Системы повышенной надежности нового поколения Siemens

Обзор

Redundancy Station AS 410H

Fault-tolerant automation systems are used to reduce the risk of production failures. The higher investment costs for fault-tolerant automation systems are frequently negligible compared to the costs resulting from production failures. The higher the costs of a production failure, the more worthwhile it is to use a fault-tolerant system.

Fault-tolerant SIMATIC PCS 7 automation systems can be used in a system configuration on their own or together with standard and safety-related automation systems.

Дизайн

The AS 410H, which consists of two redundant, galvanically isolated subsystems, can be mounted on a UR2‑H compact rack with a split backplane bus or on two separate racks (UR1 or UR2). The configuration in two racks has the advantage that the redundant subsystems are spatially separated (for example, by a fire-proof wall) and can be located far apart from each other. Depending on the sync modules used, distances from 10 m to 10 km are possible between the two subsystems. As a result of the electrical isolation, the system is also resistant to EMC interference.

Individual configuration of AS bundles

The configuration of the high availability automation systems and the Article No.''s can be defined by selecting pre-configured ordering units.

Typical combinations can be selected from tables in the section "Selection and ordering data". The complete range for selection is available via the SIMATIC PCS 7 AS 410 Redundancy Station online configurator in the Industry Mall.

Ordering information:

• For an AS 410H redundant configuration based on two AS Single Stations (AS 410S), you additionally require 4 sync modules (up to 10 m or up to 10 km) and 2 fiber-optic sync cables. The selection depends on the distance between the two AS Single Stations.
• FO sync cables longer than 1 m must always be ordered separately (2 cables required in each case).

Subsequent increase in performance

If the performance limit defined by the ordered system expansion card is reached during configuration, commissioning or operation, a subsequent increase in performance is possible by using an appropriate number of CPU 410 Expansion Packs 100 POs/500 POs. Hardware modifications are not necessary.

I/O connection via PROFIBUS DP

The distributed process I/O can be integrated into a PROFIBUS DP segment either directly or via a lower-level fieldbus (PROFIBUS PA or FOUNDATION Fieldbus H1).

Several PROFIBUS DP segments with distributed process I/Os can be operated on an AS 410H high availability automation system. A PROFIBUS DP interface is integrated in each of the two CPUs 410‑5H Process Automation. Using the online configurator in the Industry Mall or in the selection and ordering data, up to four more PROFIBUS DP interfaces can be configured for each redundant subsystem with add-on CP 443‑5 PROFIBUS DP interfaces (conformal coating).

With redundant PROFIBUS DP lines, the process I/Os can be connected to an AS 410H as follows:

• ET 200M remote I/Os stations with two IM 153‑2 High Feature interface modules on a special bus module
• ET 200iSP remote I/Os stations with two IM 152‑1 on a special terminal module
• Field devices on the PROFIBUS PA over a PA link to two redundant IM 153‑2 High Feature interface modules
• Field devices on the FOUNDATION Fieldbus H1 via an FF link with two redundant IM 153-2 FF interface modules
• Non-redundant PROFIBUS DP devices, e.g. ET 200S or ET 200pro remote I/O stations per Y‑Link

I/O connection via PROFINET IO

High availability AS 410H automation systems can be connected via PROFINET IO with remote I/O stations, for example, ET 200M or ET 200SP remote I/O stations. Only the PROFINET interfaces integrated in the CPUs can be used for this on the automation system.

The maximum availability with minimum error reaction times is achieved by the AS 410H when used in conjunction with system redundancy of the I/O devices. System redundancy refers to a type of PROFINET IO communication in which each I/O device establishes a communication link to each of the two CPUs of an AS 410H over the topological network. Then, the failure of a CPU does not automatically lead to failure of the connected I/O devices.

PROFINET IO communication with system redundancy

Communication via the Industrial Ethernet (IE) plant bus

If the PROFINET interfaces integrated in the CPUs of the AS 410H are not used for PROFINET IO, they can then also be used for the connection to the Industrial Ethernet plant bus. Otherwise, the two subsystems of the AS 410H can be connected to the plant bus using one CP 443‑1 communication module (conformal coating) each.

The plant bus can be implemented in the form of a ring structure, which can also be configured with redundant architecture if the availability requirements are high. When there are two redundant rings it makes sense to configure two IE interface/communication modules in each case and to distribute their connections between the two rings (4-way connection). Double faults such as failure of the switch on ring 1 with simultaneous interruption of the bus cable on ring 2 can thus be tolerated.

Runtime licenses

With SIMATIC PCS 7 Industry Library Runtime and the SIMATIC PCS 7 AS Runtime license, the automation systems are equipped with 100 process objects (PO) on delivery. The number of process objects can be extended by additional Runtime licenses for 100, 1 000 or 10 000 POs. The process objects of additional Runtime licenses can be added to process objects which already exist. The number and type (e.g. 100 or 1000) of additional Runtime licenses are irrelevant.

Опции

Y-Link

• Bus coupler for transition from a redundant PROFIBUS DP master system to a single-channel PROFIBUS DP master system
• For connection of devices with only one PROFIBUS DP interface to the redundant PROFIBUS DP master system

The Y-link comprises:

• 2 IM 153‑2 High Feature Outdoor high feature interface modules
• One Y coupler including RS 485 repeater
• One BM IM/IM bus module for two IM 153-2 High Feature Outdoor modules
• One BM Y coupler bus module

Evaluation of the Y-Link diagnostics (and hence indirectly of the connected DP standard slaves) is supported by driver blocks.