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SIMATIC Automation System S7-400H Fault-tolerant Systems Preface, Contents Fault-Tolerant Programmable Logic Controllers S7-400H Installation Options Getting Started Installation of a CPU 41x-H Manual System and Operating Modes of the S7-400H Linking and Synchronizing Using I/O on the S7-400H Communication Functions Configuring with STEP 7 Failure and Replacement of Components During Operation Modifying the System During Operation Synchronization module Technical Specifications 1 2 3 4 5 6 7 8 9 10 11 12 13 Appendices Edition 01/2004 Characteristic Values of Redundant Programmable Logic Controllers A Single Operation B Converting from S5-H to S7-400H C Differences Between Fault-Tolerant Systems and Standard Systems D Function Modules and Communication Processors Used on the S7-400H E Connection Examples for Redundant I/O F A5E00068197-08 Glossary, Index Safety Guidelines This manual contains notices intended to ensure personal safety, as well as to protect the products and connected equipment against damage. These notices are highlighted by the symbols shown below and graded according to severity by the following texts: ! ! ! Danger indicates that death, severe personal injury or substantial property damage will result if proper precautions are not taken. Warning indicates that death, severe personal injury or substantial property damage can result if proper precautions are not taken. Caution indicates that minor personal injury can result if proper precautions are not taken. Caution indicates that property damage can result if proper precautions are not taken. Notice draws your attention to particularly important information on the product, handling the product, or to a particular part of the documentation. Qualified Personnel Only qualified personnel should be allowed to install and work on this equipment. Qualified persons are defined as persons who are authorized to commission, to ground and to tag circuits, equipment, and systems in accordance with established safety practices and standards. Correct Usage Note the following: ! Warning This device and its components may only be used for the applications described in the catalog or the technical description, and only in connection with devices or components from other manufacturers which have been approved or recommended by Siemens. This product can only function correctly and safely if it is transported, stored, set up, and installed correctly, and operated and maintained as recommended. Trademarks SIMATIC, SIMATIC HMI and SIMATIC NET are registered trademarks of SIEMENS AG. Third parties using for their own purposes any other names in this document which refer to trademarks might infringe upon the rights of the trademark owners. Copyright W Siemens AG 1998-2004 All rights reserved Disclaim of Liability The reproduction, transmission or use of this document or its contents is not permitted without express written authority. Offenders will be liable for damages. All rights, including rights created by patent grant or registration of a utility model or design, are reserved. We have checked the contents of this manual for agreement with the hardware and software described. Since deviations cannot be precluded entirely, we cannot guarantee full agreement. However, the data in this manual are reviewed regularly and any necessary corrections included in subsequent editions. Suggestions for improvement are welcomed. Siemens AG Bereich Automation and Drives Geschaeftsgebiet Industrial Automation Systems Postfach 4848, D- 90327 Nuernberg Siemens Aktiengesellschaft  Siemens AG 1998-2004 Technical data subject to change. 6ES7988-8HA10-8BA0 Preface Purpose of the manual The present manual is intended for persons involved in the areas of configuration, commissioning and servicing of programmable logic control systems. To help you get familiar with the product, we recommend that you start with the example in Chapter 3. It shows you an easy method of getting started on the subject of fault-tolerant systems. Basic knowledge required In order to understand the manual, you will need to be familiar with the general principles of automation technology. Knowledge of S7 programs is also a prerequisite; you can read more about S7 programs in the Programming with STEP 7 manual. As you need the STEP 7 standard software while you are configuring, you should also be familiar with running the standard software, as explained in the STEP 7 User Manual. Please note – especially when using an SPS in safety–relevant areas – the information about the safety of electronic controls in the manual S7-400 Programmable Controller Hardware and Installation Target Group This manual is aimed at people with the required qualifications to commission, operate and maintain the products described. Validity of the manual The manual is relevant to the following components: • CPU 414-4H as of firmware version V3.1 • CPU 417-4H as of firmware version V3.1 • Software STEP 7 beginning with Version 5.3 Automation System S7-400H Fault-tolerant Systems A5E00068197-08 iii Preface Changes compared to the previous version The current version of the ”Redundant Systems” manual contains the following changes compared with the previous version: • The H-Systems optional Package has been integrated into the STEP 7 basic software. Note: You can identify the previous version of the ”Redundant Systems” manual by the number on the footer: A5E00068197-07. The current number is : A5E00068197-08. Certification Detailed information about the certifications and standards is available in the reference manual “Automation System S7-400, Module Specifications” in Chapter 1.1, Standards and Certifications. Place of this documentation in the information environment This manual can be order separately under the order number 6ES7988-8HA10-8BA0. It is also available in electronic version on the product CD “STEP 7”. Online Help In addition to the manual, detailed support on how to use the software is provided by the online Help system integrated in the software. The Help system can be accessed using a number of interfaces: • The Help menu contains a number of commands: Contents opens the Help index. You will find help on fault-tolerant systems at configuring fault-tolerant systems. • How to Use Help provides detailed instructions on how to use the online help system. • Context-sensitive Help provides information on the current context - for example, on an open dialog box or an active window. It is accessed by means of the “Help” button or F1. • Another form of context-sensitive Help is the status bar. A brief explanation of each menu command is displayed here when you place the mouse pointer on a command. • A brief explanation of the toolbar buttons is also shown when the mouse pointer comes to rest for a short time on the buttons. If you would like to read information from online Help in printed form, you can print individual topics, books or the entire Help. iv Automation System S7-400H Fault-tolerant Systems A5E00068197-08 Preface Finding Your Way To help you find special information quickly, the manual contains the following access aids: • At the start of the manual you will find a complete table of contents and a list of the diagrams and tables that appear in the manual. • An overview of the contents of each section is provided in the left column on each page of each chapter. • You will find a glossary in the appendix at the end of the manual. The glossary contains definitions of the main technical terms used in the manual. • At the end of the manual you will find a comprehensive index which gives you rapid access to the information you need. Note You require the following manuals and manual packages in order to program and commission an S7-400: Manual/ Manual Package Standard Software for S7 and M7 Contents • Installing and starting up STEP 7 on a programming device / PC • Working with STEP 7 with the following contents: STEP 7 Basic Information Managing projects and files Configuring and assigning parameters to the S7-400 configuration Assigning symbolic names for user programs Creating and testing a user program in STL/LAD Creating data blocks Configuring the communication between two or more CPUs Loading, storing and deleting user programs in the CPU / programming device Monitoring and controlling user programs Monitoring and controlling the CPU • Guide for efficiently implementing the programming task with the programming device / PC and STEP 7 • How the CPUs work (for example, memory concept, access to inputs and outputs, addressing, blocks, data management) • • • • • Description of STEP 7 data management Using data types of STEP 7 Using linear and structured programming Using block call instructions Using the debug and diagnostics functions of the CPUs in the user program (for example, error OBs, status word) Automation System S7-400H Fault-tolerant Systems A5E00068197-08 v Preface Manual/ Manual Package Contents STEP 7 Reference Information • Basic procedure for working with STL, LAD, or FBD (for example, structure of Statement List (STL) for S7-300 and S7-400 • • • • • • Ladder Logic (LAD) for S7-300 and S7-400 Function Block Diagram (FBD) for S7-300 and S7-400 STL, LAD, or FBD, number formats, syntax) Description of all instructions in STEP 7 (with program examples) Description of the various addressing methods in STEP 7 (with examples) Description of all functions integrated in the CPUs Description of the internal registers in the CPU Description of all system functions integrated in the CPUs Description of all organization blocks integrated in the CPUs System and Standard Functions Manual PG 7xx vi • Description of the programming device hardware • Connecting a programming device to various devices • Starting up a programming device Automation System S7-400H Fault-tolerant Systems A5E00068197-08 Preface Recycling and Disposal The S7-400 H can be recycled due to the use of non-toxic materials in its construction. For environmentally compatible recycling and disposal of your old device in accordance with the current state of the art, please contact a certified recycling company for electronic component waste. Further Support If you have any technical questions, please get in touch with your Siemens representative or agent responsible. http://www.ad.siemens.com/automation/partner H/F Competence Center The HF Competence Center in Nuremberg offers a special workshop on the subject redundant automation system SIMATIC S7. In addition, the H/F Competence Center offers you on-site assistance during configuration, commissioning or in the event of problems. Phone: +49 (911) 895-4759 Fax: +49 (911) 895-4519 Training Centers We offer a number of courses to help you become familiar with the SIMATIC S7 programmable logic controller. Please contact your regional training center or our central training center in D 90327 Nuremberg, Germany for details: Phone: +49 (911) 895-3200. Internet: http://www.sitrain.com Automation System S7-400H Fault-tolerant Systems A5E00068197-08 vii Preface A&D Technical Support Worldwide, available 24 hours a day: Nuernberg Johnson City Beijing Technical Support Worldwide (Nuernberg) Technical Support 24 hours a day, 365 days a year Phone: +49 (0) 180 5050-222 Fax: +49 (0) 180 5050-223 E-Mail: adsupport@ siemens.com GMT: +1:00 Europe / Africa (Nuernberg) United States (Johnson City) Asia / Australia (Beijing) Authorization Technical Support and Authorization Technical Support and Authorization Local time: Mon.-Fri. 7:00 to 17:00 Local time: Mon.-Fri. 8:00 to 17:00 Local time: Mon.-Fri. 8:30 to 17:30 Phone: Fax: +49 (0) 180 5050–222 +49 (0) 180 5050-223 Phone: +1 (423) 262 2522 Phone: +86 10 64 75 75 75 Fax: +1 (423) 262 2289 Fax: +86 10 64 74 74 74 E-Mail: adautorisierung@ siemens.com +1:00 E-Mail: simatic.hotline@ sea.siemens.com E-Mail: GMT: –5:00 GMT: adsupport.asia@ siemens.com +8:00 GMT: The languages of the SIMATIC Hotlines and the authorization hotline are generally German and English. viii Automation System S7-400H Fault-tolerant Systems A5E00068197-08 Preface Service & Support on the Internet In addition to our documentation, we offer our Know-how online on the internet at: http://www.siemens.com/automation/service&support where you will find the following: • The newsletter, which constantly provides you with up–to–date information on your products. • The right documents via our Search function in Service & Support. • A forum, where users and experts from all over the world exchange their experiences. • Your local representative for Automation & Drives via our representatives database. • Information on field service, repairs, spare parts and more under “Services”. Automation System S7-400H Fault-tolerant Systems A5E00068197-08 ix Preface x Automation System S7-400H Fault-tolerant Systems A5E00068197-08