Automation and Drives

High-available
SIMATIC

SIMATIC S7-400H
The high-available Automation System

Automation and Drives

Benefits
High-available
SIMATIC
Overview
Overview
Redundancy
features

Avoidance of control system failures due to individual faults

This is attained primarily through a redundant configuration

Switchover

High-availability is required in the following cases:

Synchronization

When processing valuable materials

Self-test

When downtimes or production failures would be expensive

Programming

CIR

When a control system failure would result in high restart

costs

Online repair

In order to enable operation without supervisory or

maintenance personnel

Configuration
Communication
Redundant I/O

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Automation and Drives

Industries (1)
High-available
SIMATIC
Overview
Overview
Redundancy
features

Switchover

Synchronization

Self-test

Programming

CIR

Online repair

Configuration
Communication
Redundant I/O

Power generation and distribution

(oil, gas, electricity)
Power plants
Pipelines
Offshore
District heating systems

Chemical, electrochemical, petrochemical and

pharmaceutical industries
Mining
Environmental engineering
Water treatment
Refuse incineration

Pulp and paper

Steel and metal
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Automation and Drives

Industries (2)
High-available
SIMATIC
Overview
Overview
Redundancy
features

Food and beverages

Glass industry

Switchover

Semiconductor industry (utilities)

Synchronization

Self-test

Transport

Programming

CIR

Online repair

Tunnel automation
Marine automation

Airports
Runway lighting
Baggage transport

Configuration
Communication
Redundant I/O

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Automation and Drives

System architecture
High-available
SIMATIC
Overview
Overview
Redundancy
features

Switchover

Synchronization

Self-test

Programming

CIR

Online repair

Configuration

Management level

Process level
H CPUs
Hot standby

Communication
Redundant I/O

ET 200M

Field level

Clients
Parallel
redundancy

Server
PC network/terminal busParallel
redundancy
With archivematching
Highavailable
Ethernet
communicatio
Media
n redundancy

Redundant
power supply

SW
redundancy
Warm standby

Redundant
PROFIBUS
Redundant
IM 153

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Automation and Drives

System integration
High-available
SIMATIC
Overview
Overview
Redundancy
features

Switchover

Synchronization

Self-test

Programming

CIR

Online repair

Configuration
Communication

Hidden redundancy
Transparent programming
(programming same as for nonredundant systems)
Standard system parameterization

Standard handling

All SIMATIC programming

languages can be used without
restriction
Platform for F and
FH systems

Redundant I/O

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Automation and Drives

Bumpless master-stand-by switchover

High-available
SIMATIC
Overview
Redundancy
Redundancy
features
features

Switchover
Switchover

Synchronization

Self-test

Programming

CIR

Online repair

Configuration
Communication
Redundant I/O

Switchover time
Switchover

time < 100ms

Outputs are retained during switchover
No information or alarm/interrupt is lost

Switchover criteria
Master failure
Power

supply

Rack
Sync

module
Sync cable
CPU

Failure of a DP string or DP slave interface module does

not force a switchover

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Automation and Drives

Automatic event synchronization

High-available
SIMATIC
Overview
Redundancy
Redundancy
features
features

Switchover

Synchronization
Synchronization
Self-test

Programming

CIR

Online repair

Configuration
Communication
Redundant I/O

Customer benefits
Transparent programming
All

standard SIMATIC-S7 programming languages

No command restrictions
Easy porting of the user program
from standard CPU to high-available CPU

Bumpless switchover
No

loss of information
No loss of alarms/interrupts
Because all redundancy-specific functions are handled
by the operating system, the user can feel assured
that he/she has done everything right as far as
redundancy is concerned

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Automation and Drives

Comprehensive self-test functions

High-available
SIMATIC
Overview

Self-test

Redundancy
Redundancy
features
features

Scope:

Switchover

CPU

Synchronization

Self-test
Self-test

Memory

Programming

CIR

Online repair

Configuration

Synchronization

Organization:
Startup

Communication
Redundant I/O

link

self-test

Complete test

Self-test

in cyclic mode

Executes permanently as
background task
Executes in its entirety within a specifiable amount of
time (default: 90 minutes)

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Automation and Drives

Online programming
High-available
SIMATIC
Overview
Redundancy
Redundancy
features
features

Online modifications same as for standard system

All

modifications are automatically copied to both

CPUs

Switchover

Synchronization

Connecting a PG

Self-test

At

Programming
Programming

CIR

Online repair

MPI interface
Via bus

Configuration
PROFIBUS/Ethernet

Communication
Redundant I/O

MPI/DP

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Automation and Drives

Configuration in RUN (CIR)

High-available
SIMATIC
Overview

CPU memory configuration

Redundancy
Redundancy
features
features

Adding or removing:

Switchover

Synchronization

Self-test

Programming

CIR
CIR

Online repair

Configuration

Central

I/O or CP
DP slaves
PA interface and PA slaves
Y-link and slaves
Modules in modular DP slaves

CPU parameter

Communication
Redundant I/O

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Automation and Drives

Replacing modules in RUN mode

High-available
SIMATIC
Overview
Redundancy
Redundancy
features
features

Switchover

Synchronization

Self-test

Programming

CIR

Online
Onlinerepair
repair

Configuration
Communication
Redundant I/O

Modules which can be removed and inserted in Run

mode
I/O

and CP
Sync module
Redundant IM 153-2
Redundant power supplies

Redundant components which can be replaced with the

power off:
Standard

power supplies
Central IM
CPU

CPU is automatically updated following replacement

(program and data)

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Automation and Drives

Configuration
Highlights new CPUs
High-available
SIMATIC
Overview
Redundancy
features

Switchover

Synchronization

Self-test

Programming

CIR

Online repair

Configuration
Konfiguration
Communication
Redundant I/O

Performance Increase
Average

Increase
417-4H appr. x 2,5-3
414-4H appr. x 1,2-2,2
More Memory
417-4H from 4 MB to 20MB
414-4H from 768KB to 1,4MB

Higher Reliability
Memory

with automatic Ewrror Detection and

Correction (EDC)

New Feature
Distance

500m)

between the Controller up to 10km (before

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Automation and Drives

Configuration
Technical specifications for the CPUs
High-available
SIMATIC
Overview
Redundancy
features

Switchover

Synchronization

Self-test

Programming

CIR

Online repair

Two CPU types available

CPU

417-4H with
20MB onboard
CPU 414-4H with
1,4MB onboard

General
technical specifications,
e.g. CPU 417-4 or CPU 414-3

Configuration
Configuration

4 integrated interfaces

Communication

Two

Redundant I/O

for the Sync modules

One DP interface
One MPI/DP interface

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Automation and Drives

Configuration
Redundant link
High-available
SIMATIC
Overview
Redundancy
features

Switchover

Synchronization

Self-test

Programming

CIR

Online repair

Replaceable Sync modules

Fiber-optics (FO)

Configuration
Configuration
Communication

Fiber-optics (FO)
Redundant I/O

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Automation and Drives

I/O configuration
Switched I/O: mode of operation
High-available
SIMATIC
Overview
Redundancy
features

Switchover

Synchronization

Self-test

Programming

CIR

Online repair

Configuration
Configuration
Communication

Both DP masters are active

and functioning properly
Reading

inputs:
The inputs are read only
from the preferred channel
side (active IM)

Writing

outputs:
The data are accepted by
both channels.
Only the data in the preferred
channel are forwarded to the
outputs.

Redundant I/O

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Automation and Drives

Redundant I/O
High-available
SIMATIC
Overview

New:
Redundant IO

Redundancy
features

Synchronization

Self-test

Programming

CIR

Online repair

Configuration
Communication
Redundant I/O
Redundant
I/O

Redundant Communication

Redundant Controller

PROFIBUS DP

Switchover

Redundant Profibus

Sensor/control
element

Redundant IM

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Automation and Drives

Redundant I/O
Possible redundancy structures (2)
High-available
SIMATIC
Overview
Redundancy
features

Switchover

Synchronization

Self-test

Programming

CIR

Online repair

Distributed switched
I/O modules

H-CPU in single mode

Configuration
Communication
Redundant I/O
Redundant
I/O

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Automation and Drives

Redundant I/O
Wiring digital inputs
High-available
SIMATIC

With one sensor

Overview

DI

Redundancy
features
Switchover

Synchronization

Self-test

Programming

CIR

Online repair

Configuration
Communication
Redundant I/O
Redundant
I/O

DI

DI

DI
Redundant Profibus

DI

With two sensors

Master I/O
Both Inputs are read in parallel.
The correct value is selected and processed automatically

Redundant I/O
DI

Since the function is not suitable for all module types, the manual or Internet sh
consulted to find out which modules can currently be used.
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Automation and Drives

Redundant I/O
Wiring analog inputs
High-available
SIMATIC
Overview

With voltage sensor

AE-U

AE-U

With current sensor With current sensor With 2 sensors

AI-I

AI-I

Synchronization

Self-test

Programming

CIR

Online repair

Configuration
Communication
Redundant I/O
Redundant
I/O

AE

4-wire transducers only

AI

Redundant Profibus

Switchover

AE-U
AE

Redundancy
features

AE-U

Master I/O
The CPU reads both inputs. The correct value is selected
and processed automatically
R

Redundant I/O
AI

Since the function is not suitable for every module type, the manual or Internet s
consulted to find out which modules can currently be used.
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Automation and Drives

Redundant I/O
Wiring digital outputs
High-available
SIMATIC

With diodes *

Overview

DQ

DQ

Without diodes*
DQ

DQ

* Dependant on the
module type

Redundancy
features
Switchover

Synchronization

Self-test

Programming

CIR

Online repair

Configuration
Communication
Redundant I/O
Redundant
I/O

DO
Redundant Profibus

Master I/O
Both Outputs are set

Actuator

Redundant I/O
DO

Since the function is not suitable for every module type, the manual or Internet s
consulted to find out which modules can currently be used.
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Automation and Drives

Redundant I/O
Wiring analog outputs
High-available
SIMATIC

Redundancy
features

Switchover

Synchronization

Self-test

Programming

CIR

Online repair

Configuration
Communication
Redundant I/O
Redundant
I/O

Each Output outputs half the value.

When one of the modules fails, the output that is still in
provides the full value

AO
Redundant Profibus

Overview

Master I/O
Both Outputs are set

Actuato

I
Redundant I/O
AO

Since the function is not suitable for all module types, the manual or Internet sh
consulted to find out which modules can currently be used
A&D AS, 07/2004, Chart 22
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Automation and Drives

High-available
SIMATIC
Overview
Redundancy
features

Switchover

Synchronization

Self-test

Programming

CIR

Online repair

Configuration
Communication
Redundant I/O

A&D AS, 07/2004, Chart 23

Siemens AG 2004 - Subject to change without prior