Page 1 Preface Basics of Fault Tolerance Fault-tolerant Solutions in PCS 7 SIMATIC Advantages of fault-tolerant components Process Control System PCS 7 Component Replacement Fault-tolerant Process Control and Plant Changes Systems (V8.0) Failure, Switchover and Return of Fault-tolerant Components Function Manual Diagnostics 03/2012 A5E02779471-02...
Page 2: A5E02779471
Note the following: WARNING Siemens products may only be used for the applications described in the catalog and in the relevant technical documentation. If products and components from other manufacturers are used, these must be recommended or approved by Siemens. Proper transport, storage, installation, assembly, commissioning, operation and maintenance are required to ensure that the products operate safely and without any problems.
Page 3: Table Of Contents
Table of contents Preface.................................7 Basics of Fault Tolerance...........................13 Rationale for using fault-tolerant process control systems............13 System-wide availability analyses....................15 PCS 7 redundancy concept......................16 Overview of the PCS 7 redundancy features................19 Features for the configuration phase...................20 Features for the commissioning and operation phases...............20 Features for servicing and system expansions................22 Definition of availability........................23 Definition of the standby modes....................23...
Page 4 Table of contents 3.3.5.3 Gateway between redundant and non-redundant PROFIBUS DP..........65 3.3.5.4 Connection of PROFIBUS PA to PROFIBUS DP................66 3.3.5.5 Fault-tolerant PROFIBUS PA......................68 3.3.5.6 Connecting the FOUNDATION Fieldbus to PROFIBUS DP............72 3.3.5.7 Fault-tolerant FOUNDATION Fieldbus..................74 Solutions for integrating a PCS 7 plant in a domain..............77 Solutions for OS servers......................77 Solutions for OS clients.......................81 3.6.1...
Page 5 How to configure an OS client....................144 4.5.11 How to configure an OS client for permanent operability............145 4.5.12 How to download a SIMATIC PCS 7 project to the target systems...........148 4.5.13 Evaluating the "@RM_MASTER" Redundancy Variables with Scripts........149 SIMATIC BATCH Stations......................149 4.6.1...
Page 6 Table of contents Route Control server.........................187 6.6.1 Reaction of Route Control servers to failure................187 OS clients..........................188 6.7.1 Failover reactions of OS clients with permanent operability............188 BATCH clients...........................190 6.8.1 Failover reactions of BATCH clients..................190 Route Control clients.........................190 6.9.1 Failover reaction of Route Control clients..................190 6.10 Guidelines for updating a redundant OS in runtime..............191 6.10.1...
Page 7: Preface
PCS 7 Readme carefully; it contains important information PCS 7 manuals. Please read this and amendments on PCS 7. PCS 7 Readme on the Process Control System; SIMATIC PCS 7 DVD contains ● The important information regarding PCS 7 and takes precedence over the PCS 7 documentation supplied.
Page 8 Preface ● In the section "Hardware manuals for SIMATIC PCS 7 ..." – The manuals for components approved for a PCS 7 version ● In the section "Software manuals for SIMATIC PCS 7 ..." – The complete system documentation – The separate setup program for PCS 7 documentation and the PCS 7 help system for download.
Page 9: Process Control System Pcs
Preface Manual Content Process Configuration manual ● Configuring SIMATIC connections Control System PCS 7; Operator ● Interconnecting faceplates Station ● Configuring operator stations ● Compiling the OS ● Installation guidelines Process Control System PCS 7; ● Activation of the maintenance functions Maintenance Station function ●...
Page 10 Preface Manual Content SIMATIC Operating Instructions ● Configuration options NET; Industrial Ethernet Switches ● Mounting SCALANCE X-200 ● Wiring ● Commissioning and diagnostics SIMATIC Operating Instructions ● Configuration options NET; Industrial Ethernet Switches ● Mounting SCALANCE X-400 ● Wiring ● Commissioning and diagnostics SIMATIC NET Manual Manual ●...
Page 11 Preface Changes compared to the previous version Below, you will find an overview of the most important changes in the documentation compared to the previous version: ● Using the redundant, fault-tolerant terminal bus For additional information, refer to the section "Solutions for the terminal bus (Page 46)." ●...
Page 13: Rationale For Using Fault-Tolerant Process Control Systems
Basics of Fault Tolerance Rationale for using fault-tolerant process control systems Advantages of fault-tolerant components Process control systems are responsible for controlling, monitoring and documenting production and manufacturing processes. Due to the increasing degree of automation and the demand for improved efficiency, the availability of these systems is playing an increasingly important role.
Page 14 Basics of Fault Tolerance 2.1 Rationale for using fault-tolerant process control systems Legend for the above illustration: Note The following short designations are commonly used in this documentation. Fault-tolerant Process Control Systems (V8.0) Function Manual, 03/2012, A5E02779471-02...
Page 15: System-Wide Availability Analyses
Basics of Fault Tolerance 2.2 System-wide availability analyses Short designation Meaning Engineering Engineering station, PC Station OS server Operator station, PC project data station in the project form "WinCC Server" OS client Operator station, PC visualization station in the project form "WinCC Client" BATCH server BATCH station, PC recipe and batch data station BATCH client...
Page 16: Pcs 7 Redundancy Concept
(power on or off) or operating mode (master or slave). PCS 7 redundancy concept Advantages of the PCS 7 redundancy concept Fault-tolerant process control systems can be realized with SIMATIC PCS 7 at minimal cost in all phases of a system lifecycle: ● Configuration ● Commissioning/operation ●...
Page 17 Basics of Fault Tolerance 2.3 PCS 7 redundancy concept Overview of the PCS 7 redundancy concept PCS 7 offers you a redundancy concept that reaches all levels of process automation. Note The numbering of the components in the illustration relates to the descriptions provided below. Fault-tolerant Process Control Systems (V8.0) Function Manual, 03/2012, A5E02779471-02...
Page 18 Basics of Fault Tolerance 2.3 PCS 7 redundancy concept Number Description Several clients (OS clients, BATCH clients, Route Control clients) can access data on a server (OS server, BATCH server, Route Control server). Communication between the operator stations (client and server) and communication with the engineering station is over a redundant, fault-tolerant terminal bus (Industrial Ethernet).
Page 19: Overview Of The Pcs 7 Redundancy Features
Basics of Fault Tolerance 2.4 Overview of the PCS 7 redundancy features Overview of the PCS 7 redundancy features Introduction The easiest way to increase availability is to keep replacement parts in stock on site and to have fast service at your disposal to replace defective components. In this documentation, we provide you with PCS 7 software and hardware solutions that go well beyond fast service and replacement part warehousing.
Page 20: Features For The Configuration Phase
Basics of Fault Tolerance 2.6 Features for the commissioning and operation phases Basics of increased availability Increased availability in PCS 7 is based on the following principles: ● Duplication of a component Example: Use of duplicate signal modules ● Duplication of a component and a software component that performs an automatic failover from active and passive components when a fault occurs.
Page 21 Basics of Fault Tolerance 2.6 Features for the commissioning and operation phases of process data is not interrupted during the commissioning phase. Defective components can be replaced in runtime. NOTICE If a component fails in a redundant control system, the fault tolerance is lost. This means that another failure could potentially result in the failure of the entire system, although such occurrences are rare (e.g., if both bus lines are severed in the case of a redundant bus system).
Page 22: Features For Servicing And System Expansions
Diagnostics of components without an additional example, LEDs) for fast, local error detection. programming device (PG). Faster service from SIEMENS Customer Support. The service is on site within 2 to 48 hours to maintain the availability guarantee. Repairs and component expansions (upgrades, Repair and component expansions can be made in conversions and updates) in runtime.
Page 23: Definition Of Availability
Basics of Fault Tolerance 2.9 Definition of the standby modes Definition of availability Definitions Availability is usually defined as follows: Quotient of MTBF and (MTBF + MTTR) or in short form actual operating condition / nominal operating condition. Whereby: ● MTBF = mean time between two successive error events, repair time excluded ●...
Page 24: Redundancy Nodes
Basics of Fault Tolerance 2.10 Redundancy nodes Standby operating mode Operating mode Definition Hot standby Hot standby means the parallel redundant processing of signals in redundant components. This allows a bumpless failover of the entire system to the standby components. Warm standby Warm standby means the fast continuation of the aborted function by standby components at a program continuation point.
Page 25 Basics of Fault Tolerance 2.10 Redundancy nodes Availability of a redundancy node despite faults If a component in a redundancy node fails, the overall system continues to operate. Total failure of a redundancy node The following figure shows a complete system that has ceased to operate due to a failure of the "Field bus (PROFIBUS DP)"...
Page 27: Solutions For The I/O
Fault-tolerant Solutions in PCS 7 Solutions for the I/O Introduction In this section you will learn about the I/O systems and components that contribute to increasing the availability of your system. This means using the distributed I/O in PCS 7. Distributed I/O Distributed I/O refers to modules (input/output modules and function modules) that are used in a modular, distributed I/O device such as the ET 200M or ET 200iSP.
Page 28: Redundant I/O
Note Information on which modules are released for the distributed I/O in PCS 7 can be found in PCS 7 - Released modules. You will find this documentation on the the documentation Internet at: http:\\www.siemens.com/pcs7-documentation (http:\\www.siemens.com/pcs7- documentation). 3.1.1 Redundant I/O...
Page 29 Fault-tolerant Solutions in PCS 7 3.1 Solutions for the I/O The ET 200M distributed I/O device is connected as redundant DP slave to a fault-tolerant automation system operating as the DP master via PROFIBUS DP. A redundant configuration is achieved by installing an additional ET 200M and an additional PROFIBUS DP connection. Note Use only active bus modules for the ET 200M in a fault-tolerant system with PCS 7.
Page 30: Switched I/O
Fault-tolerant Solutions in PCS 7 3.1 Solutions for the I/O Installation rules The configuration always has to be symmetrical when using redundant I/O. Follow these installation rules: ● Both subsystems of the S7 400H must be configured identically. The same modules are located at the same slots.
Page 31 Fault-tolerant Solutions in PCS 7 3.1 Solutions for the I/O Configuration A switched I/O can be set up in PCS 7 with the following distributed I/O devices: ● ET 200M For this setup, you require an ET 200M with active backplane bus modules and a redundant IM 153-2 interface module.
Page 32: Components In The Distributed I/O
Fault-tolerant Solutions in PCS 7 3.1 Solutions for the I/O The system remains available even when one component in part of a line of the redundancy node fails. There is only one I/O module and therefore no corresponding redundancy node. It is the weakest link in the complete system's chain.
Page 33: Redundant I/O Modules
Fault-tolerant Solutions in PCS 7 3.1 Solutions for the I/O The configuration is provided as an example in the section "Redundant I/O (Page 28)". ● ET 200M with redundant IM 153-2 Two IM 153-2 interface modules are mounted on the active bus module in the distributed I/O device for redundant operation.
Page 34: Redundant Actuators And Sensors
Fault-tolerant Solutions in PCS 7 3.1 Solutions for the I/O Required software and configuration You select and configure the redundant modules in HW Config. ● In order for both subsystems of the H system to be able to address redundant input/output modules, S7 driver blocks from the "Redundant I/O"...
Page 35: Solutions For Automation Systems
Fault-tolerant Solutions in PCS 7 3.2 Solutions for automation systems an actuator/sensor fails, the automation system continues to operate with the intact actuator/ sensor. This ensures that the current status of the process values can be read in or output at any time.
Page 36: S7-400H Hardware Components
Fault-tolerant Solutions in PCS 7 3.2 Solutions for automation systems 3.2.1 S7-400H hardware components Hardware components The following hardware components are available for the configuration of the fault-tolerant automation system. Hardware components Mounting rack UR2-H Mounting rack UR2 Mounting rack UR1 Central processing unit CPU 412-3H ...
Page 37 Fault-tolerant Solutions in PCS 7 3.2 Solutions for automation systems Mounting racks The following three racks are available for installing the S7-400H. Normally, the UR2-H rack is used. Module type Size Special feature UR2-H 2 x 9 slots Installation of two separate subsystems each with nine modules.
Page 38 Fault-tolerant Solutions in PCS 7 3.2 Solutions for automation systems Transmission medium The suitable physical transmission medium depends on the range, resistance to interference and the transmission rate. ● Industrial Ethernet using fiber-optic cables or triaxial or twisted-pair copper lines can be used for communication between the automation system and the OS servers.
Page 39: How The Simatic S7-400H As Operates
If the active CPU fails, the automation system automatically switches to the redundant CPU Process Control (see section "S7-400H hardware components (Page 36)" and Documentation System, SIMATIC PCS 7, Released Modules ). The failover has no effect on the ongoing process because it is bumpless. Additional information ●...
Page 40 Fault-tolerant Solutions in PCS 7 3.3 Solutions for communication ● Electrical ● Optical ● Electrical/optical combination The communication connections are grouped in three areas: ● Terminal bus ● Plant bus ● Fieldbus In PCS 7, we recommend that the bus systems are set up in a ring structure. The ring structure makes the bus "fault-tolerant", since it can compensate for the failure of a bus line.
Page 41: Network Components
Fault-tolerant Solutions in PCS 7 3.3 Solutions for communication Bus systems set up as a ring are fault-tolerant. In ring structures, the signal path remains intact even if there is a disconnection on the transmission cable at any point in the ring (for example due to a wire break).
Page 42 Fault-tolerant Solutions in PCS 7 3.3 Solutions for communication Network component Bus system Application Switch (from the Terminal bus Type-specific use in network setup SCALANCE series) Plant bus Selected SCALANCE X components enable the following: ● Transmission rates up to 1 Gbps ●...
Page 43 Fault-tolerant Solutions in PCS 7 3.3 Solutions for communication Network component Bus system Application AFD (Automatic Field Fieldbus Connection of field devices via ring redundancy Distributor) ● PROFIBUS PA ● Maximum of 31 fieldbus components on one AFDiS ● FOUNDATION Fieldbus ●...
Page 44 Fault-tolerant Solutions in PCS 7 3.3 Solutions for communication SCALANCE X switches for setting up redundant networks You can find additional information on SCALANCE X switches approved for PCS 7 in the Process Control System PCS 7; Released Modules documentation. The switches must have the necessary functions available to set up the relevant redundant network: ●...
Page 45: Media Redundancy Protocol
Fault-tolerant Solutions in PCS 7 3.3 Solutions for communication 3.3.2 Media Redundancy Protocol Use of media redundancy protocol Note HSR (High Speed Redundancy) and MRP (Media Redundancy Protocol) The X200 IRT switches cannot serve as redundancy manager and standby manager at the same time.
Page 46: Solutions For The Terminal Bus
Fault-tolerant Solutions in PCS 7 3.3 Solutions for communication 3.3.3 Solutions for the terminal bus 3.3.3.1 Connecting PC stations to the terminal bus You can connect the following PC stations to industrial Ethernet via communication modules (network adapters or communications processors): ●...
Page 47: Fault-Tolerant Terminal Bus
Fault-tolerant Solutions in PCS 7 3.3 Solutions for communication 3.3.3.2 Fault-tolerant terminal bus The terminal bus connects the servers (OS servers, BATCH servers, Route Control servers) with the clients of the process control system (OS clients, BATCH clients, Route Control clients).
Page 48 Fault-tolerant Solutions in PCS 7 3.3 Solutions for communication Availability If there is a fault in a ring line, the communication between clients and servers via the switches remains unaffected. However, if one of the switches fails, the link between the connected OS servers and the OS clients is interrupted.
Page 49: Redundant, Fault-Tolerant Terminal Bus
Fault-tolerant Solutions in PCS 7 3.3 Solutions for communication SIMATIC NET; Industrial Ethernet Switches SCALANCE X-200 ● Operating Instructions SIMATIC NET; Industrial Ethernet OSM/ESM ● Manual 3.3.3.3 Redundant, fault-tolerant terminal bus Functionality The terminal bus connects the servers (OS servers, BATCH servers, Route Control servers) etc.
Page 50: Redundant, Fault-Tolerant Terminal Bus Based On The Parallel Redundancy Protocol (Prp)
Fault-tolerant Solutions in PCS 7 3.3 Solutions for communication SIMATIC NET; PG/PC - Industrial Ethernet; SOFTNET‑IE RNA ● Operating instructions ● Readme for SOFTNET IE RNA 3.3.3.4 Redundant, fault-tolerant terminal bus based on the Parallel Redundancy Protocol (PRP) The section below describes the basic structure of a redundant fault-tolerant terminal bus using the SIMATIC NET SOFTNET-IE RNA software.
Page 51 Fault-tolerant Solutions in PCS 7 3.3 Solutions for communication Redundant, fault-tolerant terminal bus with SIMATIC NET SOFTNET-IE RNA All protocols among the redundantly connected components are automatically duplicated, sent and distributed in the mutually redundant networks. The receiver uses the first incoming frame with the same information from the redundant networks.
Page 52: Redundant, Fault-Tolerant Terminal Bus Based On The Intel Team Mode
Fault-tolerant Solutions in PCS 7 3.3 Solutions for communication using the SCALANCE X204RNA . Select this connection for infrastructure components, for example: ● Master system clock (from SICLOCK TC400) ● Domain controllers (DCs), DNS, WINS, DHCP, WSUS ● WLAN access point ●...
Page 53 Fault-tolerant Solutions in PCS 7 3.3 Solutions for communication Note Redundant linking of network segments The redundant linking of two network segments is only possible when the linking switches are capable of acting as standby manager. Example: ● Linking with SCALANCE X414-3E ●...
Page 54 Fault-tolerant Solutions in PCS 7 3.3 Solutions for communication Components The following switches can be used: ● SCALANCE series of switches Modules for optical or electrical connection are used for the connection. ● OSM (optical signal lines) The connection to the OSMs is electrical or optical. ●...
Page 55 Fault-tolerant Solutions in PCS 7 3.3 Solutions for communication Additional information ● Section "How to configure the redundant terminal bus on the basis of the INTEL TEAM mode (Page 97)" SIMATIC NET; Industrial Ethernet Switches SCALANCE X-400 ● Operating Instructions Fault-tolerant Process Control Systems (V8.0) Function Manual, 03/2012, A5E02779471-02...
Page 56: Solutions For The Plant Bus
Fault-tolerant Solutions in PCS 7 3.3 Solutions for communication 3.3.4 Solutions for the plant bus 3.3.4.1 Connecting PC stations to the plant bus Network adapters for connection to the fault-tolerant plant bus Application Network adapter ● Connection of up to 8 communication partners ●...
Page 57: Fault-Tolerant Plant Bus
Fault-tolerant Solutions in PCS 7 3.3 Solutions for communication Connecting fault-tolerant automation systems (S7-400H/FH) CP 16x3 communications processors and the licensed S7-REDCONNECT software are required for redundant communication with S7-400H/FH . Additional information Process Control System PCS 7; Released modules ●...
Page 58 Fault-tolerant Solutions in PCS 7 3.3 Solutions for communication The following automation systems can be used: ● AS 41xH Availability - ring structure In this system, one CP 443-1 may fail in each subsystem of the AS without this affecting the complete system.
Page 59: Redundant, Fault-Tolerant Plant Bus
Fault-tolerant Solutions in PCS 7 3.3 Solutions for communication Additional information ● Section "How to configure a fault-tolerant plant bus (Page 100)" SIMATIC Net Twisted Pair and Fiber-Optic Networks ● Manual SIMATIC NET Industrial Ethernet OSM/ESM Network Management ● Manual SIMATIC;...
Page 60 Fault-tolerant Solutions in PCS 7 3.3 Solutions for communication Redundant communication solutions The following communication solutions are offered to prevent a possible failure: ● Redundant electrical or optical network with switches set up as Industrial Ethernet ● Combined redundant network with switches, FO cables and electrical connection ●...
Page 61 Fault-tolerant Solutions in PCS 7 3.3 Solutions for communication Availability - redundant, fault-tolerant plant bus The block diagram for a redundant, fault-tolerant plant bus with two CPs each in both OS servers and additional switches appears as follows: In this system, one CP 16x3 can fail in each OS server or one CP 443‑1 in each subsystem of the AS without this affecting the complete system.
Page 62: Solutions For The Fieldbus
Fault-tolerant Solutions in PCS 7 3.3 Solutions for communication 3.3.5 Solutions for the fieldbus 3.3.5.1 Redundant PROFIBUS DP Functionality The field bus is used for data exchange between the automation system (AS) and the distributed I/O. PROFIBUS DP (distributed peripheral)-- the field bus standard for manufacturing and process automation--is used.
Page 63 Fault-tolerant Solutions in PCS 7 3.3 Solutions for communication Availability If the active PROFIBUS DP fails, sensors and H system can communicate with each other over the redundant bus connection. The configuration shown in the following figure provides increased availability due to the redundant interfacing of the distributed I/O. Additional information ●...
Page 64: Fault-Tolerant Fieldbus Based On Profinet
Fault-tolerant Solutions in PCS 7 3.3 Solutions for communication 3.3.5.2 Fault-tolerant fieldbus based on PROFINET Functionality The fieldbus is used for data communication between the automation system (AS) and the distributed I/O. PROFINET is a standard for manufacturing and process automation. The PROFINET-based fieldbus comprises the specifications for the following elements: ●...
Page 65: Gateway Between Redundant And Non-Redundant Profibus Dp
Fault-tolerant Solutions in PCS 7 3.3 Solutions for communication Note Fault-tolerant PROFINET It is absolutely necessary to operate the fieldbus ring with MRP (media redundancy protocol) when using rings with PROFINET. Availability If the communication connection via a CPU fails, the stations of the distributed I/O can communicate with the H system over the fault-tolerant bus line.
Page 66: Connection Of Profibus Pa To Profibus Dp
Fault-tolerant Solutions in PCS 7 3.3 Solutions for communication Configuration Functionality The Y Link creates a gateway from the redundant DP master system of an S7-400H to a non- redundant DP master system. This enables devices with only one PROFIBUS DP interface to be connected to a redundant DP master system as switched I/O.
Page 67 Fault-tolerant Solutions in PCS 7 3.3 Solutions for communication Configuration Functionality The DP/PA Coupler is a transceiver that interconnects PROFIBUS DP and PROFIBUS PA and decouples the various transmission rates. It is a slave on the PROFIBUS DP and a master on the PROFIBUS PA.
Page 68: Fault-Tolerant Profibus Pa
Fault-tolerant Solutions in PCS 7 3.3 Solutions for communication Physical bus characteristics ● The application protocols for PROFIBUS DP and PROFIBUS PA are defined according to IEC 61158-2 and are identical for these two fieldbus variants. – You can set the transmission speed on the PROFIBUS DP. The maximum transmission speed with the Y-link is 12 Mbps.
Page 69 Fault-tolerant Solutions in PCS 7 3.3 Solutions for communication Fault-tolerant communication solutions The following communication solutions are offered to prevent a possible failure: ● Ring redundancy with the AFD (Active Field Distributor) ● Coupler redundancy with the AFS (Active Field Splitter) The DP/PA coupler can be used stand-alone or in the DP/PA-Link .
Page 70 Fault-tolerant Solutions in PCS 7 3.3 Solutions for communication Configuration Examples for connections of field devices via AFD and AFS are shown in the following figures. Figure 3-1 Connection to a redundant PROFIBUS DP Fault-tolerant Process Control Systems (V8.0) Function Manual, 03/2012, A5E02779471-02...
Page 71 Fault-tolerant Solutions in PCS 7 3.3 Solutions for communication Figure 3-2 Connection to a singular PROFIBUS DP Transmission rate You have two interfacing options for the gateway between PROFIBUS DP and PROFIBUS PA. These result in different transmission rates on PROFIBUS DP. ●...
Page 72: Connecting The Foundation Fieldbus To Profibus Dp
Fault-tolerant Solutions in PCS 7 3.3 Solutions for communication Additional information ● Section " Connection of PROFIBUS PA to PROFIBUS DP (Page 66)" ● Section "How to configure redundant PROFIBUS PA (Page 107)" SIMATIC; DP/PA Coupler, DP/PA Link and Y Link Bus Couplers ●...
Page 73 Fault-tolerant Solutions in PCS 7 3.3 Solutions for communication Functionality FF Link connects PROFIBUS DP and FOUNDATION Fieldbus with one another and decouples various transmission rates. It is a slave on the PROFIBUS DP and master on the FOUNDATION Fieldbus. From the point of view of the automation system, the FF Link is a modular slave.
Page 74: Fault-Tolerant Foundation Fieldbus
Fault-tolerant Solutions in PCS 7 3.3 Solutions for communication ● If you use a SIMATIC AFDiS as a field barrier between the FF Link and the field devices, you can connect the field devices in hazardous areas of zones 0 or 1. The outputs of the SIMATIC AFDiS fulfill the requirements for types of protection EEx(ia) and EEx(ib).
Page 75 Fault-tolerant Solutions in PCS 7 3.3 Solutions for communication ● You can connect one FF segment to the FF Link . ● For the purpose of increasing availability when using ring redundancy (fault-tolerant connection), connect a maximum of 4 field devices (one field device per spur line) to an active field distributor AFD(maximum of FDC 157 8 AFD to a redundant coupler).
Page 76 Fault-tolerant Solutions in PCS 7 3.3 Solutions for communication Figure 3-4 Connection to a singular PROFIBUS DP Transmission rate You have two interconnection options for the gateway between PROFIBUS DP and FOUNDATION Fieldbus . These result in different transmission rates on PROFIBUS DP. ●...
Page 77: Solutions For Integrating A Pcs 7 Plant In A Domain
Process Control System PCS 7; Time Synchronization ● Function manual ● On the Internet pages of Customer Support in Whitepaper SIMATIC; Safety Concept PCS 7 and WinCC; Basic document (http://support.automation.siemens.com/WW/view/en/ 26462131) Solutions for OS servers Redundant OS servers PCS 7 enables you to configure two OS servers redundantly for fault-tolerant operation. This ensures that you can monitor and control your process at all times.
Page 78 Fault-tolerant Solutions in PCS 7 3.5 Solutions for OS servers Configuration The figure below shows an example of a configuration with redundant OS server and redundant central archive server. Functionality Redundant OS servers monitor each other in runtime. If one OS partner server fails, the event is detected in time.
Page 79 Fault-tolerant Solutions in PCS 7 3.5 Solutions for OS servers ● Process Historian You can set up two Process Historians with redundancy functionality for fault-tolerant operation. The associated information server can be configured in such a way that it connects to the active Process Historian to execute tasks. ●...
Page 80 Fault-tolerant Solutions in PCS 7 3.5 Solutions for OS servers Redundancy connection You need the following components to make the redundancy connection, depending on the distance to be bridged: Maximum distance Required components Connection 10 m Null modem cable Serial connection 100 m ●...
Page 81: Solutions For Os Clients
Fault-tolerant Solutions in PCS 7 3.6 Solutions for OS clients WinCC ; WinCC Redundancy ● Online help for ● Documentation on the Process Historian ● Section "How to configure a central archive server and its redundant archive partner server (Page 130)" Solutions for OS clients 3.6.1 Additional OS clients...
Page 82: Solutions For Simatic Batch
Fault-tolerant Solutions in PCS 7 3.7 Solutions for SIMATIC BATCH that the OS clients can control and monitor the automation process continuously, the OS clients are distributed between the redundant OS servers with specification of a preferred OS server. The failure of some OS clients can therefore be tolerated because the other clients remain connected to the process.
Page 83 Fault-tolerant Solutions in PCS 7 3.7 Solutions for SIMATIC BATCH ● The interface for message processing between the active BATCH server and the OS server remains available. ● The BATCH clients automatically fail over to the functioning (active) BATCH server. After the failover, it is possible to control and monitor the process from all BATCH clients.
Page 84 Fault-tolerant Solutions in PCS 7 3.7 Solutions for SIMATIC BATCH Note When a redundant server pair is used as an OS server and BATCH server, the redundancy connection must be configured via the Ethernet connection. Serial linking of the BATCH server pair is not possible in PCS 7. Availability The following two block diagrams of fully operational systems illustrates the availability of the BATCH clients and BATCH servers.
Page 85: Solutions For Route Control Server
Fault-tolerant Solutions in PCS 7 3.8 Solutions for Route Control server The BATCH servers also communicate with OS servers over the terminal bus. The OS servers are connected to the automation system over the plant bus. Note SIMATIC BATCH in "AS-based" operating mode The BATCH servers are also connected to the plant bus if SIMATIC BATCH is operated "AS- based".
Page 86 Fault-tolerant Solutions in PCS 7 3.8 Solutions for Route Control server Configuration of a redundant Route Control server The following configuration shows the basic operating principle of redundant Route Control servers. Redundancy connection You need the following components to make the redundancy connection, depending on the distance to be bridged: Maximum distance Required components...
Page 87: Solutions For Engineering Station
Fault-tolerant Solutions in PCS 7 3.9 Solutions for engineering station Note The buses marked with * (terminal bus and plant bus) can be configured redundantly with optical or electronic switch modules. Additional information ● PC station identified as faulty; see section "Solutions for OS servers (Page 77)" ●...
Page 88: Time Synchronization
Fault-tolerant Solutions in PCS 7 3.10 Time synchronization Backing up configuration data The configuration data should always be backed up following a change in the configuration. 3.10 Time synchronization Introduction Time synchronization in a PCS 7 plant is of utmost importance for synchronizing, tracing, documenting and archiving all time-critical processes.
Page 89: Creating And Expanding A Project With Pre-Configured Stations
Advantages of fault-tolerant components Creating and expanding a project with pre-configured stations PCS 7 wizards "New Project" and "Extend Project" You can create fault-tolerant stations for the AS and PC stations using the PCS 7 "New Project" and "Expand Project" wizards in the SIMATIC Manager. For redundant PC stations, you configure a redundant multiple station system using the PCS 7 wizard.
Page 90: How To Add A Simatic H Station To Your Project
Advantages of fault-tolerant components 4.2 SIMATIC H Station Step What? Configuring redundant communications processors (Page 93) Setting the CPU for the error response of input/output modules (Page 95) 4.2.2 How to add a SIMATIC H station to your project Introduction The SIMATIC H station is contained in the hardware catalog of HW Config as a stand-alone station type.
Page 91: How To Insert Synchronization Modules Into The H Cpu
Advantages of fault-tolerant components 4.2 SIMATIC H Station Additional information Automation System S7-400H; Fault-tolerant Systems ● Manual 4.2.3 How to insert synchronization modules into the H CPU Requirements ● The PCS 7 project is open in SIMATIC Manager. ● HW Config is open. ●...
Page 92 Advantages of fault-tolerant components 4.2 SIMATIC H Station Result The following figure shows an example of the configured subsystems of the fault-tolerant station in HW Config: Additional information Process Control System PCS 7; PCS 7 - Released Modules ● Documentation Automation System S7-400H;...
Page 93: How To Configure Redundant Communication Processors
Advantages of fault-tolerant components 4.2 SIMATIC H Station 4.2.4 How to configure redundant communication processors Introduction Configure at least one CP 443-1 for each H CPU on a plant bus. You can also make a redundant interconnection. Requirements ● The PCS 7 project with a SIMATIC H station is open in SIMATIC Manager. ●...
Page 94 Advantages of fault-tolerant components 4.2 SIMATIC H Station Result The following figure shows an example of configuration in HW Config. Connection to a fault- tolerant plant bus is possible. Fault-tolerant Process Control Systems (V8.0) Function Manual, 03/2012, A5E02779471-02...
Page 95: How To Set The Failure Reaction Of The Input/Output Modules On The Cpu
Advantages of fault-tolerant components 4.2 SIMATIC H Station Additional information Automation System S7-400H; Fault-tolerant Systems ● Manual 4.2.5 How to set the failure reaction of the input/output modules on the CPU Introduction Only perform the following procedure when the libraries "Redundant IO (V3.0)" or "Redundant IO (V4.0)"...
Page 96: Communication Connections
Advantages of fault-tolerant components 4.3 Communication connections 6. Please make a note of which data blocks in the "Data block no." input box are defined as standard transmitters so that you do not use them in your configuration. 7. Select the required setting for the passivation behavior from the "Passivation behavior" list in the "Redundant I/O"...
Page 97: Configuring The Connection To The Terminal Bus
● Readme file for the "SIMATIC NET SOFTNET-IE RNA" software ● You can find additional information on the individual SIMATIC NET products and their configuration on the Internet (http://www.siemens.com/automation/service&support). 4.3.2.2 How to configure the redundant terminal bus on the basis of the INTEL TEAM mode Introduction The NetPro and HW Config programs do not support configuration of the terminal bus.
Page 98 Advantages of fault-tolerant components 4.3 Communication connections Requirements Each PC station (for example, OS server, OS client, domain controller) connected to the terminal bus as a redundant component has to meet the following requirements: ● Redundant connection of the PC station to the terminal bus: Two network adapters working in INTEL Team mode on a PC.
Page 99 Advantages of fault-tolerant components 4.3 Communication connections 8. In the "Select the adapters to include in this team" list, select the network adapters through which the computer should be connected to the redundant terminal bus. – "Network adapter 1" (see table) –...
Page 100: How To Connect Singular Components To The Redundant Terminal Bus On The Basis Of The Parallel Redundancy Protocol
Advantages of fault-tolerant components 4.3 Communication connections 4.3.2.3 How to connect singular components to the redundant terminal bus on the basis of the Parallel Redundancy Protocol Introduction You can connect the following non-redundant objects to a redundant network with the SCALANCE X204RNA .
Page 101 Advantages of fault-tolerant components 4.3 Communication connections The components of the process control system are connected to the plant bus using switch modules. The degree of availability you require determines whether or not you should use additional CPs in the OS servers and in each subsystem of the automation system. This section describes the procedure for a fault-tolerant plant bus (ring) with switch modules without additional CPs.
Page 102: How To Configure A Redundant Profibus Dp
Advantages of fault-tolerant components 4.3 Communication connections Result The following figure shows the resulting configuration: Additional information STEP 7 ● Online help for 4.3.4 How to configure a redundant PROFIBUS DP Introduction The following section describes how to create and connect a redundant PROFIBUS DP. Requirements ●...
Page 103 Advantages of fault-tolerant components 4.3 Communication connections ● The UR2-H rack has been inserted twice in HW Config. ● In HW Config, each mounting rack has been fitted with an H CPU in slot 3 and the required synchronization modules. Procedure Note Steps 1 through 4 are necessary only when a CP 443-5 Extended is used for the connection...
Page 104 Advantages of fault-tolerant components 4.3 Communication connections Result The figure below shows the result of the configuration process in HW Config. Here, a distributed I/O has already been assigned to the DP master systems for the purpose of illustrating the redundancy principle: Fault-tolerant Process Control Systems (V8.0) Function Manual, 03/2012, A5E02779471-02...
Page 105: How To Configure A Fault-Tolerant Fieldbus On The Basis Of Profinet
Advantages of fault-tolerant components 4.3 Communication connections Additional information STEP 7 ● Online help on 4.3.5 How to configure a fault-tolerant fieldbus on the basis of PROFINET Introduction The following section describes how to create and connect a fault-tolerant fieldbus on the basis of PROFINET.
Page 106 Advantages of fault-tolerant components 4.3 Communication connections Result The figure below illustrates the result of the configuration in HW Config. The distributed I/O is connected to the PROFINET IO system. The physical setup is subsequently configured with the Topology Editor. Connect the components with the Topology Editor 1.
Page 107: How To Configure The Redundant Profibus Pa
Advantages of fault-tolerant components 4.3 Communication connections 3. Select the "Graphic View" tab. Note: You can move the objects displayed. You can select the section displayed via the thumbnail view. Position the objects in accordance with the cable sequence in the system. 4.
Page 108 Advantages of fault-tolerant components 4.3 Communication connections Requirements ● The PCS 7 project with a SIMATIC H station is open in SIMATIC Manager. ● Two DP master systems are configured for the SIMATIC H station in HW Config and these are used as connection paths for the redundant interface.
Page 109: Distributed I/O
Advantages of fault-tolerant components 4.4 Distributed I/O Result The following figure shows the resulting configuration in HW Config: Additional information SIMATIC DP/PA Link and Y Link Bus Couplings ● Manual Distributed I/O 4.4.1 Overview of configuration tasks Introduction The following sections describe configuring redundancy of the individual components of the distributed I/O.
Page 110: How To Configure The Redundant Interface For The I/O Device
Advantages of fault-tolerant components 4.4 Distributed I/O 4.4.2 How to configure the redundant interface for the I/O device Introduction Once you have integrated the interface module (IM 153-2 for ET 200M, IM 152-1 for ET 200iSP) as hardware in the distributed I/O device, the component is made known to the system in SIMATIC Manager with HW Config or NetPro.
Page 111 Advantages of fault-tolerant components 4.4 Distributed I/O Result The following figure shows an example configuration in HW Config: Additional information Process Control System PCS 7; High-Precision Time Stamping ● Function manual DP/PA Link and Y Link Bus Couplings ● Manual Fault-tolerant Process Control Systems (V8.0) Function Manual, 03/2012, A5E02779471-02...
Page 112: How To Configure Redundant I/O Modules
Advantages of fault-tolerant components 4.4 Distributed I/O 4.4.3 How to configure redundant I/O modules Introduction You configure the redundant I/O modules using HW Config. Note Redundant operation is possible only with certain S7-300 I/O modules of the ET 200M. For additional information, please refer to the following documents: PCS 7 - Released Modules ●...
Page 113 Advantages of fault-tolerant components 4.4 Distributed I/O Example configuration The figure below shows the setup for redundant input modules in a switched distributed configuration. Method of operation in the example configuration "Signal Module 1" is configured redundantly to "Redundant Signal Module 1". As a result, Signals E1.1 and E10.1 are redundant to one another.
Page 114 Advantages of fault-tolerant components 4.4 Distributed I/O Procedure 1. In the component view, select the SIMATIC H station and double-click the "Hardware" object in the detail window. HW Config opens. 2. If the hardware catalog is not visible, select the menu command View > Catalog. The hardware catalog opens.
Page 115 Advantages of fault-tolerant components 4.4 Distributed I/O 12.Click "Find". The "Find Redundant Module" dialog box opens. 13.In the "Subsystem" list, select the DP master system in which the redundant signal module is configured. All the available PROFIBUS addresses in this DP master system are displayed in the "PROFIBUS address"...
Page 116: How To Configure The Redundancy For Hart Field Devices
Advantages of fault-tolerant components 4.4 Distributed I/O Additional information STEP 7 ● Online help on Process Control System PCS 7; PCS 7 - Released Modules ● Documentation Automation System S7-400H; Fault-tolerant Systems ● Manual 4.4.4 How to configure the redundancy for HART field devices HART field devices can be configured with redundant modules.
Page 117 Advantages of fault-tolerant components 4.4 Distributed I/O Procedure 1. Configure redundant modules for HART field devices in HW Config as described in section "How to configure redundant I/O modules (Page 112)." in the example, the module has been configured for slot 6: –...
Page 118 Advantages of fault-tolerant components 4.4 Distributed I/O Figure 4-2 HART field device added. 3. Place the "HART field device" in the detail view of the redundant module. In the example, module 6 on ET 200M station with PROFIBUS address 6. 4.
Page 119: How To Configure The Y Link
Advantages of fault-tolerant components 4.4 Distributed I/O Additional information Process Control System PCS 7; SIMATIC PDM Operating Manual 4.4.5 How to configure the Y Link Introduction The Y Link consists of two IM 153-2 interface modules and a Y coupler. The Y Link creates a gateway from a redundant DP master system to a non-redundant DP master system.
Page 120 Advantages of fault-tolerant components 4.4 Distributed I/O Result The following figure shows an example configuration in HW Config: Fault-tolerant Process Control Systems (V8.0) Function Manual, 03/2012, A5E02779471-02...
Page 121 Advantages of fault-tolerant components 4.4 Distributed I/O Fault-tolerant Process Control Systems (V8.0) Function Manual, 03/2012, A5E02779471-02...
Page 122: Configuring Dp/Pa Link
Advantages of fault-tolerant components 4.4 Distributed I/O Additional information DP/ PA Link and Y Link Bus Couplings ● Manual 4.4.6 Configuring DP/PA Link Functionality When connecting a redundant PROFIBUS DP, the DP/PA Link consists of two IM 153-2 interface modules and one or more DP/PA couplers. The DP/PA coupler is used to build a gateway between a redundant PROFIBUS DP subnet and a non-redundant PROFIBUS PA subnet.
Page 123 Advantages of fault-tolerant components 4.4 Distributed I/O Procedure Configure the DP/PA Link as described in the section "How to configure the Y Link (Page 119)". The DP/PA Coupler does not appear in the hardware catalog for the configuration of the bus system.
Page 124: Configuring Ff Link
Advantages of fault-tolerant components 4.4 Distributed I/O Additional information SIMATIC DP/PA Link and Y Link Bus Couplings ● Manual 4.4.7 Configuring FF Link Functionality The FF Link consists of two IM 153-2 FF interface modules and one or more FDC157-0 couplers for a connection to a redundant PROFIBUS DP .
Page 125 Advantages of fault-tolerant components 4.4 Distributed I/O Example configuration The following figure shows how the FF Linkis used: Procedure Configure the FF Link in the same way as the PA link. You can find information about this in the "Configuring DP/PA Link (Page 122)" section. The FDC157-0 coupler does not appear in the hardware catalog for the configuration of the bus system.
Page 126: Configuration Of Redundant Signals
Advantages of fault-tolerant components 4.4 Distributed I/O Additional information SIMATIC; Bus links; FF Link bus link ● Operating instructions SIMATIC; PCS 7 in-practice, FOUNDATION Fieldbus ● Commissioning manual SIMATIC; SIMATIC PDM V8.0 SP1 ● Operating manual 4.4.8 Configuration of redundant signals You configure only one signal in CDC for redundantly acquired signals.
Page 127: Operator Stations
Configuring an OS client (Page 144) Configuring an OS client for permanent operability (Page 145) Downloading the SIMATIC PCS 7 project to the target systems (Page 148) 4.5.2 How to configure an OS server and its redundant OS partner server...
Page 128 Advantages of fault-tolerant components 4.5 Operator stations The example below shows the redundant connection of the OS server pair to the plant bus using two CP 1623 or CP 1613 communication processors per server. Requirements ● The PCS 7 project with a SIMATIC H station is open in SIMATIC Manager. ●...
Page 129 Advantages of fault-tolerant components 4.5 Operator stations 13.Select the menu command Insert > Station > SIMATIC PC Station. A new SIMATIC PC station is inserted in the selected project. 14.Select the SIMATIC PC station, select the menu command Edit > Object Properties and enter the desired name (in the example, OS partner server).
Page 130: How To Configure A Central Archive Server And Its Redundant Archive Partner Server
Advantages of fault-tolerant components 4.5 Operator stations Result Your project should now correspond to the project shown in the following figure. You can change the names of the components as you wish. Additional information Process Control System PCS 7; Engineering System ; section "How ●...
Page 131 Advantages of fault-tolerant components 4.5 Operator stations Requirements ● The PCS 7 project is open in SIMATIC Manager. ● Each PC has a standard network adapter for connection to the terminal bus. Procedure Note Steps 1 to 10 of this procedure have already been performed if an archive server was created in the project.
Page 132 Advantages of fault-tolerant components 4.5 Operator stations 19.In the component view, select the SIMATIC PC station and double-click the "Configuration" object in the detail window. The hardware configuration of the SIMATIC PC station opens. 20.If the hardware catalog is not visible, select the menu command View > Catalog. The hardware catalog opens.
Page 133: How To Set The Redundancy Of The Central Archive Server
Advantages of fault-tolerant components 4.5 Operator stations Additional information STEP 7 ● Online help on 4.5.4 How to set the redundancy of the central archive server The properties of the central archive server can only be set for the the archive server with the "WinCC application CAS".
Page 134: How To Set The Project Paths Of The Destination Os And Standby Os
Advantages of fault-tolerant components 4.5 Operator stations 4.5.5 How to set the project paths of the destination OS and standby OS Introduction Note The procedure described in this section applies to the following servers: ● OS server ● Maintenance server ●...
Page 135: How To Configure A Redundant Connection Between An Os And As
Advantages of fault-tolerant components 4.5 Operator stations 4. Click the "Browse" button next to the "Path to destination OS computer" box and enter the path to the MCP file of the destination OS. The destination OS computer is the computer where the project is to run. The mcp file is generated automatically when you create the OS.
Page 136 Advantages of fault-tolerant components 4.5 Operator stations Procedure 1. Open NetPro in SIMATIC Manager with the menu command Options > Configure Network. 2. Select the interface symbol in the first network adapter (e.g. CP 1613) in the picture of the OS server and use the mouse to draw a connection to the plant bus.
Page 137 Advantages of fault-tolerant components 4.5 Operator stations Result The following figure shows the redundant network connection of the two OS servers to the SIMATIC H station in NetPro: Additional information ● Section "Network components (Page 41)" ● Section "How to configure a fault-tolerant plant bus (Page 100)" STEP 7 ●...
Page 138: How To Configure Redundancy For Os Servers On The Engineering Station
Advantages of fault-tolerant components 4.5 Operator stations 4.5.7 How to configure redundancy for OS servers on the engineering station Introduction Carry out the following configuration tasks on the Engineering Station. The description for the OS server is used here. Validity The procedure described in this section applies to the following servers: ●...
Page 139 Advantages of fault-tolerant components 4.5 Operator stations 5. In the "Redundant Partner Server" field, enter the computer name of the redundant OS server. You can also use the “Browse” button to select an appropriate server from the network. 6. Select the following check boxes as required: –...
Page 140 Advantages of fault-tolerant components 4.5 Operator stations Result The "General" tab in the "Redundancy" dialog can be configured as follows: Fault-tolerant Process Control Systems (V8.0) Function Manual, 03/2012, A5E02779471-02...
Page 141: How To Set The Redundancy Connection For Os Servers
Advantages of fault-tolerant components 4.5 Operator stations Additional information WinCC ● Online help for 4.5.8 How to set the redundancy connection for OS servers Introduction You will now select the connection path for the redundancy connection between 2 OS servers. You can make the following settings directly on each of the mutually redundant OS servers.
Page 142: How To Assign An S7 Program To An Os
Advantages of fault-tolerant components 4.5 Operator stations Procedure 1. Open the Windows Explorer on the OS server. 2. Select the folder "Simatic Shell" in the tree view – Windows Server 2003/2003 R2: My Computer > Simatic Shell – Windows 7/Windows Server 2008 R2: Desktop >...
Page 143 Advantages of fault-tolerant components 4.5 Operator stations Procedure 1. Select the hierarchy folder for which you want to make the AS-OS assignment in the plant view. 2. Select the menu command Edit > Object Properties and change to the "AS-OS Assignment" tab.
Page 144: How To Configure An Os Client
Advantages of fault-tolerant components 4.5 Operator stations 4.5.10 How to configure an OS client Introduction The following section describes how to configure two OS clients, for example, that can be interconnected with a redundant pair of OS servers. Requirements ● The PCS 7 project is open in SIMATIC Manager. ●...
Page 145: How To Configure An Os Client For Permanent Operability
Advantages of fault-tolerant components 4.5 Operator stations Result Your project should now correspond to the project shown in the following figure. You can change the names of the components as you wish. Using reference clients You can set up additional monitoring stations using reference clients. They use configured OS clients as a basis.
Page 146 Advantages of fault-tolerant components 4.5 Operator stations Requirements ● The redundant OS server pair has been configured in SIMATIC Manager. ● WinCC redundancy is configured for the OS server (master). ● The OS server (master) has been compiled such that the server data have been generated. ●...
Page 147 Advantages of fault-tolerant components 4.5 Operator stations Result The "Configure server data" dialog boxes on both OS clients appear as follows: ● Dialog box on OS client 1: ● Dialog box on OS client 2: Fault-tolerant Process Control Systems (V8.0) Function Manual, 03/2012, A5E02779471-02...
Page 148: How To Download A Simatic Pcs 7 Project To The Target Systems
Process Control System PCS 7; Operator Station ● Configuration manual 4.5.12 How to download a SIMATIC PCS 7 project to the target systems Introduction You can download a PCS 7 project that you created in SIMATIC Manager along with the components of the project (AS, OS, BATCH server/client) to the various target systems in a single step with the menu command PLC >...
Page 149: Evaluating The "@Rm_Master" Redundancy Variables With Scripts
Advantages of fault-tolerant components 4.6 SIMATIC BATCH Stations Sequence when loading redundant OS servers with "Changes-only download" function The "Changes-only download" function of a redundant OS server is only available if both partner stations are in process mode (runtime). For safety reasons, downloading is not performed to a redundant OS server pair at the same time: ●...
Page 150: How To Configure A Batch Server And Its Redundant Batch Partner Server
Advantages of fault-tolerant components 4.6 SIMATIC BATCH Stations Step What? Setting redundancy of the BATCH servers (Page 154) Downloading the target systems for SIMATIC BATCH (Page 156) 4.6.2 How to configure a BATCH server and its redundant BATCH partner server Introduction The following describes how to configure a redundant BATCH server.
Page 151 Advantages of fault-tolerant components 4.6 SIMATIC BATCH Stations 12.Enter the Windows name of the computer to be used as the BATCH partner server in the "Computer name" box. 13.In the component view, select the SIMATIC PC station and double-click the "Configuration" object in the detail window.
Page 152: How To Configure A Batch Client
Advantages of fault-tolerant components 4.6 SIMATIC BATCH Stations Additional information Process Control System PCS 7; Engineering System ; section "How ● Configuration manual to Expand a Project with Pre-Configured Stations Using the PCS 7 Wizards" Process Control System PCS 7; SIMATIC BATCH ●...
Page 153: How To Set The Redundancy Monitoring Of Batch Servers
Advantages of fault-tolerant components 4.6 SIMATIC BATCH Stations Result The following figure shows the SIMATIC PC station with BATCH application client configured in HW Config: Additional information Process Control System PCS 7; SIMATIC BATCH ● Manual 4.6.4 How to set the redundancy monitoring of BATCH servers Introduction A local Ethernet network needs to be built in PCS 7 for redundancy monitoring of redundant BATCH servers.
Page 154: How To Configure The Redundancy Connection For Batch Servers On The Engineering Station
Advantages of fault-tolerant components 4.6 SIMATIC BATCH Stations Requirements ● A network adapter for the local Ethernet network is available for redundancy monitoring on each BATCH server of a server pair (referred to below as the 3rd network adapter). ● All software components have been installed on the BATCH servers. Procedure 1.
Page 155: How To Set The Redundancy Connection For Batch Servers
Advantages of fault-tolerant components 4.6 SIMATIC BATCH Stations Time needed for ending process mode of a BATCH server The time needed for ending process mode of a BATCH server depends on the size of the SIMATIC BATCH configuration. The redundancy partner reports a fault on the BATCH server after the configured time.
Page 156: How To Download The Target Systems For Simatic Batch
Advantages of fault-tolerant components 4.6 SIMATIC BATCH Stations You can make the following settings directly on each of the mutually redundant BATCH servers. Note Shared server for OS and SIMATIC BATCH The configuration for redundancy connection has to be performed only once. Requirements ●...
Page 157: Simatic Route Control Stations
Advantages of fault-tolerant components 4.7 SIMATIC Route Control stations 3. Click "Download". In the "Download from <plant>" dialog box, all PC stations for BATCH servers (single, redundant), DB servers and BATCH clients are displayed with information about their download status. 4.
Page 158 Advantages of fault-tolerant components 4.7 SIMATIC Route Control stations Requirements ● The SIMATIC Route Control software package (Route Control Engineering) has been installed in addition to the PCS 7 software. ● The PCS 7 project is open in SIMATIC Manager. Procedure 1.
Page 159 Advantages of fault-tolerant components 4.7 SIMATIC Route Control stations 18.Under "SIMATIC PC Station > Route Control ..." in the hardware catalog, select "RC application (stby)" and insert it in the configuration table by means of drag-and-drop. 19.If redundant communication processors are installed for each PC station, repeat steps 8 and 9 for the second communication processor.
Page 160: How To Configure A Route Control Client
Advantages of fault-tolerant components 4.7 SIMATIC Route Control stations Additional information Process Control System PCS 7; Engineering System ; section "How ● Configuration manual to Expand a Project with Pre-Configured Stations Using the PCS 7 Wizards" Process Control System PCS 7; SIMATIC Route Control ●...
Page 161 Advantages of fault-tolerant components 4.7 SIMATIC Route Control stations Result The following figure shows the SIMATIC PC station with Route Control application client (RC application client) configured in HW Config: Shared client for OS and Route Control If a Route Control client and OS client are operated together on a SIMATIC PC station, configure both client applications in HW Config in one SIMATIC PC station.
Page 162: How To Configure A Redundant Connection Between A Route Control Server And As
Advantages of fault-tolerant components 4.7 SIMATIC Route Control stations Additional information Process Control System PCS 7; SIMATIC Route Control ● Manual 4.7.4 How to configure a redundant connection between a Route Control server and AS Introduction The redundant connections between the Route Control server and the AS are created in NetPro using SIMATIC Route Control wizards.
Page 163 Advantages of fault-tolerant components 4.7 SIMATIC Route Control stations 4. Make the settings according to the plant configuration. The RC wizard automatically creates a fault-tolerant connection when a fault-tolerant system is the connection partner. 5. When the Route Control server and SIMATIC H station are each connected to the plant bus with two CPs, the following additional tasks need to be performed: –...
Page 164 Advantages of fault-tolerant components 4.7 SIMATIC Route Control stations tolerant plant bus. Each PC station and each CPU is connected to the plant bus with 2 CP each: Additional information ● Section "How to configure a fault-tolerant plant bus (Page 100)" Process Control ●...
Page 165: How To Set The Redundancy Connection For Route Control Servers
Advantages of fault-tolerant components 4.7 SIMATIC Route Control stations 4.7.5 How to set the redundancy connection for Route Control servers Introduction You will now select the connection path for the redundancy connection between two Route Control servers. You can make the following settings directly on each of the mutually redundant Route Control servers.
Page 166: How To Set The Redundancy Of The Route Control Servers
Advantages of fault-tolerant components 4.7 SIMATIC Route Control stations 4. Select the connection path through which the Route Control server pair is connected in the drop-down list. – For connection via RJ45 cable: In the "Network adapter" dropdown list, select the network adapter to which you want to attach the network cable for the redundant connection between the two PC stations of a server pair.
Page 167: Failure And Replacement Of Bus Components
Component Replacement and Plant Changes Failure and replacement of bus components 5.1.1 Replacement of SIMATIC components in runtime Continuous operation A crucial factor for continuous operation of fault-tolerant process control systems is the replacement of faulty or failed components in runtime. Replacement of defective components is only possible if fault-tolerant components are used.
Page 168: Replacement Of Bus Components In Runtime
Component Replacement and Plant Changes 5.1 Failure and replacement of bus components Automation System S7-400H; Fault-tolerant For the procedure used to ..refer to the manual replace components ... Systems in section ... Central racks Failure and replacement of a CPU (redundant CPU) Failure and replacement of a power supply module Failure and replacement of a communication processor Failure and replacement of a synchronization module or FO cable...
Page 169: Replacement Of Operator Stations In Runtime
Component Replacement and Plant Changes 5.1 Failure and replacement of bus components ● Bus topology (for example ring structure, spur lines, redundancy connections, disrupted bus cable) ● Connection of the bus system to "master systems": – The assignment of clients to servers –...
Page 170: Replacement Of Batch Stations In Runtime
Component Replacement and Plant Changes 5.1 Failure and replacement of bus components Replacing an OS server Follow the steps below to replace an OS server: Step What? Switch OS clients over to the server that will be remaining in operation. Deactivate and replace the OS server, Check the network addresses and download the configuration data.
Page 171: Replacement Of Route Control Stations In Runtime
Component Replacement and Plant Changes 5.1 Failure and replacement of bus components ● The same IP address is used for the new PC. ● The MAC address is adapted in the project. Replacing the BATCH server Follow the steps below to replace a BATCH server: Step What? Replace the BATCH server.
Page 172: Plant Changes In Runtime
Component Replacement and Plant Changes 5.2 Plant changes in runtime Replace the Route Control server. Follow the steps below to replace a Route Control server: Step What? Replace the Route Control server. On the engineering station: Open Route Control Engineering and download the Route Control server Start Route Control (Route Control starts as standby server).
Page 173 Component Replacement and Plant Changes 5.2 Plant changes in runtime Use cases for plant changes A plant change in which the hardware of the plant is changes occurs in the following cases: ● Hardware components of a fault-tolerant system are removed. ●...
Page 174 Component Replacement and Plant Changes 5.2 Plant changes in runtime Additional information You can find detailed, step-by-step instructions on the procedure for plant changes in runtime Automation System S7-400H; Fault-tolerant Systems. in the manual Note Note the following information: Automation System S7-400H; ●...
Page 175: Failure Of Redundant Interface Modules
Failure, Switchover and Return of Fault-tolerant Components 6.1.1 Failure of redundant interface modules Functionality Interface modules can be configured redundantly in the distributed I/O device (ET 200M, ET 200iSP). The interface modules provide the interface to the automation system through the PROFIBUS DP.
Page 176 Failure, Switchover and Return of Fault-tolerant Components 6.1 I/O Failure scenarios The following faults may occur in a module: ● Hardware or power failure in the module ● Detected signal interference (e.g. wire break, discrepancy) ● Fault on the assigned bus line to an interface module The driver blocks detect a disturbance: ●...
Page 177: Automation System
Failure, Switchover and Return of Fault-tolerant Components 6.2 Automation system ● Following a prompt from the user program via an acknowledgement signal, for example, on an OS with a "Depassivation" button at the block ● After pulling/plugging a module ● Following a diagnostic interrupt (e.g. wire break, measured value) Additional information STEP 7 ●...
Page 178: Failure Of A Fiber-Optic Cable
Failure, Switchover and Return of Fault-tolerant Components 6.2 Automation system 6.2.2 Failure of a fiber-optic cable Requirements for the example ● The S7-400H is in "Redundant" system mode in the starting scenario. ● The CPU in Rack 0 is the Master CPU and the CPU in Rack 1 is the backup CPU. ●...
Page 179 Failure, Switchover and Return of Fault-tolerant Components 6.2 Automation system ● You have access to the automation system: Turn the key switch on the failed CPU from its current position to STOP back to the setting (RUN). ● You have an Ethernet connection to the H system: In the "Operating Mode"...
Page 180: Communication
Failure, Switchover and Return of Fault-tolerant Components 6.3 Communication Result When the CPU in Rack 1 is back online, the "Operating mode" dialog box appears as follows: Communication 6.3.1 Failure of redundant bus components Functionality As soon as a fault occurs on a transmission path, the second transmission path takes over and forwards the signals.
Page 181: Os Server
Failure, Switchover and Return of Fault-tolerant Components 6.4 OS server SIMATIC; Communication with SIMATIC ● Manual SIMATIC NET; Industrial Ethernet Switches SCALANCE X-200 ● Operating Instructions SIMATIC NET; Industrial Ethernet Switches SCALANCE X-300 ● Operating Instructions SIMATIC NET; Industrial Ethernet Switches SCALANCE X-400 ●...
Page 182 Failure, Switchover and Return of Fault-tolerant Components 6.4 OS server ● By automatically interconnecting the OS clients to the preferred server or to the available OS server with master identification. The "@RM_SERVER_NAME" tag on an OS client indicates the OS server to which this OS client is currently connected. ●...
Page 183 Failure, Switchover and Return of Fault-tolerant Components 6.4 OS server The "@RM_MASTER_NAME" tag contains the name of the OS server, for example, "Server 1". You can display this tag, for example, in an I/O field of a Graphics Designer picture. Other applications or scripts can also evaluate these tags.
Page 184 Failure, Switchover and Return of Fault-tolerant Components 6.4 OS server Disrupted network connection to the OS partner server A disrupted network connection is only detected in the redundancy scheme when: ● There is a fault in the spur line. ● There is a defective connector or network adapter. ●...
Page 185 Failure, Switchover and Return of Fault-tolerant Components 6.4 OS server ● The OS client is not switched over from the failed OS server to its redundant OS partner server because the OS server is not available. ● When the failed OS server is available once again to the OS client, the OS client automatically switches back to its preferred server.
Page 186: Batch Server
Failure, Switchover and Return of Fault-tolerant Components 6.5 BATCH Server Additional information WinCC ● Online help for BATCH Server 6.5.1 Reaction of BATCH servers to failure Functionality BATCH applications and any configured WinCC applications are active on BATCH servers. A BATCH client visualizes the batch data of the BATCH server to which it is connected.
Page 187: Route Control Server
Failure, Switchover and Return of Fault-tolerant Components 6.6 Route Control server Additional information Process Control System PCS 7; SIMATIC BATCH ● Manual Route Control server 6.6.1 Reaction of Route Control servers to failure Functionality Route Control applications and any configured WinCC applications are active on Route Control servers.
Page 188: Os Clients
Failure, Switchover and Return of Fault-tolerant Components 6.7 OS clients PC station identified as faulty Additional information on this is available in the section "Failure, failover and restarting of redundant OS servers (Page 181)". Additional information Process Control System PCS 7; SIMATIC Route Control ●...
Page 189 Failure, Switchover and Return of Fault-tolerant Components 6.7 OS clients Permanent operability If OS Server 1 fails, OS Client 1 is connected to redundant OS Server 2. The identity of the redundant partner server of OS Server 1 comes from the downloaded server data on the OS client..
Page 190: Batch Clients
Failure, Switchover and Return of Fault-tolerant Components 6.9 Route Control clients Additional information WinCC ● Online help for BATCH clients 6.8.1 Failover reactions of BATCH clients Functionality If the master BATCH server fails, the BATCH clients automatically switch to the redundant BATCH server.
Page 191: Guidelines For Updating A Redundant Os In Runtime
Failure, Switchover and Return of Fault-tolerant Components 6.10 Guidelines for updating a redundant OS in runtime message window closes and the Route Control client can be operated again only when the failover from the failed Route Control server to the redundant Route Control server is complete. Note The route can be controlled from a Route Control faceplate during the switchover of a Route Control server.
Page 192 Failure, Switchover and Return of Fault-tolerant Components 6.10 Guidelines for updating a redundant OS in runtime Note Perform the steps described from Phase 1 to Phase 5 without extended interruptions because the redundancy is not available during the update. Note Updating the maintenance station Process mode on the maintenance client must be deactivated prior to updating the project on the ES.
Page 193: Overview Of The Required Tasks
Failure, Switchover and Return of Fault-tolerant Components 6.10 Guidelines for updating a redundant OS in runtime The procedure described below must be repeated for all client-server relationships in the system, as appropriate. ● If you have several redundant servers, first update only the clients interconnected with the standby server that has already been updated or that has been defined as the preferred server for these clients.
Page 194 Failure, Switchover and Return of Fault-tolerant Components 6.10 Guidelines for updating a redundant OS in runtime Initial situation ● Server_1 is master server. ● Server_2 is standby server. ● Client_1 is connected to Server_1 because this server is configured as its preferred server. Client_1 represents all OS clients connected to Server_1.
Page 195 Failure, Switchover and Return of Fault-tolerant Components 6.10 Guidelines for updating a redundant OS in runtime Phase Step Phase 1: 1. Server_2: Deactivate and exit WinCC Updating 2. Server_2: Server_2 Backup of the PCS 7 project backup of the operating system and of the PCS 7 software installation 3.
Page 196: Phase 1: Updating Server_2
Failure, Switchover and Return of Fault-tolerant Components 6.10 Guidelines for updating a redundant OS in runtime Phase Step Phase 4: 1. Client_1: Deactivate and exit WinCC Updating the 2. Client_1: OS clients Backup of the PCS 7 project which are backup of the operating system and of the PCS 7 software installation interconnected 3.
Page 197 Failure, Switchover and Return of Fault-tolerant Components 6.10 Guidelines for updating a redundant OS in runtime During the steps involved in Phase 1, your system continues to work with only one server. The system remains controllable from the OS clients that have not yet been updated. If this server fails, the automation system can no longer be controlled.
Page 198 Failure, Switchover and Return of Fault-tolerant Components 6.10 Guidelines for updating a redundant OS in runtime Process ● Install or update the operating system (information is available in the manual Control System PCS 7; PC Configuration and Authorization ). An OS server can only run on a server operating system which has been released for PCS 7. Process control system PCS 7;...
Page 199: Phase 2: Updating Os Clients Interconnected With Server_2
Failure, Switchover and Return of Fault-tolerant Components 6.10 Guidelines for updating a redundant OS in runtime ● If you are using more than one redundant OS server pair, you must first update standby server Server_2 for each. ● Carry out the Phase 1 steps, 1 through 9 for each Server_2. Result after Phase 1 ●...
Page 200 Failure, Switchover and Return of Fault-tolerant Components 6.10 Guidelines for updating a redundant OS in runtime Requirement The PCS 7 project you are updating has already been updated on the ES. Procedure - Phase 2 Phase 2 / step 1. Client_2: Backup of the PCS 7 project, of the operating system and of the PCS 7 software installation ●...
Page 201: Phase 3: Downloading The Connections, Gateways And Changes To The As
Failure, Switchover and Return of Fault-tolerant Components 6.10 Guidelines for updating a redundant OS in runtime ● Updated Client_2 is connected to its preferred server Server_2. ● The system can be controlled from all OS clients. Note Maintenance client If Server_2 is the maintenance server (last OS server pair to be updated in the project), then the maintenance client (Client_2) can be started.
Page 202: Phase 4: Updating The Os Clients Interconnected With Server_1
Failure, Switchover and Return of Fault-tolerant Components 6.10 Guidelines for updating a redundant OS in runtime ● Select an AS in SIMATIC Manager. ● Select the menu command CPU > Download. ● Select the "Changes only" check box. Note If you select the "Include user data blocks" check box, the user data blocks on the AS are overwritten.
Page 203 Failure, Switchover and Return of Fault-tolerant Components 6.10 Guidelines for updating a redundant OS in runtime ● Updated Client_2 is connected to its preferred server Server_2. ● The system can be controlled from all OS clients. Requirement The PCS 7 project you are updating has already been updated on the ES. Procedure - Phase 4 Phase 4 / 1.
Page 204: Phase 5: Updating Server_2
Failure, Switchover and Return of Fault-tolerant Components 6.10 Guidelines for updating a redundant OS in runtime The system reacts as follows: ● Client_1 is connected to Server_2 or deactivated. Result after Phase 4 ● Server_1 is master server in the PCS 7 project. ●...
Page 205 Failure, Switchover and Return of Fault-tolerant Components 6.10 Guidelines for updating a redundant OS in runtime Procedure - Phase 5 Phase 5 / 1. Server_1: Deactivate and exit WinCC ● Deactivate WinCC Runtime on Server_1. ● Exit WinCC on Server_1. ●...
Page 206 Failure, Switchover and Return of Fault-tolerant Components 6.10 Guidelines for updating a redundant OS in runtime ● Open the "Redundancy" editor and check the settings in the dialog box. Click "OK" to exit the dialog box even if you have made no changes. Phase 5 / 8.
Page 207: Guide To Updating A Redundant Batch Server In Runtime
Failure, Switchover and Return of Fault-tolerant Components 6.12 Guide to updating a redundant Route Control server in runtime 6.11 Guide to updating a redundant BATCH server in runtime 6.11.1 Software update (migration) Information is available in the SIMATIC BATCH product documentation: SIMATIC Process Control System PCS 7;...
Page 208 Failure, Switchover and Return of Fault-tolerant Components 6.12 Guide to updating a redundant Route Control server in runtime Default Master Default Standby V7.x SPx – Runtime Start the RC server (and also WinCC Runtime, if needed) Do not update the current server (default master)! and perform the update (the default standby server must be selected on a client with a new version in the RC Center using the menu command Program >...
Page 209: Diagnostics
Diagnostics Process Control System PCS 7; Service Support and Information is available in the manual Diagnostics . PCS 7 features advanced self-diagnostics for redundant software systems (servers). If this diagnostics routine detects an internal fault, and in the event that the redundant partner server is fully functioning, all communication connections on the server affected by the fault are disconnected (terminal and system bus).
Page 210 Diagnostics Additional information You can find more information in the corresponding documentation and readme files on: ● PCS 7 OS ● SIMATIC BATCH ● SIMATIC Route Control ● SIMATIC NET Fault-tolerant Process Control Systems (V8.0) Function Manual, 03/2012, A5E02779471-02...
Page 211: Index
Index Single-Channel Switched Distributed I/O, 30 Central processing units, 36 Changes in the CPU, 172 Channel-based, 95 Client, 81, 144 Configuring, 144 Actuators, 34 Communication connections, 96 Adding, 172 Configuring, 96 Components of the distributed I/O, 172 Communication lines, 39 Modules in central and expansion racks, 172 Communication modules, 36 Advantages of fault-tolerant components, 89...
Page 212 Index Configuring the Batch client, 152 Fault, 181 Connecting Network connection from the OS client to the OS Plant bus, 46 server, 181 Terminal bus, 46 Network connection to the AS, 181 Continuation, 15 Network connection to the OS partner server, Bumpless, 15 CP 1613, 46 Fault tolerance with redundancy nodes, 16...
Page 213 Index How to configure the redundant PROFIBUS PA, 107 How to download a SIMATIC Batch project to the target systems, 156 How to set the redundancy of the BATCH servers, Network components, 41 How to set the redundancy of the Route Control servers, 166 HW Config, 117 Starting, 117...
Page 214 Index Plant bus, redundant fault-tolerant, 59 Redundant OS servers, 77, 127 Availability, 59 Configuring, 127 Components, 59 Creating, 127 Setup, 59 Redundant Route Control servers, 85 Plant changes in runtime, 172 Redundant systems, 191 Power supply Updating, 191 S7-400H, 36 Redundant, fault-tolerant terminal bus, 49 Preface, 7 Reintegration, 177...
Page 215 Creating redundant OS servers, 127 OS compilation, 142 Redundant connection between AS and OS, 135 Setting the project path, 134 SIMATIC PCS 7 overview of features, 19 WinCC client, 81 For commissioning, 20 WinCC project, 181 For servicing and system expansion, 22...
Page 216 Index Y Link, 65, 119 Configuring, 119 Requirements, 119 Setup, 119 Fault-tolerant Process Control Systems (V8.0) Function Manual, 03/2012, A5E02779471-02...

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