Siemens Simatic S7-1500R, Simatic S7-1500H System Manual

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SIMATIC

S7-1500 S7-1500R/H redundant system

System Manual

10/2018

A5E41814787

Preface

Documentation guide

System overview

Application planning

Installation

Wiring

Configuration

Basics of program execution

Protection

Commissioning

Display

Maintenance

Test functions

Technical specifications

Dimension drawings

Accessories/spare parts

Safety symbols

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A5E41814787-AA

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Legal information

Warning notice system

DANGER

indicates that death or severe personal injury will result if proper precautions are not taken.

WARNING

indicates that death or severe personal injury may result if proper precautions are not taken.

CAUTION

indicates that minor personal injury can result if proper precautions are not taken.

NOTICE

indicates that property damage can result if proper precautions are not taken.

Qualified Personnel

personnel qualified

Proper use of Siemens products

WARNING

Siemens products may only be used for the applications described in the catalog and in the relevant technical

ambient conditions must be complied with. The information in the relevant documentation must be observed.

Trademarks

Disclaimer of Liability

This manual contains notices you have to observe in order to ensure your personal safety, as well as to prevent damage to property. The notices referring to your personal safety are highlighted in the manual by a safety alert symbol, notices referring only to property damage have no safety alert symbol. These notices shown below are graded according to the degree of danger.

If more than one degree of danger is present, the warning notice representing the highest degree of danger will be used. A notice warning of injury to persons with a safety alert symbol may also include a warning relating to property damage.

The product/system described in this documentation may be operated only by task in accordance with the relevant documentation, in particular its warning notices and safety instructions. Qualified personnel are those who, based on their training and experience, are capable of identifying risks and avoiding potential hazards when working with these products/systems.

Note the following:

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. The permissible

All names identified by ® are registered trademarks of Siemens AG. The remaining trademarks in this publication may be trademarks whose use by third parties for their own purposes could violate the rights of the owner.

We have reviewed the contents of this publication to ensure consistency with the hardware and software described. Since variance cannot be precluded entirely, we cannot guarantee full consistency. However, the information in this publication is reviewed regularly and any necessary corrections are included in subsequent editions.

for the specific

09/2018 Subject to change

Preface

Purpose of the documentation

Basic knowledge required

Validity of the documentation

Conventions

Note

A note contains important information on the product described in the handling of the product or on the section of the documentation to which particular attention should be paid.

Recycling and disposal

This documentation provides important information on the following aspects of the S7-1500R/H redundant system:

● An overview of the redundant system

● Configuration and failure scenarios

● How to install, wire and commission the redundant system

● Information on maintenance and fault correction

General knowledge in the field of automation engineering is required to understand this documentation.

This documentation applies to all products of the SIMATIC S7-1500R/H redundant system.

STEP 7: In this documentation, "STEP 7" is used as a synonym for all versions of the configuration and programming software "STEP 7 (TIA Portal)". Please also see the notes indicated as follows:

For environmentally friendly recycling and disposal of your old equipment, contact a certified electronic waste disposal company and dispose of the equipment according to the applicable regulations in your country.

documentation, on the

S7-1500R/H redundant system System Manual, 10/2018, A5E41814787-AA

Preface

Security information

Siemens Industry Online Support

Product support

Application examples

Services

Forums

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Siemens provides products and solutions with industrial security functions that support the secure operation of plants, systems, machines and networks.

In order to protect plants, systems, machines and networks against cyber threats, it is necessary to implement – and continuously maintain – a holistic, state-of-the-art industrial security concept. Siemens' products and solutions constitute one element of such a concept.

Customers are responsible for preventing unauthorized access to their plants, systems, machines and networks. Such systems, machines and components should only be connected to an enterprise network or the internet if and to the extent such a connection is necessary and only when appropriate security measures (e.g. firewalls and/or network segmentation) are in place.

For additional information on industrial security measures that may be implemented, please visit (https://www.siemens.com/industrialsecurity).

Siemens' products and solutions undergo continuous development to make them more secure. Siemens strongly recommends that product updates are applied as soon as they are available and that the latest product versions are used. Use of product versions that are no longer supported, and failure to apply the latest updates may increase customers' exposure to cyber threats.

To stay informed about product updates, subscribe to the Siemens Industrial Security RSS Feed under (https://www.siemens.com/industrialsecurity).

You can find current information on the following topics quickly and easily here:

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All the information and extensive know-how on your product, technical specifications, FAQs, certificates, downloads, and manuals.

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Tools and examples to solve your automation tasks – as well as function blocks, performance information and videos.

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For answers and solutions concerning automation technology.

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Your personal working area in Industry Online Support for messages, support queries, and configurable documents.

This information is provided by the Siemens Industry Online Support in the Internet (https://support.industry.siemens.com).

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Preface

Industry Mall

The Industry Mall is the catalog and order system of Siemens AG for automation and drive solutions on the basis of Totally Integrated Automation (TIA) and Totally Integrated Power (TIP).

You can find catalogs for all automation and drive products on the Internet (https://mall.industry.siemens.com).

S7-1500R/H redundant system System Manual, 10/2018, A5E41814787-AA

Preface ................................................................................................................................................... 3

1 Documentation guide ............................................................................................................................ 11

2 System overview ................................................................................................................................... 14

3 Application planning .............................................................................................................................. 49

2.1 What is the S7-1500R/H redundant system? ........................................................................ 14

2.1.1 Areas of application ............................................................................................................... 15

2.1.2 Operating principle of the S7-1500R/H redundant system .................................................... 19

2.1.3 Plant components and automation levels .............................................................................. 25

2.1.4 Scalability ............................................................................................................................... 26

2.1.5 Overview of features .............................................................................................................. 29

2.2 Configuration .......................................................................................................................... 30

2.2.1 Structure of the S7-1500R redundant system ....................................................................... 30

2.2.2 Structure of the S7-1500H redundant system ....................................................................... 31

2.2.3 Components ........................................................................................................................... 33

2.3 S7-1500 R/H-CPUs ................................................................................................................ 35

2.3.1 Overview of the CPU technical specifications ....................................................................... 35

2.3.2 Redundancy ........................................................................................................................... 36

2.3.3 Security .................................................................................................................................. 38

2.3.4 Diagnostics ............................................................................................................................. 39

2.3.5 Trace ...................................................................................................................................... 41

2.4 Communication ...................................................................................................................... 43

2.4.1 System and device IP addresses........................................................................................... 43

2.4.2 Integrated interfaces for communication ................................................................................ 45

2.4.3 HMI devices ........................................................................................................................... 46

2.5 Power supply .......................................................................................................................... 46

2.6 Software ................................................................................................................................. 47

2.6.1 TIA Portal ............................................................................................................................... 47

2.6.2 SINETPLAN ........................................................................................................................... 48

2.6.3 PRONETA .............................................................................................................................. 48

3.1 Requirements ......................................................................................................................... 49

3.2 Restrictions compared to the S7-1500 automation system ................................................... 51

3.3 Configuration versions ........................................................................................................... 54

3.3.1 S7-1500R/H configuration with IO devices in the PROFINET ring ........................................ 55

3.3.2 S7-1500R/H configuration with switches and linear topology ................................................ 57

3.4 Redundancy scenarios .......................................................................................................... 59

3.4.1 Introduction ............................................................................................................................ 59

3.4.2 Failure of the primary CPU .................................................................................................... 60

3.4.3 Failure of the backup CPU ..................................................................................................... 62

3.4.4 Failure of the PROFINET cable in the PROFINET ring ......................................................... 64

3.4.5 Specific redundancy scenarios for S7-1500H ........................................................................ 66

3.4.5.1 Failure of a redundancy connection in S7-1500H.................................................................. 66

3.4.5.2 Failure of both redundancy connections in S7-1500H > 1500 ms apart ............................... 68

3.4.5.3 Failure of both redundancy connections and the PROFINET cable in the PROFINET

ring ......................................................................................................................................... 70

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Table of contents

4 Installation ............................................................................................................................................ 96

5 Wiring ................................................................................................................................................. 108

3.5 Failure scenarios ..................................................................................................................... 72

3.5.1 Failure of an IO device in the PROFINET ring ....................................................................... 73

3.5.2 Failure of a switch (with line topology) in the PROFINET ring................................................ 75

3.5.3 Specific failure scenarios with S7-1500R ............................................................................... 77

3.5.3.1 Two cable interruptions in the PROFINET ring in S7-1500R > 1500 ms apart ...................... 77

3.5.3.2 Two cable interruptions in the PROFINET ring in S7-1500R within ≤ 1500 ms ..................... 79

3.5.3.3 Failure of the primary CPU when IO devices have failed in the PROFINET ring ................... 81

3.5.4 Specific failure scenarios with S7-1500H ............................................................................... 84

3.5.4.1 Failure of both redundancy connections in S7-1500H ≤ 1500 ms apart ................................ 84

3.5.4.2 Failure of one redundancy connection and the primary CPU in S7-1500H ............................ 86

3.6 Hardware configuration ........................................................................................................... 88

3.7 Use of a system power supply ................................................................................................ 90

3.8 Using HMI devices .................................................................................................................. 92

4.1 Basics...................................................................................................................................... 96

4.2 Installing the mounting rail ...................................................................................................... 98

4.3 Installing a load current supply ............................................................................................. 102

4.4 Installing a system power supply .......................................................................................... 104

4.5 Installing R/H-CPUs .............................................................................................................. 106

5.1 Rules and regulations for operation ...................................................................................... 108

5.2 Operation on grounded infeed .............................................................................................. 110

5.3 Electrical configuration .......................................................................................................... 113

5.4 Wiring rules ........................................................................................................................... 114

5.5 Connecting the supply voltage .............................................................................................. 115

5.6 Connecting system power supply and load current supply .................................................. 117

5.7 Connecting the CPU to the load power supply ..................................................................... 118

5.8 Connecting interfaces for communication with S7-1500R .................................................... 120

5.8.1 Connecting the PROFINET ring to S7-1500 ......................................................................... 120

5.9 Connecting interfaces for communication with S7-1500H .................................................... 123

5.9.1 Connecting redundancy connections (fiber-optic cables) ..................................................... 123

5.9.1.1 Synchronization modules for S7-1500H ............................................................................... 123

5.9.1.2 Selecting fiber-optic cables ................................................................................................... 124

5.9.1.3 Installing fiber-optic cables ................................................................................................... 128

5.9.1.4 Connecting redundancy connections (fiber-optic cables) to S7-1500H ............................... 130

5.9.2 Connecting the PROFINET ring to S7-1500H ...................................................................... 134

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Table of contents

6 Configuration ....................................................................................................................................... 136

7 Basics of program execution ................................................................................................................ 148

8 Protection ............................................................................................................................................ 168

9 Commissioning .................................................................................................................................... 178

6.1 Configuring the CPU ............................................................................................................ 136

6.2 Configuration procedure ...................................................................................................... 136

6.3 Project tree ........................................................................................................................... 143

6.4 Parameters ........................................................................................................................... 144

6.5 Process images and process image partitions .................................................................... 145

6.5.1 Process image - overview .................................................................................................... 145

6.5.2 Updating process image partitions in the user program ...................................................... 146

7.1 Programming the S7-1500R/H ............................................................................................. 148

7.2 Restrictions .......................................................................................................................... 150

7.3 Events and OBs ................................................................................................................... 153

7.4 Special instructions for S7-1500R/H redundant systems .................................................... 157

7.4.1 Disabling/enabling SYNCUP with the RH_CTRL instruction ............................................... 157

7.4.2 Determining the primary CPU with "RH_GetPrimaryID" ...................................................... 160

7.5 Asynchronous instructions ................................................................................................... 161

8.1 Overview of the protection functions .................................................................................... 168

8.2 Configuring access protection for the CPU .......................................................................... 168

8.3 Using the display to set additional password protection ...................................................... 172

8.4 Using the user program to set additional access protection ................................................ 172

8.5 Know-how protection ........................................................................................................... 173

8.6 Protection by locking the CPU ............................................................................................. 177

9.1 Overview .............................................................................................................................. 178

9.2 Check before powering on for the first time ......................................................................... 179

9.3 Commissioning procedure ................................................................................................... 180

9.3.1 Removing/plugging in SIMATIC memory cards ................................................................... 181

9.3.2 First power-on of the CPUs .................................................................................................. 184

9.3.3 CPU pairing .......................................................................................................................... 184

9.3.4 Redundancy IDs................................................................................................................... 187

9.3.5 Downloading projects to the CPUs ...................................................................................... 192

9.4 Operating and system states ............................................................................................... 197

9.4.1 Overview .............................................................................................................................. 197

9.4.2 STARTUP operating state ................................................................................................... 200

9.4.3 STOP operating state .......................................................................................................... 203

9.4.4 SYNCUP operating state ..................................................................................................... 203

9.4.5 RUN operating states ........................................................................................................... 204

9.4.6 SYNCUP system state ......................................................................................................... 205

9.4.7 System and operating state transitions ................................................................................ 217

9.4.8 Loss of redundancy .............................................................................................................. 226

9.4.9 Displaying and changing the system state .......................................................................... 229

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Table of contents

10 Display ................................................................................................................................................ 248

11 Maintenance ....................................................................................................................................... 257

12 Test functions ..................................................................................................................................... 282

13 Technical specifications ...................................................................................................................... 289

9.5 CPU memory reset ............................................................................................................... 231

9.5.1 Automatic memory reset ....................................................................................................... 232

9.5.2 Manual memory reset ........................................................................................................... 233

9.6 Backing up and restoring the CPU configuration .................................................................. 234

9.7 Time synchronization ............................................................................................................ 239

9.7.1 Example: Configuring the NTP server .................................................................................. 240

9.8 Identification and maintenance data ..................................................................................... 241

9.8.1 Reading out and entering I&M data ...................................................................................... 241

9.8.2 Record structure for I&M data ............................................................................................... 243

9.8.3 Example: Read out firmware version of the CPU with Get_IM_Data ................................... 245

10.1 CPU display .......................................................................................................................... 248

11.1 Replacing components of the S7-1500R/H redundant system ............................................ 257

11.1.1 Checking before replacing components ............................................................................... 257

11.1.2 Replacing defective R/H-CPUs ............................................................................................. 260

11.1.3 Replacing defective redundancy connections ...................................................................... 261

11.1.3.1 Replacing two defective PROFINET cables with S7-1500R ................................................ 262

11.1.3.2 Replacing a defective redundancy connection with S7-1500H ............................................ 263

11.1.3.3 Replacing defective synchronization module with S7-1500H ............................................... 263

11.1.3.4 Replacing both defective redundancy connections with S7-1500H ..................................... 264

11.1.4 Replacing defective PROFINET cables ................................................................................ 265

11.1.5 Replacing a defective SIMATIC memory card ...................................................................... 266

11.1.6 Replacing a defective system power supply PS or load power supply PM .......................... 267

11.1.7 Replacing defective IO devices/switches.............................................................................. 268

11.2 Replacing the front cover ...................................................................................................... 269

11.3 Replacing the coding element at the power connector of the system power supply and

load current supply ................................................................................................................ 270

11.4 Firmware update ................................................................................................................... 272

11.5 Resetting CPUs to factory settings ....................................................................................... 277

11.6 Maintenance and repair ........................................................................................................ 281

12.1 Test functions ........................................................................................................................ 282

12.2 Reading out/saving service data ........................................................................................... 287

13.1 Standards and Approvals ..................................................................................................... 290

13.2 Electromagnetic compatibility ............................................................................................... 296

13.3 Shipping and storage conditions ........................................................................................... 298

13.4 Mechanical and climatic ambient conditions ........................................................................ 299

13.5 Information on insulation tests, protection class, degree of protection and rated voltage .... 300

13.6 Use of S7-1500R/H in Zone 2 hazardous area .................................................................... 301

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Table of contents

A Dimension drawings ............................................................................................................................. 302

B Accessories/spare parts ....................................................................................................................... 305

C Safety symbols .................................................................................................................................... 307

Glossary .............................................................................................................................................. 310

Index ................................................................................................................................................... 323

C.1 Safety-related symbols for devices without Ex protection ................................................... 307

C.2 Safety-related symbols for devices with Ex protection ........................................................ 308

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Basic information

Device information

General information

The documentation for the redundant S7-1500R/H system is divided into three areas. This division enables you to access the specific content you require.

Figure 1-1 S7-1500R/H guide

The System Manual and Getting Started describe in detail the configuration, installation, wiring and commissioning of the redundant S7-1500R/H system. The STEP 7 online help supports you in the configuration and programming.

Product manuals contain a compact description of the module-specific information, such as properties, wiring diagrams, characteristics and technical specifications.

The function manuals contain detailed descriptions on general topics regarding the redundant S7-1500R/H system, e.g. diagnostics, communication.

You can download the documentation free of charge from the Internet (https://support.industry.siemens.com/cs/ww/en/view/109742691).

Changes and supplements to the manuals are documented in a Product Information.

You can download the product information free of charge from the Internet (https://support.industry.siemens.com/cs/ww/en/view/109742691).

S7-1500R/H redundant system System Manual, 10/2018, A5E41814787-AA

Documentation guide

S7-1500/ET 200MP Manual Collection

SIMATIC S7-1500 comparison list for programming languages

"mySupport"

"mySupport" - Documentation

"mySupport" - CAx data

The S7-1500/ET 200MP Manual Collection contains the complete documentation on the redundant S7-1500R/H system gathered together in one file.

You can find the Manual Collection on the Internet (https://support.industry.siemens.com/cs/ww/en/view/86140384).

The comparison list contains an overview of which instructions and functions you can use for which controller families.

You can find the comparison list on the Internet (https://support.industry.siemens.com/cs/ww/en/view/86630375).

With "mySupport", your personal workspace, you make the best out of your Industry Online Support.

In "mySupport", you can save filters, favorites and tags, request CAx data and compile your personal library in the Documentation area. In addition, your data is already filled out in support requests and you can get an overview of your current requests at any time.

You must register once to use the full functionality of "mySupport".

You can find "mySupport" on the Internet (https://support.industry.siemens.com/My/ww/en/).

In the Documentation area in "mySupport" you can combine entire manuals or only parts of these to your own manual. You can export the manual as PDF file or in a format that can be edited later.

You can find "mySupport" - Documentation on the Internet (https://support.industry.siemens.com/My/ww/en/documentation).

In the CAx data area in "mySupport", you can access the current product data for your CAx or CAe system.

You configure your own download package with a few clicks.

In doing so you can select:

● Product images, 2D dimension drawings, 3D models, internal circuit diagrams, EPLAN macro files

● Manuals, characteristics, operating manuals, certificates

● Product master data

You can find "mySupport" - CAx data on the Internet (https://support.industry.siemens.com/my/ww/en/CAxOnline).

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Documentation guide

Application examples

PRONETA

SINETPLAN

The application examples support you with various tools and examples for solving your automation tasks. Solutions are shown in interplay with multiple components in the system separated from the focus on individual products.

You will find the application examples on the Internet (https://support.industry.siemens.com/sc/ww/en/sc/2054).

With SIEMENS PRONETA (PROFINET network analysis), you analyze the PROFINET network during commissioning. PRONETA features two core functions:

● The topology overview independently scans PROFINET network and all connected

components.

● The IO check is a fast test of the wiring and the module configuration of a system.

You can find SIEMENS PRONETA on the Internet (https://support.industry.siemens.com/cs/ww/en/view/67460624).

SINETPLAN, the Siemens Network Planner, supports you in planning automation systems and networks based on PROFINET. The tool facilitates professional and predictive dimensioning of your PROFINET installation as early as in the planning stage. In addition, SINETPLAN supports you during network optimization and helps you to exploit network resources optimally and to plan reserves. This helps to prevent problems in commissioning or failures during productive operation even in advance of a planned operation. This increases the availability of the production plant and helps improve operational safety.

The advantages at a glance

● Network optimization thanks to port-specific calculation of the network load

● Increased production availability thanks to online scan and verification of existing systems

● Transparency before commissioning through importing and simulation of existing STEP 7

projects

● Efficiency through securing existing investments in the long term and optimal exploitation

of resources

You can find SINETPLAN on the Internet (https://www.siemens.com/sinetplan).

S7-1500R/H redundant system System Manual, 10/2018, A5E41814787-AA

2.1

What is the S7-1500R/H redundant system?

S7-1500R/H redundant system

Aims of using redundant automation systems

WARNING

Please note the difference between fault-tolerant and fail-safe systems.

For the S7-1500R/H redundant system, the CPUs are duplicated, in other words redundant. The two CPUs process the same project data and the same user program in parallel. The two CPUs are synchronized over two redundancy connections. If one CPU fails, the other CPU maintains control of the process.

Redundant automation systems are used in practice to achieve greater availability or failsafety.

● Purpose of fault-tolerant systems: to reduce the probability of production downtime by operating two systems in parallel.

● Purpose of fail-safe systems: to protect life, the environment and capital with safe shutdown to a secure state.

S7-1500R/H is a fault-tolerant automation system, but not a fail-safe system. The S71500R/H system must not be used to control safety-critical processes.

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System overview

2.1.1

Areas of application

Objective

Use

2.1 What is the S7-1500R/H redundant system?

The S7-1500R/H redundant system offers a high degree of reliability and system availability. A redundant configuration of the most important automation components reduces the probability of production downtimes and the consequences of component errors.

The higher the risks and costs of a production downtime, the more worthwhile the use of a redundant system. You can compensate for the generally higher investment costs by avoiding production downtimes.

In redundantly operated systems, failure or malfunction of individual automation components must not impede the operation of the plant. S7-1500R/H redundant systems are used in the following areas, for example:

● Tunnels

● Airports (for example baggage conveyors)

● Subways

● Shipbuilding

● Wastewater treatment plants

● High-bay warehouse

S7-1500R/H redundant system System Manual, 10/2018, A5E41814787-AA

System overview

Example 1: Avoiding downtimes

Automation task

Feature

Solution

Benefits

2.1 What is the S7-1500R/H redundant system?

An automation solution is required for a road tunnel to:

● Control the lighting in the tunnel

● Control the ventilation in the tunnel in line with the concentration of pollutants in the tunnel

Uninterrupted operation of the ventilation system is required to keep the concentration of pollutants below a set level. Constant availability must be ensured for the event that individual automation components fail, for example because of a fire in the tunnel.

Three fans (M) ventilate the tunnel. The automation solution controls the fan speeds in line with the measured pollutant concentration. Three sensors in the tunnel measure the pollutant levels in the air. The S7-1500H redundant system with two redundant CPUs is used to ensure fan availability.

As well as controlling the fans, the S7-1500H redundant system also controls the illumination and the traffic lights.

Figure 2-1 Example: Tunnel automation

The user program for controlling the fans runs on both CPUs in the S7-1500H redundant system. You can position the two CPUs up to 10 kilometers apart. If one CPU or one redundancy connection fails due to a local incident, the incident does not affect the controlled process. The fans continue to operate.

You can find a detailed description of tunnel automation with S7-1500H in Getting started (https://support.industry.siemens.com/cs/ww/en/view/109757712) Redundant system S71500R/H.

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System overview

Example 2: Avoiding high system restart costs as a result of data loss

Automation task

Feature

Solution

Benefits

2.1 What is the S7-1500R/H redundant system?

A logistics company needs a matching automation solution for controlling the storage and retrieval unit in a high-bay warehouse.

The failure of a controller would have serious consequences. After the system restart, you would have to reposition the storage and retrieval units and record the content of the containers again. The automation solution must ensure that no data is lost if a CPU fails and that the warehouse can continue to operate.

To store goods in and retrieve them from the bays, the storage and retrieval unit moves along an X, Y and Z axis. If the process is interrupted, data can be lost and the location of the goods is not known. To guard against the loss of data, the storage and retrieval unit is controlled by the S7-1500R redundant system.

Figure 2-2 Example: High-bay warehouse

If one CPU fails, the second CPU maintains control of the process. The project data and the user program are saved redundantly and are not lost if a CPU fails. Once you have replaced the defective CPU and switched it to RUN, the redundant system automatically synchronizes the project data with the user program in the new CPU. The solution saves you service time and downtime costs for the warehouse.

S7-1500R/H redundant system System Manual, 10/2018, A5E41814787-AA

System overview

Example 3: Avoiding equipment and material damage

Automation task

Feature

Solution

Benefits

2.1 What is the S7-1500R/H redundant system?

A steel works needs a matching automation solution to control a blast furnace for the steel production.

Failures, especially in the process industry, can result in damages to the system, workpieces or material. In a steelworks, there is a danger of the pig iron cooling if the process is interrupted. The pig iron then cannot be used for the production of steel. The automation solution must ensure that the plant continues to run if a CPU fails and that the material is not damaged.

The S7-1500R redundant system controls the blast furnace. The distributed automation components of the redundant system control the temperature, volume and pressure parameters.

Figure 2-3 Example: Blast furnace

The S7-1500R redundant system compensates for the possible failure of a CPU or redundant connection. You do not have to interrupt the smelting process when replacing a CPU while the plant is running. Uninterrupted plant operation avoids high restart and material costs.

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System overview

2.1.2

Operating principle of the S7-1500R/H redundant system

Introduction

S7-1500 design and operating principle

①

S7-1500R CPU

②

PROFINET cable (redundancy connections, PROFINET ring)

③

IO device

④

Switch

2.1 What is the S7-1500R/H redundant system?

S7-1500R/H redundant systems tolerate the failure of one of the two CPUs or an interruption in the PROFINET ring. The S7-1500R and S7-1500H systems differ in structure, configuration limits and performance.

The figure below shows the typical structure of the S7-1500R redundant system.

Figure 2-4 Structure of an S7-1500R redundant system

S7-1500R/H redundant system System Manual, 10/2018, A5E41814787-AA

System overview

2.1 What is the S7-1500R/H redundant system?

The S7-1500R redundant system consists of:

● Two S7-1500R CPUs

● A PROFINET ring with the Media Redundancy Protocol

● IO devices

● if needed, Switches

All PROFINET IO devices assigned to the S7-1500R system must support system redundancy S2. These PROFINET IO devices can be located in the PROFINET ring or they can be separated with a switch.

All PROFINET devices in the PROFINET ring must support media redundancy (MRP). The H-Sync forwarding function is also recommended. System redundancy S2 is not a prerequisite. For example, you can use switches and HMI devices without system redundancy S2.

The redundancy connections in an S7-1500R system are the PROFINET ring with MRP The two CPUs must be directly connected to each other with a PROFINET cable. All nodes can still communicate with each other in the event of an interruption in the ring. PROFINET devices that do not support MRP must be separated from the ring with a switch

One of the two CPUs in the redundant system takes on the role of primary CPU. The other CPU takes on the role of the following CPU (backup CPU). The role of the CPUs can change during operation. Synchronization of primary and backup CPU ensures rapid switchover between CPUs in the event of a failure of the primary CPU. If the primary CPU fails, the backup CPU takes over control of the process as the new primary CPU.

The redundancy connections use part of the bandwidth on the PROFINET cable for the synchronization of the R-CPUs. This bandwidth is therefore not available for PROFINET IO communication.

③

①

②

④

②.

④.

S7-1500R/H redundant system

20 System Manual, 10/2018, A5E41814787-AA

System overview

S7-1500H structure and operating principle

①

S7-1500H CPU

②

PROFINET cable (PROFINET ring)

③

Redundancy connections (fiber-optic cables)

④

IO device

⑤

Switch

2.1 What is the S7-1500R/H redundant system?

The figure below shows the typical structure of the S7-1500H redundant system.

Figure 2-5 Structure of an S7-1500H redundant system

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System overview

2.1 What is the S7-1500R/H redundant system?

The S7-1500H redundant system consists of:

● Two S7-1500H CPUs

● A PROFINET ring with the Media Redundancy Protocol

● Two redundancy connections

● IO devices

● if needed, Switches

All nodes in the redundant system must support system redundancy S2 and media redundancy (MRP).

All PROFINET IO devices assigned to the S7-1500H system must support system redundancy S2. These PROFINET IO devices can be located in the PROFINET ring or they can be separated with a switch.

All PROFINET devices in the PROFINET ring must support media redundancy (MRP). System redundancy S2 is not a prerequisite. For example, you can use switches and HMI devices without system redundancy S2.

As with S7-1500R, the S7-1500H redundant system requires a PROFINET ring the CPUs. All nodes can still communicate with each other in the event of an interruption in the ring. Devices that do not support MRP must be separated from the ring with a switch Unlike in S7-1500R, the PROFINET ring and redundancy connections in S7-1500H are separate. The two redundancy connections are fiber-optic cables that connect the CPUs directly over synchronization modules

One of the two CPUs in the redundant system takes on the role of primary CPU. The other CPU takes on the role of the following CPU (backup CPU). The role of the CPUs can change during operation.

④

①

②

③

⑤

② closed by

⑤.

③.

Synchronization of primary and backup CPU ensures rapid switchover between CPUs in the event of a failure of the primary CPU. If the primary CPU fails, the backup CPU takes over control of the process as the new primary CPU.

The synchronization of the H-CPUs does not affect the bandwidth on the PROFINET.

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System overview

Differences between S7-1500R and S7-1500H

S7-1500R

S7-1500H

CPU 1513R-1 PN CPU 1515R-2 PN

CPU 1517H-3 PN

Performance

Hardware

Range

Configuration limits

2.1 What is the S7-1500R/H redundant system?

Table 2- 1 S7-1500R and S7-1500H system differences

• Transfer rate of 100 Mbps (for synchronization and communication)

• Data work-memory: – CPU 1513R-1 PN: max. 1.5 MB – CPU 1515R-2 PN: max. 3 MB

• Code work-memory: – CPU 1513R-1 PN: max. 300 KB – CPU 1515R-2 PN: max. 500 KB

• The CPUs are identical in design with the respective S7-1500 standard versions.

• Synchronization of the CPUs takes place over the PROFINET ring.

• The H-Sync forwarding function is recom- mended for all nodes in the PROFINET ring.

• Part of the bandwidth on the PROFINET cable is required for synchronization of the CPUs. Less bandwidth is therefore available for PROFINET IO communication.

• Distance between the two R-CPUs: – Max. 100 m without media converter – Several kilometers with media converter

(depends on the media converter used)

• In the PROFINET ring: Max. 50 PROFINET devices, including R-CPUs (max. 16 PROFINET devices recommended)

• In the PROFINET ring and separated with switches (line): Max. 66 PROFINET devices (including R-CPUs)

• Significantly greater performance than S7-1500R due to

– separate redundancy connections over fi-

ber-optic cable

– high computing power

• transfer rate of 1 Gbps (for synchronization)

• Data work-memory: max. 8 MB

• Code work-memory: max. 2 MB

• Each CPU has two optical interfaces.

• Synchronization of the CPUs runs separately

from the PROFINET ring over fiber-optic cables.

• The full bandwidth of the PROFINET cable is available for PROFINET IO communication.

• Distance between the two H CPUs: – Maximum of 10 km (depends on the syn-

chronization modules used)

• In the PROFINET ring: Max. 50 PROFINET devices (including H-CPUs)

• In the PROFINET ring and separated with switches (line): Max. 258 PROFINET devices (including H-CPUs)

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System overview

Comparison of S7-1500 standard system and S7-1500R/H

S7-1500

S7-1500R/H

CPU 1513-1 PN CPU 1515-2 PN

CPU 1517-3 PN/DP

CPU 1513F-1 PN CPU 1515F-1 PN

CPU 1517F-3 PN/DP

CPU 1513R-1 PN CPU 1515R-2 PN CPU 1517H-3 PN

Support for distributed I/O

✓ ✓ ---

Configuration control

✓ ✓ ---

✓ ✓

CPU redundancy

---

✓

System redundancy S2

---

✓

Isochronous mode

✓ ✓ ---

Shared Device ✓ ✓

---

IRT

✓ ✓ ---

MRP

✓ ✓ ✓

MRPD ✓ ✓

---

OPC UA ✓ ✓

---

Motion Control ✓ ✓

---

PID control ✓ ✓

✓1)

Security Integrated

✓ ✓ ✓

Protection function: Copy protection

✓ ✓ ---

Safety mode 2)

--- ✓ ---

Integrated system diagnostics

✓ ✓ ✓

For personal, environmental or investment protection, you will need fail-safe automation systems (F-systems).

2.1 What is the S7-1500R/H redundant system?

The table below sets out the key features of comparable CPUs of the S7-1500 automation system and of the S7-1500R/H redundant system.

Table 2- 2 S7-1500 and S7-1500R/H comparison

Web server

Only support the PID basic functions (do not support PID_Compact, PID _3Step or PID_Temp).

---

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24 System Manual, 10/2018, A5E41814787-AA

System overview

2.1.3

Plant components and automation levels

2.1 What is the S7-1500R/H redundant system?

The schematic diagram below shows the key components of the redundant system from the management level to the control level and the field level.

Figure 2-6 Possible configuration at the management, control and field level using the example of S7-1500R

From the management level, the master PC accesses the various devices at the control and field level. The master PC is connected to the CPUs over Industrial Ethernet.

The R-CPUs at the control level are redundant in design. The IO devices at the field level are connected to the R-CPUs within a PROFINET ring.

The redundant S7-1500R system cyclically exchanges IO data with another PROFINET IO system via a PN/PN coupler. The left-hand side of the PN/PN coupler is assigned to the S7-1500R redundant system. The right-hand side of the PN/PN coupler is assigned to the CPU 1516-3 PN/DP (IO controller).

The configuration tolerates the failure of one CPU or an interruption in the PROFINET ring. The primary CPU and the backup CPU execute the user program in parallel. If one CPU fails, the second CPU maintains control of the process.

If the PROFINET ring is interrupted, for example as a result of a cable break or an IO device failure, redundancy in the ring is lost. However, the IO devices that have not failed continue to operate and can be accessed.

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System overview

2.1.4

Scalability

Introduction

S7-1500R

Note Recommendation for S7-1500R: Operate a maximum of 16 PROFINET devices (including

R-CPUs) in the PROFINET ring.

The number of devices in the PROFINET ring affects the availability of the S7 system. You should therefore operate no more than 16 PROFINET devices ( CPUs) in the PROFINET ring. Operating significantly more devices in the PROFINET ring will reduce the availability of the IO devices and the R

The technical specifications in the documentation are based on the recommended maximum of 16 PR

2.1 What is the S7-1500R/H redundant system?

Redundant systems are more cost-intensive to use than non-redundant systems:

● There are two CPUs.

● The physical connections (PROFINET ring and redundancy connections) can be required

over large distances.

The S7-1500R/H redundant system is scalable. In other words, the S7-1500R and S7-1500H systems have the same functional scope, but differ in terms of:

● Performance

● Hardware

● Range

● Configuration limits

● Costs

You connect the CPUs to the Industrial Ethernet over X2 PROFINET interfaces of CPUs S71515R-2 PN or using an additional switch.

S7-1500R supports the following number of PROFINET devices (switches, S7-1500R/H CPUs, S7-1500 CPUs (V2.5 or later), HMI devices, and IO devices such as ET 200MP and ET 200SP):

● In the PROFINET ring: max. 50 (recommended: max. 16)

● In the PROFINET ring and separated with switches (line): max. 66

-1500R

including R-

-CPUs.

OFINET devices in the ring in S7-1500R.

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26 System Manual, 10/2018, A5E41814787-AA

System overview

①

Load power supply (optional)

②

CPU S7-1515R-2 PN

③

PROFINET cable (redundancy connections, PROFINET ring)

④

IO device in the PROFINET ring

⑤

Switch

⑥

IO device outside the PROFINET ring (separated with a switch)

2.1 What is the S7-1500R/H redundant system?

The redundancy connections in S7-1500R are the PROFINET ring with MRP. The CPUs are synchronized over the PROFINET ring.

Figure 2-7 S7-1500R configuration version

S7-1500R/H redundant system System Manual, 10/2018, A5E41814787-AA

System overview

S7-1500H

①

Load power supply (optional)

②

CPU 1517H-3 PN

③

PROFINET cable (redundancy connections, PROFINET ring)

④

Redundancy connections (two duplex fiber-optic cables)

⑤

IO device in the PROFINET ring

⑥

Switch

⑦

IO device outside the PROFINET ring (separated with switch)

2.1 What is the S7-1500R/H redundant system?

You connect the CPUs to the Industrial Ethernet over a PROFINET interface or using an additional switch.

S7-1500H supports the following number of PROFINET devices (switches, S7-1500R/H CPUs, S7-1500 CPUs (V2.5 or later) and HMI devices):

● In the PROFINET ring: max. 50

● In the PROFINET ring and separated with switches (line): max. 258

The redundancy connections in S7-1500H are two duplex fiber-optic cables that connect the CPUs directly with plug-in synchronization modules.

Figure 2-8 S7-1500H configuration version

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System overview

2.1.5

Overview of features

2.1 What is the S7-1500R/H redundant system?

The S7-1500R/H redundant system meets all the requirements for a fault-tolerant system. The figure below sets out the main features.

Figure 2-9 S7-1500R/H features

S7-1500R/H redundant system System Manual, 10/2018, A5E41814787-AA

System overview

2.2

Configuration

2.2.1

Structure of the S7-1500R redundant system

Configuration

2.2 Configuration

The S7-1500R redundant system comprises the following components:

● Two R-CPUs

● Two SIMATIC memory cards

● PROFINET cable (redundancy connections, PROFINET ring)

● IO devices

● Load power supply (optional)

● System power supply (optional)

The S7-1500R redundant system should be installed either on one shared mounting rail or on two separate mounting rails. Connecting the PROFINET cable to the PROFINET interfaces X1 P2 R of the CPUs directly connects the two CPUs. You set up the PROFINET ring from the first CPU to the IO devices and the second CPU with the PROFINET interfaces X1 P1 R of the CPUs.

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System overview

Configuration example

①

Optional load or system power supply

②

CPU

③

Mounting rail with integrated DIN rail profile

④

PROFINET cable (redundancy connections, PROFINET ring)

2.2.2

Structure of the S7-1500H redundant system

Configuration

2.2 Configuration

Figure 2-10 S7-1500R configuration example

The S7-1500H redundant system comprises the following components:

● Two H-CPUs

● Two SIMATIC memory cards

● Four synchronization modules (two synchronization modules in each H-CPU)

● Two redundancy connections (two duplex fiber-optic cables)

● IO devices

● Load power supply (optional)

● System power supply (optional)

The S7-1500H redundant system should be installed either on one shared mounting rail or on two separate mounting rails. You connect the two CPUs with fiber-optic cables to two synchronization modules in each CPU. You set up the PROFINET ring with the PROFINET interfaces X1 P1 R and X1 P2 R of the CPUs.

S7-1500R/H redundant system System Manual, 10/2018, A5E41814787-AA

System overview

Configuration example

①

Optional load or system power supply

②

CPU (with two synchronization modules, connected underneath, not visible in the diagram)

③

Mounting rail with integrated DIN rail profile

④

Redundancy connections (fiber-optic cables)

⑤

PROFINET cable (PROFINET ring)

2.2 Configuration

Figure 2-11 S7-1500H configuration example

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System overview

2.2.3

Components

Components of the S7-1500R/H redundant system

Component

Function

Diagram

2.2 Configuration

Table 2- 3 S7-1500R/H components

Mounting rail The mounting rail is the rack of the S7-1500R/H automation

system. You can use the entire length of the mounting rail. You can order the mounting rail as Accessories/spare parts

(Page 305).

PE connection element for mounting rail

R/H-CPUs The CPU runs the user program.

The screw set is inserted in the mounting rail's T-profile groove, and is required for grounding the mounting rail.

The set of screws is included in the scope of delivery of the mounting rails in the standard lengths (160 mm to 830 mm) and can be ordered as Accessories/spare parts (Page 305).

Additional features and functions of the CPU:

• Communication via Industrial Ethernet

• Communication via PROFINET IO

• Redundant mode

• HMI communication

• Integrated system diagnostics

• Integrated protection functions (access and know-how

protection)

PROFINET cable You connect the CPUs and the IO devices in a PROFINET

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ring using PROFINET cables.

System overview

Component

Function

Diagram

ply and can be ordered as spare part.

2.2 Configuration

Synchronization modules (for S7-1500H)

Fiber-optic cable (for S7-1500H)

4-pin connection plug for CPU supply voltage

System power supply (PS)

You create two redundancy connections between the H-CPUs with fiber-optic cables using a total of four synchronization modules (two in each H-CPU).

The following synchronization module versions can be ordered:

• Sync module 1 GB FO 10 m: for fiber-optic cables up to 10 m in length

• Sync module 1 GB FO 10 km: for fiber-optic cables up to 10 km in length

You connect the two synchronization modules for each CPU in a pair with a fiber-optic cable. The following lengths of fiberoptic cables can be ordered:

• 1 m

• 2 m

• 10 m

• Up to 10 km (on request)

The 4-pin connection plug provides the supply voltage.

The system power supply can be connected to the backplane bus using a U connector. In the S7-1500R/H redundant system, the system power supply does not support diagnostics.

Various models of system power supplies are available:

• PS 25 W 24 V DC

• PS 60 W 24/48/60 V DC

• PS 60 W 24/48/60 V DC HF

Extended retentivity of the PS is not supported in S71500R/H.

• PS 60 W 120/230 V AC/DC

A power cable connector with coding element and U connector is included in the scope of delivery for the system power sup-

Load power supply (PM)

The load power supply (PM) supplies the system power supply (PS) and central modules (CPU) with 24 V DC.

If you are using load power supplies, we recommend the devices from our SIMATIC series. These devices can be mounted on the mounting rail.

Various models of load power supply are available:

• PM 70 W 120/230 V AC

• PM 190 W 120/230 V AC

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System overview

2.3

S7-1500 R/H-CPUs

2.3.1

Overview of the CPU technical specifications

CPU 1513R-1 PN

CPU 1515R-2 PN

CPU 1517H-3 PN

Data work-memory, max.

1.5 MB

3 MB

8 MB

Code work-memory, max.

300 KB

500 KB

2 MB

Plug-in load memory (SIMATIC memory card), max.

32 GB

32 GB I/O address area, max.

32 KB/32 KB

PROFINET IO interfaces

1 1 1

PROFINET interfaces

- 1 1

Processing time for bit operations

0.04 μs

0.03 μs

0.002 μs

Display screen size

3.45 cm

6.1 cm

Suitable PROFINET devices (switches,

PROFINET ring, max.

50 (recommended: max.

50 Suitable PROFINET devices (see

rated with switches (line), max.

258

Modules per rack, max.

2 (PM/PS and CPU)

Distance between CPUs, max.

Depends on media con-

100 m)

Depends on media con-

100 m)

Depends on the synchro-

Redundancy connections (synchronization link)

PROFINET ring

Fiber-optic cable System redundancy

Yes

Switchover time 1)

300 ms

50 ms

The switchover time is the time between failure of the primary CPU until the backup CPU takes over control of the

process as the primary CPU at the point of interruption. The switchover time can lengthen the cycle time.

2.3 S7-1500 R/H-CPUs

The S7-1500R/H redundant system tolerates the failure of one of the two R- or H-CPUs in the PROFINET ring. If the primary CPU fails, the backup CPU takes over control of the process as the new primary CPU at the point of the interruption.

All relevant data is permanently synchronized between the CPUs over the redundancy connections between primary CPU and backup CPU.

The primary CPU and the backup CPU execute the user program in parallel.

The display of the CPU shows you the control and status information in various menus. Quick access to diagnostic alarms minimizes plant downtimes in the event of a service call.

For effective commissioning and fast optimization of drives and controls, the CPUs support trace functions for all CPU tags.

The table below sets out the main technical specifications for the S7-1500 R/H CPUs.

Table 2- 4 Overview of the R/H-CPU technical specifications

S7-1500R/H CPUs, S7-1500 CPUs (V2.5 or later) and HMI devices) in the

above) in the PROFINET ring and sepa-

16)

verter used (with PROFINET cable, max.

16)

verter used (with PROFINET cable, max.

nization module used: max. 10 km

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System overview

Reference

2.3.2

Redundancy

Introduction

Media redundancy

2.3 S7-1500 R/H-CPUs

The full technical specifications can be found in the manuals for the CPUs and on the Internet (https://mall.industry.siemens.com).

The S7-1500R/H redundant system is based on media redundancy (MRP) in the PROFINET ring.

All PROFINET IO devices assigned to the S7-1500R system must support system redundancy S2. These PROFINET IO devices can be located in the PROFINET ring or they can be separated with a switch.

All PROFINET devices in the PROFINET ring must support media redundancy (MRP). The H-Sync forwarding function is also recommended for S7-1500R. System redundancy S2 is not a requirement. For example, you can use switches and HMI devices without system redundancy S2.

Media redundancy is a function for ensuring network and plant availability.

The two CPUs in the redundant system must be located in a PROFINET ring that uses the MRP media redundancy protocol.

S7-1500R uses the PROFINET ring to synchronize the two CPUs. S7-1500H uses the redundancy connections over fiber-optic cables to synchronize the two CPUs. The PROFINET ring (over PROFINET interfaces X1) of the H CPUs is also mandatory for S71500H.

To set up a ring topology with media redundancy, you need to bring together the free ends of a linear network topology in one device using two ports (ring ports, port label "R"). You specify the ring ports in the device configuration.

In the S7-1500R/H redundant system, you need to set the media redundancy role for each of the two CPUs to Manager (Auto). For all other PROFINET devices in the PROFINET ring, the media redundancy role Client must be configured. There is a communication connection based on MRP between the redundancy manager and the redundancy clients. The Media Redundancy Protocol (MRP) automatically reconfigures the data paths between the individual devices if the ring is interrupted at any point.

You configure the media redundancy role for PROFINET devices with system redundancy S2 in STEP 7. For switches without system redundancy S2, you set the media redundancy role to "Client" over the Web interface.

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System overview

System redundancy S2

Reference

2.3 S7-1500 R/H-CPUs

An IO device with system redundancy S2 supports system redundancy ARs.

In a redundant system, an IO device with system redundancy S2 has a system redundancy AR with each of the two CPUs (IO controllers). An IO device thus supports ARs of two IO controllers simultaneously (for the same modules).

A system redundancy AR can be the primary AR or the backup AR. There must only ever be one primary AR for one IO device at any given time. The other AR, if there is one, must be the backup AR. An IO device activates the data of the primary AR at the outputs. The data of the backup AR is merely saved.

● Behavior in the RUN-Redundant system state:

Both CPUs are IO controllers. PROFINET communication runs on both system redundancy ARs simultaneously, in each case between one of the CPUs (IO controller) and the IO device. If the primary CPU then fails, the backup CPU becomes the primary CPU and also switches the backup AR to primary AR. The data of this AR then becomes active at the outputs.

● Behavior in the RUN-Solo system state:

Only the primary CPU is the IO controller. PROFINET communication runs on the primary AR between the primary CPU (IO controller) and the IO device. There is no AR between the backup CPU and the IO device.

In STEP 7, you configure system redundancy S2 for an IO device by assigning the IO device to both CPUs of the S7-1500R/H redundant system.

Additional information on media redundancy and system redundancy S2 can be found in the PROFINET function manual (http://support.automation.siemens.com/WW/view/en/49948856).

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System overview

2.3.3

Security

Protection functions

Protection function

Description

and an integrated firewall

CPU lock

Protection against unauthorized access by locking the front cover with a seal or a lock

Access protection example

cannot

2.3 S7-1500 R/H-CPUs

Security means the protection of technical systems against sabotage, espionage and human error.

For the setup of secure networks, the S7-1500R/H redundant system has an integrated security concept from authorization levels up to block protection:

Table 2- 5 Overview of protection functions

Access protection Protection against unauthorized configuration changes through four authorization levels

Know-how protection Protection against unauthorized access and modifications to algorithms with password

protection

You can choose from four different access levels in the TIA Portal to restrict user access to functions and memory areas.

Figure 2-12 Access protection

If you only want to allow users access over HMI, for example, select the access level "HMI access" in the TIA Portal. Only HMI access and access to diagnostics data is then possible without entering a password.

Users can read and write tags over an HMI device with this access level.

Users

● Download blocks or the hardware configuration to the CPU

● Upload blocks or the hardware configuration from the CPU to the PG/PC

● Run writing test functions

● Change the operating state from the PG/PC

● Run firmware updates

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System overview

Advantages and customer benefits of protection functions

Reference

2.3.4

Diagnostics

2.3 S7-1500 R/H-CPUs

The protection functions listed above protect your investments from unauthorized access and manipulation, helping to secure plant availability.

You can find additional information on the protection functions described in the section Protection (Page 168) and in the STEP 7 online help.

Siemens products and solutions are only one element of a comprehensive industrial security concept. Please note the additional information on Industrial Security (http://www.siemens.com/industrialsecurity).

All levels of automation in the S7-1500R/H redundant system have integrated diagnostics. All SIMATIC products have integrated diagnostic functions that you can use to analyze, localize and log faults and errors efficiently.

System diagnostics is integrated into the firmware of the CPUs and works independently of the cyclic user program. Faults in the plant are immediately detected and reported on the display devices.

A uniform display concept visualizes error messages as plain text information over:

● TIA Portal

● HMI devices

● CPU displays

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System overview

Displaying faults in an IO device

Advantages and customer benefits

2.3 S7-1500 R/H-CPUs

The various components of the S7-1500R/H redundant system are connected over PROFINET/Industrial Ethernet (IE). The devices detect faults in their modules (for example IO device ET 200SP) and send diagnostics data to the assigned CPU. The CPU analyzes this diagnostic information and notifies the connected display media. The information analyzed is shown in graphic form in the configuration and programming software (TIA Portal), on the HMI devices and on the CPU displays.

Figure 2-13 Overview of system diagnostics in a plant

Integrated system diagnostics offers the following advantages:

● Diagnostics is always consistent with the actual state of the plant. In S7-1500R/H redundant mode, the diagnostic information is synchronized between the CPUs.

● The uniform display concept enables efficient error analysis.

● The immediate identification of the error source in the event of an error speeds up

commissioning and minimizes production downtimes.

● By configuring diagnostics events, you tailor the diagnostics to the requirements of your automation task.

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System overview

Reference

2.3.5

Trace

Note Trace restrictions

The S7 SIMATIC memory card.

2.3 S7-1500 R/H-CPUs

You will find more information on diagnostics in the Diagnostics (https://support.industry.siemens.com/cs/ww/en/view/59192926) function manual.

The trace functionality facilitates troubleshooting and optimization for the user program. Trace records device tags and evaluates the recordings. This allows you to analyze defective signal responses. Tags are, for example, drive parameters or the system and user tags of a CPU. Because the CPU records tags directly, the trace and logic analyzer function is suitable for monitoring highly dynamic processes.

-1500R/H redundant system does not support the storage of measurements on the

S7-1500R/H redundant system System Manual, 10/2018, A5E41814787-AA

System overview

Example of signal response analysis

①

Trace recordings for S7-1500R/H in the project tree

②

Trend diagram

③

Signal table

Advantages and customer benefits

2.3 S7-1500 R/H-CPUs

To analyze a specific signal response, you define the recording and trigger conditions for the signals to be recorded.

① The trace function can be called in the project tree from the "Traces" folder under the top

CPU of the redundant system.

The trend diagram lower diagram as a bit track.

The signal table options for specific properties.

② displays the selected signals of a recording. Bits are shown in the

③ lists the signals of the selected measurement and provides setting

Figure 2-14 Trace measurement for S7-1500R/H

The trace function offers the following advantages:

● Simultaneous recording of up to 16 different signals and up to four separate trace jobs

● A uniform standard for tag analysis that allows even sporadic errors to be located rapidly

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42 System Manual, 10/2018, A5E41814787-AA

System overview

Reference

2.4

Communication

2.4.1

System and device IP addresses

Device IP addresses

MAC addresses

System IP addresses

2.4 Communication

You can find additional information on the trace function in the section Test functions (Page 282) and in the Using the trace and logic analyzer function manual (http://support.automation.siemens.com/WW/view/en/64897128).

For the interfaces of the CPUs and the IO devices to be accessible, the interfaces require IP addresses that are unique within the network (device IP addresses).

The CPUs have a unique MAC address for each interface and its ports. The MAC addresses of the PROFINET ports are needed for the LLDP protocol, for example for the neighborhood discovery function.

The number range of the MAC addresses is sequential. The first and last MAC addresses are printed on the rating plate on the right-hand side of each CPU.

In addition to the device IP addresses of the CPUs, the redundant system S7-1500R/H supports system IP addresses:

● System IP address for the X1 PROFINET interfaces of the two CPUs (system IP address

● System IP address for the X2 PROFINET interfaces of the two CPUs (system IP address

You use the system IP addresses for communication with other devices (for example, HMI devices, CPUs, PG/PC). The devices always communicate over the system IP address with the primary CPU of the redundant system. This ensures that the communication partner can communicate with the new primary CPU (previously backup CPU) in the RUN-Solo system state after failure of the original primary CPU in redundant operation.

There is a virtual MAC address for each system IP address. The virtual MAC addresses of the two PROFINET interfaces must be different from each other.

X1)

X2)

You enable the system IP addresses in STEP 7.

You can find information on configuring the system IP addresses and the virtual MAC addresses in the section Configuration procedure (Page 136).

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System overview

Advantages of system IP addresses over device IP addresses

Configuration example

Reference

2.4 Communication

● Targeted communication of the communication partner with the primary CPU.

● The S7-1500R/H redundant system can continue to communicate over a system IP

address even if the primary CPU fails.

The figure below shows a configuration in which the S7-1500R/H redundant system communicates with other devices over the system IP address X2. The other devices are connected to the S7-1500 redundant system over the X2 PROFINET interfaces.

Figure 2-15 Example: Communication of the S7 1500R/H redundant system over the system IP

address X2

You can find more information on the system IP address in the S7-1500R/H redundant system in the PROFINET (http://support.automation.siemens.com/WW/view/en/49948856) function manual.

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44 System Manual, 10/2018, A5E41814787-AA

System overview

2.4.2

Integrated interfaces for communication

Communication option

Service available over:

PROFINET inter-

face X1 (device IP

address)

PROFINET inter-

face X2 (device IP

address)1)

System IP ad-

dress (at interfac-

es X1 and X2)

PROFINET IO ✓ ---

---

MRP (Media Redundancy Protocol)

✓

---

✓ ✓

diagnostics

✓ ✓

ing

✓

Open User Communication

✓3)

✓

tics

Time synchronization

✓ ✓ ---

with S7-1500R/H also fails.

Reference

2.4 Communication

The table below provides an overview of CPU communication options in the S7-1500R/H redundant system.

Table 2- 6 S7-1500R/H communication options

LLDP (network topology detection) PG communication for commissioning, testing and

HMI communication for operator control and monitor-

Data exchange via HTTP(S), for example for diagnos-

Not with CPU 1513R-1 PN Communication mainly over system IP address: If the CPU with the device IP address fails, communication with the HMI

device also fails.

Communication mainly over system IP address: If the CPU with the device IP address fails, Open User Communication

--- --- ---

---

For more information on communication options, please refer to the Communication function manual (https://support.industry.siemens.com/cs/ww/en/view/59192925).

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System overview

2.4.3

HMI devices

Reference

2.5

Power supply

Description

backplane bus via a system power supply.

system power supply (PS) supplies parts of the module electronics and the LEDs.

2.5 Power supply

HMI devices are used for machine-level process visualization and control. You use the same HMI devices for the S7-1500R/H redundant system as for the standard S7-1500 system.

Using HMI communication, one or more HMI devices exchange data with the CPUs (for example HMI Basic/Comfort/Mobile Panel).

The connection of the HMI device to the redundant system depends on the specific application. In STEP 7, you can configure the following communication options:

● The HMI device communicates with the redundant system over the system IP address.

● The HMI device communicates with the R/H-CPUs (for example for diagnostics purposes)

over the device IP addresses.

You can find additional information on using HMI devices in the section Using HMI devices (Page 92) and in the Communication function manual (https://support.industry.siemens.com/cs/ww/en/view/59192925).

You can find an overview of all available HMI devices in the Industry Mall (https://mall.industry.siemens.com/mall/en/WW/Catalog/Products/9109999?tree=CatalogTre

e).

Table 2- 7 Differences between load and system power supplies

Load power supply (PM) The load power supply (PM) supplies the system components, such as the CPU and

System power supply (PS) The system power supply (PS) only supplies system voltage required internally. The

The CPUs of the redundant system have an integrated system power supply. It provides the necessary power to the backplane bus. You can add one load power supply or one system power supply each to the integrated system power supply.

The table below sets out the key differences between load power supplies (PM) and system power supplies (PS).

system power supply (PS). You can install the load power supply directly to the left of the CPU (without connection to the backplane bus).

Supply of the R/H CPUs with 24 V DC is optional if you supply the voltage for the

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46 System Manual, 10/2018, A5E41814787-AA

System overview

2.6

Software

2.6.1

TIA Portal

2.6 Software

The SIMATIC controllers are integrated into the Totally Integrated Automation Portal. Engineering with TIA Portal offers:

● Configuration and programming

● Shared data management

● A uniform operating concept for control, visualization and drives

The TIA Portal simplifies integrated engineering in all configuration phases of a plant.

Figure 2-16 TIA Portal overview

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System overview

2.6.2

SINETPLAN

2.6.3

PRONETA

2.6 Software

SINETPLAN (https://www.siemens.com/sinetplan), the Siemens Network Planner, helps you plan automation systems and networks based on PROFINET. The tool facilitates the professional and predictive dimensioning of your PROFINET system right from the planning stage. SINETPLAN also assists with network optimization and helps you to make the best possible use of network resources and to plan for reserves. This allows you to avoid problems in commissioning and failures during productive operation even before planned use. This increases the availability of the production plant and helps improve operational safety.

The advantages at a glance

● Network optimization thanks to port-specific calculation of the network load

● Increased production availability thanks to online scan and verification of existing systems

● Transparency before commissioning with the import and simulation of existing STEP 7

projects

● Efficiency through securing existing investments in the long term and the optimal use of resources

SIEMENS PRONETA (PROFINET network analysis) allows you to analyze the plant network during commissioning. PRONETA features two core functions:

● The topology overview independently scans PROFINET and all connected components.

● The IO check is a rapid test of the wiring and the module configuration of a plant.

SIEMENS PRONETA (https://support.industry.siemens.com/cs/ww/en/view/67460624) is also available for free on the Internet.

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48 System Manual, 10/2018, A5E41814787-AA

3.1

Requirements

Introduction

Hardware requirements

Property

Requirement

redundant system.

Table 3- 1 Hardware requirements

Please note the following requirements for use of the S7-1500R/H redundant system.

S7-1500R/H CPUs

PROFINET ring A PROFINET ring is required for all configuration versions (Page 54) of the S7-1500R/H

• Two identical R or H CPUs in the redundant system

• Identical article numbers, function versions and firmware versions for the two CPUs

S7-1500R/H redundant system System Manual, 10/2018, A5E41814787-AA

Application planning

Property

Requirement

3.1 Requirements

PROFINET devices

System power supply PS or load power supply PM

• All PROFINET IO devices assigned to the S7-1500R/H system must support system redundancy S2. These PROFINET IO devices can be located in the PROFINET ring or they can be separated with a switch.

• With S7-1500R/H, all PROFINET devices in the PROFINET ring must support the media redundancy function.

• For S7-1500R, the H-Sync forwarding function1) is also recommended for the PROFINET devices in the PROFINET ring.

• The following PROFINET IO devices support system redundancy S2, media redundancy and H-Sync forwarding:

– ET 200SP IM 155-6 PN HF (6ES7155-6AU00-0CN0), FW version V4.2 or later – ET 200SP IM 155-6 PN/2 HF (6ES7155-6AU01-0CN0), FW version V4.2 or later – ET 200SP IM 155-6 PN/3 HF (6ES7155-6AU30-0CN0), FW version V4.2 or later – ET 200MP IM 155-5 PN HF (6ES7155-5AA01-0AB0), FW version V4.2 or later – PN/PN coupler (6ES7158-3AD10-0XA0), FW version V4.2 or later

• Switches of the product families XC-200, XP-200 and XF-200BA support system redun- dancy S2, media redundancy and H-Sync-Forwarding, for example SCALANCE XC208 (6GK5208-0BA00-2AC2), FW version V4.0 or later.

• In STEP 7, "Manager (auto)" is set as the media redundancy role for each of the two R/H CPUs. For all other devices in the PROFINET ring, set "Client" as the media redundancy role.

• PROFINET devices that do not support system redundancy S2 can be located in the PROFINET ring or be separated with a switch.

– Switches without system redundancy S2:

Set the media redundancy role to "Client" over the Web interface. Configure the ring ports in line with the wiring.

– HMI devices without system redundancy S2:

Set the media redundancy role to "Client" in the HMI configuration.

• S7-1500 CPUs: Firmware version V2.5 or later The redundant system does not recognize the S7-1500 CPUs when calculating the maximum number of IO devices within and outside the PROFINET ring. If you use S7-1500 CPUs, you will have to check the maximum number yourself.

System power supply PS or load power supply PM for the R/H CPUs The use of the PS or PM is optional. Suitable system power supplies:

• PS 25 W 24 V DC (not suitable for CPU 1517H-3 PN)

• PS 60 W 24/48/60 V DC

• PS 60 W 24/48/60 V DC HF

• PS 60 W 120/230 V AC/DC

Suitable load power supplies:

• PM 70 W 120/230 V AC

• PM 190 W 120/230 V AC

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50 System Manual, 10/2018, A5E41814787-AA

If you use PROFINET devices that do not support H-Sync Forwarding in S7-1500R, additional cycle time increases may occur in system state RUN-Redundant. If the cyclic program exceeds the cycle monitoring time, the timeout OB (OB 80) may be started. You can find additional information in the section Start events (Page 153).

Application planning

Special case: Operating R/H CPU individually

Software requirements

Function

Requirement

STEP 7

SIMATIC STEP 7 Professional, V15.1 or later

3.2

Restrictions compared to the S7-1500 automation system

Introduction

Hardware restrictions

Property

Restriction

power supply

tion control (option handling)

58) function manual.

3.2 Restrictions compared to the S7-1500 automation system

You can operate an R/H CPU as a single CPU. If you do, please note the following:

● You always need to configure two R- or H-CPUs for S7-1500R/H even if you only set up one.

● The MAINT LED on the CPU is always yellow (maintenance demanded):

– The R/H system is not in redundant mode.

– No partner CPU found.

Table 3- 2 Software requirements

Please note the following restrictions with the S7-1500R/H redundant system compared to the S7-1500 automation system.

Table 3- 3 Hardware restrictions

Fail-safe modules Fail-safe modules are not supported in the S7-1500R/H re-

Power segment overview with system

Series machine projects, configura-

Central I/O Central I/O is not supported in the hardware configuration of

Cycle and response times Longer cycle and response times: You can find additional

dundant system. Not supported

Not supported

the S7-1500R/H redundant system. Exceptions:

• Load power supply (PM)

• System power supply (PS); the PS cannot be configured.

information in the Cycle and response times (https://support.industry.siemens.com/cs/ww/en/view/591935

S7-1500R/H redundant system System Manual, 10/2018, A5E41814787-AA

Application planning

Software restrictions

Function

Restriction

(Page 150).

Firmware update

Firmware update via accessible devices is not supported.

the RUN-Solo system state.

I-device

Cannot be used as I-device1)

IRT

Not supported

Only programmed connections are supported.

Motion Control

Motion Control functions are not supported in the CPUs

MRPD

Not supported

Multiuser Engineering

Not supported

OPC UA

OPC UA (server and client) not supported

system state.

Protection functions

Not supported: Copy protection

CPUs.

Shared Device

Not supported

SIMATIC ProDiag

Not supported

PROFINET interface X2 of the R/H CPUs

3.2 Restrictions compared to the S7-1500 automation system

Table 3- 4 Software restrictions

Instructions Not supported, restrictions for specific instructions: You can

find additional information in the section Restrictions

Display: "Modules" menu command Not supported

Hardware detection in STEP 7 (read out configuration)

HMI tags The direct entry of tags on the HMI device is only possible in

Configured connections Connection type not support for communication connection.

Online functions

PID controller Compact PID controllers not supported:

Not supported

• Download not possible in the RUN-Redundant system state

• SIMATIC Automation Tool (SAT tool) not supported

• PID_Compact

• PID_3Step

• PID_Temp

Only the PID basic functions are supported. The PID basic functions can only be commissioned online in the RUN-Solo

Secure OUC Not supported as certificate management is not possible for

PROFINET send clock 1 ms only

S7 routing No S7 routing between PROFINET interface X1 and

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52 System Manual, 10/2018, A5E41814787-AA

the R/H CPUs: If you have enabled Secure OUC, you can compile and load

the user program but cannot add certificates to the R/H

Application planning

Function

Restriction

points

not support breakpoints" appears.

(measurements in the device) is not supported.

Web server

Not supported

Certificate management

Not supported

Distributed I/O systems can be connected over PN/PN couplers.

3.2 Restrictions compared to the S7-1500 automation system

S7-1500H: Failure of the IO devices in the PROFINET ring when PROFINET cables to primary CPU are disconnected

If you remove both PROFINET cables from the primary CPU (CPU 1517H-3 PN) in the RUN-Redundant system state, please note the following:

• The primary CPU can no longer access the IO devices in

the PROFINET ring. The IO devices will return to the substitute values.

• The redundant system will not execute a primary-backup

switchover.

• The redundant system will remain in the RUN-Redundant

system state.

Isochronous mode Isochronous mode is not supported Test function: Testing with break-

Not supported: In STEP 7, the message "The device does

Trace The storage of measurements on the SIMATIC memory card

S7-1500R/H redundant system System Manual, 10/2018, A5E41814787-AA

Application planning

3.3

Configuration versions

Introduction

3.3 Configuration versions

You can configure different versions of the S7-1500R/H redundant system. A PROFINET ring is essential in all configuration versions.

For the configuration versions of the S7-1500R/H system, there is redundancy for the following components:

● R/H-CPUs

● Interfaces of synchronization

● Network in the PROFINET ring

This section describes the admissible configuration versions and their advantages/benefits.

The following convention applies:

Figure 3-1 Green traffic light

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54 System Manual, 10/2018, A5E41814787-AA

Application planning

3.3.1

S7-1500R/H configuration with IO devices in the PROFINET ring

Introduction

Advantages/benefits

S7-1500R configuration

①

CPU 1

②

CPU 2

③

PROFINET cable (redundancy connections, PROFINET ring)

④

IO device ET 200MP (with system redundancy S2)

⑤

IO device ET 200SP (with system redundancy S2)

3.3 Configuration versions

The following sections set out configurations of the S7-1500R/H redundant system with IO devices in the PROFINET ring.

● The IO devices are connected in the PROFINET ring with system redundancy.

● The redundant system continues to operate following a cable interruption anywhere in the

PROFINET ring. One of the two communication connections of the IO devices remains. A SYNCUP is prevented.

Figure 3-2 S7-1500R configuration with IO devices in the PROFINET ring

S7-1500R/H redundant system System Manual, 10/2018, A5E41814787-AA

Application planning

S7-1500H configuration

①

CPU 1

②

CPU 2

③

Two fiber-optic cables (redundancy connections)

④

IO device ET 200SP (with system redundancy S2)

⑤

IO device ET 200MP (with system redundancy S2)

⑥

PROFINET cable (PROFINET ring)

3.3 Configuration versions

Figure 3-3 S7-1500H configuration with IO devices in the PROFINET ring

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56 System Manual, 10/2018, A5E41814787-AA

Application planning

3.3.2

S7-1500R/H configuration with switches and linear topology

Introduction

Benefits/advantages

S7-1500R configuration

①

CPU 1

②

CPU 2

③

PROFINET cable (redundancy connections, PROFINET ring)

④

IO device ET 200MP (with system redundancy S2)

⑤

IO device ET 200SP (with system redundancy S2)

⑥

Switch

⑦

HMI device

3.3 Configuration versions

The following sections set out configurations of the S7-1500R/H redundant system with switches and line topology.

● You can use a switch to add an additional line topology to the PROFINET ring. Unlike the PROFINET ring, the line topology is not redundant.

● PROFINET IO devices assigned to the S7-1500R/H system must always support system redundancy S2. These PROFINET IO devices can be located in the PROFINET ring or they can be separated with a switch.

Figure 3-4 S7-1500R configuration with switches and line topology

S7-1500R/H redundant system System Manual, 10/2018, A5E41814787-AA

Application planning

S7-1500H configuration

①

CPU 1

②

CPU 2

③

Two fiber-optic cables (redundancy connections)

④

IO device ET 200SP (with system redundancy S2)

⑤

IO device ET 200MP (with system redundancy S2)

⑥

Switch

⑦

PROFINET cable (PROFINET ring)

⑧

HMI device

3.3 Configuration versions

Figure 3-5 S7-1500H configuration with switches and line topology

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58 System Manual, 10/2018, A5E41814787-AA

Application planning

3.4

Redundancy scenarios

3.4.1

Introduction

3.4 Redundancy scenarios

This section describes possible redundancy scenarios on the basis of various different configuration versions. The redundancy scenarios do not result in process restrictions. In the examples shown, the failures are tolerated by the redundant system.

The following convention applies:

Figure 3-6 Yellow traffic light

S7-1500R/H redundant system System Manual, 10/2018, A5E41814787-AA

Application planning

3.4.2

Failure of the primary CPU

Introduction

Redundancy scenario

①

Primary CPU → failed

②

Backup CPU → becomes new primary CPU

③

PROFINET cable (redundancy connections, PROFINET ring)

④

IO device ET 200MP

⑤

IO device ET 200SP

Sequence of events

3.4 Redundancy scenarios

The following redundancy scenario describes the effects of a defective primary CPU.

Figure 3-7 Failure of the primary CPU (using S7-1500R as an example)

1. The primary CPU of the redundant system fails in the RUN-Redundant system state.

2. The redundant system switches to the backup CPU. The backup CPU becomes the new

3. The new primary CPU exchanges process data with the IO devices.

4. The redundancy of the system is restricted. The restriction has no impact on the process.

primary CPU. The redundant system switches to the RUN-Solo system state. You can find additional information on the RUN-Solo system state in the section Operating and system states (Page 197).

If another system component or another network segment fails, this can result in the failure of the S7-1500R/H redundant system. You can find additional information in the section Failure scenarios (Page 72).

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Application planning

Diagnostics

Note

To get detailed diagnostics information, evaluate the diagnostics buffer.

Solution

3.4 Redundancy scenarios

System state, operating states and error displays after primary-backup switchover:

● Redundant system → RUN-Solo system state

● Primary CPU (previously backup CPU) → RUN operating state

– MAINT LED → yellow light: The R/H system is not in the RUN-Redundant system

state; no partner CPU found in the redundant system.

● Backup CPU (previously primary CPU) → failed

Replace the defective CPU. You can find additional information on the procedure in the section Replacing defective R/H CPUs (Page 260).

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Application planning

3.4.3

Failure of the backup CPU

Introduction

Redundancy scenario

①

Primary CPU

②

Backup CPU → failed

③

PROFINET cable (redundancy connections, PROFINET ring)

④

IO device ET 200MP

⑤

IO device ET 200SP

Sequence of events

3.4 Redundancy scenarios

The following redundancy scenario describes the effects of a defective backup CPU.

Figure 3-8 Failure of the backup CPU (using S7-1500R as an example)

1. The backup CPU of the redundant system fails in the RUN-Redundant system state.

2. The redundant system switches to the RUN-Solo system state. You can find additional

3. The primary CPU continues to exchange process data with the IO devices.

4. The redundancy of the system is restricted. The restriction has no impact on the process.

information on the RUN-Solo system state in the section Operating and system states (Page 197).

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Application planning

Diagnostics

Note

To get detailed diagnostics info

Solution

3.4 Redundancy scenarios

System state, operating states and error displays after primary-backup switchover:

● Redundant system → RUN-Solo system state

● Primary CPU → RUN operating state

– MAINT LED → yellow light: The R/H system is not in the RUN-Redundant system

state. No partner CPU has been found in the redundant system.

● Backup CPU → failed

rmation, evaluate the diagnostics buffer.

Replace the defective CPU. You can find additional information on the procedure in the section Replacing defective R/H CPUs (Page 260).

S7-1500R/H redundant system System Manual, 10/2018, A5E41814787-AA

Application planning

3.4.4

Failure of the PROFINET cable in the PROFINET ring

Introduction

Redundancy scenario

①

Primary CPU

②

Backup CPU

③

PROFINET cable (redundancy connections, PROFINET ring) → interrupted

④

IO device ET 200MP

⑤

IO device ET 200SP

3.4 Redundancy scenarios

The following redundancy scenario describes the effects of a defective PROFINET cable in the PROFINET ring.

Figure 3-9 Failure of a PROFINET cable in the PROFINET ring (using S7-1500R as an example)

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Application planning

Sequence of events

Diagnostics

Note

To get detailed diagnostics information, evaluate the diagnostics buffer.

Solution

3.4 Redundancy scenarios

1. A defective or disconnected PROFINET cable interrupts the PROFINET ring of the redundant system.

2. The redundant system remains in the RUN-Redundant system state: The primary and backup CPUs remain in the RUN-Redundant operating state.

3. The redundant system selects an alternative connection over the backup CPU. This allows the redundant system to access all IO devices in the PROFINET ring again.

4. The redundancy of the system is restricted. The restriction has no effect on the process. In the following examples, other components also fail in the redundancy scenario described. The result is a failure scenario:

If another system component or another network segment fails, this can result in the failure of the S7-1500R/H redundant system.

– If the primary CPU fails in addition to a PROFINET cable, the backup CPU switches to

the STOP operating state.

– If the PROFINET cable is also interrupted at another point, IO devices in the

PROFINET ring may fail depending on the location of the interruption.

– You can find additional information in the section Failure scenarios (Page 72).

System state, operating states and error displays after the failure of the PROFINET cable:

● Redundant system → RUN-Redundant system state

● Primary CPU → RUN-Redundant operating state

– MAINT LED → yellow light: The PROFINET ring is open. There is only one redundancy

connection remaining in the redundant system.

● Backup CPU → RUN-Redundant operating state

– MAINT LED → yellow light: The PROFINET ring is open. There is only one redundancy

connection remaining in the redundant system.

Replace the defective PROFINET cable or reconnect the disconnected PROFINET cable. You can find additional information on the procedure in the section Replacing defective PROFINET cables.

S7-1500R/H redundant system System Manual, 10/2018, A5E41814787-AA

Application planning

3.4.5

Specific redundancy scenarios for S7-1500H

3.4.5.1

Failure of a redundancy connection in S7-1500H

Introduction

Redundancy scenario

①

Primary CPU

②

Backup CPU

③

One fiber-optic cable (redundancy connection) → interrupted

④

IO device ET 200SP

⑤

IO device ET 200MP

⑥

PROFINET cable (PROFINET ring)

3.4 Redundancy scenarios

The following redundancy scenario describes the effects of a defective redundancy connection in S7-1500H.

Figure 3-10 Failure of a redundancy connection

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66 System Manual, 10/2018, A5E41814787-AA

Application planning

Sequence of events

Diagnostics

Note

To get

Solution

3.4 Redundancy scenarios

1. One of the two redundancy connections (fiber-optic cables) is interrupted.

2. The primary CPU continues to exchange process data with the IO devices.

3. The redundancy of the system is restricted. The redundant system will remain in the RUN-Redundant system state. The restriction has no effect on the process. If the primary CPU fails as well as the redundancy connection, the backup CPU switches to the STOP operating state. You can find additional information in the section Failure scenarios (Page 72).

System state, operating states and error displays after the failure of a redundancy connection:

● Redundant system → RUN-Redundant system state

● Primary CPU → RUN-Redundant operating state

– MAINT LED → yellow light: There is only one redundancy connection remaining in the

H system.

● Backup CPU → RUN-Redundant operating state

– MAINT LED → yellow light: There is only one redundancy connection remaining in the

H system.

detailed diagnostics information, evaluate the diagnostics buffer.

Replace the defective redundancy connection. You can find additional information on the procedure in the section Replacing defective redundancy connections (Page 261).

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Application planning

3.4.5.2

Failure of both redundancy connections in S7-1500H > 1500 ms apart

Introduction

Redundancy scenario

①

Primary CPU (S7-1500H)

②

Backup CPU (S7-1500H)

③

Two fiber-optic cables (redundancy connections) → interrupted

④

IO device ET 200MP

⑤

IO device ET 200SP

⑥

PROFINET cable (PROFINET ring)

3.4 Redundancy scenarios

The following redundancy scenario describes the effects of a defect in each of the two redundancy connections in S7-1500H. In this redundancy scenario, the time between the redundancy connection failures is > 1500 ms.

Figure 3-11 Failure of both redundancy connections (> 1500 ms apart)

S7-1500R/H redundant system

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Sequence of events

Diagnostics

Note

To get detailed diagnostics information, evaluate the diagnostics buffer.

Solution

3.4 Redundancy scenarios

1. The two redundancy connections (fiber-optic cables) are interrupted, one > 1500 ms after the other.

2. The redundant system switches to the RUN-Solo system state. The primary CPU remains in the RUN operating state. The backup CPU switches to the STOP operating state.

3. The primary CPU continues to exchange process data with the IO devices.

4. The redundancy of the system is restricted. The restriction has no impact on the process. If another system component or another network segment fails, this can result in the failure of the S7-1500R/H redundant system. You can find additional information in the section Failure scenarios (Page 72).

System state, operating states and error displays after the failure of both redundancy connections:

● Redundant system → RUN-Solo system state

● Primary CPU → RUN operating state

– MAINT LED → yellow light: The H-system is not in the RUN-Redundant system state.

No partner CPU has been found in the H-system.

● Backup CPU → STOP operating state

– MAINT LED → yellow light: The H-system is not in the RUN-Redundant system state.

No partner CPU has been found in the H-system.

Replace the defective redundancy connections. You can find additional information on the procedure in the section Replacing defective redundancy connections (Page 261).

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Application planning

3.4.5.3

Failure of both redundancy connections and the PROFINET cable in the PROFINET ring

Introduction

Redundancy scenario

①

Primary CPU

②

Backup CPU

③

Two fiber-optic cables (redundancy connections) → interrupted

④

IO device ET 200SP

⑤

IO device ET 200MP

⑥

PROFINET cable (PROFINET ring) → interrupted

3.4 Redundancy scenarios

The following redundancy scenario describes the effects of a defect in each of the two redundancy connections and in the PROFINET cable in the PROFINET ring. In this redundancy scenario, the time between the redundancy connection failures is > 1500 ms.

Figure 3-12 Failure of both redundancy connections and a PROFINET cable in the PROFINET ring

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Sequence of events

Diagnostics

Note

To get detailed diagnostics information, evaluate the diagnostics buffer.

Solution

3.4 Redundancy scenarios

1. Both redundancy connections (fiber-optic cables) fail in the redundant system. The time between the failures is > 1500 ms.

2. The redundant system switches to the RUN-Solo system state. The primary CPU remains in the RUN operating state. The backup CPU switches to the STOP operating state.

3. A defective PROFINET cable also interrupts the PROFINET ring.

4. The redundant system accesses all IO devices in the PROFINET ring again over the remaining PROFINET cables.

5. The redundancy of the system is restricted. The restrictions have no effect on the process.

System state, operating states and error displays after the failure of the redundancy connections and PROFINET cable:

● Redundant system → RUN-Solo system state

● Primary CPU → RUN operating state

– MAINT LED → yellow light: The H-system is not in the RUN-Redundant system state.

No partner CPU has been found in the H-system. The PROFINET ring is open.

● Backup CPU → STOP operating state

– MAINT LED → yellow light: The H-system is not in the RUN-Redundant system state.

No partner CPU has been found in the H-system. The PROFINET ring is open.

Replace the defective redundancy connections and the defective PROFINET cable. You can find more information on the procedure in the following sections:

● Replacing defective redundancy connections (Page 261)

● Replacing defective PROFINET cables

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Application planning

3.5

Failure scenarios

Introduction

3.5 Failure scenarios

This section describes possible failure scenarios with the various configuration versions. The failure scenarios lead to process restrictions. In the examples shown, the redundant system cannot tolerate the failures any longer.

The following convention applies:

Figure 3-13 Red traffic light

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3.5.1

Failure of an IO device in the PROFINET ring

Introduction

Failure scenario

①

Primary CPU

②

Backup CPU

③

PROFINET cable (redundancy connections, PROFINET ring)

④

IO device ET 200MP

⑤

IO device ET 200SP → failed

Sequence of events

3.5 Failure scenarios

The following failure scenario describes the effects of a defective IO device in the PROFINET ring.

Figure 3-14 Failure of an IO device in the PROFINET ring (using S7-1500R as an example)

1. An IO device in the PROFINET ring fails.

2. The PROFINET ring is interrupted.

3. The redundant system selects an alternative connection over the backup CPU. This

4. The failure of the IO device has an impact on the process. If the failed inputs and outputs

allows the redundant system to access all remaining IO devices in the PROFINET ring again.

have an important function in the system, their failure can have a critical impact on the process.

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Application planning

Diagnostics

Note

To get detailed diagnostics information, evalua

Solution

3.5 Failure scenarios

System state, operating states and error displays after the failure of an IO device:

● Redundant system → RUN-Redundant system state

● Primary CPU → RUN-Redundant operating state

– MAINT LED: → yellow light: The PROFINET ring is open.

– ERROR LED → flashes red: An IO device has failed.

● Backup CPU → RUN-Redundant operating state

– MAINT LED → yellow light: The PROFINET ring is open.

– ERROR LED → flashes red: An IO device has failed.

te the diagnostics buffer.

Replace the defective IO device. You can find additional information on the procedure in the section Replacing defective I/O devices/switches (Page 268).

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3.5.2

Failure of a switch (with line topology) in the PROFINET ring

Introduction

Failure scenario

①

Primary CPU

②

Backup CPU

③

PROFINET cable (redundancy connections, PROFINET ring)

④

IO device ET 200MP

⑤

IO device ET 200SP

⑥

Switch → failed

⑦

IO device ET 200SP

⑧

HMI device

3.5 Failure scenarios

The following failure scenario describes the effects of a defective switch (with line topology) in the PROFINET ring.

Figure 3-15 Failure of a switch in the PROFINET ring (using S7-1500R as an example)

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Application planning

Sequence of events

Diagnostics

Note

To get detailed diagnostics information, evaluate the diagnostics buffer.

Solution

3.5 Failure scenarios

1. A switch (with connected line topology) in the PROFINET ring fails.

2. The PROFINET ring is interrupted.

3. If applicable, the redundant system selects an alternative connection to the IO devices

⑤ over the backup CPU. This allows the redundant system to access all IO devices

and in the PROFINET ring again.

4. The failure of the switch has an impact on the process as the IO devices in the line topology can no longer be accessed. If the failed inputs and outputs have an important function in the system, their failure can have a critical impact on the process.

System state, operating states and error displays after the failure of a switch:

● Redundant system → RUN-Redundant system state

● Primary CPU → RUN-Redundant operating state

– MAINT LED → yellow light: The PROFINET ring is open.

– ERROR LED → flashes red: One or more IO devices have failed.

● Backup CPU → RUN-Redundant operating state

– MAINT LED → yellow light: The PROFINET ring is open.

– ERROR LED → flashes red: One or more IO devices have failed.

④

Replace the defective switch. You can find additional information on the procedure in the section Replacing defective I/O devices/switches (Page 268).

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3.5.3

Specific failure scenarios with S7-1500R

3.5.3.1

Two cable interruptions in the PROFINET ring in S7-1500R > 1500 ms apart

Introduction

Failure scenario

①

Primary CPU

②

Backup CPU

③

PROFINET ring → interrupted at two points

④

IO device ET 200MP

⑤

IO device ET 200SP

3.5 Failure scenarios

The following failure scenario describes the effects of two cable interruptions in the PROFINET ring. In this failure scenario, the time between the two cable interruptions is > 1500 ms.

Figure 3-16 Two cable interruptions in the PROFINET ring (> 1500 ms apart)

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Application planning

Sequence of events

Diagnostics

Note

To get detailed diagnostics information, evaluate the diagnostics buffer.

Solution

3.5 Failure scenarios

1. The PROFINET ring is interrupted at one point.

2. The redundant system remains in the RUN-Redundant system state: The primary and backup CPUs remain in the RUN-Redundant operating state.

3. The PROFINET ring is interrupted at a second point > 1500 ms later.

4. The redundant system switches to the RUN-Solo system state. The primary CPU remains in the RUN operating state. The backup CPU switches to the STOP operating state.

5. CPU redundancy has failed. The failure has an impact on the process. The RUN-Solo system state and the cable interruptions mean that not all IO devices in the PROFINET ring can be accessed. If the failed inputs and outputs have an important function in the system, their failure can have a critical impact on the process.

System state, operating states and error displays after the cable interruptions:

● Redundant system → RUN-Solo system state

● Primary CPU → RUN operating state

– MAINT LED → yellow light: The R system is not in the RUN-Redundant system state.

No partner CPU has been found in the R system. The PROFINET ring is open.

– ERROR LED → flashes red: One or more IO devices cannot be accessed.

● Backup CPU → STOP operating state

– MAINT LED → yellow light: The R system is not in the RUN-Redundant system state.

No partner CPU has been found in the R system. The PROFINET ring is open.

– ERROR LED → flashes red: One or more IO devices cannot be accessed.

Replace the defective PROFINET cables. You can find additional information on the procedure in the section Replacing defective redundancy connections (Page 261).

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3.5.3.2

Two cable interruptions in the PROFINET ring in S7-1500R within ≤ 1500 ms

Introduction

Failure scenario

①

Primary CPU

②

Backup CPU

③

PROFINET ring → interrupted at two points

④

IO device ET 200MP

⑤

IO device ET 200SP

3.5 Failure scenarios

The following failure scenario describes the effects of two cable interruptions in the PROFINET ring. In this failure scenario, the time between the two cable interruptions is ≤ 1500 ms.

Figure 3-17 Two cable interruptions in the PROFINET ring (within ≤ 1500 ms)

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Application planning

Sequence of events

WARNING

Undefined system state of the S7-1500R redundant system at the same time as a cable interruption in the PROFINET ring at two points within ≤ 1500 ms.

Diagnostics

Note

To get detailed diagnostics information, evaluate the diagnostics buffer.

3.5 Failure scenarios

1. The PROFINET ring is interrupted at two points within ≤ 1500 ms.

2. The redundant system switches to an undefined system state: The primary CPU remains in the RUN operating state. The backup CPU becomes the primary CPU and remains in RUN operating state.

3. The two primary CPUs continue to exchange process data with the accessible IO devices.

4. The redundancy of the system is defective. The redundant system is in an undefined system state. The undefined system state can lead to dangerous states in the process.

Lay the PROFINET cables so that they are securely protected from damage. PROFINET cables should also always be laid separately from each other. This makes simultaneous damage to the PROFINET cables (within ≤ 1500 ms) unlikely.

System state and operating states after cable interruptions:

● Redundant system → System state defective (undefined: Each R-CPU is in the RUN-Solo system state).

● Primary CPU → RUN operating state

– MAINT LED → yellow light: The R system is not in the RUN-Redundant system state.

The PROFINET ring is open.

– ERROR LED → flashes red: An IO device has failed.

● Primary CPU (previously backup CPU) → RUN operating state

– MAINT LED → yellow light: The R system is not in the RUN-Redundant system state.

The PROFINET ring is open.

– ERROR LED → flashes red: An IO device has failed.

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Solution

Note

Before you replace the defective PRO STOP operating state. Only then repair the PROFINET cables in the PROFINET ring. Afterwards, switch the R

3.5.3.3

Failure of the primary CPU when IO devices have failed in the PROFINET ring

Introduction

Failure scenario

①

Primary CPU → failed (2nd failure in runtime sequence)

②

Backup CPU → switches to STOP operating state

③

PROFINET cable (redundancy connections, PROFINET ring)

④

IO device ET 200MP

⑤

IO device ET 200SP → failed (1st failure in sequence)

3.5 Failure scenarios

Please note the following solution:

FINET cables, you must switch both R-CPUs to the

-CPUs back to the RUN operating state.

You can find additional information on the procedure in the section Replacing defective redundancy connections (Page 261).

The following failure scenario describes the effects of a defective IO device in the PROFINET ring and a defective primary CPU.

Figure 3-18 Failure of an IO device in the PROFINET ring and the primary CPU (using S7-1500R as

an example)

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Application planning

Sequence of events

Note

The backup CPU does not differentiate between the following scenarios:

•

cond point and the primary CPU may

That is why the backup CPU does not become the primary CPU. This prevents an undefined system state.

Diagnostics

Note

To get detailed diagnostics information, evaluate the d

3.5 Failure scenarios

1. An IO device in the PROFINET ring fails.

2. As a result, the PROFINET ring is interrupted.

3. The redundant system selects an alternative connection over the backup CPU. This allows the redundant system to access all remaining IO devices in the PROFINET ring again.

4. The primary CPU also fails.

5. The redundant system does not switch to the backup CPU and switches to the STOP system state. The role of the backup CPU remains unchanged.

It can no longer access the primary CPU because the latter has failed. The PROFINET ring has been interrupted at a se

still be running.

6. The redundant system has failed. The process is no longer controlled by the redundant system.

System state, operating states and error displays after the failure of the IO device in the PROFINET-Ring and the STOP of Backup CPU:

● Redundant system → STOP system state

● Primary CPU → failed

● Backup CPU → STOP operating state

– MAINT LED → yellow light: The R system is not in the RUN-Redundant system state.

No partner CPU has been found in the R system. The PROFINET ring is open.

– ERROR LED → flashes red: One or more IO devices have failed.

iagnostics buffer.

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Solution

Note

Proceed as follows if yo state and can access all important IO devices:

3.5 Failure scenarios

Replace the defective IO device and the defective primary CPU. You can find additional information on the procedure in the sections Replacing defective R/H CPUs (Page 260) and Replacing defective I/O devices/switches (Page 268).

u have ensured that the CPU is still working in the STOP operating

Replace the defective IO device. Switch the CPU from STOP operating state to the RUN operating state. Replace the defective CPU. Switch the new CPU to the RUN operating state.

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Application planning

3.5.4

Specific failure scenarios with S7-1500H

3.5.4.1

Failure of both redundancy connections in S7-1500H ≤ 1500 ms apart

Introduction

Failure scenario

①

Primary CPU

②

Backup CPU

③

Two fiber-optic cables (redundancy connections) → interrupted

④

IO device ET 200SP

⑤

IO device ET 200MP

⑥

PROFINET cable (PROFINET ring)

3.5 Failure scenarios

The following failure scenario describes the effects of a defect in each of the two redundancy connections in S7-1500H. In this failure scenario, the time between the redundancy connection failures is ≤ 1500 ms.

Figure 3-19 Failure of both redundancy connections

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Sequence of events

WARNING

Undefined system state of the S7-1500H redundant system when two redundancy connections are interrupted ≤ 1500 ms apart.

Diagnostics

Note

To get detailed diagnostics information, evaluate the diagnostics buffer.

Solution

Note

Before you replace the defective redundancy connections, you must switch both H the STOP operating state. Only then repair the redundancy connections. Switch the H-CPUs back to the RUN operating state.

3.5 Failure scenarios

1. The two redundancy connections (fiber-optic cables) are interrupted ≤ 1500 ms apart.

2. The redundant system switches to an undefined system state: The primary CPU remains

in the RUN operating state. The backup CPU becomes the primary CPU and remains in RUN operating state.

3. The two primary CPUs continue to exchange process data with the PROFINET devices.

4. The redundancy of the system is defective. The redundant system is in an undefined

system state. The undefined system state can lead to dangerous states in the process.

Lay the redundancy connections so that the fiber-optic cables are securely protected from damage. Also make sure when laying the cables that the two redundancy connections are always separate from each other. This makes simultaneous damage to the redundancy connections (< 1500 ms apart) unlikely.

System state and operating states after the failure of both redundancy connections:

● Redundant system → System state defective (undefined: Each H-CPU is in the RUN-Solo

system state).

● Primary CPU → RUN operating state

– MAINT LED → yellow light: The H-system is not in the RUN-Redundant system state.

No partner CPU has been found in the H-system.

● Primary CPU (previously backup CPU) → RUN operating state

– MAINT LED → yellow light: The H-system is not in the RUN-Redundant system state.

No partner CPU has been found in the H-system.

Please note the following solution:

You can find additional information on the procedure in the section Replacing defective redundancy connections (Page 261).

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-CPUs to

Application planning

3.5.4.2

Failure of one redundancy connection and the primary CPU in S7-1500H

Introduction

Failure scenario

①

Primary CPU → failed (2nd failure in runtime sequence)

②

Backup CPU

③

One fiber-optic cable (redundancy connection) → interrupted (1st failure in runtime sequence)

④

IO device ET 200SP

⑤

IO device ET 200MP

⑥

PROFINET cable (PROFINET ring)

3.5 Failure scenarios

The following failure scenario describes the effects of a defect in a redundancy connection and the primary CPU in S7-1500H. In this failure scenario, the time between the redundancy connection failure and the Primary CPU is > 1500 ms.

Figure 3-20 Failure of one redundancy connection and the primary CPU

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Sequence of events

Note

The backup CPU does not differentiate between the following scenarios:

•

• The other redundancy connection has also been interrupted and the primary CPU may

Tha undefined system state.

Diagnostics

Note

To get detailed diagnostics information, evaluate the diagnostics buffer.

Solution

3.5 Failure scenarios

1. One of the two redundancy connections is interrupted.

2. Availability is restricted. The redundant system will remain in the RUN-Redundant system

state.

3. The primary CPU also fails. Due to the failure, the primary CPU is no longer visible for the

backup CPU.

4. The redundant system does not switch to the backup CPU, probe switches to the STOP

system state. The role of the backup CPU remains unchanged.

It can no longer access the primary CPU because the latter has failed.

still be running.

t is why the backup CPU does not become the primary CPU. This prevents an

5. System redundancy has failed. The process is no longer controlled by the redundant

system.

System state and operating states after the failure of the redundancy connection and primary CPU:

● Redundant system → STOP system state

● Primary CPU → failed

● Backup CPU → STOP operating state

– MAINT LED → yellow light: The H-system is not in the RUN-Redundant system state.

No partner CPU has been found in the H-system.

– ERROR LED → flashes: IO devices cannot be accessed.

Replace the defective redundancy connection and the primary CPU. You can find additional information on the procedure in the sections Replacing defective redundancy connections (Page 261) and Replacing defective R/H CPUs (Page 260).

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Application planning

3.6

Hardware configuration

Modules suitable for R/H-CPUs

Module type

Maximum number of modules, primary CPU (mounting rail)

Maximum number of modules, backup CPU (mounting rail)

Load power supply (PM) 1)

unlimited

CPU

Connection to the backplane bus cannot be configured. The RUN LED on the PS flashes green.

①

Optional load power supply and first R/H-CPU

②

Optional load power supply and second R/H-CPU

3.6 Hardware configuration

The integrated system power supply of the R/H-CPU supplies the required power for operation. Optionally, you can also use a system power supply (PS) or load power supply. The system power supply (PS) must be connected to the left of the primary and backup CPU.

The system power supply PS and load power supply PM cannot be configured with S71500R/H in STEP 7. The RUN LED of the PS therefore flashes permanently. You cannot evaluate pending diagnostics or errors of the PS over the R/H-CPUs.

The table below shows which modules can be used in the various R/H-CPU slots:

Table 3- 5 Assignment of slot numbers

System power supply (PS) 2) 1 1

No connection to the backplane bus.

Figure 3-21 Maximum configuration

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Application planning

PROFINET devices suitable for the redundant system

PROFINET devices

Maximum number, S71500R

Maximum number, S7-1500H

16) 1)

PROFINET devices in the ring in S7-1500R.

3.6 Hardware configuration

The table below shows the maximum number of PROFINET devices in the redundant system. The maximum number includes switches, S7-1500R/H CPUs, S7-1500 CPUs (V2.5 or later) and HMI devices. It does not include media converters.

Table 3- 6 Number of PROFINET devices in the redundant system

In the PROFINET ring 50 (Recommendation

In the PROFINET ring and separated with switches (line)

Recommendation: The number of devices in the PROFINET ring affects the availability of the S7-

1500R system. You should therefore operate no more than 16 PROFINET devices (including RCPUs) in the PROFINET ring. If you operate significantly more devices in the PROFINET ring, the availability of the IO devices and R-CPUs is reduced. The technical specifications in the documentation are based on the recommended maximum of 16

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Application planning

3.7

Use of a system power supply

Infeed options

Infeed via the CPU

Procedure

Infeed via CPU and system power supply

3.7 Use of a system power supply

There are three options for the infeed of the required system voltage in the backplane bus:

● Infeed via the CPU

● Infeed via the CPU and system power supply

● Infeed only via system power supply in slot 0

Supply the CPU with the permissible supply voltage 24 V DC.

Proceed as follows to set up the supply via the CPU:

1. In STEP 7, open the "Properties" tab for the R/H-CPU. Select "System power supply" in the navigation.

2. Select the option "Connection to supply voltage L+".

Figure 3-22 Supply voltage via CPU only

Supply the system power supply with the permissible supply voltage and the CPU with 24 V DC.

Both the system power supply and the CPU supply current to the backplane bus. The supplied power is summed.

Power addition: Infeed power of the system power supply + infeed power of the CPU

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Procedure

Infeed via system power supply only

Procedure

Note

If you sel CPU is supplied through the system power supply only. If you then compile the hardware configuration in STEP

ing

has no effect on the functioning of the user program or of the redundant system.

3.7 Use of a system power supply

Proceed as follows to set up the supply through the CPU and system power supply:

1. In STEP 7, open the "Properties" tab for the CPU. Select "System power supply" in the

navigation.

2. Select the option "Connection to supply voltage L+".

Figure 3-23 Supply voltage via the CPU and system power supply

You can also feed the required power into the backplane bus using only a system power supply. In this case, the CPU is supplied from the backplane bus rather than with 24 V DC. In this case, the system power supply must be inserted to the left of the R/H-CPU in slot 0.

In general, you can use a system power supply with AC or DC infeed for the configuration.

To set up infeed only via the system power supply, follow these steps:

1. In STEP 7, open the "Properties" tab for the CPU. Select "System power supply" in the

navigation.

2. Select the option "No connection to supply voltage L+".

Figure 3-24 No supply to the backplane bus through the CPU

ect the option "No connection to supply voltage L+", the power required for the R/H

7, the warning "Power segment undersupplied" appears. This warn

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Application planning

3.8

Using HMI devices

Introduction

3.8 Using HMI devices

You can use the same HMI devices for the S7-1500R/H redundant system as for the S7-1500 automation system.

If you use HMI devices in the PROFINET ring with S7-1500R, those HMI devices must support media redundancy; we also recommend that you use the H-Sync forwarding function.

If you use HMI devices in the PROFINET ring with S7-1500H, those HMI devices must support media redundancy.

You transfer the HMI configuration to your HMI device using the configuration and programming software (Engineering Station).

You can connect the HMI device to the redundant system with the system IP address. Connection to the redundant system is possible within and outside the PROFINET ring. The HMI device always communicates with the primary CPU over the system IP address in the RUN-Redundant, RUN-Solo and STOP system states, provided you have activated the system IP address and selected it in the connection configuration for the HMI device.

If the role of primary CPU switches to the other CPU, the communication relationship of the HMI device also switches to the other (primary) CPU.

As an alternative to the system IP address, you can also use the device IP address to connect the HMI device to an R/H-CPU. The HMI device then only communicates with the connected CPU.

When exchanging data via device proxy data, make sure that the IP addresses and system IP addresses are correctly assigned to the PROFINET interfaces. You can find additional information on devices proxy data in the STEP 7 online help.

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Connecting HMI devices over Industrial Ethernet, example with CPU 1517H-3 PN

Note

A PROFINET device (such as an HMI device) can only communicate with the redundant system over the s connect the PROFINET device to the same interfaces, X1 or X2, on both R/H mix interfaces X1 and X2: If you mix interfaces X1 with X2, the HMI connection is no longer redundant.

The R/H address of the PROFINET X2 interfaces, only the backup CPU will be accessible if the cable to the primary CPU is interrupted.

3.8 Using HMI devices

The figure below is an example of how you can connect the CPU 1517H-3 PN to an HMI device over Industrial Ethernet.

Figure 3-25 H-CPU configuration example

CPU 1517H-3 PN has a PROFINET IO interface with two ports (X1 P1 R and X1 P2 R) and one PROFINET interface (X2 P1).

To connect an HMI device to the CPUs over Industrial Ethernet, you use the X2 PROFINET interfaces of the CPU. PROFINET interface X2 supports PROFINET basic functionality. The interface is, for example, suitable for communication with an HMI device or configuration and programming software (Engineering Station).

ystem IP address if it has been connected to both R/H-CPUs. Always

-CPUs. Do not

-CPUs do not support S7 routing: If you connect the HMI device over the system IP

You can find additional information on the interfaces of CPU 1517H-3 PN in the relevant device manual.

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Application planning

Connecting HMI devices over Industrial Ethernet, example with CPU 1513R-1 PN

3.8 Using HMI devices

The figure below shows how to connect an HMI device over Industrial Ethernet with the CPU 1513R-1 PN.

Figure 3-26 Configuration example with HMI device connected over a switch

CPU 1513R-1 PN has a PROFINET IO interface with two ports (X1 P1 R and X1 P2 R).

To connect an HMI device to the CPUs over Industrial Ethernet, you set up the PROFINET ring over PROFINET interface X1. Integrate a switch into the PROFINET ring. Use this to establish an Industrial Ethernet connection.

You can find additional information on the interfaces of CPU 1513R-1 PN in the relevant device manual.

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Application planning

Connecting HMI devices within the PROFINET ring, example with CPU 1515R-2 PN

Reference

3.8 Using HMI devices

The figure below shows an example of how to connect an HMI device with CPU 1515R-2 PN within the PROFINET ring.

Figure 3-27 Ring configuration example

CPU 1515R-2 PN has a PROFINET IO interface with two ports (X1 P1 R and X1 P2 R) and one PROFINET interface (X2 P1).

Integrate a switch into the PROFINET ring to connect an HMI device to the PROFINET ring. Use this to establish a connection to the HMI device.

The PROFINET ring is set up using the PROFINET IO interfaces (X1) of the CPUs. If you operate HMI devices within the ring, you need to assign the MRP role "Client" to the MRP domain. You can find more information on HMI device application planning in the section Requirements (Page 49).

You can find more information on the interfaces of CPU 1515R-2 PN in the relevant device manual.

You can find more information on the system IP address in the section Configuration process (Page 136) and in the Communication (https://support.industry.siemens.com/cs/ww/de/view/59192925/en) function manual.

More information on how to set up an HMI connection to the S7-1500R/H redundant system is available in the Communication (https://support.industry.siemens.com/cs/ww/de/view/59192925/en) function manual.

S7-1500R/H redundant system System Manual, 10/2018, A5E41814787-AA

4.1

Basics

Installation site

Installation position

Mounting rail

All modules of the S7-1500R/H redundant system are unenclosed equipment. You may only install unenclosed equipment in housings, cabinets or electrical operating rooms. The housings, cabinets and electrical operating rooms must guarantee protection against electric shock and spread of fire. The requirements for mechanical strength must also be met. The housings, cabinets, and electrical operating rooms must not be accessible without a key or tool. Personnel with access must have been trained or authorized.

The S7-1500R/H redundant system is designed for use in the following mounting positions:

● Horizontal mounting position up to 60° C

● Vertical mounting position up to 40° C

Additional information can be found in the section Mechanical and climatic environmental conditions.

You can mount the following components on the mounting rails alongside the S7-1500R/H CPUs, load and system power supplies:

● Terminals

● Circuit breakers

● Small contactors

● Similar components

These components can influence the installation dimensions for the cable duct.

Modules can be mounted right to the outer edge of the mounting rail.

The mounting rails are available in various lengths. You order the mounting rails using the online catalog or the online ordering system. The available lengths and article numbers can be found in the appendix Accessories/spare parts (Page 305).

S7-1500R/H redundant system

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Installation

Minimum clearances

①

Upper edge of the mounting rail

Installation rules

WARNING

Protection from conductive contamination

4.1 Basics

Modules can be mounted right to the outer edge of the mounting rail. Maintain the following minimum clearances when installing or dismantling the S7-1500R/H redundant system.

Figure 4-1 Minimum clearances in the control cabinet

The redundant system configuration consists of:

R/H-CPU and an optional load or system power supply.

Taking into consideration the ambient conditions, the devices must be protected from conductive contamination.

Protection from conductive contamination can, for example, be achieved by installing the devices in a control cabinet with the appropriate degree of protection.

S7-1500R/H redundant system System Manual, 10/2018, A5E41814787-AA

Installation

4.2

Installing the mounting rail

Introduction

Lengths and drill holes

Tools required

4.2 Installing the mounting rail

The R/H-CPUs should be mounted either on one mounting rail or on two separate mounting rails.

The mounting rails are delivered in six lengths:

● 160 mm

● 245 mm

● 482.6 mm (19 inches)

● 530 mm

● 830 mm

● 2000 mm

You can find the article numbers in the appendix Accessories/spare parts (Page 305).

The mounting rails (from 160 to 830 mm) come with two drill holes for fixing screws. A set of screws for grounding the mounting rail is provided.

The 2000 mm mounting rail is designed for assemblies with special lengths and does not have holes for fixing screws. No set of screws for grounding is included with the mounting rail (can be ordered as accessories/spare parts (Page 305)).

The specifications of the maximum offsets between two drill holes can be found in the table, "Dimensions for the drill holes".

● Commercially available hacksaw

● Drill ∅ 6.5 mm

● Screwdriver

● Size 10 adjustable screw-wrench or socket wrench for grounding cable connection

● Adjustable screw-wrench, matching the selected fixing screws

● Stripping tool and crimp tool for the grounding cable

S7-1500R/H redundant system

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Installation

Accessories required

For ...

use ...

Explanation

ISO 1207/ISO 1580 (DIN 84/DIN 85)

(DIN 433).

Dimensions for the drill holes

"Standard" mounting rails

"Longer" mounting rails

Length of the mounting rail

Distance a

Distance b

160 mm

10 mm

140 mm

245 mm

10 mm

225 mm

482.6 mm

8.3 mm

466 mm

530 mm

15 mm

500 mm

830 mm

15 mm

800 mm

Additional fixing screws (for mounting rails > 530 mm)

4.2 Installing the mounting rail

Use the following screw types for fastening the mounting rails:

Table 4- 1 Accessories required

• Outer fixing screws

• Additional fixing screws (for mount-

ing rails > 482.6 mm)

Table 4- 2 Dimensions for the drill holes

M6 fillister head screws according to

M6 hexagon head screws according to ISO 4017 (DIN 4017)

Choose a suitable screw length for your assembly.

You also need washers for cylinder head screws with an internal diameter of 6.4 mm and an external diameter of 11 mm in accordance with ISO 7092

For mounting rails > 530 mm, we recommend using additional fixing screws at intervals of ≤ 500 mm on the identification groove.

S7-1500R/H redundant system System Manual, 10/2018, A5E41814787-AA

Siemens Simatic S7-1500R, Simatic S7-1500H System Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Legal information

Preface

Table of contents

What is the S7-1500R/H redundant system?

Areas of application

Operating principle of the S7-1500R/H redundant system

Plant components and automation levels

Scalability

Overview of features

Structure of the S7-1500R redundant system

2.2 Configuration

Structure of the S7-1500H redundant system

Components

Overview of the CPU technical specifications

2.3 S7-1500 R/H-CPUs

Redundancy

Security

Diagnostics

Trace

System and device IP addresses

2.4 Communication

Integrated interfaces for communication

HMI devices

2.5 Power supply

TIA Portal

2.6 Software

SINETPLAN

PRONETA

Requirements

3.2 Restrictions compared to the S7-1500 automation system

3.3 Configuration versions

S7-1500R/H configuration with IO devices in the PROFINET ring

S7-1500R/H configuration with switches and linear topology

Introduction

3.4 Redundancy scenarios

Failure of the primary CPU

Failure of the backup CPU

Failure of the PROFINET cable in the PROFINET ring

Specific redundancy scenarios for S7-1500H

Failure of a redundancy connection in S7-1500H

Failure of both redundancy connections in S7-1500H > 1500 ms apart

Failure of both redundancy connections and the PROFINET cable in the PROFINET ring

3.5 Failure scenarios

Failure of an IO device in the PROFINET ring

Failure of a switch (with line topology) in the PROFINET ring

Specific failure scenarios with S7-1500R

Two cable interruptions in the PROFINET ring in S7-1500R > 1500 ms apart

Two cable interruptions in the PROFINET ring in S7-1500R within ≤ 1500 ms

Failure of the primary CPU when IO devices have failed in the PROFINET ring

Specific failure scenarios with S7-1500H

Failure of both redundancy connections in S7-1500H ≤ 1500 ms apart

Failure of one redundancy connection and the primary CPU in S7-1500H

3.6 Hardware configuration

3.7 Use of a system power supply

3.8 Using HMI devices

Basics

4.2 Installing the mounting rail