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
1
System overview
2
Application planning
3
Installation
4
Wiring
5
Configuration
6
Basics of program execution
7
Protection
8
Commissioning
9
Display
10
Maintenance
11
Test functions
12
Technical specifications
13
Dimension drawings
A
Accessories/spare parts
B
Safety symbols
C
-AA
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A5E41814787-AA
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Copyright © Siemens AG 2018.
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NOTICE
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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.
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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
3
Preface
Security information
Siemens Industry Online Support
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Application examples
Services
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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
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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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This information is provided by the Siemens Industry Online Support in the Internet
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S7-1500R/H redundant system
4 System Manual, 10/2018, A5E41814787-AA
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
5
Table of contents
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
S7-1500R/H redundant system
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1
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
11
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).
S7-1500R/H redundant system
12 System Manual, 10/2018, A5E41814787-AA
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
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2
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.
S7-1500R/H redundant system
14 System Manual, 10/2018, A5E41814787-AA
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
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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.
S7-1500R/H redundant system
16 System Manual, 10/2018, A5E41814787-AA
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.
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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.
S7-1500R/H redundant system
18 System Manual, 10/2018, A5E41814787-AA
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
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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
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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
S7-1500R/H 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.
S7-1500R/H redundant system
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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)
S7-1500R/H redundant system
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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
✓ ✓ ✓
1)
2)
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).
---
S7-1500R/H redundant system
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System overview
2.1.3
Plant components and automation levels
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.
S7-1500R/H redundant system
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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.
S7-1500R/H redundant system
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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
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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
S7-1500R/H redundant system
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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
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