09 EN DataBackup 032007 PDF

Manual 03/2007 Edition
solutions
for powertrain
TRANSLINE
Data Backup
General Information 1
Data 2
Solutions for Powertrain Distributed or central 3

data management
TRANSLINE - Data Backup Data-Backup media 4

Manual
General Documentation Data servers 5
Data backup tools 6
Data backup on a 7
server
10
11
12
Appendix A
03.07 Edition
SINUMERIK® Documentation
Printing history
Brief details of this edition and previous editions are listed below.
The status of each edition is shown by the code in the „Remarks“ column.
Status codes in the „Remarks“ column:
A .... New documentation.

B .... Unrevised reprint with new Order No.
C .... Revised edition with new status.
Edition Order No. Remarks

03.01 6FC5297-0AG07 - 0BP0 A
03.02 6FC5297-0AG07 - 0BP1 C
03.03 6FC5297-0AG07 - 0BP2 C
03.04 A&D MC - Extranet C
03.06 A&D MC - Extranet B
03.07 A&D MC - Extranet C
Further information is available on the Internet under: Other functions not described in this documentation might be
http://www.automation.siemens.com executable in the control. This does not, however, represent an
obligation to supply such functions with a new control or when
This publication was produced with WinWord V 7.0 and Designer V 6.0 servicing.
using the documentation tool AutWinDoc.
We have checked that the contents of this document correspond to the
The reproduction, transmission or use of this document or its contents hardware and software described. Nonetheless, differences might
is not permitted without express written authority. Offenders will be exist. The information contained in this document is, however,
liable for damages. All rights, including rights created by patent grant or reviewed regularly and any necessary changes will be included in the
registration of a utility model or design, are reserved. next edition. We welcome suggestions for improvement.
© Siemens AG 1995- 2001. All Rights Reserved.

Subject to change without prior notice.
Available at A&D MC - Extranet Siemens-Aktiengesellschaft.

Printed in the Federal Republic of Germany
03.07 Contents
Contents
0
1 General information ......................................................................................1-9
1.1 Why do data get lost?...............................................................................1-11
1.2 Avoiding data loss ....................................................................................1-11
1.3 Value of the data ......................................................................................1-12
1.4 Data backup terminology..........................................................................1-12
2 Data..............................................................................................................2-15
2.1 Data types ................................................................................................2-15
2.2 Manageability of the data .........................................................................2-16
3 Distributed or central data management.......................................................3-17
3.1 Distributed data management ..................................................................3-17
3.2 Central data management ........................................................................3-19
3.3 Basic information on data backup and management................................3-19
4 Data-backup media ......................................................................................4-21
4.1 Data backup using floppy disks ................................................................4-21
4.2 Data backup with CD-ROM or comparable memory media......................4-23
4.3 Data backup on a server ..........................................................................4-24
5 Data servers .................................................................................................5-25
5.1 Servers and networks...............................................................................5-25
5.2 Secure hard disk system with RAID technology .......................................5-26
6 Data backup tools.........................................................................................6-27
6.1 Data backup using Ghost®.......................................................................6-27

6.1.1 Using Ghost .........................................................................................6-27
6.1.2 The Norton Ghost product....................................................................6-28
6.1.3 Norton Ghost functions ........................................................................6-29
6.1.4 Backing-up a hard disk using Norton Ghost .........................................6-29
© Siemens AG 2007 All Rights Reserved

Solutions for Powertrain TRANSLINE - Data Backup (VS) - 03.07 Edition 0-v
Contents 03.07
6.2 Data back-up of embedded systems for Sinumerik sl...............................6-31

6.2.1 Overview ..............................................................................................6-31
6.2.2 Prerequisites for backing-up the embedded OS...................................6-31
6.2.3 Backing-up data of embedded systems ...............................................6-31
6.3 A&D DataManagement™ .........................................................................6-32

6.3.1 Overview ..............................................................................................6-32
6.3.2 Which components does ADDM support? ...........................................6-34
6.3.3 How does A&D DataManagement work? .............................................6-35
6.3.4 Backup concept....................................................................................6-39
6.3.5 Operator interface components............................................................6-41
6.3.6 Operator interface of A&D DataManagementTM ...................................6-42
7 Data backup on a server ..............................................................................7-43
7.1 Server concept with direct access ............................................................7-44
7.2 Server concept with indirect access via mobile PC/PG ............................7-45
7.3 A&D DataManagement Server .................................................................7-47

7.3.1 Archive manager ..................................................................................7-47
7.3.2 Job manager ........................................................................................7-48
A Appendix ......................................................................................................A-49
A.1 Abbreviations ...........................................................................................A-49
A.2 Index of changes......................................................................................A-49

A.2.1 Changes from Version 2.2.1 to Version 03.01......................................A-49
A.2.2 Changes from Version 03.01 to Version 03.02.....................................A-49

0-vi Solutions for Powertrain TRANSLINE - Data Backup (VS) - 03.07 Edition
03.07 Contents
Figures
Figure 5-1 Host with RAID system......................................................................................................5-25

Figure 5-2 RAID level 5 ......................................................................................................................5-26
Figure 6-1 Norton Ghost® ..................................................................................................................6-28
Figure 6-2 Backing-up and restoring image files with Ghost...............................................................6-29
Figure 6-3 Uniform operator interface for all control components .......................................................6-32
Figure 6-4 Hardware connections for fast recovery ............................................................................6-35
Figure 6-5 ADDM solution concept in the network..............................................................................6-39
Figure 6-6 DataManagement operator interface .................................................................................6-42
Figure 7-1 Server structure.................................................................................................................7-43
Figure 7-2 Server concept with Ethernet networking ..........................................................................7-44
Figure 7-3 Server concept without Ethernet networking .....................................................................7-45
Figure 7-4 ADDM Job Manager ..........................................................................................................7-47

Solutions for Powertrain TRANSLINE - Data Backup (VS) - 03.07 Edition 0-vii
Contents 03.07
Notes

0-viii Solutions for Powertrain TRANSLINE - Data Backup (VS) - 03.07 Edition
03.07 1 General information
1.1 Why do data get lost?
1 General information
1
As a result of the increasing degree of automation and the increasing use of PC
components in production, the management of the huge amounts of data being
generated has exactly the same significance as for today's system administration
in the office environment.
The importance and significance of data in the office environment means that
administration units or internal departments are tasked, and will be in the future, to
manage systems and organize the data. Access authorization levels and
hierarchies are defined and PC specialists update the appropriate hardware. It
goes without saying that there is a special department looking after the tasks.
The structure in a production environment is only now starting to apply these
principles. Various issues mean that procedures, often used in the office
environment, cannot be applied in the production environment. It is especially the
following basic situation which results in problems when managing and maintaining
data and systems:
• In production areas, there is often not the required level of know-how about the
PC systems or if it is available, only in part.
• There is no knowledge about the data itself.
• The importance of the data in relationship to the hardware is not correctly
estimated in production environments.
• There is insufficient know-how about how a PC network functions.
• Necessary safety measures are incorrectly incorporated or incorrectly
evaluated.
However, by taking into account the various situations, a concept can be generated
which resolves these issues. An appropriate infrastructure can be created in order
to handle the tasks at hand.
The following description explains the recommendations associated with the
Solutions for Powertrain TRANSLINE 2000 data backup concept and therefore
offers a solution to guarantee production operation fit for the future.

Solutions for Powertrain TRANSLINE - Data Backup (VS) - 03.07 Edition 1-9
1 General information 03.07

Various investigations indicate that the most frequent cause for lost data is the user
himself. For approximately 70-80% of the cases, data is lost due to user error or
user carelessness.
The second most frequent cause for lost data is due to technical problems. Data
can be lost if modules fail or other technical problems occur which may cause, for
instance, power failure.
Additional causes can be in the area of viruses, hackers, theft, industrial espionage
or even sabotage. However, when viewed collectively, these causes represent the
lowest proportion of data loss but may not be neglected in the overall perspective.
1.2 Avoiding data loss
Note
By applying just one single measure, all of the potential reasons for data loss can
be eliminated. The measure is called data backup.
The frequency of data backup routines is defined by various factors (refer to

Section 2 Data). However, one thing can be clearly stated:
! Important
All relevant data must be backed-up after any change is made.
If the data has been backed-up, the data medium must also be carefully stored so
that this is not lost (also not stolen).

1-10 Solutions for Powertrain TRANSLINE - Data Backup (VS) - 03.07 Edition
1.3 Value of the data
1.3 Value of the data

The actual value of the data can only be defined with extreme difficulty. However,
the costs for procuring the data again can be used as basis. The reason for this is
that the costs to procure the data again are often a multiple of the original costs. In
addition to the costs for procuring and generating the data again, damage as a
result of shifted delivery dates, loss of order or production failure must also be
considered.
Every company must evaluate for itself just what the data used in the company is
actually worth.
In the production and manufacturing environments, too little emphasis is placed on
backing-up and updating data. However, the legal situation is quite clear. The user
himself is responsible for data backup.
Insurance companies evaluate the insurance sum, as between 5,000 € and
10,000 € per Megabyte of data. The insurance sum is calculated from the
appropriate amount. However, if data has not been backed-up, this is considered
as "gross neglect" and the insurance becomes null and void.
1.4 Data backup terminology
Data backup
In this document, data backup is considered the operation involved with

transferring the data from a data source to be backed-up to a data storage
medium. The data which has been backed-up must now also be integrated into a
data management system so that it is safely stored and archived.
Data source
Data is retrieved from the data source and transferred to the data target. The data
source can be, for instance, the hardware to be saved, for example, an S7 control
or the data source is in a management system and the data is transferred from
there to the hardware.

Source data
Source data is data which has been configured or developed for a hardware
platform or a specific task. Generally, this data is generated using a specific
programming language, and after development, is compiled into a code which can
be executed. The source data is modified and re-compiled if the function changes.
Generally, it is not possible to re-compile into the source data. This must be taken
into account in the data management.
Data management
Data management is a defined management system in which data can be archived

in a structured fashion. This data management depends very heavily on the
memory medium selected. In the most basic case, this can be a cabinet for floppy
disks with the appropriate compartments so that the floppy disks can be clearly
arranged or a database system with software archived on a RAID system.
However, it is decisive that the data is securely stored and when required, can be
quickly found and arranged. A functioning data management must always be
updated.
Data memory medium / data backup media
Various memory media have established themselves in the PC environment. The

floppy disk and the hard disk of a PC are the most well-known memory media. The
rate with which memory media change in the PC environment is extremely fast.
The following criteria are especially important when selecting a memory medium to
securely manage data:
• High MTBF time of the data medium
• Long data storage time
• High storage density
• Fast access to stored data
• Rugged encapsulation for interchangeable drives
• Longtime availability of data mediums and read-write devices
• A list of the various data mediums and their features are provided in the
section "Backup media".
A deeper look at different data mediums is provided in the section 4 „Data-backup
media“.

Definition of data
Data are programs, files or information which have been generated for the
operation of a component and these are downloaded to operate these components
or are read out of the components for backup purposes.

Notes

03.07 2 Data
2.1 Data types
2 Data
2
The data obtained using suitable backup techniques and methods must be
managed. The type of data which has to be managed is decisive when designing a
data management system. In this case, the characteristics of the data must be
carefully analyzed.
2.1 Data types

All data can be assigned to a defined data type, whereby other classifications may
also apply. Each data type has certain features, which must be evaluated. The
costs necessary to manage the data are simultaneously defined.
System programs, operating systems
This data type is used for the basic function of a system or device. The system
program or operating system is frequently saved on the hardware or transferred
into the hardware generally using special mechanisms. For PC systems, operating
systems must be installed. Generally, for these types of data, conditions of license
or defined user authorization rights must be observed.
Changing the data:
This type of data only change when initiated by the manufacturer of the device or
the hardware, which means extremely seldom.
Configuring data, commissioning and optimization data
This data is generated and downloaded into the hardware (e.g. PLC control) via
defined mechanisms before a system (piece of equipment) functions. This gives
the device or the control a precisely defined function.
Changing the data:
This data type is only changed by the configuring engineer or if the function of the
device changes (even slightly). The frequency that this data is changed is
increasing.

2 Data 03.07
2.2 Manageability of the data
Online data
This data is often defined by a configuring engineer as part of the configuring

process. However, this data type is also changed by the program in operation.
Changing the data:
The frequency that the data is changed is either high or extremely high.
2.2 Manageability of the data

The frequency that the data is changed is of decisive importance when considering
the data management costs. The shorter the time between data changes then that
much higher the data management costs.
This means that data which seldomly or never changes during operation, is the
most simply to manage. If the data is backed-up on re-writable backup media, the
data backup must be renewed before the data medium memory time expires. For
floppy disks, this must be carried-out at least once a year. The CDs also have a
limited storage time.
Suitable data backup algorithms must be generated for data which frequently
changes. In this case, the personnel who modify the data must also be taken into
consideration. Generally, this group of people should also back-up the data as they
are aware of every change (e.g. setting-up technicians for NC machines).
Data, which change in operation as a result of programs can generally only be
backed-up with extreme difficulty by personnel. The frequency that this data is
changed is extremely high which means that it is possible to generate suitable
strategies for individual cases within the scope of Solutions for Powertrain
TRANSLINE 2000. There is not a standard data backup mechanism.

03.07 3 Distributed or central data management
3.1 Distributed data management
3
3 Distributed or central data management
The generated data and backed-up data must be managed in an appropriate form
for the data manager. The form of data management is defined by the type of data
and when this is to be accessed, as well as by the data quantity and the data
storage type. In order to avoid data losses, the data must always be safely
archived, protected against destruction. There are two basic types of data
management - the distributed or central data management.
3.1 Distributed data management

The distributed data management does not collect the data but provides the data
there where it is required. If required, data is collected for smaller areas and is
stored close to the components where data should be backed-up.
• Distributed data management systems allow fast access to the data as the
data is stored locally on site.
• The amount of data at the collection location is low and is therefore
transparent.
• Various personnel manage and update the data which means that there is
danger that many versions or backup copies will be created and the situation
can become non-transparent.
• Often, secure data storage is not guaranteed (for instance, where data is
stored in a cabinet).
• Data can be easily lost or is not up-to-date.

3 Distributed or central data management 03.07
3.2 Central data management
3.2 Central data management

Central data management collects all of the data associated with a production area
at one location. There, the data is stored, where at all possible, in secure areas.
The central data management has the following characteristics/features:
• Central data management systems collect the data at a location which means
that the data can be more easily updated.
• Secure data storage is generally guaranteed.
• For central data management systems, data update is simpler and more
transparent because there is only data storage location.
• The data update status is always transparent.
• The danger of having several versions is significantly lower than for distributed
data management systems.
• The data quantities are relatively large when collected and archived at one
location.
3.3 Basic information on data backup and management

Independent of the selected data management type, the costs associated with
updating the data are comparable in all of these cases and is only determined by
the amount of data.
Data update is of decisive importance and for distributed data management, in
practice, is often not correctly carried-out. This is the reason that IT departments in
office environments have gone over to central data management systems.
The type of data storage is independent of the selected data management type
and is defined by the existing infrastructure, the data quantity and the personnel
available.
Personnel who update the data are responsible for the data. Personnel must be
made absolutely clear of this. A poorly updated data archive only becomes evident
when it is required. However, it is then too late.
Time and personnel are required to generate data archives. This must be planned.
Furthermore, access to the appropriate equipment and components must be
planned for generating data backups.

03.07 3 Distributed or central data management
The data archive itself must also be backed-up. The Solutions for Powertrain
TRANSLINE 2000 concept includes the appropriate recommendations.
A storage form should be selected which guarantees secure data storage.
If data mediums are used to backup data, then the data must be backed-up
according to the father-son-grandson principle. This means that not only one data
backup should be generated, but three backups must be generated, staggered
over time .
The data backups must be generated from the original. A copy of the data backup
can result in data loss if the first data backup is erroneous.

3 Distributed or central data management 03.07
Notes

03.07 4 Data-backup media
4.1 Data backup using floppy disks
4 Data-backup media
4
The data archiving medium has a decisive impact on the costs of the data backup
solution. In this case, not only are the data medium costs itself a criterion, but far
more important, are the costs associated with updating the data and fast access
when faults/errors occur.
4.1 Data backup using floppy disks
General information
The data from the control systems and the data from the machine OEMs is
transferred to floppy disks using a similar archiving technique. In this case, the data
of the individual devices must be separately archived. Changes made to the data
must also be made in the data management system.
Depending on how often the data is changed, all of the data mediums must be
saved a second or third time. This should be made according to the father-son
principle. A main backup should be made at least once a week. This main backup
should be stored in an environment which is safe for the data medium for security
reasons.
For a presently estimated data volume of approx. 3 Gigabytes, this would mean
managing approximately 3000 - 6000 floppy disks with an appropriate logical
segmentation of the data.
Advantages
• No equipment cost
• Extremely low procurement costs (supposedly)

4 Data-backup media 03.07
4.2 Data backup with CD-ROM or comparable memory media
Disadvantages
• Complex management
• No security when handling
• Low level of data security
• Large quantities of data mediums
• Multiple sources exist
• Manual second/third backup necessary
• High degree of exposure for the production process
• High update costs
4.2 Data backup with CD-ROM or comparable memory media
General information
Data is backed-up on MOD (Magnetic Optical Disk) or CD in a similar way to floppy

disks. However, the amount of data which can be stored on each data medium is
significantly higher than for floppy disks. This is also true for so-called ZIP drives.
Depending on the frequency with which data is changed, all of the data mediums
must be backed-up a second time. This should be realized according to the father-
son principle. A main data backup should be made at least once a week.
For an assumed data volume of approx. 3-5 Gigabytes, this would mean managing
approx. 30-50 MODs or CDs. In order that the data can be easily processed, it is
practical to combine the data in a data management unit. This can be, for example,
data backup for a machine. This increases the number of CDs to be managed to
approx. 100-300 CDs.
Advantages
• Low equipment cost

• Low procurement costs
• More secure data mediums than floppy disks
Disadvantages
• The data medium availability is not guaranteed

• When using CDs, a longer time is required
• A CD must be checked after it has been written into
• A new data medium must be generated, even if only small changes were
made.
• A manual 2nd backup is required
• Multiple sources are possible
• Average up to high update costs

03.07 4 Data-backup media
4.3 Data backup on a server
General information
Presently, data backup on a network server is the safest and most secure way to
backup data. An absolute safe and secure data backup is guaranteed by
combining interruption-free power supplies and RAID hard disk systems. The data
can be very easily brought-into created structures via a network coupling and data
access is comparable, from a time perspective, to that for standard hard disks.
Servers can easily handle data accesses. The data is automatically backed-up a
second time using a streamer.
Advantages
• Large data quantities can be processed

• Absolute safe and secure data backup using the RAID system
• Transparent data management
• Fast data access
• Low time required
• Multiple access
• Only one data source
• No manual second backup
• Low data management costs
Disadvantages
• Initial procurement costs

4 Data-backup media 03.07
Notes

03.07 5 Data servers
5.1 Servers and networks
5 Data servers
5
5.1 Servers and networks
LAN
HOST #1
SCSI
RAID-Controller
SCSI
RAID Diskbox
Figure 5-1 Host with RAID system
A server is a PC with integrated network connection. The server essentially only

has one operating system and the drivers which are required to link it to the
network. Generally, the server includes an interruption-free power supply (UPS).
When the power fails, this maintains server operation and if the line supply is down
for a longer period of time, the server can be run-down without creating any errors.
Generally, several servers are used.
The servers (hosts) are installed in special secure rooms, as often sensitive data is
stored on the hard disks. The servers are linked to the network (LAN Local Area
Network) and defined clients can be accessed via a password. A RAID controller
with a RAID hard disk system is connected at the host computer.
Additional information about configuring networks is provided in the Solutions for
Powertrain TRANSLINE Manual IT Configuration.

5 Data servers 03.07
5.2 Secure hard disk system with RAID technology
5.2 Secure hard disk system with RAID technology

Hard disks are magnetic data mediums with mechanical parts which are subject to
natural wear in operation. If hard disks are used as secure data medium, then this
must be taken into account. If a hard disk fails, it is not permissible that data is lost.
So-called RAID systems were developed especially for this purpose.
Characteristics/features:
The parity information is distributed
Disk 0 Disk 1 Disk 2 Disk 3 Disk 4
over all hard disks of the array
Advantages:
Data security using distributed
parity information
High data transfer and transaction
rates using overlapping hard disk
RAID Controller read/write operations
P
P Disadvantages:
Complex parity generation
P procedure
P
Applications:
Used in file server an database
applications using the simultaneous
read-write operation capability
Host
Figure 5-2 RAID level 5
Today, connected RAID hard disk systems are written onto using a RAID level 5.
This security level has established itself for data servers as a result of its
advantages. Data is distributed on the hard disk and the distributed parity
information gives this RAID level an extremely high degree of data security. The
disadvantage of the complex parity generation system is balanced by the high level
of data security and by the fact that the generation is carried-out by the controller
system.
By using a hot standby hard disk, the RAID system can compensate even if two
hard disks fail. These hard disks can be replaced during operation (hot plug).
The servers with their RAID systems are supported and serviced by the company's
IT departments. This means that the availability of the data storage system is
guaranteed over a long period of time.

03.07 6 Data backup tools
6.1 Data backup using Ghost®
6 Data backup tools

6
The data backup procedure itself is carried-out using the appropriate engineering
tools provided by the manufacturers of the devices. When using the tool, the ability
to save data on the appropriate backup media is integrated in the tool itself, It goes
without saying that the tools utilize the actual operating system mechanisms and
their properties.

PC-based systems are being increasingly used in production environments.
Generally, these systems have hard disks which are subject to a certain wear. In
this case, redundant hard disks or RAID systems are too costly.
This means that it is absolutely necessary to have an effective hard disk backup
routine in place.
6.1.1 Using Ghost

A hard disk in the system is defective and must be replaced. In this particular case,
the hard disk can be restored using the installation file. The time required is
immense.
In this case, the solution is to generate an image file of the hard disk before it
becomes defective. After a hard disk has been replaced, this image can be quickly
and simply downloaded. This means that the system is up and running in the
shortest time.
In this case, the tool required is the backup software Norton Ghost®.

6 Data backup tools 03.07
6.1.2 The Norton Ghost product
Figure 6-1 Norton Ghost®
Norton Ghost is a SYMANTEC product.
The system requirements are:

• IBM-PC or 100% compatible
• DOS 5.0 or higher
• 80486 SX processor or higher
• 32 MB RAM for Win 95/98 - 64 MB RAM for Win NT/2000/XP
• VGA monitor (minimum requirement)
The following operating systems are supported:

• DOS
• Windows 3.x / 9x / NT / 2000 / XP
• Linux

6.1.3 Norton Ghost functions
Backup
Complete hard disks/partitions can be written in compressed image files (an image
file is the physical image of a hard disk, its files and directory structures).
Restore
These image files can also be downloaded onto hard disks. In this case, image
files can be downloaded to non-partitioned or non-formatted hard disks ("formats
on the fly"). The new target hard disk can even be bigger or smaller than the
original one (as long as the data quantity is not too high). This means that images
are subsequently independent of larger replacement hard disks.
6.1.4 Backing-up a hard disk using Norton Ghost
Ghos slave
Backup PC
Ghost master CD-ROM, streamer,

preinstalled on each network drive
drive (recommended)
Server
LPT
Ethernet
Ethernet
OP012 Field PG
Figure 6-2 Backing-up and restoring image files with Ghost
For backup and restore, a backup computer is connected to the PC via the parallel
interface. A ghost slave is started on the backup computer. The Ghost master must
now be started on the other side.

Ghost is installed as standard on all PCU hard disks and is also entered in the
standard service menu. The Ghost master is started here using the appropriate
menu items. Data backup or restore runs without having to do anything else. If the
server menu extension still does not exist, then the Ghost master can be manually
supplied with the required parameters or via the command line.
The image files can be saved locally on drives, CD-ROMs, streamers or also on
network drives. We recommend that data is saved on a server.
A detailed description of the server concept is provided in the TRANSLINE 2000
Manual: IT Configuration.

6.2 Data back-up of embedded systems for Sinumerik sl
6.2 Data back-up of embedded systems for Sinumerik sl
6.2.1 Overview
Embedded systems with Windows, Unix or Linux are being increasingly used in
production equipment. Generally, these do not require any hard disks and run on
integrated memories or on memory cards that are separately inserted (e.g. CF
card). This has the advantage that the complex data back-up of hard disks is
eliminated - and in turn, it goes without saying, that significant costs can be saved.
Further, embedded systems are significantly less prone to viruses and Trojan
horses as only the drivers that are absolutely necessary run on this "mini operating
system".
6.2.2 Prerequisites for backing-up the embedded OS

Siemens uses an embedded operating system in all NCU 7x0 devices. This is
based on Linux and runs on a CF card. Both the operating system and all data are
saved on the CF card. This is the reason that the data on this card must be backed
up each time you enter changes.
Before backing up data, generate a bootable service system on a USB memory.
This is also known as "Emergency Boot System" or EBS.
You can now boot the NCU from the service system in order to execute various
service tasks in a service shell (for example, a data back-up or updates).
Two partitions are set up on the service system:
- A Linux partition that is not visible under Windows.
- A FAT32 partition for DOS or Windows applications.
6.2.3 Backing-up data of embedded systems

As already mentioned, a service system is required to back up the embedded
operating system. Data can be saved on the following media:
- Data can be backed up on a USB memory
- Data can be backed up on a network driver
If the back-up file is generated on the service system (USB memory), then this is
generated under the directory /data. When saving the back-up file on a network
drive, the directory can be freely selected.

6.3 A&D DataManagement™
! Important
A&D DataManagement requires a PC-based systems (PCU 50) and is not

executable on an embedded system.
6.3.1 Overview
A&D DataManagement (ADDM) is in the concept Solutions for Powertrain
TRANSLINE 2000 the data storage system for control components.
ADDM manages the data and programs of the components used in a simple
manner via one uniform operator interface.
STEP7/5 SINUMERIK SIMATIC NET
ProTool MCU-PIT Files

ProTool/Pro or
WinCC hard disk
partitions
STEP7/
OP NC MCU CP PC
STEP5
data data data data data
data
DataManagement
Figure 6-3 Uniform operator interface for all control components
A&D DataManagement makes the data backup independence from configuration

tools, data types and formats. It creates an exact image of the production facility.
Even complex production lines can be easily imaged in clearly understandable
directory trees. The display is based on the Windows Explorer from Microsoft. The
navigation is not oriented on abstract data structures, but on real conditions.

Identical components can be supplied with identical data. The standardization of

the configuration makes service and maintenance easier.
Features
• Production-oriented structure: uncomplicated overview, easy to handle

• Reduced plant downtimes for replacing defective hardware components
• (fast disaster recovery)
• Increased security and availability of all data stocks
• Works with already existing standard configuration tools
• Supports as standard a multitude of components
• No special knowledge needed, for example of programming
A&D DataManagement increases plant availability
Replacement components are promptly supplied with the relevant data. There is no
time-consuming parameterizing and configuring.
In this context, it is irrelevant whether you need to copy over individual files or
complete hard disk partitions in the form of a compressed image file (imaging).
High safety level with A&D DataManagement–company wide
A&D DataManagement allows you to store data centrally on servers and mass
storage systems. You can therefore integrate your entire data stock into highly
available client-server architectures and fault tolerant online storage. This enables
the plant control to provide the highest possible safety standards for your data.
A&D DataManagement provides extensive options for drive-independent
DataManagement:
• Data can be stored online on a server.
• Removable disks may be used.
• Loading data and settings after component replacement.
• Backup of complete hard disks or hard disk partitions (imaging).
• Restoration of hard disks or partitions from an image file.
• Reloading to an unpartitioned and unformatted hard disk.
• Logging of all modifications in a log book.

6.3.2 Which components does ADDM support?

Various software and hardware modules have been integrated into ADDM. All the
relevant data and programs of the hardware components existing in ADDM can be
managed, backed-up and loaded.
Supported hardware components
• S7: S7-300, S7-400, WIN AC, WIN AC RTX

• C7: C7-623, C7-626, C7-633, C7-634, C7-635
• CPs: CP342-5, CP343-1,CP443-1, CP443-5
• NCU: SINUMERIK 810D, 840D, 840Di : PLC-Data via S7-CPU
• SINUMERIK: archive files for SINUMERK 810D, 840D und 840Di
• MCU: MCU172A, PLC-Data via S7-CPU
• Drives: 611U, -HRE, -HRR, 611UE, -HRE, 611D via NCU
POSMO A, -CD, -CA, -SI,
• Path: Folder/ Files
• Hard disks complete Hard disks or Partion (PCU)
• OPs: OP3, OP7, OP15, OP17, OP25, OP27, OP35, OP37,
OP170B, OP270
• TDs/TPs: TD17, TP27, TP37, TP170A, TP170B, TP270
• MPs MP270, MP370
• PCIN: PHG, OP030, MMC100 and MMC100.2
• HMI DOS: DOS-Package for MMC103.
• S5: SIMATIC S5 90U, 95U, 100U, 115U, 130W, 130WB, 135U,
155U, with restrictions 150A, -K, -S, -U
• Serial: RS-232 interface for transferring any desired data
• third-party system via neutral component
Supported software tools
• IBN611D, Mini-DNC
• SimoComU/A
• MCU-PIT
• STEP7, NCM
• ProTool or ProSave
• Transline 2000 Setup tool for HMI DOS and HMI PRO (from V6.2 via neutral
component)
• General RS-232 transfers

• General software tools with an open interface
6.3.3 How does A&D DataManagement work?

A&D DataManagement manages the data and programs existing in the production
facilities in a uniform plant structure. To do this, it represents the structure of the
production facility as a directory tree in the interface, which is based on the
WINDOWS Explorer. Via this plant structure it manages the data and programs
existing for each control component– and backup or load as required.
For this ADDM uses the existing standard software tools for the components. You
can thus manage the data both with the standard software tool and with the A&D
DataManagement software.
In order to enable fast disaster recovery, defective components are replaced by
new ones. Then the previous parameterization is loaded into the component
concerned with ADDM.
Hardware connection for fast recovery
The hardware connection for restoring the parameterizing is made in various ways,
depending upon the defective control component.
CP34 2-5
SIMATIC MPI V.24 Serial

SIMATIC
S7-300/400 S IM ATIC
S 7-3 00
SIMATI C
S7 -3 0 0
PROFIBUS PROFIBUS
Operator
C7 Ethernet
PROFIBUS Panels
CPs Ethernet
V.24 Serial
S IMATIC
S 7-30 0
PCIN
SINUMERIK MPI / BTSS /

Parallel HMI DOS
NCU PROFIBUS
MCU ADDM
Drives V.24 Serial SINEC H1

AS 511 SIMATIC
611U PROFIBUS
S5
POSMO
Parallel
TCP/IP V.24 Serial Serial
PCU
HD
Path
HMI PRO
Figure 6-4 Hardware connections for fast recovery

S7-CPU
S7-CPU is loaded directly over the MPI-, or DP-connection. If an Ethernet-CP

exists, the PLC can be also reached over this CP.
C7
The C7-units 623, 626, 633 and 634 are loaded over the serial interface. The C7-
635 can also be addressed via MPI.
CP
The CPs 342-5 and 443-5 are loaded directly over PROFIBUS and the CPs 343-1
and 443-1 over Ethernet. All CPs can also be addressed via S7-CPU.
NCU
The NCUs are connected over MPI-, BTSS- or PROFIBUS-connection. The

internal PLC will be managed as a separate S7-CPU component.
SINUMERIK
The SINUMERIK component allows to create a series start-up file in consideration

of the reset status. There the contents can be defined.
MCU
The MCU is linked over MPI-connection. The internal PLC will be managed as a
separate S7-CPU component.
Drives
The 611U-Drives are managed over serial interface or over present PROFIBUS-
interface. The POSMO-Drives needs only the PROFIBUS-connection. The Drives
can be reached over the PLC route way. The 611D-Drives are managed via NCU.
Path
Folder and Files are managed over local or mapped Drives.
Hard disks
Complete hard disks e.g. of the PCU are loaded under ADDM via the parallel
interface (not under Windows NT 4.0 or Windows 2000) or via the TCP/IP network.

Operator Panels
All operator panels: OPs/ TDs/ TPs/MPs are connected over the serial interface
(RS-232). The units OP3, OP25, OP35 and the unit family 27, 37 and 170 can also
be addressed via the internal PROFIBUS-interface. The units of the family 270 and
370 can be addressed as well via PROFIBUS as via Ethernet. The Backup of the
components is only possible with using of ProSave.
PCIN
The Embedded SINUMERIK System like PHG, OP030, MMC100 and MMC100.2
as well the user texts of HT6 can be loaded over serial interface with data.
HMI DOS
The operator units with HMI DOS are linked via Interlink (parallel or serial interface)
with the ADDM PC.
S5-CPU
The S5-CPU is via SINEC H1 reachable. For this are CP’s needed, mounted in the
rack of the S5-PLC and in PG/PC.
The S5-CPUs 90U, 95U and 100U are connect over serial For Communication
over H1 are CP’s needed, mounted in the rack of the S5-PLC and in PG/PC.
Serial and Miscellaneous
Even older control systems and non-Siemens systems can be connected to ADDM.
In such cases, the crucial factor is whether the systems use standard transfer
mechanisms. Older SINUMERIK systems such as the 3/8, 810, 820, 850 and 880
systems use a serial interface without a protocol for data output. Machine data, for
example, are output via this interface. ADDM can receive and store data with the
serial component. After the data exchange, this data can be transferred to the
systems again.
Systems such as SINUMERIK 840C have a PC which can be backed up and
loaded with the DOS drivers Interlink and Interserv. These drivers were
components of the Microsoft MSDOS operating system and are therefore subject
to the relevant licensing laws. For this reason, these drivers are not supplied with
ADDM.
If these drivers are present on the backup computer, ADDM can recognize this
serial or parallel coupling and backup and reload data via the path component.
Additional ADDM offers a neutral component. This component can approach the
interface of several software tools. This way it is possible to manage not integrated
systems.

Neutral Component
The neutral component offers the easy possibility to include any application and
that way additional hardware in A&D DataManagement. The application must be
able to control via command interface or batch file. ADDM provides for certain
components and software tools already finished batch file templates, e.g. for
TRANSLINE HMI PRO (ex Version 6.2).

6.3.4 Backup concept

ADDM supports different hardware configurations for backing up configuration and
system data:
• ADDM (Single User) runs as a single-user-solution in the automation system or
on a mobile backup computer.
• ADDM-Client runs on a mobile network computer with data storage on a
central server. This client allows to transfer the data between the backup
component and the central server.
• ADDM-Client runs on a stationary network computer (e.g. operator panel) and
access the data on the server and the linked automation system like the mobile
network computer.
• ADDM-Agent runs on a stationary network computer (e.g. operator panel) and
takes over the communication with the automation system. An existing Client in
the network takes over the communication with the central server. This way all
function can be done via the network without the need of a full Client
installation direct on the operator panel.
An installation of the software STEP 7 is required on the ADDM computer (Single

User and Client installation) to communicate with the automation systems!
Stationary ADDM PC
Server
(Client)
• ADDM interface Central ADDM Server
• Data storage
Ethernet TCP/IP • Archiving
• Versioning
Stationary ADDM • STEP 7 Project
(Client) OP012 OP012 • ADDM Project
• ADDM interface PCU PCU
(Agent)
• Communication
OPI OPI
PG /PC
840D 840D Mobiles ADDM
NC NC
MPI (Single User)
PLC MPI PLC • Data carrier
• ADDM interface
Drives Drives
Figure 6-5 ADDM solution concept in the network
! Important
The ADDM project and the source project must lie on a common drive for all
solutions!

At stationary computers like operator panels the size of memory is limited in

general. Therefore a complete Client installation is not possible. In that case an
ADDM-Agent will be installed. An ADDM-Client in the network can communicate
with this ADDM-Agent and access the subordinate components. This way the
components can be saved without connecting a mobile ADDM computer to the
station. The ADDM-Client commissions the ADDM-Agent to perform the function of
the client. There is an ongoing communication between the agent and client for the
time of the task. The Agent is the executive unit for the client.
The ADDM-Agent is not including an operating interface. It is just the
communication router between the operate panel and the ADDM-Client computer.
All setups for the agent are done at the ADDM-Client.
Supported hardware components by the Agent
The following hardware components can be backed-up, loaded and compared with
the ADDM-Agent.
• S7: S7-300, S7-400, WIN AC, WIN AC RTX
• NCU: SINUMERIK 810D, 840D, 840Di : PLC-Data via S7-CPU
• Drives: 611U, -HRE, -HRR, 611UE, -HRE, 611D via NCU
POSMO A, -CD, -CA, -SI,
• SINUMERIK Creating of ARC-files
! Important
The communication between the ADDM-Client and the ADDM-Agent is realized
via DCOM mechanism from Microsoft. Both computers must be located in one
network, so the client can reach the agent. The computers shall be in the same
domain.
! Important
An installed STEP 7 is required for the installation of A&D DataManagement as

well for a Client as for a Single user license. The Agent can be installed without a
STEP 7.

6.3.5 Operator interface components

DataManagement software use is sub-divided into the "Download and back-up"
and "Configuring the data structures" sections.
Configuring
When configuring the data structures, a directory structure can be created on a

drive using DataManagement. Generally, this system structure corresponds to the
production environment. The user can freely select the labels/names using a
properties dialog box.
The components, in the machine/unit, are entered in the righthand window. These
can be downloaded from A&D DataManagement™.
Handling is similar to that of WINDOWS Explorer.
Downloading and backing-up
If the structures have been configured, the configuring section is disabled in the
A&D Data Management. This means, that none of the elements can be
accidentally removed. However, the software allows all of the backup functionality
of the components, and beyond this, various service functions associated with the
components:
• Hardware diagnostics
• Scanning for nodes/stations which can be accessed
• Setting the PC/PC interface
• General PLC reset
• Status of modules/blocks
• Comparison

6.3.6 Operator interface of A&D DataManagementTM

The operator interface is similar to that of WINDOWS Explorer. This means that the
software is extremely easy to get to know. Special programming know-how is not
required.
Figure 6-6 DataManagement operator interface

03.07 7 Data backup on a server
7.1 Server concept with direct access
7 Data backup on a server

7
Servers are ideally suited for central data backup and management. However, all
of the data associated with production or a production area aren't located on the
server. This means that it is absolutely necessary to generate an appropriate
arrangement criterion for data archiving. The arrangement on the server permits
• data to be saved in a structured fashion
• archived data can be quickly found
• data can be simply updated
• saved data can be selectively accessed
The user is responsible in generating the structure. This is because only he knows
the data to be backed-up. Furthermore, the arrangement criteria of the user can be
taken into consideration in the structure. Often, it helps to take into account the
inventory numbers of the objects in the structure. This helps to quickly find the
appropriate data.
Figure 7-1 Server structure

7 Data backup on a server 03.07
Data associated with production areas can be assigned to a server. This means
that the system administrator can selectively assign the access authorization to the
production areas, and a user can only access data which is relevant for him. The
other areas are blocked. This enhances the data security level.
The server data must also be backed-up. By linking the server into the IT
department management, the server can be serviced and updated by this
department. Furthermore, the servers are accommodated in secure rooms. These
secure rooms fulfill certain safety criteria against unauthorized access, theft of data
etc. By linking the server to the general network, data can be transferred to the
backup server for additional backup and archiving. Here, data is stored on tapes
and it is archived so that it is safe from fire.

The data structures can be set-up and managed on the servers using A&D Data
Management™.
Data server Office
OP17
V.24
Ethernet TCP/IP
Switch Switch Switch
OP012 SIN840D SIN840D
SIMATIC S7
CP342-5
SIM ATIC S IMATIC

S7-300 S 7-30 0
PP012
Transfer line 1 Machine 1
Figure 7-2 Server concept with Ethernet networking
Data can be directly accessed via the networks. If Data Management is installed on
networked control PCs, the connected control systems can be directly accessed.
For components which do not have a network connection, data must be
downloaded via a backup/archiving computer with network connection. This
means, for example, data can be downloaded into OP using a backup computer or
mobile PG. The computer or the PG can access the data via the network.

7.2 Server concept with indirect access via mobile PC/PG
This central data management system can be simply and quickly updated/serviced.
Data can always be accessed via the network eliminating time-consuming data
transfer.
7.2 Server concept with indirect access via mobile PC/PG

There is hardly a production environment where all of the machines are connected
to existing networks. In this case, a backup computer is used as router. Data can
be directly transferred from the network into the various components via the
backup computer.
If there is no network connection, the data section of the system can be transferred
to the local hard disk of the backup computer using a user-friendly project copying
function. The backup computer can now be moved to the system and the data
downloaded into the control.
Data server Office
OP17
V.24
Ethernet TCP/IP Switch

Switch Switch
PROFIBUS
SIN
OP012 840D SIN840D
SIMATIC
S7
V.24 CP342-5
SIMATIC SIMATIC
S7-300 S7-30 0
PP012
Transfer line 1 Machine 1
Figure 7-3 Server concept without Ethernet networking
A detailed description of the server concept is provided in the Solutions for

Powertrain TRANSLINE 2000 Manual: IT Configuration.

7.3 A&D DataManagement Server

The A&D DataManagement-Server enables the user domainwide to manage
clientsystem- and clientprojectdata automatically or manually (save, backup,
comparision of archiv- and onlinedata, versioncontrol).
The A&D DataManagement-Server consists of three applications:
Archive Manager: The Archive Server A&D DataManagement archives and ma-
nages different versions of configuration of various A&D
DataManagement-Clients throughout an entire domain.
User Manager: A usercontrol which helps the administrator to manage the
A&D DataManagement members. It works throughout a do-
main or workgroup. It can be startet by the server or by the
client.
Job Manager Tasks can be scheduled (example: compare, archiving) in a
joblist.
7.3.1 Archive manager

The archive manager is the platform for managing archives. The archive manager
is part of ADDM Server and is only started on the server.
The archive function can be started in the ADDM Client by selecting Archive
Functions in the menu bar. The Client allows the user the following archiving
functions:
• Displaying version numbers
• Archiving
• Comparing
• Displaying the archive content
• Dearchiving
• Selecting the archive server
Deleting and swapping out archives are functions which are reserved for the
archive manager and they cannot be selected in ADDM Client.

7.3.2 Job manager

A&D DataManagement offers the user the use of a job server in the Client-Server
application. ADDM can automatically compare the data of the components of an
ADDM project at defined times via the job server. ADDM can create a safety
backup if a comparison reveals a difference.
ADDM server
JOB list ADDM clients
ADDM
project
Switch
Ethernet TCP/IP
Switch Switch Switch Switch
Switch
Switch
ADDM clients
Figure 7-4 ADDM Job Manager
The JOB list containing the desired JOBs is created via the clients. When the time
entered has been reached, the JOB server gives the client the JOB which has to
be done. The actual JOB is performed by the client. The client reports the result of
the JOB to the JOB server. Depending upon the type of JOB, the JOB server now
order the client to take actions.
If an operator panel (PCU) of the control is used as the ADDM client, the data of
the control (e.g. NCU) can be compared with the data backed up on the server
without further operator action. The JOB server can order the client to make a
"safety backup" if a difference is found between the online and offline data. The
client creates this backup.

Notes

03.07 A Appendix
A
A Appendix
A.1 Abbreviations
The list of abbreviations of the overview, TRANSLINE 2000, is in the Solutions for
Powertrain TRANSLINE 2000 Manual – Attachment.
A.2 Index of changes
A.2.1 Changes from Version 2.2.1 to Version 03.01
No changes in the contents were made.
A.2.2 Changes from Version 03.01 to Version 03.02
Subsection 6.1.4 Backing-up a hard disk using Norton Ghost
Functionality of the PCU extended by Ethernet
Subsection 6.2.1 Overview
New defailed explanation of the subsection 6.2.1 – why do I need

DataManagement
Subsection 6.2.2 Which components does ADDM support?
New defailed explanation of the subsection 6.2.3 – which components can be

managed?

Solutions for Powertrain TRANSLINE - Data Backup (VS) - 03.07 Edition A-49
A Appendix 03.07
Subsection 6.2.3 How does A&D DataManagement work?
New defailed explanation of the subsection 6.2.2 – what does the

DataManagement software package offer?
Subsection 6.2.4 Backup concept
New subsection
Section 7.3 A&D DataManagement Server
New section
New Components of the Version 5.1 is included.
New Components of the Version 5.1 is included and new revision of description.
Include of the integration of HMI PRO

A-50 Solutions for Powertrain TRANSLINE - Data Backup (VS) - 03.07 Edition
03.07 A Appendix
Add the neutral component
Add the neutral component
Subsection 6.2.4 Backup concept
Add the ADDM Agent

No changes
Section 6.2 Data back-up of embedded systems for Sinumerik sl
New section

Solutions for Powertrain TRANSLINE - Data Backup (VS) - 03.07 Edition A-51
A Appendix 03.07
Notes

A-52 Solutions for Powertrain TRANSLINE - Data Backup (VS) - 03.07 Edition
To Suggestions
Siemens AG Corrections
TRANSLINE Support for Publication/Manual:
P. O. Box 106026 Solutions for Powertrain

TRANSLINE - Data Backup
D-70049 Stuttgart
General Documentation
Tel. +49 (0) 711 / 137 - 3964
Fax +49 (0) 711 / 137 - 2838
email: transline-support.ad.sdw.rd@siemens.com
From Manual
Name: Available at A&D MC - Extranet
03.07 Edition
Company/Dept. Should you come across any printing errors
when reading this publication, please notify us
Address: on this sheet. Suggestions for improvements
are also welcome.
____________
Telephone: __________ /
Telefax: ________ /
Suggestions and/or corrections

Siemens AG
Automation and Drives
Motion Control Systems © Siemens AG 2007
P.O. Box 3180, D – 91050 Erlangen Reserved for changes
Federal Republic of Germany Available at A&D MC - Extranet
www.automation.siemens.com Printed in Federal Republic of Germany

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Manual 03/2007 Edition

Solutions for Powertrain Distributed or central 3

TRANSLINE - Data Backup Data-Backup media 4

General Documentation Data servers 5

Data backup tools 6

Status codes in the „Remarks“ column:

A .... New documentation.

Edition Order No. Remarks

© Siemens AG 1995- 2001. All Rights Reserved.

Available at A&D MC - Extranet Siemens-Aktiengesellschaft.

1.1 Why do data get lost?...............................................................................1-11

1.2 Avoiding data loss ....................................................................................1-11

1.3 Value of the data ......................................................................................1-12

1.4 Data backup terminology..........................................................................1-12

2.1 Data types ................................................................................................2-15

2.2 Manageability of the data .........................................................................2-16

3 Distributed or central data management.......................................................3-17

3.1 Distributed data management ..................................................................3-17

3.2 Central data management ........................................................................3-19

3.3 Basic information on data backup and management................................3-19

4 Data-backup media ......................................................................................4-21

4.1 Data backup using floppy disks ................................................................4-21

4.2 Data backup with CD-ROM or comparable memory media......................4-23

4.3 Data backup on a server ..........................................................................4-24

5 Data servers .................................................................................................5-25

5.1 Servers and networks...............................................................................5-25

5.2 Secure hard disk system with RAID technology .......................................5-26

6 Data backup tools.........................................................................................6-27

6.1 Data backup using Ghost®.......................................................................6-27

© Siemens AG 2007 All Rights Reserved

6.2 Data back-up of embedded systems for Sinumerik sl...............................6-31

6.3 A&D DataManagement™ .........................................................................6-32

7 Data backup on a server ..............................................................................7-43

7.1 Server concept with direct access ............................................................7-44

7.3 A&D DataManagement Server .................................................................7-47

A.1 Abbreviations ...........................................................................................A-49

A.2 Index of changes......................................................................................A-49

© Siemens AG 2007 All Rights Reserved

Figure 5-1 Host with RAID system......................................................................................................5-25

© Siemens AG 2007 All Rights Reserved

© Siemens AG 2007 All Rights Reserved

© Siemens AG 2007 All Rights Reserved

1.1 Why do data get lost?

1.2 Avoiding data loss

The frequency of data backup routines is defined by various factors (refer to

© Siemens AG 2007 All Rights Reserved

1.3 Value of the data

1.4 Data backup terminology

In this document, data backup is considered the operation involved with

© Siemens AG 2007 All Rights Reserved

Data management is a defined management system in which data can be archived

Data memory medium / data backup media

Various memory media have established themselves in the PC environment. The

© Siemens AG 2007 All Rights Reserved

© Siemens AG 2007 All Rights Reserved

© Siemens AG 2007 All Rights Reserved

2.1 Data types

System programs, operating systems

Configuring data, commissioning and optimization data

© Siemens AG 2007 All Rights Reserved

This data is often defined by a configuring engineer as part of the configuring

2.2 Manageability of the data

© Siemens AG 2007 All Rights Reserved