Automation and Drives
SIMATIC S7-400H
Fault Tolerant
Automation System
Automation and Drives
Motivation for the use of H-PLC Systems
SIMATIC
S7-400H
 Expensive downtimes or processing of valuable material
Application fields
Overview
Redundany Features
Configuration
 High restart costs after control failure
 Operation without monitoring or maintenance personal
Communication
Ordering
SIMATIC S7-400H
Automation and Drives
AUTOMATE S7-400H
Domaines d‘application
SIMATIC
S7-400H
 Energie
Pipeline, Offshore et Central Thermique
 Chimie, Petrochimie, Pharmacie
 Industrie minière
 Environnement
Traitement des eaux, Incinération des déchets
 Transport
Gestion Tunnel
Construction naval
 Industrie du verre
 Industrie alimentaire
SIMATIC S7-400H
Automation and Drives
High Availability
Overview
SIMATIC
S7-400H
Clients
Parallel
Redundancy
Supervisiory
level
Application fields
Overview
Redundany Features
PC-Network/Terminalbus
Server
Parallel
Redundancy
Configuration
Communication
Ordering
Process level
S7-400H
Field
level
PROFIBUS / Ethernet
H-CPUs
Hot-Standby
Re
d.
PS
Red.
IM
157
ET 200M
Red.
IM
153
SIMATIC S7-400H
High available
Communication
Red.
DP-Bus
MediumRedundancy
SW-Redundanz
Warm-Standby
Red.
DPBus
Red.
IM
153
Automation and Drives
Definitions
SIMATIC
S7-400H
Terminologie
Buts
H (High availability) Eviter les arrêts de production
Disponibilité
quelque soit l ’élément qui
tombe en défaut.
F (Failsafe)
Eviter les dégats, corporels,
sur le matériel ou
l ’environnement
Sécurité
FH
ou
HF
Sécurité ET
Disponibilité
Eviter les arrêts de production
Et éviter les dégats, corporels,
sur le matériel ou
l ’environnement
SIMATIC S7-400H
Réaction
Dans le cas d ’un défaut sur le
système actif, celui-ci va basculer
automatiquement sur le second
système
Dans le cas d ’un défaut le système
se place en état de sécurité
Dans le cas d ’un défaut dans la
partie dite de sécurité le système
se place en état de sécurité pour
cette partie là, le reste de
l ’installation continue de fonctionner
Automation and Drives
Redundancy Principles
SIMATIC
S7-400H
Redundancy with
Application fields
identical components
(homogenous redundancy)
Overview
different components
(Diversified redundancy)
Not used with SIMATIC
Redundany Features
redundancyprinciple
S7-400H
Configuration
Communication
majority redundancy
passive redundancy
active redundancy
Ordering
m-v-n
A
1-v-2
B
C
A
R
1-v-2
A
1
B
2oo2
2oo2
Hot-Standby =
High availability
automatic switch
in ms-range
Warm-Standby =
m-from-n
high availability
and fail-safe
HW or SW Voting
automatic switch
in second range
1-v-2
2oo2
A
2-v-2
R
A

B
1oo2
Fail-safe
Cold-stand-by =
manuel switch
SIMATIC S7-400H
Automation and Drives
Architecture
SIMATIC
S7-400H
Application fields
Overview
Redundany Features
P C B D A AC
S P I O I OP
U
Synchronisation,
Data
and State Exchange
P C B B A AC
S P I O I OP
U
Configuration
Communication
Ordering
I I B B A A F
M M I O I O M
Process
SIMATIC S7-400H
Automation and Drives
Highlights S7-400H:
Complete SIMATIC System Integration
SIMATIC
S7-400H
Application fields
Overview
Redundany Features
Configuration
Communication
Ordering
 User hidden redundancy
 Transparent
programming (programming same as nonredundant systems)
 Easy system parameterisation with option package
 Handling like non-redundant systems
 All standard programming languages can be used
without limitation
 Use of standard components (I/O, CP, FM)
 Hardware platform for F/FH systems
SIMATIC S7-400H
Automation and Drives
Synchronisation Principle
SIMATIC
S7-400H
EventSynchronisation
Application fields
Overview
Without
Cycle-
Time-
Clock-
Synchronisation
Synchronisation
Synchronisation
Synchronisation
Redundany Features
Configuration
Communication
SIMATIC S7-400H
CPU B
CPU A
CPU B
CPU A
CPU B
CPU A
CPU B
CPU A
Ordering
Automation and Drives
Principe de la synchronisation évènementielle
SIMATIC
S7-400H
Cette fonction est prise en charge par le
firmware des CPU‘s
Points de synchronisation




Mise à jour de la MIE
Accès direct à la périphérie
Interruptions,alarmes
Evaluation des temporisations
 Echanges des données lors de fonctions de
communications
SIMATIC S7-400H
B B
Teil-AG
Partial PLC
Définition
Les CPU‘s se synchronisent sur toute
instruction dont l‘exécution pourrait
conduire à des branches de programmes
différentes dans chaque CPU
Partial PLC A
Synchronisation évènementiell
(Brevet Siemens)
Automation and Drives
Synchronisation évènementielle
Exemple de déroulement de fonctionnement
SIMATIC
S7-400H
P C
S P
U
Synchronization,
Information
and Status Exchange
A
S
:
:
L
I 10.0
O 8.0
PEW100
P C
S P
U
A
S
Value
:
:
L
I 10.0
O 8.0
PEW100 Synchronisation
Acknowledge
L
SIMATIC S7-400H
DW 10
L
+
DW 10
F
T
L
+
PAW130 Synchronisation
DW 12
F
Automation and Drives
Event Synchronisation
Cycle
SIMATIC
S7-400H
CPU 0
Application fields
Self test
Self test
Overview
PII switched and
PII switched and one-sided
PII Exchange
one-sided
Redundany Features
Configuration
CPU 1
Alarms,
Diagnostic OB
Alarms,
Diagnostic OB
OB 1
synch.
Communication
synch.
1
synch.
1
Ordering
synch.
2
synch.
2
synch.
synch.
synch.
User program
User program
n
n
PIQ Comparison
PIQ switched,
one-sided
SIMATIC S7-400H
PIQ switched and one-sided
Automation and Drives
Event Synchronisation
Customer Advantages
SIMATIC
S7-400H
Application fields
Overview
Redundany Features
Configuration
Communication
Ordering
 Transparent Programming
 All
command from standard can be used
 User program directly portable from standard CPU to H CPU
and back
 All standard SIMATIC S7 programming languages can be
used
 Guaranteed bumpless Switch-Over
 Quick
Switch-Over time
 No loss of information
 No loss of alarms
SIMATIC S7-400H
Automation and Drives
Self Test
SIMATIC
S7-400H
 What is tested
Application fields
Overview
 CPU
(Processor, ASIC)
Redundany Features
 Memory
Configuration
 Synchronisation
Communication
Ordering
SIMATIC S7-400H
connection
Automation and Drives
Self test
Organization
SIMATIC
S7-400H
Application fields
Overview
Redundany Features
Configuration
Communication
Ordering
 Start-up self test
 Complete
test
 When errors occur, the CPU goes to the state „defect“
 Self test in cycle operation
 Runs
in background
 The entire test is distributed over multiple cycles
 Runs completely through during a time that can be
parameterized (default value 90mn)
SIMATIC S7-400H
Automation and Drives
Automate H : 1 seul point d’entrée
SIMATIC
S7-400H
MPI/DP
PG/PC pour configuration
chargement de programme
modification en ligne , etc...
SIMATIC S7-400H
Automation and Drives
Programming
Connection Examples
SIMATIC
S7-400H
Application fields
Overview
Redundany Features
Profibus/Ethernet
Configuration
Communication
MPI/DP
Ordering
MPI
SIMATIC S7-400H
Automation and Drives
Programming
Online Program Corrections
SIMATIC
S7-400H
 Fully online programming through a CPU
Application fields
Overview
 the
program is automatically copied to the redundant CPU
Redundany Features
Configuration
Communication
Ordering
SIMATIC S7-400H
Automation and Drives
Online Repair
SIMATIC
S7-400H
Application fields
Overview
Redundany Features
Configuration
Communication
 S7-400 Components
 I/O
and CP can be exchanged in RUN mode
 IM
and CPU via Power off

exchanged CPU is automatically updated after power ON
 Sync-Modules
Ordering
 PS

Standard PV via power off

Redundant PS in RUN mode
 DP Components
 IM
153-2 in RUN mode
 I/O
modules can be exchanged in RUN mode
SIMATIC S7-400H
Automation and Drives
AUTOMATE S7-400H
Configuration de base
SIMATIC
S7-400H
Alimentation Redondante
2 Châssis
Standard UR1/UR2
P P CSV
S S P
U
P-Bus
P P CSV
S S P
U
P-Bus
K-Bus
K-Bus
Alimentation Redondante
Châssis de base
divisé UR2-H
SIMATIC S7-400H
P P CSV
S S P
U
P-Bus
P P CSV
S S P
U
P-Bus
K-Bus
K-Bus
Automation and Drives
AUTOMATE S7-400H
CPU Redondantes
SIMATIC
S7-400H
CPU 417-H/414-H avec 4
interfaces integrés:
 2 Modules de synchro
 1 Interface DP
 1 Interface MPI/DP
CPU 417H
CPU 417H
X2
34
X2
34
Sync-Module
SIMATIC S7-400H
Redundancy Module
X2
34
Redundancy Module
X2
34
Redundancy Module
Redundancy Module
Liaison FO
Haute vitesse
X2
34
X2
34
Automation and Drives
Configuration
CPU
SIMATIC
S7-400H
Application fields
Overview
Redundany Features
Configuration
 CPUs
 High
 Mid
end: CPU 417H (4MB expandable to 20MB)
mrange: CPU 414H (768KB)
 4 integrated interfaces
CPU 417H
Communication
 Sync-Module
 Sync-Module
X2
34
 DP
Sync-Module
 MPI/DP
X2
34
Sync-Module
Ordering
X2
34
SIMATIC S7-400H
Automation and Drives
Redondance des Entrées,Sorties
SIMATIC
S7-400H
Entrées/Sorties
1 canal
2 canaux
Monovoie
Commutée
Redondante
standard
Disponibilité
Haute
Disponibilité
(en préparation)
SIMATIC S7-400H
Automation and Drives
I/O Configuration
Redundant PROFIBUS
SIMATIC
S7-400H
Redundant IM 153-2
Application fields
Overview
Redundany Features
Configuration
Profibus-DP
Communication
Ordering
L+
L+
Available as separate components
IM:
6ES7 153-2AA02-0XB0
BM:
6ES7 195-7HD00-0XA0
or as Bundle (2 x IM + 1 BM)
6ES7 153-2AR00-0XA0
SIMATIC S7-400H
ET 200M
with active backplane bus
Special bus module (BM)
IM
Active
backplane bus
IM
Automation and Drives
Fonctionnement d‘un API H
Réseaux redondants,périphérie commune
SIMATIC
S7-400H
Les deux CPU‘s sont
actives
 Lecture
des entrées
Les deux CPU‘s lisent les
entrées et la MIE est
constituée à partir des
coupleurs actifs
 Ecriture des sorties

- Les deux CPU‘s
transfèrent la MIS sur les
coupleurs.
 - Les coupleurs actifs
transmettent la MIS sur
les sorties.
SIMATIC S7-400H
Automation and Drives
I/O Configuration
Connection of PROFIBUS PA via DP/PA Link
SIMATIC
S7-400H
Application fields
Overview
Redundany Features
Configuration
Communication
Profibus-DP
IM 157 (DP PA Link)
Ordering
DP PA Coupler
SIMATIC S7-400H
Automation and Drives
I/O Configuration
Connection of single DP slaves via Y Link
SIMATIC
S7-400H
Application fields
Overview
Redundany Features
Configuration
Communication
Ordering
2xIM 157
Y-Link
SIMATIC S7-400H
Automation and Drives
Communication
Configuration of single Communication
SIMATIC
S7-400H
Application fields
Overview
Redundany Features
Configuration
Communication
Ordering
Profibus-DP
PzP Kommunikation
CP 341
SIMATIC S7-400H
Single controller
Automation and Drives
High Available Communication
Principle
SIMATIC
S7-400H
Application fields
The communication switches automatically from the active to
the reserve connection after a fault
Overview
Active + Reserve Connection = H Connection
Redundany Features
Configuration
Communication
Ordering
Active Connection
Reserve Connection
SIMATIC S7-400H
Automation and Drives
High Available Communication
Configuration of the connections
SIMATIC
S7-400H
Application fields
Overview
Redundany Features
 Active and reserve connections are automatically
offered by the HW configuration tool
 H connections can be created between H stations,
one-channel H-CPUs and PC stations (on PC
Redconnect package required).
Configuration
Communication
Ordering
SIMATIC S7-400H
Automation and Drives
AUTOMATE S7-400H
Configuration :CPU et réseaux redondants
SIMATIC
S7-400H
Communication
Haute disponibilité
Superviseur avec
Soft de Redondance
S7 Red-Connect
API S7-400H avec CPU 417H
dans un chassis UR2-H
avec liaison redondante
PROFIBUS-DP
Périphérie
commutée/
Redondante
SIMATIC S7-400H
Peripherie IM153-2 avec
châssis Actif !
Peripherie IM153-2 avec
châssis Actif !
Automation and Drives
High Available Communication
Configuration with redundant Bus
SIMATIC
S7-400H
Application fields
Overview
Ethernet
Redundany Features
Configuration
Communication
Ordering
H-CPU im Single Mode
Redundancy Diagram
PS
CPU
CP
Bus
CP
CPU
PS
PS
CPU
CP
Bus
CP
CPU
PS
SIMATIC S7-400H
Automation and Drives
High Available Communication - Configuration
with redundant Bus and redundant CP
SIMATIC
S7-400H
Application fields
Overview
Ethernet
Redundany Features
Configuration
Communication
Ordering
H-CPU in Single Mode
Redundancy Diagram
PS
CPU
CP
CP
PS
CPU
CP
CP
SIMATIC S7-400H
Bus
CP
CP
CPU
PS
Bus
CP
CP
CPU
PS
Automation and Drives
High Available Communication
Configuration with single Bus
SIMATIC
S7-400H
Application fields
Overview
Ethernet
Redundany Features
Configuration
S7-400H
S7-400H
Communication
Ordering
H-CPU in Single Mode
Redundancy Diagram:
PS
CPU
CP
CP
CPU
PS
CP
CPU
PS
Bus
PS
SIMATIC S7-400H
CPU
CP
Automation and Drives
High Available Communication
Configuration with optical Ringbus
SIMATIC
S7-400H
Application fields
Overview
Redundant optical Ringbus
Redundany Features
Configuration
Communication
S7-400H
S7-400H
Ordering
H-CPU im Single Mode
Redundancy Diagram
PS
CPU
CP
Bus
CP
CPU
PS
PS
CPU
CP
Bus
CP
CPU
PS
SIMATIC S7-400H
Automation and Drives
Haute Disponibilité
Automate Redondant
SIMATIC
S7-400H
Prix + élevé que Api standard.
Hautes performances, Solution Haute
disponibilité
(Hot stand-by) avec Firmware H.
Utilisation de périphérie décentralisée standard.
Pas de programme applicatif (firmware
uniquement)
Fonctions transparentes (on-line).
Redondance :
 temps de basculement Maître-Réserve de l‘ordre de la ms,
 Alimentations, Unités centrales, Périphérie d‘entrées/sorties, coupleurs
réseaux, modules technologiques.
SIMATIC S7-400H
Automation and Drives
Automatisation
SIMATIC
S7-400H
Totally Integrated
Automation
avec
SIMATIC
S7- 400H
SIMATIC S7-400H
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