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Automation and Drives SIMATIC S7-400H Fault Tolerant Automation System.

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Présentation au sujet: "Automation and Drives SIMATIC S7-400H Fault Tolerant Automation System."— Transcription de la présentation:

1 Automation and Drives SIMATIC S7-400H Fault Tolerant Automation System

2 Automation and Drives SIMATIC S7-400H SIMATIC S7-400H Totally Integrated Automation SIMATIC S7- 400H Haute disponibilité à Architecture redondante

3 Automation and Drives SIMATIC S7-400H SIMATIC S7-400H Motivation for the use of H-PLC Systems Application fields Expensive downtimes or processing of valuable material High restart costs after control failure Operation without monitoring or maintenance personal Overview Redundany Features Configuration Communication Ordering

4 Automation and Drives SIMATIC S7-400H SIMATIC S7-400H AUTOMATE S7-400H Domaines dapplication Energie Pipeline, Offshore et Central Thermique Chimie, Petrochimie, Pharmacie Industrie minière Environnement Traitement des eaux, Incinération des déchets Transport Gestion Tunnel Construction naval Industrie du verre Industrie alimentaire

5 Automation and Drives SIMATIC S7-400H SIMATIC S7-400H High Availability Overview Supervisiory level PC-Network/Terminalbus Process level Field level ET 200M PROFIBUS / Ethernet High available Communication H-CPUs Hot-Standby Red. IM 157 Red. IM 153 Red. DP-Bus S7-400H Clients Parallel Redundancy Server Parallel Redundancy Medium- Redundancy Re d. PS SW-Redundanz Warm-Standby Red. IM 153 Red. DP- Bus Application fields Overview Redundany Features Configuration Communication Ordering

6 Automation and Drives SIMATIC S7-400H SIMATIC S7-400H Definitions

7 Automation and Drives SIMATIC S7-400H SIMATIC S7-400H Redundancy Principles passive redundancy active redundancy different components (Diversified redundancy) Not used with SIMATIC different components (Diversified redundancy) Not used with SIMATIC majority redundancy Redundancy with identical components (homogenous redundancy) m-from-n high availability and fail-safe HW or SW Voting ABC m-v-n Hot-Standby = automatic switch in ms-range Warm-Standby = automatic switch in second range A Cold-stand-by = manuel switch R AR 1-v-2 2oo2 redundancy- principle S7-400H High availability Fail-safe AB AB 1 2-v-2 1-v-2 2oo2 1oo2 Application fields Overview Redundany Features Configuration Communication Ordering

8 Automation and Drives SIMATIC S7-400H SIMATIC S7-400H Architecture Synchronisation, Data and State Exchange IM BIBIBIBIAIAO BOBOBOBOIMFM Process Application fields Overview Redundany Features Configuration Communication Ordering

9 Automation and Drives SIMATIC S7-400H SIMATIC S7-400H Highlights S7-400H: Complete SIMATIC System Integration User hidden redundancy Transparent programming (programming same as non- redundant systems) Easy system parameterisation with option package Handling like non-redundant systems All standard programming languages can be used without limitation Use of standard components (I/O, CP, FM) Hardware platform for F/FH systems Application fields Overview Redundany Features Configuration Communication Ordering

10 Automation and Drives SIMATIC S7-400H SIMATIC S7-400H Synchronisation Principle CPU A CPU B Cycle- Synchronisation CPU ACPU B Time- Synchronisation Clock- Synchronisation CPU A CPU B CPU ACPU B Without Synchronisation Event- Synchronisation Application fields Overview Redundany Features Configuration Communication Ordering

11 Automation and Drives SIMATIC S7-400H SIMATIC S7-400H Principe de la synchronisation évènementielle Définition Les CPUs se synchronisent sur toute instruction dont lexécution pourrait conduire à des branches de programmes différentes dans chaque CPU Cette fonction est prise en charge par le firmware des CPUs Points de synchronisation Mise à jour de la MIE Accès direct à la périphérie Interruptions,alarmes Evaluation des temporisations Echanges des données lors de fonctions de communications Synchronisation évènementielle (Brevet Siemens) Partial PLC A Teil-AG B Partial PLC B

12 Automation and Drives SIMATIC S7-400H SIMATIC S7-400H Event Synchronisation Principle Event synchronization (Siemens Patent) CPU A Teil-AG B CPU B Definition: Synchronisation of all commands whose execution would trigger different states in both PLC parts. Fully automatic operating system function Synchronized events: Updating the process image Direct access to the I/O Interrupts, alarms Updating the timers Changing data through Communication functions Application fields Overview Redundany Features Configuration Communication Ordering

13 Automation and Drives SIMATIC S7-400H SIMATIC S7-400H Synchronisation évènementielle Exemple de déroulement de fonctionnement A I 10.0A : : SO 8.0 : : S LDW 10 +F L LPEW100L Acknowledge Value Synchronisation T PAW130 Synchronisation Synchronization, Information and Status Exchange +F LDW 12

14 Automation and Drives SIMATIC S7-400H SIMATIC S7-400H Event Synchronisation Principle A I 10.0A : : SO 8.0 : : S LDW 10 +F L LPW100L Acknowledge Value Synchronisation T PW130 Synchronisation Synchronisation, Information and Status Exchange +F LDW 12 Application fields Overview Redundany Features Configuration Communication Ordering

15 Automation and Drives SIMATIC S7-400H SIMATIC S7-400H Event Synchronisation Cycle Self test PIQ switched, PIQ switched and one-sided PIQ Comparison one-sided PII switched and PII switched and one-sided PII Exchange one-sided synch nn OB 1 CPU 0 CPU 1 User program Alarms, Diagnostic OB synch. Alarms, Diagnostic OB Application fields Overview Redundany Features Configuration Communication Ordering

16 Automation and Drives SIMATIC S7-400H SIMATIC S7-400H Event Synchronisation Customer Advantages Transparent Programming All command from standard can be used User program directly portable from standard CPU to H CPU and back All standard SIMATIC S7 programming languages can be used Guaranteed bumpless Switch-Over Quick Switch-Over time No loss of information No loss of alarms Application fields Overview Redundany Features Configuration Communication Ordering

17 Automation and Drives SIMATIC S7-400H SIMATIC S7-400H Self Test What is tested CPU (Processor, ASIC) Memory Synchronisation connection Application fields Overview Redundany Features Configuration Communication Ordering

18 Automation and Drives SIMATIC S7-400H SIMATIC S7-400H Self test Organization Start-up self test Complete test When errors occur, the CPU goes to the state defect Self test in cycle operation Runs in background The entire test is distributed over multiple cycles Runs completely through during a time that can be parameterized (default value 90mn) Application fields Overview Redundany Features Configuration Communication Ordering

19 Automation and Drives SIMATIC S7-400H SIMATIC S7-400H Architecture Synchronisation, Data and State Exchange IM BIBIBIBIAIAO BOBOBOBOIMFM Process Application fields Overview Redundany Features Configuration Communication Ordering

20 Automation and Drives SIMATIC S7-400H SIMATIC S7-400H Automate H : 1 seul point dentrée MPI/DP PG/PC pour configuration chargement de programme modification en ligne, etc...

21 Automation and Drives SIMATIC S7-400H SIMATIC S7-400H Programming Connection Examples Profibus/Ethernet MPI/DP MPI Application fields Overview Redundany Features Configuration Communication Ordering

22 Automation and Drives SIMATIC S7-400H SIMATIC S7-400H Programming Online Program Corrections Fully online programming through a CPU the program is automatically copied to the redundant CPU Application fields Overview Redundany Features Configuration Communication Ordering

23 Automation and Drives SIMATIC S7-400H SIMATIC S7-400H Online Repair S7-400 Components I/O and CP can be exchanged in RUN mode IM and CPU via Power off exchanged CPU is automatically updated after power ON Sync-Modules PS Standard PV via power off Redundant PS in RUN mode DP Components IM in RUN mode I/O modules can be exchanged in RUN mode Application fields Overview Redundany Features Configuration Communication Ordering

24 Automation and Drives SIMATIC S7-400H SIMATIC S7-400H AUTOMATE S7-400H Configuration de base 2 Châssis Standard UR1/UR2 SV P-Bus K-Bus CPUCPU PSPS PSPS SV P-Bus K-Bus CPUCPU PSPS PSPS Alimentation Redondante Châssis de base divisé UR2-H SV P-Bus K-Bus CPUCPU PSPS PSPS SV P-Bus K-Bus CPUCPU PSPS PSPS Alimentation Redondante

25 Automation and Drives SIMATIC S7-400H SIMATIC S7-400H AUTOMATE S7-400H CPU Redondantes CPU 417H Redundancy Module X X Redundancy Module X CPU 417H Redundancy Module X X Redundancy Module X Sync-ModuleLiaison FO Haute vitesse CPU 417-H/414-H avec 4 interfaces integrés: 2 Modules de synchro 1 Interface DP 1 Interface MPI/DP

26 Automation and Drives SIMATIC S7-400H SIMATIC S7-400H CPU 417H Sync-Module X X Sync-Module X Configuration CPU CPUs High end: CPU 417H (4MB expandable to 20MB) Mid mrange: CPU 414H (768KB) 4 integrated interfaces Sync-Module DP MPI/DP Application fields Overview Redundany Features Configuration Communication Ordering

27 Automation and Drives SIMATIC S7-400H SIMATIC S7-400H Redondance des Entrées,Sorties Monovoie Commutée standard Disponibilité 1 canal2 canaux Entrées/Sorties Haute Disponibilité Redondante (en préparation)

28 Automation and Drives SIMATIC S7-400H SIMATIC S7-400H I/O Configuration Redundant PROFIBUS Profibus-DP IM Special bus module (BM) Active backplane bus ET 200M with active backplane bus L+ Redundant IM Available as separate components IM: 6ES AA02-0XB0 BM: 6ES HD00-0XA0 or as Bundle (2 x IM + 1 BM) 6ES AR00-0XA0 Application fields Overview Redundany Features Configuration Communication Ordering

29 Automation and Drives SIMATIC S7-400H SIMATIC S7-400H Fonctionnement dun API H Réseaux redondants,périphérie commune Les deux CPUs sont actives Lecture des entrées Les deux CPUs lisent les entrées et la MIE est constituée à partir des coupleurs actifs Ecriture des sorties - Les deux CPUs transfèrent la MIS sur les coupleurs. - Les coupleurs actifs transmettent la MIS sur les sorties.

30 Automation and Drives SIMATIC S7-400H SIMATIC S7-400H I/O Configuration Connection of PROFIBUS PA via DP/PA Link Profibus-DP IM 157 (DP PA Link) DP PA Coupler Application fields Overview Redundany Features Configuration Communication Ordering

31 Automation and Drives SIMATIC S7-400H SIMATIC S7-400H I/O Configuration Connection of single DP slaves via Y Link 2xIM 157 Y-Link Application fields Overview Redundany Features Configuration Communication Ordering

32 Automation and Drives SIMATIC S7-400H SIMATIC S7-400H Principe de Redondance Redondance avec Composants identiques (Redondance Homogène) m- out of -n Haute disponibilité et Sécurité Vote par Hardware ou Software Redondance Majoritaire ABC m-sur-n Sécurité AB 2-sur-2 Hot-Standby = Basculement automatique en ms AB 1 1-sur-2 Redondance Active Redondance Passive Composants différents (Redondance diversifiée) Cold- stand-by = Basculeme nt manuel AR 1-sur-21-sur-2 AR 1-sur-21-sur-2 Warm-Standby = Basculement automatique Composants différents (Redondance Hétérogène)

33 Automation and Drives SIMATIC S7-400H SIMATIC S7-400H I/O Configuration Redundant PROFIBUS: Function One IM of the station is active Input data: CPU reads data from the active IM Output data: - CPU writes data to both IM - Data from the active IM are transferred to the Outputs. Application fields Overview Redundany Features Configuration Communication Ordering

34 Automation and Drives SIMATIC S7-400H SIMATIC S7-400H Communication Configuration of single Communication Profibus-DP PzP Kommunikation Single controller CP 341 Application fields Overview Redundany Features Configuration Communication Ordering

35 Automation and Drives SIMATIC S7-400H SIMATIC S7-400H High Available Communication Principle The communication switches automatically from the active to the reserve connection after a fault Active + Reserve Connection = H Connection Active Connection Reserve Connection Application fields Overview Redundany Features Configuration Communication Ordering

36 Automation and Drives SIMATIC S7-400H SIMATIC S7-400H High Available Communication Configuration of the connections Active and reserve connections are automatically offered by the HW configuration tool H connections can be created between H stations, one-channel H-CPUs and PC stations (on PC Redconnect package required). Application fields Overview Redundany Features Configuration Communication Ordering

37 Automation and Drives SIMATIC S7-400H SIMATIC S7-400H AUTOMATE S7-400H Configuration :CPU et réseaux redondants Communication Haute disponibilité API S7-400H avec CPU 417H dans un chassis UR2-H avec liaison redondante Peripherie IM153-2 avec châssis Actif ! PROFIBUS-DP Périphérie commutée/ Redondante Superviseur avec Soft de Redondance S7 Red-Connect

38 Automation and Drives SIMATIC S7-400H SIMATIC S7-400H High Available Communication Configuration with redundant Bus Ethernet H-CPU im Single Mode Redundancy Diagram PS Bus CP PS CPU Application fields Overview Redundany Features Configuration Communication Ordering

39 Automation and Drives SIMATIC S7-400H SIMATIC S7-400H High Available Communication - Configuration with redundant Bus and redundant CP Redundancy Diagram PS CPU Bus CP CPU PS CP Ethernet H-CPU in Single Mode Application fields Overview Redundany Features Configuration Communication Ordering

40 Automation and Drives SIMATIC S7-400H SIMATIC S7-400H High Available Communication Configuration with single Bus Redundancy Diagram: PS CPU Bus CP CPU PS Ethernet H-CPU in Single Mode S7-400H Application fields Overview Redundany Features Configuration Communication Ordering

41 Automation and Drives SIMATIC S7-400H SIMATIC S7-400H High Available Communication Configuration with optical Ringbus Redundancy Diagram PS CPU CP CPU PS Bus H-CPU im Single Mode S7-400H Redundant optical Ringbus Application fields Overview Redundany Features Configuration Communication Ordering

42 Automation and Drives SIMATIC S7-400H SIMATIC S7-400H Haute disponibilité Configuration API-H mode simple PS CPU Bus CP CPU PS Diagramme de Redondance:

43 Automation and Drives SIMATIC S7-400H SIMATIC S7-400H Haute disponibilité Configuration avec réseau Optique en anneau API-H PS CPU CP CPU PS Bus Diagramme de Redondance:

44 Automation and Drives SIMATIC S7-400H SIMATIC S7-400H AUTOMATE S7-400H Principe des automates Redondants (H) Monovoie Unilatérale Monovoie Unilatérale Monovoie Commuté S7-400 Synchronisation ET 200M (Esclave) PROFIBUS

45 Automation and Drives SIMATIC S7-400H SIMATIC S7-400H Entrées/Sorties monovoie, commutée Système Redondant (H) 2 châssis Station décentralisée commutée Fibre optique EntréesSorties

46 Automation and Drives SIMATIC S7-400H SIMATIC S7-400H Entrées/Sorties Redondantes Système Redondant (H) mono bloc (2 UC) Station décentralisée redondante Fibre optique Entrées Sorties (non encore pris en charge par le firmware)

47 Automation and Drives SIMATIC S7-400H SIMATIC S7-400H API Redondant (H) Station décentralisée commutée Fibre optique EntréesSorties Haute disponibilité Capteurs/Actionneurs PS CPU Diagramme de Redondance: E_Tor 2 sur 3

48 Automation and Drives SIMATIC S7-400H SIMATIC S7-400H Redondance Logicielle Configuration

49 Automation and Drives SIMATIC S7-400H SIMATIC S7-400H Concept global Haute disponibilité avec SIMATIC S7 Supervision Niveau process Niveau terrain Profibus-DP IM 157 (DP-PA-Link) Coupleur DP-PA Profibus-DP ET 200M Redond. réseau Serveur Redond. parallele avec synchro darchive Red. IM 153 Alim Red. Peripherie red. 1sur2 et 2sur3 CPUs H: hot standby Redondance SW warm standby BUS DP redondant BUS DP redondant CPUs H: hot standby Cluster Redond. parallele Red. IM 157 Red. IM 153 PC-Netzwerk/Terminalbus Profibus-DP Communication à Haute dispon. PROFIBUS/ Ethernet Redond. réseau Raccordement d esclaves DP standard

50 Automation and Drives SIMATIC S7-400H SIMATIC S7-400H Disponibilité Redondance logicielle Prix faible/ Performance faible. Prix faible/ Performance faible. Pour application qui accepte des temps de basculement Maître Réserve de lordre de la seconde(s). Pour application qui accepte des temps de basculement Maître Réserve de lordre de la seconde(s). Solution utilisable avec du matériel standard. Solution utilisable avec du matériel standard. Programmation/Paramétrage du programme liée à la redondance -> Coûts à prévoir. Programmation/Paramétrage du programme liée à la redondance -> Coûts à prévoir.

51 Automation and Drives SIMATIC S7-400H SIMATIC S7-400H Haute Disponibilité Automate Redondant Prix + élevé que Api standard. Hautes performances, Solution Haute disponibilité (Hot stand-by) avec Firmware H. Utilisation de périphérie décentralisée standard. Pas de programme applicatif (firmware uniquement) Fonctions transparentes (on-line). Redondance : temps de basculement Maître-Réserve de lordre de la ms, Alimentations, Unités centrales, Périphérie dentrées/sorties, coupleurs réseaux, modules technologiques.

52 Automation and Drives SIMATIC S7-400H SIMATIC S7-400H Haute Disponibilité & Sécurité Architecture solution S7 400H/F RUN-P RUN STOP CMRES CPU 417H Module standard Redondant Profibus DP Module F redondant RUN-P RUN STOP CMRES Programme Standard et application F Module de Sécurité F ProfiSafe- Profibus DP S SSSSS Télégramme Standard Module standard Redondant

53 Automation and Drives SIMATIC S7-400H SIMATIC S7-400H Sécurité Intégrée Vue densemble Sécurité logicielle Sécurité répartie

54 Automation and Drives SIMATIC S7-400H SIMATIC S7-400H Automatisation Totally Integrated Automation avec SIMATIC S7- 400H


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