: ... I Os The system with two fault tolerant CPUs 410 5H and one sided I Os described below is taken as 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 Redundant CPUs with single channel one sided or switched I O One sided distributed I O Base line 1 Switched distributed I O PROFIBUS DP C...

Page 331: ...5H Process Automation System Manual 09 2014 A5E31622160 AB 331 Switched distributed I O PROFINET CCF 2 Factor approx 10 The estimate applies if the process allows for any device to fail Redundant CPUs with redundant I O The comparison only took account of the I O modules Single channel one sided I O MTBF factor 1 ...

Page 332: ...x 4 Analog input modules distributed AI 6x13Bit 6ES7 336 1HE00 0AB0 approx 5 AI8x12Bit 6ES7 331 7KF02 0AB0 approx 5 Digital output modules distributed DO 10xDC24V 2A 6ES7 326 2BF01 0AB0 approx 5 DO8xDC24V 2A 6ES7 322 1BF01 0AA0 approx 3 DO32xDC24V 0 5A 6ES7 322 1BL00 0AA0 approx 3 Summary Several thousand redundant automation systems are in use in different configurations in manufacturing and proc...

Page 333: ...nt communication The next section shows a comparison between 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 lin...

Page 334: ...Characteristic values of redundant automation systems A 2 Comparison of MTBF for selected configurations CPU 410 5H Process Automation 334 System Manual 09 2014 A5E31622160 AB ...

Page 335: ...e used centrally Module Article No Release One sided Redundant Function module FM 458 1 DP 6DD 1607 0AA2 As of firmware 2 0 0 Yes No Communication processor CP 443 1 Multi Industrial Ethernet ISO and TCP IP 2 port switch Without PROFINET IO and PROFINET CBA 6GK7 443 1EX20 0XE0 As of product version 1 As of firmware V2 1 Yes Yes 6GK7 443 1EX30 0XE0 As of product version 1 As of firmware V3 0 Yes Ye...

Page 336: ...E0 As of product version 1 As of firmware V2 0 0 Communication processor CP 342 2 ASI bus interface module 6GK7 342 2AH01 0XA0 As of product version 1 As of firmware V1 10 Communication processor CP 343 2 ASI bus interface module 6GK7 343 2AH00 0XA0 As of product version 2 As of firmware V2 03 Counter module FM 350 2 6ES7 350 2AH00 0AE0 As of product version 2 Control module FM 355 C 6ES7 355 0VH1...

Page 337: ...dules The MTA terminal modules are connected to the I O modules using 3 m or 8 m long preassembled cables Details on combinable ET 200M modules and suitable connection cables as well as the current MTA product range are available at this address Update and expansion of the MTA terminal modules http support automation siemens com WW view en 29289048 C 2 Interconnection of output modules Interconnec...

Page 338: ...U_r 200 V and I_F 1 A e g types from the series 1N4003 1N4007 It is advisable to separate the ground of the module and the ground of the load There must be equipotential bonding between both Information on connecting analog output modules via diodes Suitable diodes are diodes with U_r 200 V and I_F 1 A e g types from the series 1N4003 1N4007 A separate load supply is advisable There must be equipo...

Page 339: ...ocess Automation System Manual 09 2014 A5E31622160 AB 339 C 3 8 channel HART analog input MTA The following figure shows the connection of an encoder to two SM 331 AI 8 x 0 4 20mA HART via an 8 channel HART analog input MTA Figure C 1 Interconnection example for SM 331 Al 8 x 0 4 20mA HART ...

Page 340: ...Automation 340 System Manual 09 2014 A5E31622160 AB C 4 8 channel HART analog output MTA The following figure shows the connection of an encoder to two redundant SM 322 AI 8 x 0 4 20mA HART via an 8 channel HART analog output MTA Figure C 2 Interconnection example for SM 322 Al 8 x 0 4 20mA HART ...

Page 341: ...s Automation System Manual 09 2014 A5E31622160 AB 341 C 5 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 Figure C 3 Example of an interconnection with SM 321 DI 16 x DC 24 V ...

Page 342: ...em Manual 09 2014 A5E31622160 AB C 6 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 Figure C 4 Example of an interconnection with SM 321 DI 32 x DC 24 V ...

Page 343: ...omation System Manual 09 2014 A5E31622160 AB 343 C 7 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 Figure C 5 Example of an interconnection with SM 321 DI 16 x AC 120 230 V ...

Page 344: ...utomation 344 System Manual 09 2014 A5E31622160 AB C 8 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 Figure C 6 Example of an interconnection with SM 321 DI 8 x AC 120 230 V ...

Page 345: ...omation System Manual 09 2014 A5E31622160 AB 345 C 9 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 Figure C 7 Example of an interconnection with SM 321 DI 16 x DC 24V ...

Page 346: ...omation 346 System Manual 09 2014 A5E31622160 AB C 10 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 Figure C 8 Example of an interconnection with SM 321 DI 16 x DC 24V ...

Page 347: ... Automation System Manual 09 2014 A5E31622160 AB 347 C 11 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 Figure C 9 Example of an interconnection with SM 326 DO 10 x DC 24V 2A ...

Page 348: ...Automation 348 System Manual 09 2014 A5E31622160 AB C 12 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 Figure C 10 Example of an interconnection with SM 326 DI 8 x NAMUR ...

Page 349: ...ss Automation System Manual 09 2014 A5E31622160 AB 349 C 13 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 Figure C 11 Example of an interconnection with SM 326 DI 24 x DC 24 V ...

Page 350: ...ss Automation 350 System Manual 09 2014 A5E31622160 AB C 14 SM 421 DI 32 x UC 120 V 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 Figure C 12 Example of an interconnection with SM 421 DI 32 x UC 120 V ...

Page 351: ...utomation System Manual 09 2014 A5E31622160 AB 351 C 15 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 Figure C 13 Example of an interconnection with SM 421 DI 16 x 24 V ...

Page 352: ...cess Automation 352 System Manual 09 2014 A5E31622160 AB C 16 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 Figure C 14 Example of an interconnection with SM 421 DI 32 x 24 V ...

Page 353: ...cess Automation System Manual 09 2014 A5E31622160 AB 353 C 17 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 Figure C 15 Example of an interconnection with SM 421 DI 32 x 24 V ...

Page 354: ...al 09 2014 A5E31622160 AB C 18 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 Figure C 16 Example of an interconnection with SM 322 DO 8 x DC 24 V 2 A ...

Page 355: ... SM 322 DO 32 x DC 24 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 Figure C 17 Example of an interconnection with SM 322 DO 32 x DC 24 V 0 5 A ...

Page 356: ...ess Automation 356 System Manual 09 2014 A5E31622160 AB C 20 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 Figure C 18 Example of an interconnection with SM 322 DO 8 x AC 230 V 2 A ...

Page 357: ...22 DO 4 x DC 24 V 10 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 Figure C 19 Example of an interconnection with SM 322 DO 16 x DC 24 V 10 mA EEx ib ...

Page 358: ...22 DO 4 x DC 15 V 20 mA EEx 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 Figure C 20 Example of an interconnection with SM 322 DO 16 x DC 15 V 20 mA EEx ib ...

Page 359: ...tomation System Manual 09 2014 A5E31622160 AB 359 C 23 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 Figure C 21 Example of an interconnection with SM 322 DO 8 x DC 24 V 0 5 A ...

Page 360: ...omation 360 System Manual 09 2014 A5E31622160 AB C 24 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 Figure C 22 Example of an interconnection with SM 322 DO 16 x DC 24 V 0 5 A ...

Page 361: ...SM 332 AO 8 x 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 Figure C 23 Example of an interconnection with SM 332 AO 8 x 12 Bit ...

Page 362: ...SM 332 AO 4 x 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 Figure C 24 Example of an interconnection with SM 332 AO 4 x 0 4 20 mA EEx ib ...

Page 363: ...s Automation System Manual 09 2014 A5E31622160 AB 363 C 27 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 Figure C 25 Example of an interconnection with SM 422 DO 16 x 120 230 V 2 A ...

Page 364: ... 28 SM 422 DO 32 x DC 24 V 0 5 A 6ES7 422 7BL00 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 Figure C 26 Example of an interconnection with SM 422 DO 32 x DC 24 V 0 5 A ...

Page 365: ...anual 09 2014 A5E31622160 AB 365 C 29 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 Figure C 27 Example of an interconnection with SM 331 AI 4 x 15 Bit EEx ib ...

Page 366: ...rocess Automation 366 System Manual 09 2014 A5E31622160 AB C 30 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 Figure C 28 Example of an interconnection with SM 331 AI 8 x 12 Bit ...

Page 367: ...ion System Manual 09 2014 A5E31622160 AB 367 C 31 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 Figure C 29 Example of an interconnection with SM 331 AI 8 x 16 Bit ...

Page 368: ...ion 368 System Manual 09 2014 A5E31622160 AB C 32 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 Figure C 30 Example of an interconnection with SM 331 AI 8 x 16 Bit ...

Page 369: ... 0AB0 CPU 410 5H Process Automation System Manual 09 2014 A5E31622160 AB 369 C 33 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 Figure C 31 Example of an interconnection AI 6xTC 16Bit iso ...

Page 370: ...A5E31622160 AB C 34 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 Figure C 32 Interconnection example 1 SM 331 AI 8 x 0 4 20mA HART The diagram below shows the connection of a 2 wire transmitter to two redundant SM 331 AI 8 x 0 4 20mA HART ...

Page 371: ...amples for redundant I Os C 34 SM331 AI 8 x 0 4 20mA HART 6ES7 331 7TF01 0AB0 CPU 410 5H Process Automation System Manual 09 2014 A5E31622160 AB 371 Figure C 33 Interconnection example 2 SM 331 AI 8 x 0 4 20mA HART ...

Page 372: ...60 AB C 35 SM 332 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 Figure C 34 Example of an interconnection with SM 332 AO 4 x 12 Bit ...

Page 373: ...1 0AB0 CPU 410 5H Process Automation System Manual 09 2014 A5E31622160 AB 373 C 36 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 Figure C 35 Interconnection example 3 SM 332 AO 8 x 0 4 20mA HART ...

Page 374: ...Connection examples for redundant I Os C 36 SM332 AO 8 x 0 4 20mA HART 6ES7 332 8TF01 0AB0 CPU 410 5H Process Automation 374 System Manual 09 2014 A5E31622160 AB ...

Page 375: ...erview 242 S7 communication 244 Communication via MPI and communication bus Cycle load 300 Comparison error 117 Components Basic system 25 27 Duplicating 59 Configuration 23 Connecting with diodes 338 Connection Fault tolerant S7 257 S7 257 Consistent data Accessing work memory 279 Continued bumpless operation 107 CPU Parameter 48 Resetting to the factory settings 141 CPU 410 5H DP address ranges ...

Page 376: ...1 Fail safe 57 Failure of a redundancy node 61 Failure of components of distributed I Os 194 Fault tolerant 57 Fault tolerant communication 256 Fault tolerant connections Configuration 270 Programming 260 271 Fiber optic cable 28 Cable pull in 208 Installation 206 Replacement 191 192 Selection 209 Storage 207 Function modules 335 G Gateway 246 H Hardware Components 25 27 Hardware interrupt process...

Page 377: ...racy 126 Configuration 127 MRP media redundancy protocol 74 MSTR 41 MTBF 323 328 Multiple bit errors 118 N Network configuration 240 Network functions S7 communication 244 Networking configuration 240 Non redundant encoders 82 85 O OB 121 116 Online help 16 Operating mode Changing 51 Operating objectives 57 Operating state changes 234 Operating states LINK UP 104 STARTUP 102 System 109 UPDATE 104 ...

Page 378: ...ions on other subnets 246 Application example 248 Gateway 246 Requirements 246 S7 400H Configuration and programming 30 Documentation 19 I O 29 User program 293 S7 400H Blocks 293 S7 410 AS Update block type in RUN 150 S7 REDCONNECT 268 269 Save service data 148 Scope of validity of the manual 15 Self test 108 116 Services S7 communication 244 SFB 14 280 SFB 15 280 SFBs S7 communication 245 SFC 10...

Page 379: ... requirements 52 Stand alone operation 52 System redundancy 70 System states 109 System status list Compatibility 235 T Technical Support 17 Time monitoring 123 Time response 134 Time out 124 Tolerance window 84 Tools 30 U Update 121 122 125 283 292 297 Block types in multiproject with S7 410 AS 150 Minimum input signal duration 286 Monitoring times 297 Sequence 288 Time response 125 125 UPDATE 10...

Page 380: ...Index CPU 410 5H Process Automation 380 System Manual 09 2014 A5E31622160 AB ...

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