Siemens SIMATIC S7-400H User guide

SIMATIC Fault-tolerant Systems S7-400H
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Preface
1
Fault-tolerant automation
systems
2
S7-400H installation options
3
Getting started
4
Installation of a CPU 41x–H
5
Special functions of a
CPU 41x-H
6
S7–400H in PROFIBUS DP
mode
7
System and operating states
of the S7–400H
8
Link-up and update
9
Using I/Os in S7–400H
10
Communication
11
Configuring with STEP 7
12
Failure and replacement of
components during operation
13
System modifications in
operation
14
Synchronization modules
15
S7-400 cycle and reaction
times
16
Technical data
17
Characteristic values of
redundant automation
systems
A
SIMATIC
Fault-tolerant Systems
S7-400H
System Manual
09/2007
A5E00267695-03

Safety Guidelines
Safety Guidelines
This manual contains notices you have to observe in order to ensure your personal safety, as well as to prevent
damage to property. The notices referring to your personal safety are highlighted in the manual by a safety alert
symbol, notices referring only to property damage have no safety alert symbol. These notices shown below are
graded according to the degree of danger.
DANGER
indicates that death or severe personal injury will result if proper precautions are not taken.
WARNING
indicates that death or severe personal injury may result if proper precautions are not taken.
CAUTION
with a safety alert symbol, indicates that minor personal injury can result if proper precautions are not taken.
CAUTION
without a safety alert symbol, indicates that property damage can result if proper precautions are not taken.
NOTICE
indicates that an unintended result or situation can occur if the corresponding information is not taken into
account.
If more than one degree of danger is present, the warning notice representing the highest degree of danger will
be used. A notice warning of injury to persons with a safety alert symbol may also include a warning relating to
property damage.
Qualified Personnel
The device/system may only be set up and used in conjunction with this documentation. Commissioning and
operation of a device/system may only be performed by qualified personnel. Within the context of the safety notes
in this documentation qualified persons are defined as persons who are authorized to commission, ground and
label devices, systems and circuits in accordance with established safety practices and standards.
Prescribed Usage
Note the following:
WARNING
This device may only be used for the applications described in the catalog or the technical description and only
in connection with devices or components from other manufacturers which have been approved or
recommended by Siemens. Correct, reliable operation of the product requires proper transport, storage,
positioning and assembly as well as careful operation and maintenance.
Trademarks
All names identified by ® are registered trademarks of the Siemens AG. The remaining trademarks in this
publication may be trademarks whose use by third parties for their own purposes could violate the rights of the
owner.
Disclaimer of Liability
We have reviewed the contents of this publication to ensure consistency with the hardware and software
described. Since variance cannot be precluded entirely, we cannot guarantee full consistency. However, the
information in this publication is reviewed regularly and any necessary corrections are included in subsequent
editions.
Siemens AG
Automation and Drives
Postfach 48 48
90327 NÜRNBERG
GERMANY
Ordernumber: A5E00267695-03
Ⓟ 10/2007
Copyright © Siemens AG 2007.
Technical data subject to change

S7-400H
System Manual, 09/2007, A5E00267695-03 3
Table of contents
1 Preface .................................................................................................................................................... 15
1.1 Preface.........................................................................................................................................15
2 Fault-tolerant automation systems........................................................................................................... 21
2.1 Redundant automation systems in the SIMATIC series ..............................................................21
2.2 Increasing system availability ......................................................................................................23
3 S7-400H installation options .................................................................................................................... 25
3.1 S7-400H installation options ........................................................................................................25
3.2 Rules for the assembly of fault-tolerant stations..........................................................................27
3.3 The S7-400H base system ..........................................................................................................28
3.4 I/O modules for S7-400H .............................................................................................................30
3.5 Communication ............................................................................................................................31
3.6 Tools for configuration and programming....................................................................................31
3.7 The user program ........................................................................................................................32
3.8 Documentation.............................................................................................................................33
4 Getting started......................................................................................................................................... 35
4.1 Getting started..............................................................................................................................35
4.2 Requirements...............................................................................................................................35
4.3 Hardware installation and S7-400H commissioning ....................................................................36
4.4 Examples of the reaction of the fault-tolerant system to faults ....................................................38
5 Installation of a CPU 41x–H..................................................................................................................... 39
5.1 Control and display elements of the CPUs..................................................................................39
5.2 Monitoring functions of the CPU ..................................................................................................44
5.3 Status and error displays .............................................................................................................46
5.4 Mode selector switch ...................................................................................................................49
5.5 Security levels..............................................................................................................................50
5.6 Operating sequence for memory reset ........................................................................................51
5.7 Structure and Functions of the Memory Cards............................................................................54
5.8 Multipoint interface (MPI).............................................................................................................57
5.9 PROFIBUS DP interface..............................................................................................................58
5.10 Overview of the parameters for the S7-400H CPUs....................................................................59

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6 Special functions of a CPU 41x-H............................................................................................................ 61
6.1 Updating the firmware without a memory card ........................................................................... 61
6.2 Firmware update in RUN mode .................................................................................................. 63
6.3 Reading service data .................................................................................................................. 64
7 S7-400H in PROFIBUS DP mode............................................................................................................ 65
7.1 CPU 41x–H as PROFIBUS DP master ....................................................................................... 65
7.1.1 DP address areas of 41xH CPUs ............................................................................................... 66
7.1.2 CPU 41xH as PROFIBUS DP master......................................................................................... 66
7.1.3 Diagnostics of a 41xH CPU operating as PROFIBUS DP master.............................................. 69
7.2 Consistent Data........................................................................................................................... 73
7.2.1 Consistency of communication blocks and functions ................................................................. 74
7.2.2 Access to the CPU RAM............................................................................................................. 74
7.2.3 Consistency rules for SFB 14 "GET" or reading tag and SFB 15 "PUT" or writing tag .............. 74
7.2.4 Reading data consistently from a DP standard slave and writing consistently to a DP
standard slave............................................................................................................................. 75
7.2.5 Consistent data access without using SFC 14 or SFC 15.......................................................... 76
8 System and operating states of the S7-400H........................................................................................... 79
8.1 System and operating states of the S7-400H ............................................................................. 79
8.2 Introduction ................................................................................................................................. 80
8.3 The system states of the S7-400H.............................................................................................. 82
8.4 The operating states of the CPUs............................................................................................... 83
8.4.1 STOP operating state.................................................................................................................. 84
8.4.2 STARTUP operating state........................................................................................................... 85
8.4.3 LINK-UP and UPDATE operating states..................................................................................... 85
8.4.4 RUN operating state.................................................................................................................... 86
8.4.5 HOLD operating state ................................................................................................................. 87
8.4.6 TROUBLESHOOTING operating state ....................................................................................... 87
8.5 Self-test ....................................................................................................................................... 89
8.6 Time-based reaction ................................................................................................................... 92
8.7 Evaluation of process interrupts in the S7-400H system ............................................................ 92
9 Link-up and update.................................................................................................................................. 93
9.1 Effects of link-up and updating.................................................................................................... 93
9.2 Conditions for link-up and update ............................................................................................... 94
9.3 Link-up and update ..................................................................................................................... 95
9.3.1 Link-up sequence........................................................................................................................ 99
9.3.2 Update sequence ...................................................................................................................... 101
9.3.3 Switch to CPU with modified configuration or expanded memory configuration ...................... 103
9.3.4 Disabling link-up and update..................................................................................................... 105
9.4 Time monitoring ........................................................................................................................ 106
9.4.1 Time-based reaction ................................................................................................................. 108
9.4.2 Determining the monitoring times ............................................................................................. 109
9.4.3 Performance values for link-up and update .............................................................................. 115
9.4.4 Influences on time-based reaction ............................................................................................ 116
9.5 Special features in link-up and update operations.................................................................... 117

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10 Using I/Os in S7-400H........................................................................................................................... 119
10.1 Using I/Os in S7-400H ...............................................................................................................119
10.2 Introduction ................................................................................................................................119
10.3 Using single-channel, one-sided I/Os ........................................................................................121
10.4 Using single-channel switched I/Os...........................................................................................123
10.5 Connecting redundant I/Os........................................................................................................127
10.5.1 Evaluating the passivation status ..............................................................................................149
10.6 Other options for connecting redundant I/Os.............................................................................151
11 Communication...................................................................................................................................... 157
11.1 Communication ..........................................................................................................................157
11.2 Fundamentals and basic concepts ............................................................................................158
11.3 Usable networks ........................................................................................................................161
11.4 Usable communication services ................................................................................................161
11.5 Communications via fault-tolerant S7 connections....................................................................162
11.5.1 Communication between fault-tolerant systems........................................................................163
11.5.2 Communication between fault-tolerant systems and a fault-tolerant CPU ................................166
11.5.3 Communication between fault-tolerant systems and PCs .........................................................167
11.6 Communication via S7 connections...........................................................................................169
11.6.1 Communication via S7 connections - one-sided mode .............................................................169
11.6.2 Communication via redundant S7 connections .........................................................................172
11.6.3 Communication via a point-to-point CP on the ET200M ...........................................................173
11.6.4 Custom linking to single-channel systems.................................................................................174
11.7 Communication performance.....................................................................................................175
11.8 General issues in communication..............................................................................................177
12 Configuring with STEP 7........................................................................................................................ 179
12.1 Configuring with STEP 7............................................................................................................179
12.2 Configuring with STEP 7............................................................................................................179
12.2.1 Rules for the assembly of fault-tolerant stations........................................................................180
12.2.2 Configuring hardware.................................................................................................................180
12.2.3 Assigning parameters to modules in a fault-tolerant station......................................................181
12.2.4 Recommendations for setting the CPU parameters ..................................................................182
12.2.5 Configuring networking ..............................................................................................................183
12.3 Programming device functions in STEP 7 .................................................................................184
13 Failure and replacement of components during operation ..................................................................... 185
13.1 Failure and replacement of components during operation ........................................................185
13.2 Failure and replacement of components during operation ........................................................186
13.2.1 Failure and replacement of a CPU ............................................................................................186
13.2.2 Failure and replacement of a power supply module..................................................................188
13.2.3 Failure and replacement of an input/output or function module ................................................189
13.2.4 Failure and replacement of a communication module...............................................................191
13.2.5 Failure and replacement of a synchronization module or fiber-optic cable ...............................192
13.2.6 Failure and replacement of an IM 460 and IM 461 interface module ........................................195

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13.3 Failure and replacement of components of the distributed I/Os ............................................... 196
13.3.1 Failure and replacement of a PROFIBUS-DP master .............................................................. 196
13.3.2 Failure and replacement of a redundant PROFIBUS-DP interface module ............................. 197
13.3.3 Failure and replacement of a PROFIBUS-DP slave ................................................................. 197
13.3.4 Failure and replacement of PROFIBUS-DP cables .................................................................. 198
14 System modifications in operation ......................................................................................................... 199
14.1 System modifications in operation ............................................................................................ 199
14.2 Possible hardware modifications .............................................................................................. 200
14.3 Adding components in PCS 7 ................................................................................................... 204
14.3.1 PCS 7, step 1: Modification of hardware................................................................................... 205
14.3.2 PCS 7, Step 2: Offline modification of the hardware configuration........................................... 205
14.3.3 PCS 7, Step 3: Stopping the standby CPU............................................................................... 206
14.3.4 PCS 7, Step 4: Loading new hardware configuration in the standby CPU............................... 206
14.3.5 PCS 7, Step 5: Switch to CPU with modified configuration ...................................................... 207
14.3.6 PCS 7, Step 6: Transition to redundant state ........................................................................... 208
14.3.7 PCS 7, Step 7: Editing and downloading the user program ..................................................... 209
14.3.8 Adding interface modules in PCS 7 .......................................................................................... 210
14.4 Removing components in PCS 7 ..............................................................................................211
14.4.1 PCS 7, step I: Offline modification of the hardware configuration ............................................ 212
14.4.2 PCS 7, step II: Editing and downloading the user program...................................................... 213
14.4.3 PCS 7, step III: Stopping the standby CPU .............................................................................. 214
14.4.4 PCS 7, step IV: Loading new hardware configuration in the standby CPU.............................. 214
14.4.5 PCS 7, step V: Switch to CPU with modified configuration ...................................................... 215
14.4.6 PCS 7, step VI: Transition to redundant state...........................................................................216
14.4.7 PCS 7, step VII: Modification of hardware ................................................................................ 217
14.4.8 Removing interface modules in PCS 7 .....................................................................................218
14.5 Adding components in STEP 7 ................................................................................................. 219
14.5.1 STEP 7, step 1: Adding hardware............................................................................................. 220
14.5.2 STEP 7, step 2: Offline modification of the hardware configuration ......................................... 221
14.5.3 STEP 7, step 3: Expanding and downloading OBs .................................................................. 221
14.5.4 STEP 7, step 4: Stopping the standby CPU ............................................................................. 222
14.5.5 STEP 7, step 5: Loading new hardware configuration in the standby CPU ............................. 222
14.5.6 STEP 7, step 6: Switch to CPU with modified configuration..................................................... 223
14.5.7 STEP 7, step 7: Transition to redundant state.......................................................................... 224
14.5.8 STEP 7, step 8: Editing and downloading the user program.................................................... 225
14.5.9 Adding interface modules in STEP 7 ........................................................................................ 226
14.6 Removing components in STEP 7 ............................................................................................ 227
14.6.1 STEP 7, step I: Offline modification of the hardware configuration .......................................... 228
14.6.2 STEP 7, step II: Editing and downloading the user program.................................................... 228
14.6.3 STEP 7, step III: Stopping the standby CPU ............................................................................ 229
14.6.4 STEP 7, step IV: Loading new hardware configuration in the standby CPU ............................ 229
14.6.5 STEP 7, step V: Switch to CPU with modified configuration .................................................... 230
14.6.6 STEP 7, step VI: Transition to redundant state......................................................................... 231
14.6.7 STEP 7, step VII: Modification of hardware ..............................................................................232
14.6.8 STEP 7, step VIII: Editing and downloading organization blocks ............................................. 232
14.6.9 Removing interface modules in STEP 7 ................................................................................... 233
14.7 Editing CPU parameters ........................................................................................................... 234
14.7.1 Editing CPU parameters ........................................................................................................... 234
14.7.2 Step A: Editing CPU parameters offline.................................................................................... 235
14.7.3 Step B: Stopping the standby CPU........................................................................................... 236
14.7.4 Step C: Loading new hardware configuration in the standby CPU........................................... 236
14.7.5 Step D: Switch to CPU with modified configuration .................................................................. 237
14.7.6 Step E: Transition to redundant state ....................................................................................... 238

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14.8 Changing the CPU memory configuration .................................................................................239
14.8.1 Changing the CPU memory configuration .................................................................................239
14.8.2 Expanding load memory ............................................................................................................239
14.8.3 Changing the type of load memory............................................................................................240
14.9 Reconfiguration of a module......................................................................................................243
14.9.1 Reconfiguration of a module......................................................................................................243
14.9.2 Step A: Editing parameters offline .............................................................................................244
14.9.3 Step B: Stopping the standby CPU............................................................................................244
14.9.4 Step C: Loading new hardware configuration in the standby CPU............................................245
14.9.5 Step D: Switch to CPU with modified configuration...................................................................245
14.9.6 Step E: Transition to redundant state ........................................................................................247
15 Synchronization modules....................................................................................................................... 249
15.1 Synchronization modules for S7-400H ......................................................................................249
15.2 Installation of fiber-optic cables..................................................................................................252
15.3 Selecting fiber-optic cables ........................................................................................................254
16 S7-400 cycle and reaction times............................................................................................................ 259
16.1 Cycle time ..................................................................................................................................259
16.2 Calculating the cycle time ..........................................................................................................261
16.3 Different cycle times...................................................................................................................266
16.4 Communication load ..................................................................................................................268
16.5 Reaction time .............................................................................................................................271
16.6 Calculating cycle and reaction times .........................................................................................277
16.7 Examples of calculating the cycle and reaction times ...............................................................278
16.8 Interrupt reaction time ................................................................................................................281
16.9 Example of calculation of the interrupt reaction time.................................................................283
16.10 Reproducibility of delay and watchdog interrupts ......................................................................284
17 Technical data ....................................................................................................................................... 285
17.1 Technical specifications of the CPU 412–3H; (6ES7 412–3HJ14–0AB0) .................................285
17.2 Technical specifications of the CPU 414–4H; (6ES7 414–4HM14–0AB0) ................................293
17.3 Technical specifications of the CPU 417–4H; (6ES7 417–4HT14–0AB0) .................................301
17.4 Technical specifications of the memory cards...........................................................................309
17.5 Runtimes of the FCs and FBs for redundant I/Os......................................................................310
A Characteristic values of redundant automation systems........................................................................311
A.1 Basic concepts...........................................................................................................................311
A.2 Comparison of MTBF for selected configurations......................................................................316
A.2.1 System configurations with centralized I/Os ..............................................................................316
A.2.2 System configurations with distributed I/Os...............................................................................317
A.2.3 Comparison of system configurations with standard and fault-tolerant communication............319
B Stand-alone operation ........................................................................................................................... 321
C Migrating from S5-H to S7-400H............................................................................................................ 327
C.1 General aspects.........................................................................................................................327
C.2 Configuration, programming and diagnostics ............................................................................328

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D Differences between fault-tolerant systems and standard systems........................................................ 329
E Function modules and communication processors supported by the S7-400H...................................... 333
F Connection examples for redundant I/Os............................................................................................... 335
F.1 SM 321; DI 16 x DC 24 V, 6ES7 321–1BH02–0AA0 ................................................................ 335
F.2 SM 321; DI 32 x DC 24 V, 6ES7 321–1BL00–0AA0................................................................. 337
F.3 SM 321; DI 16 x AC 120/230V, 6ES7 321–1FF00–0AA0 ......................................................... 338
F.4 SM 321; DI 8 x AC 120/230 V, 6ES7 321–1FF01–0AA0 .......................................................... 339
F.5 SM 321; DI 16 x DC 24V, 6ES7 321–7BH00–0AB0 ................................................................. 340
F.6 SM 321; DI 16 x DC 24V, 6ES7 321–7BH01–0AB0 ................................................................. 341
F.7 SM 326; DO 10 x DC 24V/2A, 6ES7 326–2BF01–0AB0 .......................................................... 342
F.8 SM 326; DI 8 x NAMUR, 6ES7 326–1RF00–0AB0................................................................... 343
F.9 SM 326; DI 24 x DC 24 V, 6ES7 326–1BK00–0AB0 ................................................................ 344
F.10 SM 421; DI 32 x UC 120 V, 6ES7 421–1EL00–0AA0............................................................... 345
F.11 SM 421; DI 16 x DC 24 V, 6ES7 421–7BH01–0AB0 ................................................................ 346
F.12 SM 421; DI 32 x DC 24 V, 6ES7 421–1BL00–0AB0................................................................. 347
F.13 SM 421; DI 32 x DC 24 V, 6ES7 421–1BL01–0AB0................................................................. 348
F.14 SM 322; DO 8 x DC 24 V/2 A, 6ES7 322–1BF01–0AA0 .......................................................... 349
F.15 SM 322; DO 32 x DC 24 V/0,5 A, 6ES7 322–1BL00–0AA0...................................................... 350
F.16 SM 322; DO 8 x AC 230 V/2 A, 6ES7 322–1FF01–0AA0......................................................... 351
F.17 SM 322; DO 16 x DC 24 V/10 mA [EEx ib], 6ES7 322–5SD00–0AB0 ..................................... 352
F.18 SM 322; DO 8 x DC 24 V/0,5 A, 6ES7 322–8BF00–0AB0 ....................................................... 353
F.19 SM 322; DO 16 x DC 24 V/0,5 A, 6ES7 322–8BH01–0AB0 ..................................................... 354
F.20 SM 332; AO 8 x 12 bit, 6ES7 332–5HF00–0AB0...................................................................... 355
F.21 SM 332; AO 4 x 0/4...20 mA [EEx ib], 6ES7 332–5RD00–0AB0 .............................................. 356
F.22 SM 422; DO 16 x AC 120/230 V/2 A, 6ES7 422–1FH00–0AA0 ............................................... 357
F.23 SM 422; DO 32 x DC 24 V/0,5 A, 6ES7 422–7BL00–0AB0...................................................... 358
F.24 SM 331; AI 4 x 15 Bit [EEx ib]; 6ES7 331–7RD00–0AB0 ......................................................... 359
F.25 SM 331; AI 8 x 12 Bit, 6ES7 331–7KF02–0AB0 ....................................................................... 360
F.26 SM 331; AI 8 x 16 Bit; 6ES7 331–7NF00–0AB0 ....................................................................... 361
F.27 SM331; AI 8 x 0/4...20ma HART, 6ES7 331-7TF01-0AB0 ....................................................... 362
F.28 SM 332; AO 4 x 12 bit; 6ES7 332–5HD01–0AB0 ..................................................................... 364
F.29 SM332; AO 8 x 0/4...20ma HART, 6ES7 332-8TF01-0AB0 ..................................................... 365
F.30 SM 431; AI 16 x 16 bit, 6ES7 431–7QH00–0AB0..................................................................... 366
Glossary ................................................................................................................................................ 367
Index...................................................................................................................................................... 371

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Tables
Table 5-1 LEDs on the CPUs.......................................................................................................................41
Table 5-2 Mode selector switch settings ......................................................................................................49
Table 5-3 Levels of protection of a CPU ......................................................................................................50
Table 5-4 Types of memory card .................................................................................................................55
Table 7-1 41x CPUs, MPI/DP interface as PROFIBUS DP .........................................................................66
Table 7-2 Meaning of the "BUSF" LED of the 41x CPU operating as DP master .......................................69
Table 7-3 Reading out the diagnostics information with STEP 7.................................................................69
Table 7-4 Event detection of the CPU 41xH as a DP master ......................................................................71
Table 8-1 Overview of S7-400H system states............................................................................................82
Table 8-2 Causes of error leading to redundancy loss ................................................................................86
Table 8-3 Reaction to errors during the self-test..........................................................................................89
Table 8-4 Reaction to a recurring comparison error ....................................................................................90
Table 8-5 Reaction to checksum errors .......................................................................................................90
Table 8-6 Hardware fault with one-sided call of OB 121, checksum error, second occurrence..................91
Table 9-1 Properties of link-up and update functions ..................................................................................93
Table 9-2 Conditions for link-up and update ................................................................................................94
Table 9-3 Typical values for the user program part ...................................................................................115
Table 10-1 Interfaces for the use of single-channel switched I/O................................................................123
Table 10-2 Signal modules for channel-oriented redundancy .....................................................................133
Table 10-3 Signal modules for channel-oriented redundancy .....................................................................134
Table 10-4 Interconnecting digital output modules with/without diodes.......................................................141
Table 10-5 Analog input modules and encoders .........................................................................................146
Table 10-6 Assignment of the status byte....................................................................................................149
Table 10-7 Assignment of status bytes ........................................................................................................150
Table 10-8 Example of redundant I/O, OB 1 part .......................................................................................154
Table 10-9 Example of redundant I/O, OB 122 part ....................................................................................155
Table 10-10 For the monitoring times I/O used redundantly..........................................................................155
Table 14-1 Modifiable CPU parameters.......................................................................................................234
Table 15-1 Accessory fiber-optic cable ........................................................................................................254
Table 15-2 Specification of fiber-optic cables for indoor applications..........................................................255
Table 15-3 Specification of fiber-optic cables for outdoor applications........................................................256
Table 16-1 Cyclic program execution...........................................................................................................260
Table 16-2 Factors influencing cycle time....................................................................................................261
Table 16-3 Allocation of the process image transfer time, CPU 412-3H .....................................................262
Table 16-4 Portion of the process image transfer time, CPU 414–4H.........................................................263

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Table 16-5 Portion of the process image transfer time, CPU 417-4H........................................................ 264
Table 16-6 Extension of the cycle time ....................................................................................................... 264
Table 16-7 Operating system execution time at the scan cycle checkpoint ............................................... 265
Table 16-8 Cycle time extension due to nested interrupts.......................................................................... 265
Table 16-9 Direct access of the CPUs to I/O modules................................................................................ 275
Table 16-10 Direct access of the CPUs to I/O modules in the expansion unit with local link ....................... 275
Table 16-11 Direct access of the CPUs to I/O modules in the expansion unit with remote link ................... 276
Table 16-12 Example of calculating the reaction time .................................................................................. 277
Table 16-13 Process and interrupt reaction times; maximum interrupt reaction time without
communication .......................................................................................................................... 281
Table 16-14 Reproducibility of time-delay and cyclic interrupts of the CPUs ............................................... 284
Table 17-1 Runtimes of the blocks for redundant I/Os................................................................................ 310
Figures
Figure 2-1 Operating objectives of redundant automation systems............................................................. 21
Figure 2-2 Totally integrated automation solutions with SIMATIC ............................................................... 23
Figure 2-3 Example of redundancy in a network without an error or fault.................................................... 24
Figure 2-4 Example of redundancy in a 1-of-2 system with error/fault......................................................... 24
Figure 2-5 Example of redundancy in a 1-out-of-2 system with total failure ................................................ 24
Figure 3-1 Overview ..................................................................................................................................... 26
Figure 3-2 Hardware of the S7-400H base system ...................................................................................... 28
Figure 3-3 User documentation for fault-tolerant systems ........................................................................... 33
Figure 4-1 Hardware installation................................................................................................................... 36
Figure 5-1 Arrangement of the operator controls and displays on the CPU 412-3H ................................... 39
Figure 5-2 Layout of the control and display elements of the CPU 414-4H/417-4H .................................... 40
Figure 5-3 Jack ............................................................................................................................................. 43
Figure 5-4 Mode selector switch settings ..................................................................................................... 49
Figure 5-5 Design of the memory card......................................................................................................... 54
Figure 7-1 Diagnostics with CPU 41xH ........................................................................................................ 70
Figure 7-2 Diagnostic addresses for DP master and DP slave.................................................................... 71
Figure 7-3 DP slave properties..................................................................................................................... 77
Figure 8-1 Synchronizing the subsystems ................................................................................................... 81
Figure 8-2 System and operating modes of the fault-tolerant system.......................................................... 83
Figure 9-1 Sequence of link-up and update ................................................................................................. 96
Figure 9-2 Update sequence ........................................................................................................................ 97
Figure 9-3 Example of minimum signal duration of an input signal during the update ................................ 98

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Figure 9-4 Meanings of the times relevant for updates...............................................................................107
Figure 9-5 Correlation between the minimum I/O hold time and the maximum disable time for priority
classes > 15 ...............................................................................................................................110
Figure 10-1 Single-channel, switched ET 200M distributed I/O....................................................................124
Figure 10-2 Redundant I/O in central and expansion units...........................................................................127
Figure 10-3 Redundant I/O in the one-sided DP slave .................................................................................128
Figure 10-4 Redundant I/O in the switched DP slave ...................................................................................129
Figure 10-5 Redundant I/O in single mode ...................................................................................................130
Figure 10-6 Fault-tolerant digital input module in 1-out-of-2 configuration with one encoder.......................139
Figure 10-7 Fault-tolerant digital input modules in 1-out-of-2 configuration with two encoders....................140
Figure 10-8 Fault-tolerant digital output modules in 1-out-of-2 configuration ...............................................140
Figure 10-9 Fault-tolerant analog input modules in 1-out-of-2 configuration with one encoder....................142
Figure 10-10 Fault-tolerant analog input modules in 1-out-of-2 structure with two encoders.........................146
Figure 10-11 Fault-tolerant analog output modules in 1-out-of-2 configuration..............................................147
Figure 10-12 Redundant one-sided and switched I/O.....................................................................................151
Figure 10-13 Flow chart for OB 1 ....................................................................................................................153
Figure 11-1 Example of an S7 connection ....................................................................................................159
Figure 11-2 Example of how number of resulting subconnections depends on the configuration................160
Figure 11-3 Example of redundancy with fault-tolerant system and redundant ring.....................................164
Figure 11-4 Example of redundancy with fault-tolerant system and redundant bus system ........................164
Figure 11-5 Example of fault-tolerant system with additional CP redundancy..............................................165
Figure 11-6 Example of redundancy with fault-tolerant system and fault-tolerant CPU ...............................166
Figure 11-7 Example of redundancy with fault-tolerant system and redundant bus system ........................167
Figure 11-8 Example of redundancy with a fault-tolerant system, redundant bus system, and CP
redundancy on PC .....................................................................................................................168
Figure 11-9 Example of linking of standard and fault-tolerant systems to a redundant ring.........................170
Figure 11-10 Example of linking standard and fault-tolerant systems to a redundant bus system.................170
Figure 11-11 Example of redundancy with fault-tolerant systems and a redundant bus system with
redundant standard connections................................................................................................172
Figure 11-12 Example of linking of a fault-tolerant system and a single-channel third-party system.............173
Figure 11-13 Example of linking of a fault-tolerant system to a single-channel external system ...................174
Figure 11-14 Communication load as a variable of data throughput (basic profile)........................................175
Figure 11-15 Communication load as a function of the response time (basic profile) ....................................176
Figure 15-1 Synchronization module.............................................................................................................250
Figure 15-2 Fiber-optic cables, installation using distribution boxes.............................................................257
Figure 16-1 Elements and composition of the cycle time..............................................................................260
Figure 16-2 Different cycle times...................................................................................................................266

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Figure 16-3 Minimum cycle time................................................................................................................... 267
Figure 16-4 Formula: Influence of communication load ............................................................................... 268
Figure 16-5 Distribution of a time slice ......................................................................................................... 268
Figure 16-6 Dependency of the cycle time on the communication load....................................................... 269
Figure 16-7 DP cycle times on the PROFIBUS DP network ........................................................................ 272
Figure 16-8 Shortest reaction time ............................................................................................................... 273
Figure 16-9 Longest reaction time................................................................................................................ 274
Figure A-1 MDT........................................................................................................................................... 312
Figure A-2 MTBF......................................................................................................................................... 313
Figure A-3 Common Cause Failure (CCF) ................................................................................................. 314
Figure A-4 Availability ................................................................................................................................. 315
Figure B-1 Overview: System structure for system modifications during operation ................................... 324
Figure F-1 Example of an interconnection with SM 321; DI 16 x DC 24 V................................................. 336
Figure F-2 Example of an interconnection with SM 321; DI 32 x DC 24 V................................................. 337
Figure F-3 Example of an interconnection with SM 321; DI 16 x AC 120/230 V........................................ 338
Figure F-4 Example of an interconnection with SM 321; DI 8 x AC 120/230 V.......................................... 339
Figure F-5 Example of an interconnection with SM 321; DI 16 x DC 24V.................................................. 340
Figure F-6 Example of an interconnection with SM 321; DI 16 x DC 24V.................................................. 341
Figure F-7 Example of an interconnection with SM 326; DO 10 x DC 24 V/2 A ........................................ 342
Figure F-8 Example of an interconnection with SM 326; DI 8 x NAMUR................................................... 343
Figure F-9 Example of an interconnection with SM 326; DI 24 x DC 24 V................................................. 344
Figure F-10 Example of an interconnection with SM 421; DI 32 x UC 120 V............................................... 345
Figure F-11 Example of an interconnection with SM 421; DI 16 x 24 V....................................................... 346
Figure F-12 Example of an interconnection with SM 421; DI 32 x 24 V....................................................... 347
Figure F-13 Example of an interconnection with SM 421; DI 32 x 24 V....................................................... 348
Figure F-14 Example of an interconnection with SM 322; DO 8 x DC 24 V/2 A .......................................... 349
Figure F-15 Example of an interconnection with SM 322; DO 32 x DC 24 V/0.5 A ..................................... 350
Figure F-16 Example of an interconnection with SM 322; DO 8 x AC 230 V/2 A ........................................ 351
Figure F-17 Example of an interconnection with SM 322; DO 16 x DC 24 V/10 mA [EEx ib]...................... 352
Figure F-18 Example of an interconnection with SM 322; DO 8 x DC 24 V/0.5 A ....................................... 353
Figure F-19 Example of an interconnection with SM 322; DO 16 x DC 24 V/0.5 A ..................................... 354
Figure F-20 Example of an interconnection with SM 332, AO 8 x 12 bit...................................................... 355
Figure F-21 Example of an interconnection with SM 332; AO 4 x 0/4...20 mA [EEx ib]............................... 356
Figure F-22 Example of an interconnection with SM 422; DO 16 x 120/230 V/2 A ..................................... 357
Figure F-23 Example of an interconnection with SM 422; DO 32 x DC 24 V/0.5 A ..................................... 358
Figure F-24 Example of an interconnection with SM 331, AI 4 x 15 bit [EEx ib] .......................................... 359

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Figure F-25 Example of an interconnection with SM 331; AI 8 x 12 bit ........................................................360
Figure F-26 Example of an interconnection with SM 331; AI 8 x 16 bit ........................................................361
Figure F-27 Interconnection example 1 SM 331; AI 8 x 0/4...20 mA HART..................................................362
Figure F-28 Interconnection example 2 SM 331; AI 8 x 0/4...20 mA HART..................................................363
Figure F-29 Example of an interconnection with SM 332, AO 4 x 12 bit.......................................................364
Figure F-30 Interconnection example 3 SM 332; AO 8 x 0/4...20 mA HART................................................365
Figure F-31 Example of an interconnection with SM 431; AI 16 x 16 bit ......................................................366

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S7-400H
14 System Manual, 09/2007, A5E00267695-03

S7-400H
System Manual, 09/2007, A5E00267695-03 15
Preface 1
1.1 Preface
Purpose of the manual
This manual represents a useful reference and contains information on operating options,
functions and technical specifications of the S7-400H CPUs.
For information on installing and wiring those and other modules to install an S7-400H
system, refer to the
S7-400 Programmable Controllers, Installation manual.
Basic knowledge required
A general knowledge of automation technology is considered essential for the understanding
of this manual.
We presume that the readership has sufficient knowledge of computers or equipment similar
to a PC, such as programming devices, running under the operating system Windows 2000
or XP. An S7-400H is configured using the STEP 7 basic software, and you should thus be
familiar in the handling of this software. This knowledge is provided in the
Programming with
STEP 7
manual.
In particular when operating an S7-400H system in safety areas, you should always observe
the information on the safety of electronic control systems provided in the appendix of the
S7-400 Programmable controllers, Installation manual.
Validity of the manual
The manual is relevant to the following components:
● CPU 412–3H; 6ES7 412–3HJ14–0AB0 with firmware version V4.5.0 or higher
● CPU 414–4H; 6ES7 414–4HM14–0AB0 with firmware version V4.5.0 or higher
● CPU 417–4H; 6ES7 417–4HT14–0AB0 with firmware version V4.5.0 or higher

Preface
1.1 Preface
S7-400H
16 System Manual, 09/2007, A5E00267695-03
Versions required or order numbers of essential system components
System component Version required or order number
External master on PROFIBUS DP
CP443-5 Extended
Order no. 6GK7 443–5DX03–0XE0 hardware version 1 or higher, and firmware
version 5.1.4 or higher
Order no. 6GK7 443–5DX03–0XE0 hardware version 1 or higher, and firmware
version 6.4.0 or higher
Communication module CP443–1
(Industrial Ethernet, TCP / ISO transport)
6GK7 443–1EX10–0XE0, hardware version 1 or higher, and firmware version 2.6.7
or higher
6GK7 443–1EX11–0XE0, hardware version 1 or higher, and firmware version 2.6.7
or higher
Communication module CP443–5 Basic
(PROFIBUS; S7 communication)
6GK7 443–5FX02–0XE0 hardware version 2 or higher, and firmware version 3.2
or higher
Note
There may be further restriction for various modules. Refer to the information in the
corresponding product information and FAQs, or in SIMATIC NET News.
Installing the STEP 7 hardware update
In addition to STEP 7, you also need a hardware update. You can download the update files
directly from the STEP 7 pages on the Internet. You can do this in "STEP 7 -> Configuring
Hardware" with the "Options-> Install Hardware Updates" menu command.
Certification
For details on certifications and standards, refer to the S7-400 Programmable Controllers,
Module Data
manual, section 1.1, Standards and Certifications.
Position in the information landscape
This manual can be ordered separately under order no. 6ES7988–8HA11–8BA0. It is also
supplied in electronic format on your "STEP 7" product CD.

Preface
1.1 Preface
S7-400H
System Manual, 09/2007, A5E00267695-03 17
Online help
In addition to the manual, you will find detailed support on how to use the software in the
integrated online help system of the software.
The help system can be accessed using various interfaces:
● The Help menu contains several commands: Contents opens the Help index. You will find
help on H systems in Configuring H-Systems.
● Using Help provides detailed instructions on using the online help system.
● The context-sensitive help system provides information on the current context, for example,
on an open dialog box or an active window. You can call this help by clicking "Help" or
using the F1 key.
● The status bar provides a further form of context-sensitive help. It shows a short description
of each menu command when you position the mouse pointer over a command.
● A short info text is also shown for the toolbar buttons when you hold the mouse pointer
briefly over a button.
If you prefer to read the information of the online help in printed form, you can print individual
topics, books or the entire help system.
Finding your way
The manual contains various features supporting quick access to specific information:
● At the beginning of the manual you will find a complete table of contents.
● The left column on each page of the sections provides an overview of the contents of
each section.
● The appendix is followed by a glossary which defines important specialist terminology
used in this manual.
● At the end of the manual, you will find a comprehensive index that allows quick access to
information on specific subjects.
Recycling and disposal
The S7-400H system contains environmentally compatible materials and can be recycled.
To recycle and dispose of your old device in an environmentally friendly way, please contact
a company certified to deal with electronic waste.
Additional support
If you have any questions relating to the products described in this manual, and do not find
the answers in this documentation, please contact your Siemens partner at our local offices.
You will find information on who to contact at:
http://www.siemens.com/automation/partner
A guide to the technical documents for the various SIMATIC products and systems is
available at:
http://www.siemens.de/simatic-tech-doku-portal
You will find the online catalog and order system at:
http://mall.ad.siemens.com/

Preface
1.1 Preface
S7-400H
18 System Manual, 09/2007, A5E00267695-03
H/F Competence Center
The H/F Competence Center in Nuremberg offers a special workshop on the topic of
fault-tolerant SIMATIC S7 automation systems. The H/F Competence Center also offers
configuration and commissioning support, and help in finding solutions for problems in your
plant.
Phone: [phone]
Fax: [phone]
E-mail: [email protected]
Training center
We offer a range of courses to help you to get started with the SIMATIC S7 automation
system. Please contact your regional Training Center, or the Central Training Center in
Nuremberg, 90327 Germany.
Telephone: [phone]
Internet: http://www.sitrain.com
A&D Technical Support
Worldwide, available 24 hours a day:
Worldwide (Nuremberg)
Technical support
Local time:
24 hours a day, 365 days a year
Telephone: [phone]
Fax: [phone]
E-mail: [email protected]
GMT: +1:00
Europe / Africa (Nuremberg)
Authorization
United States (Johnson City)
Technical Support and
Authorization
Asia / Australia (Peking)
Technical Support and
Authorization
Local time:
Mon. - Fri. 8:00 a.m. to 5:00 p.m.
Telephone: [phone]
Fax: [phone]
E-mail:
[email protected]
GMT: +1:00
Local time:
Mon. - Fri. 8:00 a.m. to 5:00 p.m.
Telephone: [phone]
Fax: [phone]
E-mail:
[email protected]
GMT: -5:00
Local time:
Mon. - Fri. 8:00 a.m. to 5:00 p.m.
Telephone: [phone]
Fax: [phone]
E-mail:
[email protected]
GMT: +8:00
German and English are spoken on the Technical Support and Authorization hotline.

Preface
1.1 Preface
S7-400H
System Manual, 09/2007, A5E00267695-03 19
Service & Support on the Internet
In addition to the information in our documentation, you can also access our knowledge base
online at:
http://www.siemens.com/automation/service&support
There you will find:
● The newsletter, which constantly provides you with up-to-date information on your
products.
● The right documentation for you using our Service & Support search engine.
● A forum, where users and experts from all over the world exchange their experiences.
● Your local Automation & Drives representative.
● Information on field service, repairs and spare parts. Even more information is available
on the "Services" pages.

Preface
1.1 Preface
S7-400H
20 System Manual, 09/2007, A5E00267695-03