Automation and Drives

SIMATIC S7
Software Redundancy

Automation and Drives

SW Redundancy Principle
SIMATIC SW Redundancy
Principle

Positioning
Application Fields Configuration Features Order number and delivery form REDUNDANCY Area

Steam Production
Boiler 1 Mixer Boiler 2 Dryer

SIMATIC Software Redundancy

A&D AS SM6 R.Fischer 2

Automation and Drives

SW Redundancy Positioning
SIMATIC SW Redundancy
Principle

Low Cost / Low Performance Redundancy solution based on standard components Universal solution for all CPU from CPU 315-2DP until CPU 417-4 Marketing parallel to S7-400H

Positioning
Application Fields Configuration Features Order number and delivery form

SIMATIC Software Redundancy

A&D AS SM6 R.Fischer 3

Automation and Drives

SW Redundancy Application Fields

SIMATIC SW Redundancy
Principle

Application for processes that tolerate a Master-Slave switchover time of about a second Examples:
Water treatment Control of cooling systems Control and monitoring of
temperature levels

Positioning
Application Fields Configuration Features Order number and delivery form

Traffic control Measuring registration

SIMATIC Software Redundancy

A&D AS SM6 R.Fischer 4

Automation and Drives

SW Redundancy with S7-400 Configuration

SIMATIC SW Redundancy
Principle MPI/ Profibus/ Ethernet Redundancy Connection

Positioning
Application Fields Configuration Features Order number and delivery form

Master controller

Back up controller

ET 200M with IM 153-2

Non redundant Area

Redundant Area

Non redundant Area

Active Bus
SIMATIC Software Redundancy

Backup Bus
A&D AS SM6 R.Fischer 5

Profibus DP Redundancy with Standard IM 153-2

SIMATIC SW Redundancy
Principle

Automation and Drives

Redundant IM 153-2
Profibus DP

Positioning
Application Fields Configuration Features Order number and delivery form

L+ L+

ET 200M with active Bus modules

Bus module (BM)

Available as individual components IM: 6ES7 153-2AA02-0XB0 BM: 6ES7 195-7HD00-0XA0

or as Bundle (2 x IM + 1 BM) 6ES7 153-2AR00-0XA0

IM IM

Active Bus module

SIMATIC Software Redundancy

A&D AS SM6 R.Fischer 6

SW Redundancy Function
SIMATIC SW Redundancy
Principle

Automation and Drives

Master
Reading of Inputs Non redundant user program processing Reception of status information from reserve controller Redundant user program processing Transmission of redundant data to reserve controller Writing of non redundant and redundant outputs

Reserve
Reading of Inputs Non redundant user program processing Reception of information from master controller

Positioning
Application Fields Configuration Features Order number and delivery form

Transmission of information to the master controller Writing of non redundant outputs

SIMATIC Software Redundancy

A&D AS SM6 R.Fischer 7

Automation and Drives

SW Redundancy with S7-400

SIMATIC SW Redundancy
Principle

Positioning
Application Fields Configuration Features Order number and delivery form

MPI/ PROFIBUS/ Ethernet Redundancy Connection

Master controller

Back up controller

Redundant area

SIMATIC Software Redundancy

A&D AS SM6 R.Fischer 8

Automation and Drives

SW Redundancy with S7-400 and WinCC

SIMATIC SW Redundancy
Principle WinCC Redundancy script

Positioning
Application Fields Configuration Features Order number and delivery form Master controller Back up controller PROFIBUS/MPI/Ethernet

Non redundant area

Redundant area Redundanzbereich

SIMATIC Software Redundancy

A&D AS SM6 R.Fischer 11

SW Redundancy with single PROFIBUS

SIMATIC SW Redundancy
Principle

Automation and Drives

Positioning
Application Fields Configuration Features Order number and delivery form

MPI/PROFIBUS/ Ethernet

Master controller

Back up controller

SIMATIC Software Redundancy

A&D AS SM6 R.Fischer 13

SW Redundancy with redundant Ringbus

SIMATIC SW Redundancy
Principle MPI/PROFIBUS/ Ethernet

Automation and Drives

Positioning
Application Fields Configuration Features Order number and delivery form Master controller Back up controller

OLM

SIMATIC Software Redundancy

A&D AS SM6 R.Fischer 14

Automation and Drives

SW Redundanz with Multi Redundancy

SIMATIC SW Redundancy
Principle

Positioning
Application Fields Configuration Features Order number and delivery form

Back up controller

Non redundant area

Redundant area

Redundant area

Non redundant area

SIMATIC Software Redundancy

A&D AS SM6 R.Fischer 15

Automation and Drives

SW Redundancy Features
SIMATIC SW Redundancy
Principle

Master slave switchover time

dependant on:
CPU-Type number of I/O and number of DP-slaves volume of data to be transfered

Positioning
Application Fields Configuration Features Order number and delivery form

communication device

Example with 2 CPU 414-2 DP, 4 DP-Slaves, 4 kBytes Data, communication throught Profibus
Data transfer time DP-Slave swithover appr. 1 s appr. 20 ms

Fault detection time

Sum

appr. 100ms
appr. 1,1 s

SIMATIC Software Redundancy

A&D AS SM6 R.Fischer 16

Automation and Drives

SW Redundancy Features
SIMATIC SW Redundancy
Principle

Switchover procedure
Outputs are beeing frozen during the switchover After the switchover, the transfered data are used

Positioning
Application Fields Configuration Features Order number and delivery form

Switchover reasons
Master failure (Power off or CPU-STOP) Failure of the Profibus-DP of the master controller Manual switchover

Memory requirement is 10 kBytes

STEP7 V 4.02 is required

SIMATIC Software Redundancy

A&D AS SM6 R.Fischer 17

Automation and Drives

SIMATIC S7
Software-Redundancy