S7-1500R/H

Redundant System
Unrestricted © Siemens AG 2019 http://www.siemens.com/S7-1500
Film

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Page 2 January 2019 Team Innovation Tour
Redundancy and High Available systems –
Applications

Airport Logistics Tunnel

HVAC Water and Wastewater

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Redundancy and High Available systems –
Motivation

Avoidance of shutdowns Avoidance of data loss

Higher availability avoids or reduces All data stay synchronized and long
the production shutdowns resumption of operation after failure
are avoided
Avoidance of damage
of goods manufactured Operation without supervision
Higher availability avoids material The schedule of Service-Trips might
damage to the plant or the goods not be so urgent due the higher
manufactured availability of the system

Engineering is simpler
The Engineering is simpler compared
to Applicative Solutions which are often
complicated and hard to maintain

Redundant Systems reduce costs and ensures higher availability of a process

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Page 4 January 2019 Team Innovation Tour
SIMATIC S7-1500R/H –
The easiest way to a redundant solution

Based on Standard S7-1500 CPUs and Profinet

Transparent Programming
Standard Engineering Tool TIA Portal V15.1
• Redundancy functions fully integrated in TIA Portal
• General handling like standard
• No deep Redundancy Know-How needed

Extensive Scalability
• Scalability of switch-over time
• Scalability of the Redundancy Architecture
• Scalability of the CPU Performance (1513 → 1517)

Focus on PROFINET as Fieldbus System

• Based on PROFINET System Redundancy Standard
• No support of PROFIBUS planned

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Page 5 January 2019 Team Innovation Tour
SIMATIC S7-1500R/H –
… completes the range of controller types of the S7-1500
Engineered with TIA Portal
Efficient
Advanced Controller engineering
SIMATIC S7-1500
Software Controllers
SIMATIC S7-1500 Innovative
Design
System performance

Reliable
Diagnostics
Distributed Controllers CPU1513R-1
SIMATIC ET 200 CPU CPU1515R-2
CPU1517H-3 Safety
Integrated
Basic Controllers New
SIMATIC S7-1200
Security
Integrated

Technology
Complexity of application Integrated

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Page 6 January 2019 Team Innovation Tour
SIMATIC S7-1500R/H –
Order numbers – PLC Hardware

CPU 1513R-1 6ES7513-1RL00-0AB0

CPU 1515R-2 6ES7515-2RM00-0AB0

CPU 1517H-3 6ES7517-3HP00-0AB0

6ES7960-1CB00-0AA5 (up to 10 m)
Synchronization-Module
6ES7960-1FB00-0AA5 (up to 10 km)

6ES7960-1BB00-5AA5 (1 m)
FO-cable 6ES7960-1BC00-5AA5 (2 m)
6ES7960-1CB00-5AA5 (10 m)

S7-1500H Bundle 6ES7500-0HP00-0AB0

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Page 7 January 2019 Team Innovation Tour
SIMATIC S7-1500R/H –
Order numbers – Devices supporting PN NAP S2

I/O-systems

6ES7155-6AU01-0CN0
ET 200SP – IM155-6PN HF (FW>=4.2)
6ES7155-6AU30-0CN0

ET 200MP – IM155-5PN HF (FW>=4.2) 6ES7155-5AA00-0AC0

PN/PN-Coupler 6ES7158-3AD10-0XA0

Drives

S120, CU310-2PN (FW ≥5.2) 6SL3040-1LA01-0AA0

S120, CU320-2PN (FW ≥5.2) 6SL3040-1MA01-0AA0

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Page 8 January 2019 Team Innovation Tour
SIMATIC S7-1500R/H –
Order numbers – Devices supporting PN NAP S2

Network switches

SCALANCE XC-200 series Several order numbers

SCALANCE XP-200 series Several order numbers

SCALANCE XF204-2BA 6GK5204-2AA00-2GF2

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Page 9 January 2019 Team Innovation Tour
SIMATIC S7-1500R/H –
System overview

Redundant S7-1500R High Available S7-1500H

Primary Backup Primary Backup

Universal Concept:
Sync Identical Synchronization H-Sync
Mechanism

1-Ring 1-Ring
Scaling of switch-over
performance through
available bandwidth of
the Sync-Connection
ET 200SP ET 200MP ET 200SP ET 200MP

CPU 1513R/CPU 1515R CPU-Type CPU 1517H

via PROFINET Ring (MRP) Synchronization via Sync-Module

200 – 500 ms Switchover time <100 ms

ET 200SP and ET 200MP I/O-System ET 200SP and ET 200MP

Single IM (PN-Redundancy S2) Type of Interface Single IM (PN-Redundancy S2)

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Page 10 January 2019 Team Innovation Tour
R/H PROFINET Network configuration –
1513R/1515R Length of the synchronization connection

Primary Backup
Direct link up to 100 m
≤100 m

Sync

Single MRP Ring

Fiber optic link

(media converter) up to 3 km
ET 200SP ET 200MP ≤3 km

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Page 11 January 2019 Team Innovation Tour
R/H PROFINET Network configuration –
1517H Length of the synchronization connection

Primary Backup
Short distance Sync
modules up to 10 m (LED) ≤10 m

Single MRP Ring

Long distance Sync

modules up to 10 km ≤10 km
ET 200SP ET 200MP

The sync cables are redundant.

The loss of one fiber optic cable has no impact on the runtime behavior.

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Page 12 January 2019 Team Innovation Tour
SIMATIC S7-1500R/H –
Integrated system functions save engineering time

Feature/Function Benefit
Two synchronized CPUs Significantly higher availability
Peripheral connection via compared to single CPU systems
PROFINET-Ring

Engineering nearly as Little engineering know-how

with a standard CPU required for redundancy

System IP address HMI and SCADA can be connected

like a standard CPU. No redundancy
know-how necessary

Automatic data synchronization No configuration necessary.

All data is always up to date

Automatic program synchronization The latest program always runs

in case of a CPU exchange or
in the case of a changeover

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R/H PROFINET Network configuration

Requirements for the PROFINET

Redundant 1500R network configuration High Available 1500H
• MRP Ring (default setting
Primary Backup in the configuration) Primary Backup

• PN IO only at X1 interface H-Sync

• PLCs need to be part of the ring
Sync
• 1500R → no devices in the
connection between the two PLCs
Single MRP Ring Single MRP Ring
• PN Devices need to support PN
System redundancy NAP S2 (V1.11)

ET 200SP ET 200MP ET 200SP ET 200MP

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Page 14 January 2019 Team Innovation Tour
R/H PROFINET Network configuration –
MRP – Media Redundant Protocol
MRP-Manager MRP-Client
Advantages
PROFINET PROFINET
• Increased system machine availability device device
Test
• Fast network diagnosis during grid disturbances telegrams

without breakdown
• Maintenance work without system failure PROFINET PROFINET
device device
• Reduced costs in the case of errors due to prevented
MRP-Client MRP-Client
production downtimes

Requirements and restrictions

MRP-Manager MRP-Manager MRP-Manager MRP-Manager
• Reconfiguration time 200 ms (Auto) (Auto) (Auto) (Auto)

• Up to 50 participants in the MRP-Ring S7-1500R/H S7-1500R/H

• Connections only via configured ports

• All devices must belong to the same redundancy domain

Link (SIOS)
https://support.industry.siemens.com/cs/ww/de/view/109739614
MRP-Client MRP-Client MRP-Client MRP-Client

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Page 15 January 2019 Team Innovation Tour
PNO PROFINET System redundancy

S1 Mode S2 Mode R1 Mode R2 Mode

H- H- H- H- H- H-
PLC
PLC PLC PLC PLC PLC PLC

PROFINET IO Network PROFINET IO Network PROFINET IO Network PROFINET IO Network

IM IO IM IO IM IM IO IM IM IO

NAP S1 Device NAP S2 Device NAP R1 Device NAP R2 Device

S → Single NAP S → Single NAP R → Redundant NAP R → Redundant NAP
1 → One connection 2 → Can switch 1 → Each NAP has one 2 → Each NAP can
(AR) to one PLC between two connection (AR) to switch between
AR’s (Application one PLC two AR’s
Relations)
Standard PLC For R/H Release1 The next step

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Page 16 January 2019 Team Innovation Tour
R/H PROFINET Network configuration –
PROFINET Devices – NAP S2

PN-Devices NAP S2 Standard PN-Device

ET 200MP HF ET 200M/MP
Primary Backup

H-Sync
PN-Device

PN/PN ET 200SP HF ET 200S/SP

PN-Controller DP-Slaves

S7-1200 S7-1500 ET 200M/MP DP Slave

S7-300 S7-400 DP/DP ET 200S/SP

Only NAP S2 devices

are supported in the ring
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Page 17 January 2019 Team Innovation Tour
R/H PROFINET Network configuration –
PROFINET Devices – PN Controller

PN-Devices NAP S2 Standard PN-Device

ET 200M/MP
Primary Backup

H-Sync
PN-Device

ET 200S/SP

PN-Controller DP-Slaves

S7-1200 S7-1500 ET 200M/MP DP Slave

S7-300 S7-400 DP/DP ET 200S/SP

PN/PN coupler for network separation

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Page 18 January 2019 Team Innovation Tour
R/H PROFINET Network configuration –
PROFINET Devices – Standard Devices

PN-Devices NAP S2 Standard PN-Device

ET 200M/MP
Primary Backup

H-Sync
PN-Device

ET 200S/SP

PN-Controller DP-Slaves

ET 200M/MP DP Slave

DP/DP ET 200S/SP

NAP S1 Devices in subordinated PN Network

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Page 19 January 2019 Team Innovation Tour
R/H PROFINET Network configuration –
PROFINET Devices – DP Slaves

PN-Devices NAP S2 Standard PN-Device

DP Slaves via DP Master of Sub-Controller

Primary Backup

H-Sync

PN-Controller DP-Slaves

ET 200M/MP DP Slave

DP/DP ET 200S/SP

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Page 20 January 2019 Team Innovation Tour
R/H PROFINET Network configuration –
PROFINET Devices – NAP S2

PN-Devices NAP S2

ET 200MP HF
Primary Backup

H-Sync

PN/PN ET 200SP HF

PN-F-Controller PN-F-Device

S7-1500F ET200S/SP F

SINAMICS F

ET200M/MP F

Only NAP S2 devices are supported in the ring

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Page 22 January 2019 Team Innovation Tour
R/H PROFINET Network configuration –
PROFINET Devices – PN F-Controller

PN-Devices NAP S2
PN/PN coupler for
network separation Primary Backup

H-Sync

PN-F-Controller PN-F-Device

S7-1500F ET200S/SP F

SINAMICS F

ET200M/MP F

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Page 23 January 2019 Team Innovation Tour
R/H PROFINET Network configuration –
PROFINET Devices – Safety Devices

PN-Devices NAP S2

Primary Backup

H-Sync

PN-F-Controller PN-F-Device

ET200S/SP F

SINAMICS F

ET200M/MP F

MRP Ring
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Page 24 January 2019 Team Innovation Tour
R/H PROFINET Network configuration –
PROFINET Devices – Safety Devices

PN-Devices NAP S2
Devices in subordinated
PN network Primary Backup

H-Sync

PN-F-Controller PN-F-Device

Reduce SPoF

MRP Ring
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Page 25 January 2019 Team Innovation Tour
Communication –
System IP

Using System IP instead

Industrial Ethernet
of PLC interface IP
• Transparent communication between System: IP3
standard PLC and R/H-System X2: IP1 X2: IP2
• The standard communication partner
is automatically connected
to the primary PLC
Standard Controller
Basic/Comfort Panel

S7-151xR/H System

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Page 26 January 2019 Team Innovation Tour
Communication –
System IP in the PN-MRP-Ring

Include Standard Controllers in the MRP Ring Primary Backup

H-Sync
The S7-1500H does not support Single PN Devices
(NAP S1) or i-Devices.
Nevertheless, it is possible to physically include a
S7-1500 per Switch or directly into the MRP Ring,
to communicate to the H-System via OUC.
PLC FW ≥V2.5 will be required.

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Page 27 January 2019 Team Innovation Tour
SIMATIC S7-1500R/H –
The easiest way to a redundant solution

Efficient Engineering Automatic program and

Integrated Engineering of data synchronization
controller and visualization Simplifies the configuration
in TIA Portal and handling of both CPUs

System-IP
Multiple execution levels Simple connection via
The application program Ethernet to other devices
can be structured into (e.g. HMI, Scada)
several tasks like with single-CPU
systems

Smooth changeover Higher Availability

The changeover has The CPU-redundancy
no negative impact on significantly increases the
the process availability compared to
single CPUs systems
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Page 28 January 2019 Team Innovation Tour
Engineering of an S7-1500RH System

Live Demo

Engineering of an
S7-1500RH System
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Page 29 January 2019 Team Innovation Tour
Teşekkürler...

Team Innovation Tour

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Page 30 January 2019 Team Innovation Tour