1. Automation and Drives
High-available
SIMATIC
SIMATIC S7-400H
The high-available Automation System

2. Automation and Drives
Benefits
High-available
SIMATIC
Overview Avoidance of control system failures due to individual faults
 This is attained primarily through a redundant configuration
Redundancy features
 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  When a control system failure would result in high restart costs
 CIR
 In order to enable operation without supervisory or maintenance personnel
 Online repair
Configuration
Communication
Redundant I/O
A&D AS, 07/2004, Chart 2
© Siemens AG 2004 - Subject to change without prior notice

3. Automation and Drives
Industries (1)
High-available
SIMATIC
Overview Power generation and distribution
(oil, gas, electricity)
Redundancy features  Power plants
 Pipelines
 Switchover
 Offshore
 Synchronization
 District heating systems
 Self-test
 Programming Chemical, electrochemical, petrochemical and pharmaceutical
 CIR industries
 Online repair
Mining
Configuration
Environmental engineering
Communication  Water treatment
 Refuse incineration
Redundant I/O
Pulp and paper
Steel and metal
A&D AS, 07/2004, Chart 3
© Siemens AG 2004 - Subject to change without prior notice

4. Automation and Drives
Industries (2)
High-available
SIMATIC
Overview Food and beverages
Redundancy features
Glass industry
 Switchover Semiconductor industry (utilities)
 Synchronization
Transport
 Self-test  Tunnel automation
 Programming  Marine automation
 CIR
 Online repair
Airports
 Runway lighting
Configuration  Baggage transport
Communication
Redundant I/O
A&D AS, 07/2004, Chart 4
© Siemens AG 2004 - Subject to change without prior notice

5. Automation and Drives
System architecture
High-available
SIMATIC
Overview
Clients
Redundancy features Management level Parallel redundancy
 Switchover
Server
 Synchronization PC network/terminal bus Parallel redundancy
With archive-matching
 Self-test
High-available
 Programming communication
Ethernet
 CIR Media
Process level redundancy
 Online repair
H CPUs SW redundancy
Configuration Hot stand-by Warm stand-by
Redundant
Communication power supply
ET 200M
Redundant I/O
Field level
Redundant
PROFIBUS
Redundant
IM 153
A&D AS, 07/2004, Chart 5
© Siemens AG 2004 - Subject to change without prior notice

6. Automation and Drives
System integration
High-available
SIMATIC
Overview Hidden redundancy
 Transparent programming
Redundancy features (programming same as for non-
redundant systems)
 Switchover
 Standard system parameterization
 Synchronization
 Self-test
 Standard handling
 Programming
 CIR All SIMATIC programming
 Online repair languages can be used without restriction
Configuration
Platform for F and
Communication FH systems
Redundant I/O
A&D AS, 07/2004, Chart 6
© Siemens AG 2004 - Subject to change without prior notice

7. Automation and Drives
Bumpless master-stand-by switchover
High-available
SIMATIC
Overview Switchover time
 Switchover time < 100ms
Redundancy features
Redundancy features
 Outputs are retained during switchover
 Switchover
Switchover  No information or alarm/interrupt is lost
 Synchronization
 Self-test
Switchover criteria
Programming
Master failure

 CIR
 Power supply
 Online repair
 Rack
Configuration  Sync module
Communication
 Sync cable
 CPU
Redundant I/O
Failure of a DP string or DP slave interface module does not
force a switchover
A&D AS, 07/2004, Chart 7
© Siemens AG 2004 - Subject to change without prior notice

8. Automation and Drives
Automatic event synchronization
High-available
SIMATIC
Overview Customer benefits
Redundancy features
Redundancy features
Transparent programming
 Allstandard SIMATIC-S7 programming languages
 Switchover
 No command restrictions
 Synchronization
Synchronization
 Self-test
 Easy porting of the user program
 Programming
from standard CPU to high-available CPU
 CIR
 Online repair Bumpless switchover
 No loss of information
Configuration
 No loss of alarms/interrupts
Communication
 Because all redundancy-specific functions are handled by the
Redundant I/O operating system, the user can feel assured that he/she has done
everything right as far as redundancy is concerned
A&D AS, 07/2004, Chart 8
© Siemens AG 2004 - Subject to change without prior notice

9. Automation and Drives
Comprehensive self-test functions
High-available
SIMATIC
Overview Self-test
Redundancy features
Redundancy features Scope:
 Switchover  CPU
 Synchronization  Memory
 Self-test
Self-test
 Synchronization link
 Programming
 CIR
 Online repair
Organization:
 Startup self-test
Configuration
 Complete test
Communication  Self-test in cyclic mode
Redundant I/O
 Executes permanently as
background task
 Executes in its entirety within a specifiable amount of time (default: 90
minutes)
A&D AS, 07/2004, Chart 9
© Siemens AG 2004 - Subject to change without prior notice

10. Automation and Drives
Online programming
High-available
SIMATIC
Overview Online modifications same as for standard system
 All modifications are automatically copied to both CPUs
Redundancy features
Redundancy features
 Switchover Connecting a PG
 Synchronization  At MPI interface
 Self-test
 Via bus
 Programming
Programming
 CIR
 Online repair
Configuration
PROFIBUS/Ethernet
Communication
Redundant I/O
MPI/DP
A&D AS, 07/2004, Chart 10
© Siemens AG 2004 - Subject to change without prior notice

11. Automation and Drives
Configuration in RUN (CIR)
High-available
SIMATIC
Overview CPU memory configuration
Redundancy features
Redundancy features Adding or removing:
 Switchover  Central I/O or CP
 Synchronization  DP slaves
 Self-test
 PA interface and PA slaves
 Programming
 Y-link and slaves
 CIR
 Modules in modular DP slaves
 Online repair
Configuration
CPU parameter
Communication
Redundant I/O
A&D AS, 07/2004, Chart 11
© Siemens AG 2004 - Subject to change without prior notice

12. Automation and Drives
Replacing modules in RUN mode
High-available
SIMATIC
Overview Modules which can be removed and inserted in Run mode
 I/Oand CP
Redundancy features
Redundancy features
 Sync module
 Switchover
 Redundant IM 153-2
 Synchronization
 Redundant power supplies
 Self-test
 Programming
Redundant components which can be replaced with the power
 CIR
off:
 Online repair
 Standard power supplies
Configuration
 Central IM
Communication  CPU
Redundant I/O
 CPU is automatically updated following replacement
(program and data)
A&D AS, 07/2004, Chart 12
© Siemens AG 2004 - Subject to change without prior notice

13. Automation and Drives
Configuration
Highlights new CPUs
High-available
SIMATIC
Overview Performance Increase
 Average Increase
Redundancy features
417-4H appr. x 2,5-3
Switchover

414-4H appr. x 1,2-2,2
 Synchronization  More Memeory
 Self-test
417-4H from 4 MB to 20MB
 Programming
414-4H from 768KB to 1,4MB
 CIR
 Online repair Higher Reliability
Konfiguration
Configuration  Memory with automatic Ewrror Detection and Correction (EDC)
Communication
New Feature
Redundant I/O  Distance between the Controller up to 10km (before 500m)
A&D AS, 07/2004, Chart 13
© Siemens AG 2004 - Subject to change without prior notice

14. Automation and Drives
Configuration
Technical specifications for the CPUs
High-available
SIMATIC
Overview Two CPU types available
 CPU 417-4H with
Redundancy features
20MB onboard
 Switchover  CPU 414-4H with
 Synchronization 1,4MB onboard
 Self-test
 Programming General
 CIR technical specifications,
 Online repair e.g. CPU 417-4 or CPU 414-3
Configuration
Configuration
4 integrated interfaces
Communication  Two for the Sync modules
 One DP interface
Redundant I/O
 One MPI/DP interface
A&D AS, 07/2004, Chart 14
© Siemens AG 2004 - Subject to change without prior notice

15. Automation and Drives
Configuration
Redundant link
High-available
SIMATIC
Overview
Redundancy features
 Switchover
 Synchronization
 Self-test
Replaceable Sync modules
 Programming
 CIR
 Online repair Fiber-optics (FO)
Configuration
Configuration
Communication
Fiber-optics (FO)
Redundant I/O
A&D AS, 07/2004, Chart 15
© Siemens AG 2004 - Subject to change without prior notice

16. Automation and Drives
I/O configuration
Switched I/O: mode of operation
High-available
SIMATIC
Overview Both DP masters are active
and functioning properly
Redundancy features
 Reading inputs:
 Switchover
The inputs are read only
 Synchronization from the preferred channel
 Self-test side (active IM)
 Programming
 Writingoutputs:
 CIR
The data are accepted by
 Online repair both channels.
Configuration
Configuration Only the data in the preferred
channel are forwarded to the
Communication outputs.
Redundant I/O
A&D AS, 07/2004, Chart 16
© Siemens AG 2004 - Subject to change without prior notice

17. Automation and Drives
Redundant I/O
High-available
SIMATIC
Overview
Redundancy features New:
 Switchover Redundant IO
Redundant Communication
 Synchronization
 Self-test
 Programming
Redundant Controller
 CIR
 Online repair
Redundant Profibus
PROFIBUS DP
Configuration
Communication
Sensor/control
Redundant I/O element
Redundant IM
A&D AS, 07/2004, Chart 17
© Siemens AG 2004 - Subject to change without prior notice

18. Automation and Drives
Redundant I/O
Possible redundancy structures (2)
High-available
SIMATIC
Overview Distributed switched
H-CPU in single mode
I/O modules
Redundancy features
 Switchover
 Synchronization
 Self-test
 Programming
 CIR
 Online repair
Configuration
Communication
Redundant I/O
A&D AS, 07/2004, Chart 18
© Siemens AG 2004 - Subject to change without prior notice

19. Automation and Drives
Redundant I/O
Wiring digital inputs
High-available
SIMATIC
With one sensor With two sensors
Overview
DI DI DI DI
Redundancy features
 Switchover
 Synchronization
 Self-test
 Programming DI
 CIR
Master I/O
Redundant Profibus
 Online repair
Both Inputs are read in parallel.
Configuration The correct value is selected and processed automatically
Communication
Redundant I/O
Redundant I/O
DI
Since the function is not suitable for all module types, the manual or Internet should be
consulted to find out which modules can currently be used.
A&D AS, 07/2004, Chart 19
© Siemens AG 2004 - Subject to change without prior notice

20. Automation and Drives
Redundant I/O
Wiring analog inputs
High-available
SIMATIC
With voltage sensor With current sensor With current sensor With 2 sensors
Overview AE-U AE-U AI-I AI-I AE-U AE-U
AE AE
Redundancy features
R
 Switchover
U I I
 Synchronization 4-wire transducers only
 Self-test
 Programming AI
 CIR
Master I/O
Redundant Profibus
 Online repair
The CPU reads both inputs. The correct value is selected
Configuration and processed automatically R I
Communication
Redundant I/O
Redundant I/O
AI
Since the function is not suitable for every module type, the manual or Internet should be
consulted to find out which modules can currently be used.
A&D AS, 07/2004, Chart 20
© Siemens AG 2004 - Subject to change without prior notice

21. Automation and Drives
Redundant I/O
Wiring digital outputs
High-available
SIMATIC
With diodes * Without diodes* * Dependant on the
Overview
DQ DQ DQ DQ module type
Redundancy features
 Switchover
 Synchronization
 Self-test
 Programming DO
 CIR
Master I/O
Redundant Profibus
 Online repair Actuator
Both Outputs are set
Configuration
Communication
Redundant I/O
Redundant I/O
DO
Since the function is not suitable for every module type, the manual or Internet should be
consulted to find out which modules can currently be used.
A&D AS, 07/2004, Chart 21
© Siemens AG 2004 - Subject to change without prior notice

22. Automation and Drives
Redundant I/O
Wiring analog outputs
High-available
SIMATIC
Overview Each Output outputs half the value.
Redundancy features
When one of the modules fails, the output that is still intact
provides the full value
 Switchover
 Synchronization
 Self-test
 Programming AO
 CIR
Master I/O
Redundant Profibus
 Online repair Actuator
Both Outputs are set
Configuration
I
Communication
Redundant I/O
Redundant I/O
AO
Since the function is not suitable for all module types, the manual or Internet should be
consulted to find out which modules can currently be used
A&D AS, 07/2004, Chart 22
© Siemens AG 2004 - Subject to change without prior notice

23. 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 notice