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Automation systems - Fault-tolerant automation systems

Automation systems - Fault-tolerant automation systems

Overview
Fault-tolerant automation systems are applied 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 automation systems can be installed in one or two racks. The design in two racks allows physical separation of the redundant subsystems, e.g. by a fireproof partition. Fault-tolerant automation systems can be used on their own in a plant configuration, or together with standard and safety-related automation systems.

Design
The fault-tolerant automation systems are available complete with rack, power supply, CPU, memory card and PROFIBUS DP interfaces. They are delivered already assembled and tested. Each version has a different main memory:

AS type AS 412H AS 414H AS 417H

Main memory 768 KB (512 KB for program and 256 KB for data) 2.8 MB (1.4 MB each for program and data) 30 MB (15 MB each for program and data)

Versions with 120/230 V AC/DC or 24 V DC power supply can be selected depending on the application. The range also includes preconfigured systems without power supply or memory card; you can equip these with your choice from the range of individual components.

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Automation systems - Fault-tolerant automation systems

AS 412-3-1H, AS 414-4-1H and AS 417-4-1H automation systems

The AS 412-3-1H, AS 414-4-1H and AS 417-4-1H automation systems are initially equipped with just one CPU. They are used in particular when the redundant subsystems have to be physically separated from one another for safety reasons or when the customer would like to keep open his options for a redundant configuration in the future. The safety-related AS 412F, AS 414F and AS 417F automation systems are also based on the corresponding version of this hardware. There are two configuration possibilities for the AS 412-3-1H, AS 414-4-1H and AS 417-4-1H automation systems:

Configuration with two standard racks (UR1 or UR2) This configuration is ideal when the two redundant subsystems have to be completely separated for availability reasons. Each subsystem is equipped with a CPU, a potentially redundant power supply module (AC/DC), and a communications processor for Industrial Ethernet. Configuration with a UR2-H rack The UR2-H compact rack with split backplane bus is suitable for configuring a complete fault-tolerant automation system. The UR2-H is equipped with a CPU, a potentially redundant power supply module, and a communications processor for Industrial Ethernet.

Another 4 sync modules (for distances up to 10 m or 10 km) and 2 sync cables have to be ordered in addition to create a redundant system from two AS 412-3-1H, AS 414-4-1H or AS 417-4-1H automation systems (UR1/UR2 racks) and to subsequently expand an AS 412-3-1H, AS 414-4-1H or AS 417-4-1H in a UR2-H rack into a redundant AS 412-3-2H, AS 414-4-2H or AS 417-4-2H system. Note: The AS 412H (AS 412-3-1H/AS 412-3-2H) automation systems currently only support sync modules with a range up to 10 m.

AS 412-3-2H, AS 414-4-2H and AS 417-4-2H automation systems

In the case of the redundant AS 412-3-2H, AS 414-4-2H and AS 417-4-2H automation systems, the two subsystems are accommodated in the UR2-H rack. Each subsystem is usually equipped with a CPU, a potentially redundant power supply module and a communications processor for Industrial Ethernet.

Runtime licenses
Each fault-tolerant automation system bundle is combined with a SIMATIC PCS 7 AS Runtime license for 100 process objects (PO). The number of process objects can be extended by additional Runtime licenses for 100, 1000 or 10000 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. The AS Runtime licenses are administered on a SIMATIC PCS 7 engineering system or in the SIMATIC PCS 7 BOX.

Connection of process I/Os

Several PROFIBUS DP lines with distributed process I/Os can be operated on each sub-AS through the internal PROFIBUS DP interface or by using additional communications processors. The distributed ET 200M remote I/O stations are connected via two IM 153-2 High Feature modules on a special bus module to two redundant PROFIBUS DP segments, the intelligent field devices on the PROFIBUS PA via a DP/PA Link with two redundant IM 153-2 High Feature modules. It is also possible to connect non-redundant PROFIBUS DP devices, e.g. ET 200S distributed I/O devices, to the redundant PROFIBUS DP by using the Y-link. These configurations can also be mixed together.

Communication over the plant bus

The redundant, fault-tolerant AS 412H, AS 414H and AS 417H automation systems are connected by one communications processor per sub-AS to the plant bus. 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 use two communications processors per sub-AS and to distribute their connections between the two rings. Double faults such as failure of the OSM/SCALANCE switch on ring 1 with simultaneous interruption in the bus cable on ring 2 can thus be tolerated.

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Automation systems - Fault-tolerant automation systems

Function
The fault-tolerant automation systems of SIMATIC PCS 7 are based on the 1-out-of-2 principle. In the event of a fault, they switch over to the standby system. These systems use a completely redundant design to maximize availability. Therefore all important system components are present twice, such as:

Central processing unit Power supply Hardware for linking the two CPUs

Which other components are also made available in pairs in the interest of availability depends on the particular automation task. The two subsystems of a redundant automation system are electrically isolated from one another. This increases the system stability with respect to electromagnetic interference. The firmware of the fault-tolerant automation systems listed in this catalog can be updated in two manners:

Per Flash-EPROM memory card (8 MB) From the central engineering system via the Industrial Ethernet plant bus

Options
Y-Link

Bus coupler for transition from a redundant PROFIBUS DP master system to a singlechannel PROFIBUS DP master system For connecting devices with only one PROFIBUS DP interface to the redundant PROFIBUS DP master system AS 412H / AS 414H / AS 417H

The Y-link comprises:

Two IM 153-2 High Feature interface modules for extended temperature range One Y-coupler incl. RS 485 repeater One IM157 (IM/IM) bus module for two IM 153-2 High Feature modules, for extended temperature range 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.

Price list version 01.10.2007 (Version 25.00)

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