PROFINET-system

redundancy with
SINAMICS drives
Siemens
SINAMICS / V1.1 Industry
Online
https://support.industry.siemens.com/cs/ww/en/view/109744811 Support
 Warranty and liability

Warranty and liability

Note The Application Examples are not binding and do not claim to be complete
regarding the circuits shown, equipping and any eventuality. The Application
Examples do not represent customer-specific solutions. They are only intended
to provide support for typical applications. You are responsible for ensuring that
the described products are used correctly. These Application Examples do not
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We do not accept any liability for the information contained in this document.
Any claims against us – based on whatever legal reason – resulting from the use of
the examples, information, programs, engineering and performance data etc.,
described in this Application Example shall be excluded. Such an exclusion shall
not apply in the case of mandatory liability, e.g. under the German Product Liability
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 Table of contents

Table of contents
Warranty and liability ................................................................................................... 2
1 Introduction ........................................................................................................ 4
1.1 Overview............................................................................................... 4
1.2 Mode of operation ................................................................................ 5
1.3 Components used ................................................................................ 6
2 Engineering ........................................................................................................ 7
2.1 Installation of hardware ........................................................................ 7
2.2 Configuration ........................................................................................ 9
2.2.1 HW Config of SIMATIC H-CPUs .......................................................... 9
2.2.2 HW Config of SINAMICS drive ........................................................... 15
2.2.3 Configuration of topology ................................................................... 19
2.2.4 Download of HW-Config ..................................................................... 20
2.2.5 Configuration of SINAMICS drive ....................................................... 24
2.3 Commissioning of the sample project ................................................ 31
2.4 Controlling the servo motor ................................................................ 33
2.5 Operation ............................................................................................ 36
3 Additional information .................................................................................... 38
3.1 System and media redundancy .......................................................... 38
3.2 PN design versions ............................................................................ 41
3.3 Specific blocks for S7-400H ............................................................... 42
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4 Appendix .......................................................................................................... 43
4.1 Service and Support ........................................................................... 43
4.2 Contact ............................................................................................... 44
4.3 Links and Literature ............................................................................ 44
4.4 Change documentation ...................................................................... 44

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 1 Introduction

1 Introduction
1.1 Overview
Introduction
Thanks to SINAMICS S120, G130, G150 and S150 PROFINET Control Unit, the
assembly of system-redundant systems (S2-system redundancy) is possible.
Precondition for system-redundant systems is a so-called H-system. The H-system
consists of 2 fault-tolerant controls – master and reserve CPU – which are
constantly synchronized via fiber-optic cables. If one controller fails, the other
automatically takes on the job. This reduces system downtimes.

NOTE PROFINET system redundancy is not supported by SINAMICS G120 Control

units!

Overview of the automation task

The figure below provides an overview of the automation task.
Figure 1-1 Task overview

H-system
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SINAMICS
CU

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 1 Introduction

1.2 Mode of operation

Schema
The following figure displays the most important components of the solution:
Figure 1-2 Solution overview

H-system

SINAMICS
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CU

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 1 Introduction

Benefits
 No system downtime in the case of a controller failure
 Component replacement possible during ongoing operation
 Configuration changes possible during ongoing operation
 Automatic synchronization after replacing components

Restrictions
 PROFINET-IRT is not supported
 No simultaneous operation of Shared Device and Shared I-Device
 Maximum 2 cyclical PROFINET connections
 System redundancy only via the onboard interface of SINAMICS
PROFINET Control Unit S120, G130, G150 and S150
 For the duration of switching from one controller to the other, the setpoints
of the last connection remain frozen and valid.

Knowledge required
Basic knowledge of SINAMICS drives and H-Systems is assumed.
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1.3 Components used

This application example has been created with the following hardware and
software components:
Table 1-1
Component Number Article number Note
CPU 412-5H PN/DP 2 6ES7412-5HK06-0AB0 Rack: UR2-H
SINAMICS S120 CU310-2 1 6SL3040-1LA01-0AA0 Firmware V4.8 HF 2
PN/DP
Training case 1 6ZB2480-0AD00 Servo motor with
Drive-Cliq is used
STEP 7 1 - V5.5 SP4 HF 11
STARTER 1 - V4.5

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2 Engineering
2.1 Installation of hardware
Following pictures show the hardware and the topology of the hardware.

Figure 2-1 Hardware

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Central processing units

The two CPUs are the heart of the S7-400H. Use the switch on the rear of the CPU
to set the rack numbers. In the following sections, we will refer to the CPU in rack 0
as CPU 0, and to the CPU in rack 1 as CPU 1.

Note
An incorrectly set rack number prevents online access and the CPU might not
start up.

Rack for S7-400H

The UR2-H rack supports the installation of two separate subsystems with nine
slots each, and is suitable for installation in 19" cabinets.
You can also set up the S7-400H in two separate racks. The racks UR1 and UR2
are available for this purpose.

Power supply
You require one power supply module from the standard range of the S7-400 for
each HCPU, or to be more precise, for each of the two subsystems of the S7-
400H.
To increase availability of the power supply, you can also use two redundant power
supplies in each subsystem.

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Synchronization modules
The synchronization modules are used to link the two CPUs. They are installed in
the CPUs and interconnected by means of fiber-optic cables.
There are two types of synchronization modules: one for distances up to 10
meters, and one for distances up to 10 km between the CPUs.
A fault-tolerant system requires 4 synchronization modules of the same type.

Fiber-optic cable
The fiber-optic cables are used to interconnect the synchronization modules for the
redundant link between the two CPUs. They interconnect the upper and lower
synchronization modules in pairs.

Figure 2-2 Interconnection

SIMATIC S7 SIMATIC S7
CPU 412-5H CPU 412-5H
CPU0 CPU1
IF1 IF2 P1 P2 IF1 PN
IF2 P1 P2

PROFINET IE
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-X150 P1 P2

SINAMICS S120
CU310-2 PN

Note The port interconnection must correspond to your STEP7 configuration.

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2.2 Configuration
2.2.1 HW Config of SIMATIC H-CPUs

Table 2-1 Configuration SIMATIC H-CPU

No. Action
1. Create a new STEP7 project.
2. Insert a new SIMATIC H Station.
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3. Open the Hardware-config.

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No. Action
4. Insert your used rack two times.
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No. Action
5. Drag &drop your used power supply into both racks respectively.
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No. Action
6. Afterwards insert your CPUs (here: SIMATIC CPU 412-5H PN/DP V6.0) into
both racks.
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7. Create a new Ethernet subnet and assign an IP address. (here: 192.168.0.1 /

255.255.255.0).

PROFIBUS properties don’t have to be parameterized. Confirm with OK.

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No. Action
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8. Configure your H-Sync module:

Configure CPU1 respectively and assign an IP-address and subnet mask(here:

192.168.0.2 / 255.255.255.0).

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No. Action
9. Now there are two racks, two CPUs and two PROFINET systems configured.
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2.2.2 HW Config of SINAMICS drive

The SINAMICS drive can be configured with the OM (ObjectManager, Drive ES

BASIC, hardware catalog) or with the help of a GSD file.
In the application example the drive is configured via the OM.

Table 2-2 HW Config SINAMICS drive

No. Action
1. Drag the SINAMICS drive CU310-2 PN V4.8 to one of the existing PROFINET networks.
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2. Select the existing Ethernet subnet and assign an IP address. (here: 192.168.0.3).

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No. Action
3. Double-click the added SINAMICS drive to open the properties window.
Define the device name (here: „SINAMICS-S120-CU310-2PN“).
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Check in the tab „Redundancy“, if the SINAMICS is connected with both PROFINET systems.

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Note For the steps described in the following, a functional connection is required
between the engineering PC and the hardware being used!

In SIMATIC Manager, using the menu item "Options > Set PG/PC
Interface…" open the window to set the PG/PC interface. There, for the
access point "S7ONLINE", select the network card of your engineering PC that
you are using with the supplement "TCPIP.1" (not "TCPIP.Auto.1").
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No. Action
4. The device name must then be assigned to the SINAMICS drive.
For this purpose mark the PROFINET IO system.
Open the window for the name assignment with “PLC > Ethernet > Assign Device
Name”.

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5. Select the device name configured in HW config using the drop-down menu (1).
Then select the SINAMICS drive from the list of available devices (2) and assign the device name
using the "Assign name" (3) button.

(1)
(3)

(2)
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2.2.3 Configuration of topology

Table 2-3 Configuration of topology

No. Action
1. Open the topology via rightclick on the SINAMICS in HW-config.
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2. Connect both ports 1 of the H-CPUs with port 1 and port 2 of your SINAMICS CU.

Confirm with OK.

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2.2.4 Download of HW-Config

Table 2-4 Download of HW-Config

No. Action
1. Save and compile the HW Config.

2. Download it into the SIMATIC CPU.

3. To do this, select the corresponding target device, and confirm your selection using the "OK"
button.
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No. Action
4. If the SIMATIC CPU is still in the factory setting (i.e. the IP address is 0.0.0.0), a download is
only possible after assigning the IP address configured in HW Config. Browse through the
network for controllers that can be accessed by pressing the "View" button.
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No. Action
All of the controllers that can be accessed are displayed. Select the corresponding controller by
identifying it based on its MAC address and confirm your selection by pressing the "OK" button.
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Note
First reset the interface of the controller to the factory settings, if the SIMATIC CPU already has
an IP address, which does not match the IP address configured in HW Config!
("PLC > Ethernet > Edit Ethernet Node > Browse > Select CPU > OK >
Reset")
5. Confirm the following message with "Yes", to assign the IP address configured in HW Config to
the controller (192.168.0.1) (permanent IP address!).

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No. Action
6. Then switch the SIMATIC CPU back into the "RUN" operating state.
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2.2.5 Configuration of SINAMICS drive

The standard configuration of the SINAMICS drive with the STARTER engineering
system is shown below.

Table 2-5 Configuration SINAMICS drive

No. Action
1. Open the current project in the STARTER engineering system from the SIMATIC Manager.
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2. Establish an online connection to the SINAMICS drive.

Note
To establish an online connection, the network card of the engineering PC being used must be in
the same IP subnet as the target device. Ensure that this precondition is complied with and if
required adapt the IP configuration of your network card!

Example
 IP address of the target device 192.168.0.2
subnet mask 255.255.255.0
 IP address of the engineering PC 192.168.0.99
subnet mask 255.255.255.0

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No. Action
3. Select the configured SINAMICS drive (set the checkmark in the checkbox) and confirm your
selection by pressing the "OK" button.
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No. Action
4. After this, restore the factory settings at the SINAMICS (if this has still not been done).
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5. Confirm the following message with "Yes".

The drive is then reset to the factory settings.

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6. Afterwards carry out the automatic configuration of the drive.

7. Start the configuration by pressing the "Configure" button.

The Drive-CliQ topology of the drive is read out.
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8. A servo motor is used in the SINAMICS training case.

9. If the firmware version of the drive has changed compared to the last commissioning, after the
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automatic configuration it may be necessary to "Power OFF/ON" the drive to update the
firmware of the Drive-CliQ components

Note
Before "Power OFF/ON" execute the "RAM to ROM" function at the drive to save the previous
configuration in a non-volatile way.

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10. Open the drive telegram configuration using the menu item "Communication > Telegram
configuration".

Note
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Carry out the following steps that are described offline!

11. The following telegrams are used for cyclic communication between the controller and drive in
the sample project:
 SERVO_02 Standard telegram 1, PZD-2/2
 CU_S SIEMENS telegram 390, PZD-2/2

Set these telegrams in the drive telegram configuration and align the telegram configuration with
HW Config ("Set up addresses").

Note
Confirm the message that follows with "Yes". A blue tick after the telegrams indicates that the
telegram configuration has been successfully aligned with HW Config.

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No. Action
12. Change to the HW Config of the SIMATIC CPU, and check the size of the process image of the
controller (double click on the CPU > tab "Cycle/Clock Memory").
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Note
If required, adapt the size of the process image of the inputs and outputs so that the input and
output data of the SINAMICS drive telegrams are completely inside of the process image of the
controller!
13. Save and compile the configuration of the SINAMICS drive in STARTER and in the HW Config of
the SIMATIC CPU.

14. Establish an online connection with the drive.

15. Download to the SINAMICS drive and load HW Config into the controller.

16. Execute the "RAM to ROM" function in the drive to save its configuration in a non-volatile way.

17. The communication between the SIMATIC CPU and SINAMICS drive has therefore been
configured.

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2.3 Commissioning of the sample project

Overview
An executable sample project is included in the zip archive
“109744811_Systemredundancy_v10.zip“.

Commissioning of the sample project

The steps described in the following must be performed to commission the sample
project.
Table 2-6 Commissioning
No. Action
1. All hardware components are available and interconnected.
2. All PROFINET components are networked and accessible from the engineering system.
3. The Ethernet interface of the engineering system is configured correctly and is working.

Example
IP address: 192.168.0.99
subnet mask: 255.255.255.0
4. Start the STEP 7 SIMATIC Manager engineering system.
5. Retrieve the sample project “109744811_Systemredundancy_v10.zip".
6. Open the HW Config of the SIMATIC CPU.
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7. Download the HW Config and all blocks from the block container into the controller.
8. Carry out a node initialization of the SINAMICS drive. To do this, change to HW Config of the
controller and select the PROFINET network. Using the menu item "PLC > Ethernet >
Assign Device Name…" open the window to assign a name.

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No. Action
9. Select the device name configured in HW Config using the drop-down menu (1).
Then select the SINAMICS drive from the list of available devices (2) and assign the device name
using the "Assign name" (3) button.

(1)
(3)

(2)

Note
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Only IO devices are listed here.

IO controllers receive their device name by downloading the HW Config.
10. As an alternative, the Primary Setup Tool (PST) can also be used to perform the node
initialization. The PST can be downloaded at the following link.
http://support.automation.siemens.com/WW/view/en/19440762
11. Start the STARTER engineering system from the project in the SIMATIC Manager.

12. Establish an online connection with the SINAMICS drive.

13. Download the configuration of the drive into the target device.

14. Then execute the "RAM to ROM" function.

15. The sample project is now ready for operation.

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2.4 Controlling the servo motor

In the sample project, the cyclic communication between SIMATIC CPU and
SINAMICS drive is implemented in OB1. The OB1 contains the user program
subsequently described.

Table 2-7 Control of the servo motor

No. Action
1.

W#16#4000
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The user must specify the speed setpoint used to operate the servo motor ("N_SOLL_USER").
The calculation of the speed setpoint is based on the specified definitions of the PROFIdrive
profile. 6000 rpm corresponds to the value "W#16#4000".
The calculated speed is then buffered so that it can be further accessed ("N_SOLL").
The servo motor is operated with the calculated speed and is stopped again by setting the
"boMove" flag.

Note
The rated speed of the servo motor installed in the training case is 6000 rpm.
The maximum speed is 10000 rpm.

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No. Action
2.
2#0000_0100_0111_1110

2#0000_0010_0001_0001

2#0000_0100_0111_1111

If flag "boMove" is controlled to a value of "1", then the required releases are set in control
word 1("STW1") of the servo motor (W#16#47E), so that it can be moved.
To ensure that the motor is only moved when all releases required are actually present, its status
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word 1 ("ZSW1") is compared with a constant word that represents the required releases
(W#16#211).
Only when status word 1 ("ZSW1") matches this value, the bit in control word 1 ("STW1") is set,
that switches on the servo motor (W#16#47F). The servo motor is then moved with the speed
setpoint entered by the user.
3.

2#0000_0100_0000_0000

2#0000_0100_1000_0000

The speed setpoint of the servo motor is 0 rpm as long as the "boMove" flag is not controlled to
a value of "1".
In control word 1 ("STW1"), only bit 10 ("Control by PLC") is set (W#16#400).
If faults are active, flag "boReset" can be controlled to a value of "1".
As a consequence, in control word 1 ("STW1") of the servo motor additionally bit 7
("Acknowledge faults") is set, which acknowledges the fault (W#16#480). In this case, flag
"boMove" must have the value "0"!

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Note The structure of the relevant (standard) telegram (i.e. STW1, NSOLL_B, etc.) is
defined in the PROFIdrive profile. You can find further information about this at
the following link:
SINAMICS S120 / S150 List Manual (Chapter 2.9)

Note The following addresses are used in the sample project to control the SINAMICS
drive:

 AW 256 Control word 1 ("STW1")

 AW 258 Speed setpoint ("NSOLL_B")
 EW 256 Status word 1 ("ZSW1")
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2.5 Operation
The sample project is operated using the variable table "Drive control" of the
SIMATIC CPU in the SIMATIC Manager.
Here, the user can enter the set point speed for the servo motor as well as
switching the motor on and off. Possibly upcoming faults of the servo motor can
also be acknowledged.

Table 2-8 Operation

No. Action
1. Open the variable table "Drive control", which is located in the block container of the
SIMATIC CPU.
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2. In the variable table, switch to the online view using button "Monitor variable" (1).
Then enter the required speed setpoint in column "Modify value" into flag double word MD100
(unit: rpm) and the value "true" or "1" into flag M0.0 (2).
Activate the values by using the button "Activate modify values" (3).

(1) (3)

(2)

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No. Action
3. The speed "N_SOLL_USER" entered by the user is scaled according to the definitions of the
PROFIdrive profile and entered at the servo motor as speed setpoint.
Further, the required releases are set in control word 1 ("STW1") of the drive to move it.

Note
The speed setpoint can also be changed if the servo motor is already in operation, i.e. flag
"boMove" is set.
4. By setting flag "boReset", possible faults present at the servomotor can be acknowledged.

Note
Pending faults can be acknowledged only when the servomotor is not operational, i.e. the
"boMove" flag must not be set!
Further it should be noted that flag "boReset" is not automatically reset to the value "0". This
must be done manually after the acknowledgement of the faults!
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3 Additional information

3.1 System and media redundancy

System redundancy
With system redundancy a PROFINET device is initiating more than one
communication relation to a redundant controller. Thereby it is distinguished
between different forms of system redundancy.
In this example only S2-system redundancy is used which describes a compact
PROFINET device that can be operated with a highly available system without any
additional hardware.
Figure 3-1 S2-system redundancy
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 3 Additional information

Requirement for realizing the system redundancy is the application of an H system.

The H system consists of two fault-tolerant controllers (master and reserve CPU). If
one H-CPU fails, the other automatically takes over.
System redundancy is a connection of IO devices via PROFINET (PN devices), for
which there is a communication connection between each PN device and each of
both H-CPUs (see picture below).
Figure 3-2 System redundancy

H-system

PN-devices
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The IO devices need to support the system redundancy; otherwise, they can be
operated in the same network, however only one of both H-CPUs can be assigned
(unilateral periphery).
The used topology (line, star, ring) plays no role for the system redundancy. This
distinguishes the system redundancy from the media redundancy.
System redundant periphery is often also referred to as switched periphery. This
does not refer to the fault tolerance between I/O groups or systems.
An example for switched periphery (system-redundant periphery) are PN devices,
which support the system redundancy and can be assigned to an H system (e.g.
ET 200M, SINAMICS CU320-2PN, etc.. ). In contrast, the ET 200S, for example,
can only be assigned to an H-CPU unilaterally (no H system).

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 3 Additional information

Media redundancy
Media redundancy ensures the network availability and contributes to increasing
the plant availability.
The ring topology is used here. The media redundancy protocol (MRP) ensures
that when one transmission path fails, an alternative communication path is
available.
For media redundancy with MRP, one device is the media redundancy manager
(MRM), all other devices are redundancy clients. In the picture below, the CPU is
the MRP-Manager.
In the case of a failed connection, the MRM selects the alternative communication
path.

Figure 3-3 Media redundancy

CPU
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PN-Devices
Ring

Context
System and media redundancy have no mutual impact on each other.

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 3 Additional information

3.2 PN design versions

The following PN module design versions are available:

 Single-channel, one-sided configuration with standard availability

With the single-channel, one-sided design, single PN devices are
available. The PN devices are located in only one subsystem, and are
only addressed by this subsystem.
However, in redundant mode, both CPUs are interconnected via the
redundant link and thus execute the user program identically.

 Single-channel, switched configuration with enhanced availability

Switched single-channel distributed configurations contain only single
PN devices, but they can be addressed by both subsystems.

 Redundant dual-channel configuration with maximum availability

A redundant dual-channel configuration contains two sets of the I/O
modules which can be addressed by both subsystems.

The SINAMICS S120 drive is realized as single-channel, switched configuration

with enhanced availability in this application example.
 Siemens AG 2017 All rights reserved

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 3 Additional information

3.3 Specific blocks for S7-400H

In addition to the blocks supported both in the S7-400 and S7-400H systems, the
S7-400H software provides further blocks which you can use to influence the
redundancy functions.
You can react to redundancy errors of the S7-400H using the following
organization block:
 OB 70, I/O redundancy errors
 OB 72, CPU redundancy errors

SFC 90 "H_CTRL" can be used to influence fault-tolerant systems as follows:

 You can disable interfacing in the master CPU.
 You can disable updating in the master CPU.
 You can remove, resume or immediately start a test component of the
cyclic self-test.
 You can execute a programmed master to standby changeover. The
following changeovers are possible:
o The current standby CPU becomes a master CPU.
o The CPU in rack 0 becomes a master CPU.
o The CPU in rack 1 becomes a master CPU.
 Siemens AG 2017 All rights reserved

Always download these error OBs to the S7-400H CPU: OB 80, OB 82, OB 83,
Note
OB 85, OB 86, OB 88, OB 121 and OB 122.
If you do not download these OBs, the fault-tolerant system goes into STOP
when an error occurs.

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 4 Appendix

4 Appendix
4.1 Service and Support
Industry Online Support
Do you have any questions or need assistance?
Siemens Industry Online Support offers round the clock access to our entire
service and support know-how and portfolio.
The Industry Online Support is the central address for information about our
products, solutions and services.
Product information, manuals, downloads, FAQs, application examples and videos
– all information is accessible with just a few mouse clicks at:
https://support.industry.siemens.com

Technical Support
The Technical Support of Siemens Industry provides you fast and competent
support regarding all technical queries with numerous tailor-made offers
– ranging from basic support to individual support contracts. You send queries to
Technical Support via Web form:
www.siemens.com/industry/supportrequest

Service offer
 Siemens AG 2017 All rights reserved

Our range of services includes, inter alia, the following:

 Product trainings
 Plant data services
 Spare parts services
 Repair services
 On-site and maintenance services
 Retrofitting and modernization services
 Service programs and contracts
You can find detailed information on our range of services in the service catalog:
https://support.industry.siemens.com/cs/sc

Industry Online Support app

You will receive optimum support wherever you are with the "Siemens Industry
Online Support" app. The app is available for Apple iOS, Android and Windows
Phone:
https://support.industry.siemens.com/cs/ww/en/sc/2067

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 4 Appendix

4.2 Contact
Siemens AG
Digital Factory Division
Factory Automation
Production Machines
DF FA PMA APC
Frauenauracher Str. 80
91056 Erlangen, Germany
mailto: [email protected]

4.3 Links and Literature

Table 4-1
No. Topic
\1\ Siemens Industry Online Support
https://support.industry.siemens.com
\2\ https://support.industry.siemens.com/cs/ww/en/view/109744811ownload page of
this entry
https://support.industry.siemens.com/cs/ww/en/view/109744811
 Siemens AG 2017 All rights reserved

\3\ SINAMICS S120 Function Manual Drive Functions

https://support.industry.siemens.com/cs/ww/en/view/109740020
\4\ Configuration Examples for S7-400H with PROFINET SIMATIC S7-400H as of V6.0
https://support.industry.siemens.com/cs/ww/en/view/90885106
\5\ System manual "SIMATIC Fault-tolerant systems S7-400H"
https://support.industry.siemens.com/cs/ww/en/view/82478488

4.4 Change documentation

Table 4-2
Version Date Modifications
V1.0 05/2017 First version
V1.1 07/2017 Small additions

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