Redundant Systems
SIMATIC S7-1500 R/H
Technical details
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SIMATIC S7-1500 Redundant Systems
Content
Motivation and product strategy
Switchover behavior
System Overview S7-1500R/H
Siemens Products
PROFINET System Redundancy
System Redundancy R1
with ET 200SP
Failure Scenarios
HMI Connection
R1 Configuration in TIA Portal
System IP and Device IP addresses
Load Program / Project
Examples S7-1500R
Network Configuration
HW extensions with IO-Link
Safety for Redundant Systems
Examples S7-1500H with S2
Programming Recommendations
Notes for application
Examples S7-1500H with R1
Connection of subordinate
components
What‘s new with Firmware V3.0
Security
Supplements
Ordering Information
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Specific Functions for R/H
Feature Comparison /
Restrictions
Motivation and product
strategy
SIMATIC S7-1500 Redundant Systems
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SIMATIC S7-1500 Redundant Systems
Motivation
Avoiding plant downtimes
High availability during operation,
avoidance of production downtimes
Prevention of data loss
The data is retained and long recovery
times after a failure are eliminated.
Prevention of damage
Avoidance of unplanned production
stops, where the product to be
processed would be permanently
damaged.
Operation without persons on site
Trips for maintenance are easier to
plan
Save maintenance effort
Applicative solutions are usually
complicated and difficult to maintain
Redundant Systems reduce costs
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SIMATIC S7-1500 Redundant Systems
Product Strategy SIMATIC S7-1500R/H
Based on standard S7-1500 CPUs and PROFINET
•
•
The basis is hardware of the standard and Failsafe CPUs​
The basis is the PROFINET communication standard
Transparent programming (like standard)
• Standard engineering tools incl. all programming languages
• Complete Integration in TIA Portal​
• No special redundancy know-how required
• Easy scaling:
Standard CPU  S7-1500 R  S7-1500 H
Standard F-CPU  S7-1500HF
Scale extensively
• Scaling the switching time (S7-1500 R  S7-1500 H)
• Scaling the redundancy architecture
• Scaling performance from CPU 1513 to 1518
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System Overview
SIMATIC S7-1500 Redundant Systems
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SIMATIC S7-1500 Redundant Systems
System Overview
Consistent concept –
Identical
Synchronization process
Redundant S7-1500R
High Available S7-1500H
CPU Type
CPU 1513R / CPU 1515R
CPU 1517H / CPU 1518HF
Synchronization
via PROFINET Ring (MRP)
via Sync-Module / FO
Hot-Standby
Yes fail-over time ca. 300 ms
Yes fail-over time ca. 50 ms
Max distance between CPUs
100 m, with media converters a few km
40 km
PROFINET System Redundancy
S2 and S1 switched
R1, S2 and S1 switched
Structure of the PROFINET network
MRP Ring
Any
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SIMATIC S7-1500 Redundant Systems
CPU Types
New
Program/
Memory
Interfaces
Firmware
SIPLUS variant
New
CPU 1513R-1 PN
CPU 1515R-2 PN
CPU 1517H-3 PN
CPU 1518HF-4 PN
6ES7513-1RM03-0AB0
6ES7515-2RN03-0AB0
6ES7517-3HP00-0AB0
6ES7518-4JP00-0AB0
600 kB Code
2.5 MB of data
1 MB Code
4.5 MB of data
2 MB Code
8 MB data
9 MB Code
60 MB data
X1
X1
X2
X1
X2
X3
X4
X1
X2
X3
X4
From V3.0
From V3.0
From V2.6
From V2.8
-
-
6AG1517-3HP00-4AB0
-
Fail-safe
PROFINET IO Controller, Supports RT, MRP, TCP/IP, Open User Communication
PROFINET Basic Services, TCP/IP, Open User Communication
SFP module slot for H-synchronization
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X5
SIMATIC S7-1500 Redundant Systems
Sync modules and sync lines
Sync Module
4 pieces per H-system
Sync Cable
2 pieces per H-system
Distance
Sync Module
Sync Cable
Fiber Type /
Connector
Up to 10 m
6ES7960-1CB00-0AA5
Pre-fabricated:
6ES7 960-1BB00-5AA5 (1m)
6ES7 960-1BC00-5AA5 (2m)
6ES7 960-1CB00-5AA5 (10m)
Multimode / LC
From 2 m to 10 km
6ES7960-1FB00-0AA5
Single mode fiber 9/125 µm
Specification OS1 or OS2
Single Mode/LC
From 8 km to 40 km
6ES7960-1FE00-0AA5
Single mode fiber 9/125 µm
Specification OS2
Single Mode/LC
New
Overview of fiber optics at Siemens:
https://mall.industry.siemens.com/mall/en/en/Catalog/Products/10000396?tree=CatalogTree
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PROFINET
System Redundancy
SIMATIC S7-1500 Redundant Systems
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PROFINET System Redundancy
Concept
PROFINET System
Redundancy
A system of redundant PN
controllers and singular or
redundant PN devices.
Three levels:
1. PN Controller
PN
Controller
PN
Controller
PN
Controller
PN Controller
PROFINET
Network
2. PROFINET network
3. PN-Device
The redundancy of one layer is
independent of the other layers.
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2 connections
PN Device
PROFINET System Redundancy
Redundancy operating modes with PROFINET
•
•
Without System Redundancy
(S1)
System Redundancy S2
System Redundancy R1
Single Interface Module
•
Single Interface Module
•
Redundant Interface Module
1 connection to the controller
•
2 connections to red. controllers
•
2x1 connection to red. controller
PN
Controller
Redundant
PN
Controller 1
PN IO Network
PN IO Network
IM
S1
IM
I/O
PN S1 Device
Redundant
PN
Controller 2
S2
Redundant
PN
Controller 1
PN IO Network
I/O
PN S2 Device
PN S1 devices can also be operated on redundant
controllers S7-1500 R/H with the "Switched S1" function
Controller Redundancy
IM
R1
Redundant
PN
Controller 2
PN IO Network
IM
PN R1 Device
• Controller Redundancy
• Network Redundancy
• IM Redundancy
No redundancy
Details on PN System Redundancy operating modes: See https://support.industry.siemens.com/cs/ww/de/view/109756450
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I/O
PROFINET System Redundancy
Redundancy operating modes with PROFINET
The system tolerates the following failures (Fault Tolerance)
Without System Redundancy
(S1)
Fault tolerance:
• CPU (with bump)
• PROFINET Failure
With System Redundancy S2
Fault tolerance:
• CPU (bumpless)
• PROFINET Failure
S1
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S2
With System Redundancy R1
Fault tolerance:
• CPU (bumpless)
• PROFINET Failure
• Interface Module
• Subnet
R1
PROFINET System Redundancy
Support of PN System Redundancy with SIMATIC S7-1500
S7-1500
(Non-redundant)
S1
Operation of PN devices
without System
Redundancy
Yes
S2
Operation of PN devices
with
S2 System Redundancy
Yes
R1
Operation of PN devices
with
R1 System Redundancy
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(S1 mode only)
No
S7-1500R
S7-1500H
Yes
Yes
(Switched S1)
(Switched S1)
Yes
Yes
No
Yes
from firmware V3.0 and TIA Portal V18
Switching behavior without
System Redundancy
Scenario: Controller failure
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Switching behavior without PROFINET System Redundancy
Initial Situation
Primary RUN
Controller
Primary CPUs has a
Connection (AR) to the
S1-Device
S1
RUN
Backup
Controller
PROFINET
S1-Device
Process values are exchanged
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Process Values
Standard AR
Switching behavior without PROFINET System Redundancy
Scenario: A controller fails – switching process begins
S1
RUN
Remaining controller takes over
automatically.
There is no connection to the S1
device
Primary
Controller
PROFINET
S1-Device
I/O Data
Transfer of process values is
interrupted. Outputs go to "0" or to
substitute value
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Process Values
Standard AR
Switching behavior without PROFINET System Redundancy
Scenario: A controller fails - connection establishment
S1
RUN
Primary
Controller
Connection to the S1 device is reestablished
PROFINET
S1-Device
I/O Data
Transfer of process values is
interrupted1). Outputs go to "0" or to
substitute value
1) Duration
depends on the start-up behavior of the
S1 device. Minimum approx. 600ms
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Process Values
Standard AR
Switching behavior without PROFINET System Redundancy
Scenario: One Controller Fails - Operation Complete
S1
RUN
Primary
Controller
Remaining controller has a
connection to the S1 device
PROFINET
S1-Device
I/O Data
Process values are exchanged
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Process Values
Switching behavior with
System Redundancy S2
Scenario: Controller failure
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Switching behavior with PROFINET System RedundancyS2
Initial Situation
Primary RUN
Controller
Both CPUs have a
Connection (AR) to the
S2-Device
S2
RUN
Backup
Controller
PROFINET
S2-Device
Process values are exchanged
Process Values
Primary AR
Backup AR
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Switching behavior with PROFINET System RedundancyS2
Scenario: A controller fails – switching process begins
S2
RUN
Remaining controller takes over
automatically.
The existing connection is activated
Primary
Controller
PROFINET
S2-Device
I/O Data
Process values are used for a very
short time1) frozen:
I/O values remain at the last value
1) S7-1500R
300ms / S7-1500H 50ms
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Process Values
Primary AR
Backup AR
Switching behavior with PROFINET System RedundancyS2
Scenario: One Controller Fails - Operation Complete
S2
RUN
Primary
Controller
Remaining controller has a
connection to the S2 device
PROFINET
S2-Device
I/O Data
Process values are exchanged
Process Values
Primary AR
Backup AR
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Switching behavior with
System Redundancy R1
Scenario: Controller failure
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Switching behavior with PROFINET System RedundancyR1
Initial Situation
Primary
Controller
Primary Controller is connected to
Interface Module 1 (IM1)
Backup Controller is connected to
Interface Module 2 (IM2)
RUN
R1
RUN
PROFINET
Backup
Controller
PROFINET
R1-Device
IM1 IM2
Process values are exchanged
Process Values
Primary AR
Backup AR
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Switching behavior with PROFINET System RedundancyR1
Scenario: A controller fails – switching process begins
R1
RUN
Remaining controller takes over
automatically.
The existing connection is activated
PROFINET
Primary
Controller
PROFINET
R1-Device
IM1 IM2
Process values are used for a very
short time1) frozen:
I/O values remain at the last value
1) Duration
approx. 40ms
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Process Values
Primary AR
Backup AR
Switching behavior with PROFINET System RedundancyR1
Scenario: One Controller Fails - Operation Complete
R1
RUN
Primary
Controller
Remaining controller has a
connection to interface module 2
PROFINET
PROFINET
R1-Device
IM1 IM2
Process values are exchanged
Process Values
Primary AR
Backup AR
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Switching behavior with
System Redundancy R1
Scenario: Failure of a PROFINET interface module
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Switching behavior with PROFINET System RedundancyR1
Initial Situation
Primary
Controller
Primary Controller is connected to
Interface Module 1 (IM1)
Backup Controller is connected to
Interface Module 2 (IM2)
RUN
R1
RUN
PROFINET
Backup
Controller
PROFINET
R1-Device
IM1 IM2
Process values are exchanged
Process Values
Primary AR
Backup AR
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Switching behavior with PROFINET System RedundancyR1
Scenario: An interface module fails – switching process begins
Primary
Controller
Backup Controller enables
connection to
Interface-Module 2 (IM2)
RUN
R1
RUN
PROFINET
Backup
Controller
PROFINET
R1-Device
IM1 IM2
Process values are used for a very
short time1) frozen:
I/O values remain at the last value
1) Duration
approx. 40ms
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Process Values
Primary AR
Backup AR
Switching behavior with PROFINET System RedundancyR1
Scenario: An interface module fails - operation complete
Primary
Controller
I/O data is transferred via sync line
via the backup controller to the
Primary controller.
There is no controller switching.
RUN
R1
RUN
PROFINET
Backup
Controller
PROFINET
R1-Device
IM1 IM2
Process values are exchanged
Process Values
Primary AR
Backup AR
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Siemens products with
System Redundancy function
SIMATIC S7-1500 Redundant Systems
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PROFINET System Redundancy
Siemens I/O systems with PN S2 function (I)
Product
S2
Article
ET 200SP
IM155-6 PN HF (FW>=4.2)
IM 155-6MF (Multi Fieldbus)
ET 200MP
IM155-5 PN HF (FW>=4.2)
Also with active backplane bus for
pulling/plugging in operation
ET 200eco PN M12-L
6ES7155-6AU01-0CN0
6ES7155-6AU30-0CN0
6ES7155-6MU00-0CN0
6ES7155-5AA00-0AC0
6ES7590-0BL00-0AA0
The active backplane bus allows the pulling and plugging of
ET 200MP modules while the CPU is in operation.
6ES7 14*-6**00-0BB0
(from FW 1.1)
PN/PN coupler
Overview in detail: https://support.industry.siemens.com/cs/ww/en/view/102325771
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6ES7158-3AD10-0XA0
PROFINET System Redundancy
Siemens I/O systems with PN S2 function (II)
Product
S2
Article
ET 200SP HA
6DL1155-6AU00-0PM0
IM155-6 PN HA (with Single IM)
(without F-Modules)
ET 200iSP
6ES7152-1BA00-0AB0
IM 152-1PN (with Single IM)
(without F-Modules)
For use in Ex zone 1
SIMATIC CFU
Compact Field Unit
Enables the connection of PROFIBUS PA field devices
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6ES7655-5PX11-1XX0
PROFINET System Redundancy
Siemens drives with PN S2 function
Product
SINAMICS S120, S150,
G130, G150
S2
Article
6SL3040-1LA01-0AA0
with CU310-2PN (FW >=5.1 HF1)
(as GSDML)
SINAMICS S120, S150,
G130, G150
6SL3040-1MA01-0AA0
with CU320-2PN (FW >= 5.1 HF1)
(as GSDML)
An application example exists for configuring the SINAMICS drives on S7-1500R/H: https://support.industry.siemens.com/cs/ch/en/view/109744811
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PROFINET System Redundancy
Switches with PN S2 function
Product
S2
Article
SCALANCE XC-200 series
6GK5 2 . . - . . . 00 - 2 . C2
SCALANCE XP-200 Serie
6GK5 2 . . - 0 . A00 - . . S6
SCALANCE XF204-2BA
6GK5 204-2AA00-2GF2
SCALANCE X400
6GK5408-. G.00-2AM2
6GK5416-. G.00-2AM2
from FW 6.3
SCALANCE X500
from FW 6.3
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6GK552 . - . . . 00 - . AR2
PROFINET System Redundancy
Siemens I/O systems with PN R1 function
Product
R1
Article
ET 200SP
6ES7155-6AU00-0HM0
IM155-6 PN R1(with redundant IM)
ET 200SP HA
6DL1155-6AU00-0PM0
IM155-6 PN HA (with redundant IM)
(without F-Modules)
ET 200iSP
IM155-6 PN HA (with redundant IM)
(without F-Modules)
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6ES7152-1BA00-0AB0
System Redundancy R1
with ET 200SP
SIMATIC S7-1500 Redundant Systems
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PROFINET System Redundancy
ET 200SP with System Redundancy R1
2
An ET 200SP R1 system consists of:
4
1
•
2x IM 155-6 PN R1
2
•
1x BU-Type M0
3
•
5
3
3
2x same bus adapters from the ET 200SP
spectrum
4
•
1x SIMATIC system rail
5
•
Any IO modules
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1
1
ET 200SP with System Redundancy R1
Ordering data
1
Designation
IM 155-6 PN R1
BU Type M0
Article
6ES7155-6AU00-0HM0
6ES7193-6BR00-0HM0
SIMATIC system rail,
Length 482,6mm
SIMATIC system rail,
Length 530mm
SIMATIC system rail,
Length 830mm
SIMATIC system rail,
Length 2000mm
6ES7193-6MR00-0AA0
2
6ES7193-6MR00-0BA0
6ES7193-6MR00-0CA0
6ES7193-6MR00-0DA0
4
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ET 200SP with System Redundancy R1
System Rail
Required when using the IM 155-6 PN R1
• Tight dimensional tolerances for operating conditions
under high mechanical stress (significantly better than
dimensional tolerance standard EN 60715)
• long-term stable surface treatment for optimum
interference dissipation
• stable design for self-supporting construction
• integrated Bosch profile grooves (6mm profile grooves,
B-type)
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Configuration System
Redundancy R1
SIMATIC S7-1500 Redundant Systems
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Configuration System Redundancy R1
Option 1: Separate subnets
1 subnet is used between controller and IO
device.
Advantage:
Same (symmetric) IP addresses in both networks
can be used
Disadvantage:
No double-sided connection of S1 or S2 devices
possible (via Y-Switch)
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Configuration System Redundancy R1
Option 2: Shared subnet
Controller and IO devices are connected to a
common subnet
Advantage:
Allows two-sided connection of S1 or S2 devices
via Y-Switch
Disadvantage:
No symmetric IP addresses possible
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Configuration System Redundancy R1
Option 2: Shared subnet – configuration with S1 and S2 IO devices
R1-Device
Y-Switch
S2-Device
Y-Switch Details: See part “Configuration Examples S7-1500H with R1 Redundancy”
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Configuration System Redundancy
Display of the redundancy mode in the TIA Portal
The distinction S1/S2/R1 is displayed
in the "Mode" column in the
“I/O communication" table.
Here: ET 200MP: S2 Redundancy
In the network view, S1, S2
and R1 devices are displayed
as "Multi-Assigned"
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Failure Scenarios
SIMATIC S7-1500 Redundant Systems
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Failure scenarios for S7-1500 R/H
IO connection via Ring topology
Initial state
Primary
RUN-redundant
Backup
RUN-redundant
I/O data
Primary CPU or backup CPU
failure
IO communication is switched to the remaining
CPU
Primary
RUN-Solo
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Failure of an IO device
Failure of a PROFINET cable in
the ring
IO communication takes place via MRP ring
from Primary CPU to remaining
IO-Devices
IO communication continues via
MRP Ring.
Primary
Backup
Primary
RUNredundant
RUNredundant
Backup
RUNredundant
RUNredundant
Failure scenarios for S7-1500 H (from firmware V3.0)
IO connection via Line topology
New
Initial state
Primary
Backup
RUNredundant
RUNredundant
IO communication takes place via Fiber H-Sync
Connection from Primary CPU to remaining
IO-Devices
Primary
Primary
RUN-Solo
RUNredundant
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H-Sync
IO communication is switched to the remaining
CPU
Failure of a
PROFINET line
Failure of an IO device
IO communication takes place directly or via
Fiber H-Sync Connection from Primary CPU
Backup
Primary
RUNredundant
RUNredundant
H-Sync
Primary CPU or backup CPU
failure
I/O data
Backup
RUNredundant
Failure scenarios for S7-1500 R/H
Double fault: Failure of an IO device AND der Primary-CPU
Behavior with S7-1500R
Primary
RUN-redundant
Backup
RUN-redundant
Primary
RUN-redundant
Backup
Primary
RUN-redundant
STOP
IO device fails  System continues
Primary CPU fails  System failure!
Backup
RUN-redundant
Primary
RUN-redundant
Backup
RUN-redundant
IO device fails  System continues
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H-Sync
Primary
RUN-redundant
H-Sync
Behavior with S7-1500H
Primary
RUN-Solo
Primary CPU fails  System continues
Failure scenarios for S7-1500 R
Failure of redundancy connections to CPU synchronization
Behavior with S7-1500R
Primary
RUN-redundant
Backup
RUN-redundant
Primary
RUN-redundant
Backup
RUN-redundant
Direct redundancy connection fails
 System remains in RUN redundant
Primary
RUN-Solo
Backup
STOP
Additional: Failure of a Profinet connection
in the ring
Case 1: Time interval between the two
failures > 100ms
 Run-solo operation with partial failure of
IO devices
Case 2: Time interval between the two
failures < 100ms
 Both CPUs are in the primary role
(undefined state)
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Failure scenarios for S7-1500 H
Failure of redundancy connections to CPU synchronization
Backup
RUN-redundant
Primary
RUN-redundant
Backup
Primary
RUN-redundant
RUN-Solo
1 fiber optic redundancy connection fails
 System remains in RUN redundant
H-Sync
Primary
RUN-redundant
H-Sync
Behavior with S7-1500H
Backup
STOP
Additional: Failure of the second fiber optic
redundancy connection
Case 1: Time interval between the two
failures > 55ms
 Run-Solo operation
Recommendation:
Routing sync lines
separately on the HSystem
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Case 2: Time interval between the two
failures < 55ms
 Both CPUs are in the primary role
(undefined state)
Failure scenarios for S7-1500 H (from firmware V3.0)
Design with system redundancy R1 and MRP rings
New
Initial state
Primary
Backup
RUNredundant
RUNredundant
Network 2
Primary
RUN-Solo
Network 1
Network 2
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IO communication takes place via Fiber H-Sync
Connection from Primary CPU to remaining
IO-Devices
Primary
RUNPrimary
H-Sync
IO communication is switched to the remaining
CPU and the second interface module.
Failure of a
PROFINET network
Failure of an interface module
redundant
Network 1
Backup
RUNBackup
redundant
Network 2
IO communication takes place directly or via
Fiber H-Sync Connection von Primary CPU
Primary
Primary
RUN-
H-Sync
Network 1
Primary CPU or backup CPU
failure
I/O data
redundant
Network 1
Backup
RUNBackup
redundant
Network 2
Specific failure scenarios for S7-1500 H
Setup with system redundancy R1 – failure of one Pilotages
2 MRP Rings
Line topology - with feeding from
the same direction
New
Line topology – with feeding from
different directions
Primary
Backup
Primary
Backup
Primary
Backup
RUN-Redundant
RUN-Redundant
RUN-Redundant
RUN-Redundant
RUN-Redundant
RUN-Redundant
After MRP reconfiguration, all IO devices
continue to work
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IO data is forwarded to the IO devices
via the backup CPU
IO data is forwarded via the backup
CPU.
All IO devices continue to work
Specific failure scenarios for S7-1500 H
Setup with system redundancy R1 – failure of two Pilotages
2 MRP Rings
Line topology - with feeding from
the same direction
New
Line topology – with feeding from
different directions
Primary
Backup
Primary
Backup
Primary
Backup
RUN-Redundant
RUN-Redundant
RUN-Redundant
RUN-Redundant
RUN-Redundant
RUN-Redundant
After MRP reconfiguration, all IO devices
continue to work
Unrestricted | © Siemens 2023 | DI FA | 23.02.2023
IO devices fail after interruption
IO data is forwarded via the backup
CPU.
All IO devices continue to work
Communication via System IP
and Device IP addresses
SIMATIC S7-1500 Redundant Systems
Unrestricted | © Siemens 2023 | DI FA | 23.02.2023
Communication via System IP
IP addresses for the R/H system
In addition to the Device IP addresses, for each interface pair
of the R/H system, another
System IP address can be activated.
X2 interface
X2: System-IP1
X2: Device IP11
Primary
X2: Device IP12
Backup
X1 interface
X1: System-IP2
Unrestricted | © Siemens 2023 | DI FA | 23.02.2023
X1: Device IP21
X1: Device IP22
Communication via System IP
Behavior assigned to the primary CPU.
The System IP address is automatically assigned to the
primary CPU.
For a communication partner (e.g. standard PLC or HMI), the
R/H system behaves like a "normal" (non-redundant)
connection partner.
X2: System-IP1
Primary
X1: System-IP2
Unrestricted | © Siemens 2023 | DI FA | 23.02.2023
Backup
Communication via System IP
Behavior with Primary Backup Failover
If the primary controller fails, the System IP addresses are
automatically moved to the backup PLC
 A standard controller / HMI can continue to communicate via
the same IP address
X2: System-IP1
Primary
X1: System-IP2
Unrestricted | © Siemens 2023 | DI FA | 23.02.2023
Communication via Device IP addresses
Behavior automatically assigned to the primary CPU.
Communication via Device IP addresses works both via the Primary as well as via the backup CPU.
Please note: Using the connection via the Backup-PLC leads to higher sync load in the system.
Communication via Primary PLC
Communication via the Backup PLC
Receiving data
2
X2: Device IP 11
Data is requested
Primary
1
Synchronizing
data
Unrestricted | © Siemens 2023 | DI FA | 23.02.2023
Receiving data
Data is
forwarded
X2: Device IP 12
SYNC
Backup
3
X2: Device IP 11
Data is requested
Primary
1
3
Synchronizing job
4
X2: Device IP 12
Backup
SYNC
2
5
Synchronizing
data
HMI Connection via
System IP and Device IP
SIMATIC S7-1500 Redundant Systems
Unrestricted | © Siemens 2023 | DI FA | 23.02.2023
HMI Connection
via a non-redundant network using System IP address
An HMI connection via the System IP addresses for a nonredundant network is possible in all cases.
Panel
WinCC
Note when connected via X2:
If the connection to the Primary PLC is interrupted, communication with the R/H system is no
longer possible because the System IP address remains with the Primary PLC. In this case,
the role of the PLCs can be changed programmatically to remedy the situation. See slide
RH_CTRL Instruction
System IP (X2)
System IP (X1)
Communication
interrupted
Communication
OK
Role exchange
System-IP
Primary
System-IP
Backup
Unrestricted | © Siemens 2023 | DI FA | 23.02.2023
Backup
Primary
X2
X2
X1
X1
HMI Connection
via a non-redundant network using Device IP addresses
Panel
WinCC
An HMI connection via the Device IP addresses requires a
switching option on the HMI side. This is possible with
• WinCC OA ab V3.18
• WinCC V7.5 SP1 via Scripting
• SIMATIC Panels via Scripting
X2: IP1
X2: IP 2
The following application example is available for connecting SIMATIC
panels to an R/H system:
https://support.industry.siemens.com/cs/ww/de/view/109781687
X1: IP3
Unrestricted | © Siemens 2023 | DI FA | 23.02.2023
X1: IP4
HMI Connection
via redundant network using Device IP addresses
The HMI connection via a redundant network using Device
IP addresses is possible with
WinCC
WinCC
• WinCC OA ab V3.18
• WinCC V7.5 SP1 via Scripting
The communication connection is switched by WinCC in the event of a fault.
See
https://support.industry.siemens.com/cs/ww/de/view/109773067
Unrestricted | © Siemens 2023 | DI FA | 23.02.2023
X2: IP1
X2: IP 2
HMI Connection
via redundant network using System IP addresses
The HMI connection via a redundant network using
System IP addresses is possible with
WinCC
• WinCC OA ab V3.18
• WinCC V7.5 SP1 via Scripting
Use of R/H interfaces:
System IP of X1 and X2 for CPU 1515R-2 PN and CPU 1517H-3 PN
System IP of X2 and X3 with CPU 1518HF-4 PN
Behavior in case of error:
• If the primary CPU fails, the RH system switches over by moving the
System IP addresses
• If a network fails, WinCC switches over
Unrestricted | © Siemens 2023 | DI FA | 23.02.2023
X2: System IP
X3: System IP
X2
X3
X2
X3
HMI Connection in S2-Rings
Use of System IP address with MRP Ring
Initial Situation
Behavior in case of ring interruption
Primary
System IP
Primary
Fault
System IP
Reconfiguration of the MRP Ring
 IO data continues to be transferred
 Communication between HMI panel
and primary CPU is done via the
remaining route
  HMI communication is maintained
Unrestricted | © Siemens 2023 | DI FA | 23.02.2023
HMI Connection in Line Topology
Use of System IP address with line topology
Initial Situation
Behavior in case of ring interruption
Primary
System IP
Primary
Fault
System IP
 IO data continues to be transferred
 No more connection between HMI panel and
primary CPU 1)
  Communication to HMI panel fails
1) Only IO data is forwarded via the H-Sync line but no IP communication
Recommendation: Use the device IP address of the CPUs for HMI communication
Unrestricted | © Siemens 2023 | DI FA | 23.02.2023
HMI Connection with R1 Redundancy Networks
Combination of R1 and HMI devices
Backup PLC
Primary PLC
R1 configurations can be
extended with HMI devices
using a Y-switch.
Network 1
Network 2
R1
R1 devices
Y-Switch
SCALANCE XF204-2BA DNA
6GK5204-2AA00-2YF2
6GK5204-0BA00-2YF2
HMI
MRP Ring (optional)
Unrestricted | © Siemens 2023 | DI FA | 23.02.2023
HMI Connection with R1 Redundancy Networks
Combination of R1 and HMI devices
Backup PLC
Primary PLC
If the connection to the Y-Switch
fails, the connected HMI device
also fails in line topology.
Network 1
Network 2
Solution:
Use device IP addresses of the
CPUs or build a ring structure
R1
R1 devices
Y-Switch
SCALANCE XF204-2BA DNA
6GK5204-2AA00-2YF2
6GK5204-0BA00-2YF2
HMI
MRP Ring (optional)
Unrestricted | © Siemens 2023 | DI FA | 23.02.2023
Network
Configuration
SIMATIC S7-1500 Redundant Systems
Unrestricted | © Siemens 2023 | DI FA | 23.02.2023
Network configuration with S7-1500R/H
Overview
S7-1500R
S7-1500H/HF
H-Sync
Controller
PROFINET
Topology
S7-1500H/HF
MRP Ring
MRP Ring
H-Sync
Line
Redundant MRP Ring
Redundant line
From FW V3.0
From FW V3.0
Additional
Topologies
IO-Devices
System
Redundancy1)
MRP-Interconnection
S2
S1
MRP-Interconnection,
combined topology
S2
S1
From FW V3.0
MRP-Interconnection,
combined topology
R1
S2
S1
Via Y-Switch
Unrestricted | © Siemens 2023 | DI FA | 23.02.2023
Configuration Examples
S7-1500R
Unrestricted | © Siemens 2023 | DI FA | 23.02.2023
Configuration Examples S7-1500R
Ring Topology with MRP
Ring Topology
• MRP ring is a prerequisite - the CPUs must be part of the ring
• R-CPUs must be set as "MRP Automanager"
• If the ring is interrupted, MRP reconfiguration is triggered
Sync
• No devices allowed in the connection between the two CPUs
• Recommendation: Max. 16 devices in the ring
MRP Ring
• Connecting S1 Devices via a Switch 1)
• Devices with more than two ports
(e.g. switches) must support H-Sync forwarding
H-Sync Forwarding
must be supported
S1 Devices
connected via switch
Unrestricted | © Siemens 2023 | DI FA | 23.02.2023
1) Reason: S1 devices do not route the H-Sync telegrams during an MRP reconfiguration phase. This would lead to a high CPU
cycle time if the segment was interrupted. See chapter "H-Sync Forwarding" in the system manual S7-1500R/H
Configuration Examples S7-1500R
Ring Topology – Supplemented with MRP Interconnection
Ring coupling via MRP interconnection
 MRP interconnection switches allow the coupling of multiple MRP rings:
Ring on S7-1500R + up to 10 additional MRP rings
 Thanks to redundant switch architecture, the coupled network remains
functional even if one switch fails.
 Can be used with the following SCALANCE switches:
XR500, XM400, XC200, XF204-2BA, XP200
Sync
MRP Ring
 The requirement of the " H-Sync Forwarding " function applies only to the
devices that are found in the ring of R-CPUs. Reason: There are no HSync telegrams in the additional MRP rings.
MRP Ring
No requirement for "Hsync forwarding" in
coupled rings
Unrestricted | © Siemens 2023 | DI FA | 23.02.2023
Configuration Examples
S7-1500H with S2 Redundancy
Unrestricted | © Siemens 2023 | DI FA | 23.02.2023
Configuration example S7-1500H with S2 Redundancy
Example with ring topology
Ring topology with S2 Redundancy
 H-CPUs must be set as "MRP Automanager"
 If the ring is interrupted, MRP reconfiguration is triggered
H-Sync
MRP Ring
Behavior in case of ring interruption
Primary
Backup
H-Sync
MRP Ring
Unrestricted | © Siemens 2023 | DI FA | 23.02.2023
Configuration example S7-1500H with S2 Redundancy
Coupling of multiple MRP rings
Primary
Backup
H-Sync
MRP Ring 1
MRP-i Switches.
MRP Ring 2
Unrestricted | © Siemens 2023 | DI FA | 23.02.2023
MRP Ring 3
Ring coupling via MRP interconnection
 MRP interconnection switches allow the
coupling of multiple MRP rings:
Ring on S7-1500H + up to 10 additional
MRP rings
 Thanks to redundant switch architecture, the
coupled network remains functional even if
one switch fails.
 Up to 50 devices can be connected per ring
 The total number of participants of an R/H
CPU can also be achieved without spur
lines.
 Can be used with the following SCALANCE
switches:
XR500, XM400, XC200, XF204-2BA, XP200
Configuration example S7-1500H with S2 Redundancy
Example for Combined Topology – For example: Backbone-Ring
H-Sync
Backbone-Ring
1..10 Git/s
From FW V3.0 / V18
Unrestricted | © Siemens 2023 | DI FA | 23.02.2023
Connection to backbone ring
 As of firmware V3.0, the ring no longer has to be routed through the CPUs
 This allows connection to existing infrastructure
 In the ring there is no restriction to 100MBit/s transmission speed
Configuration examples S7-1500H with S2 Redundancy
Example with line topology
H-Sync
Line topology with S2 Redundancy
 MRP protocol is not used
 If a distance in the ring is interrupted, IO data transmission takes place via
the H-Sync line
 Requires firmware version from V3.0 and TIA Portal from V18
Behavior in case of ring interruption
Primary
Backup
H-Sync
From FW V3.0 / V18
Unrestricted | © Siemens 2023 | DI FA | 23.02.2023
Configuration example S7-1500H without PN devices
Special case for operation without PROFINET devices
H-Sync
Operation without PROFINET devices
 If no PROFINET devices (S1, S2, R1) are connected, the X1 interfaces of
the CPUs from V3.0 no longer need to be connected
 Examples: Exclusive communication via Open User Communication or
Modbus/TCP (e.g. communication concentrator")
Required setup with firmware < V3.0
Primary
Backup
H-Sync
X1
From FW V3.0 / V18
Unrestricted | © Siemens 2023 | DI FA | 23.02.2023
X1
Configuration Examples
S7-1500H with R1
Redundancy
From firmware V3.0 and TIA Portal V18
Unrestricted | © Siemens 2023 | DI FA | 23.02.2023
Configuration examples S7-1500H with R1 Redundancy
Example with ring topology
Ring topology with R1 Redundancy
 A separate ring is set up for each H-CPU
 H-CPUs must be set as "MRP Automanager"
 If a track in the ring is interrupted, MRP reconfiguration takes place
 Separate networks – same (mirror-image) IP addresses can be used
MRP Ring
MRP Ring
From FW V3.0 / V18
Unrestricted | © Siemens 2023 | DI FA | 23.02.2023
Configuration examples S7-1500H with R1 Redundancy
Ring topology for S7-1500H – extended with MRP Interconnection
Redundant ring coupling via MRP interconnection
 Redundant R1 rings can also be connected via MRP interconnection
 Thanks to redundant switch architecture, the coupled network remains
functional even if one switch fails.
 Up to 50 devices can be connected per ring  The total number of
participants of an H CPU can also be achieved without spur lines.
 Can be used with the following SCALANCE switches:
XR500, XM400, XC200, XF204-2BA, XP200
MRP Ring
MRP Ring
MRP Ring
MRP Ring
Unrestricted | © Siemens 2023 | DI FA | 23.02.2023
Configuration examples S7-1500H with R1 Redundancy
Example for Combined Topology –For example: Backbone-Ring
Connection to separate ring
 R1 rings do not have to be passed through the CPU
 This enables connection to existing redundant network infrastructure
 In the rings there is no restriction to 100MBit/s transmission speed
Ring 1
Backbone Rings
1..10 Git/s
Ring 2
From FW V3.0 / V18
Unrestricted | © Siemens 2023 | DI FA | 23.02.2023
Configuration examples S7-1500H with R1 Redundancy
Unsupported Topology - Single R1 Ring
This topology is not supported because the availability is
unfavorable:
The probability of a fault in the ring is also twice as high as with
an S2 setup due to twice the number of IMs
Unrestricted | © Siemens 2023 | DI FA | 23.02.2023
Configuration examples S7-1500H with R1 Redundancy
Example with line topology
Line topology with R1 Redundancy
 Line topology is also supported for R1 setup
 Up to 256 devices can be connected in this topology
 The feeding of the PN line from different sides increases the availability
in case of double line interruption
Single-sided feeding
If both lines are interrupted, devices behind them fail
X
X
Feeding from two sides
If both lines are interrupted, all devices can be
reached
From FW V3.0 / V18
Unrestricted | © Siemens 2023 | DI FA | 23.02.2023
Configuration examples S7-1500H with R1 Redundancy
Combination of R1 and S1/S2 devices
R1 configurations can be extended with S2
or S1 devices using a Y-switch.
The prerequisite for this is the configuration
in the TIA Portal on 1 subnet
Result: Unique IP addresses in
Network 1+2 are required
Backup PLC
Primary PLC
Network 1
Network 2
R1
Y-Switch
SCALANCE XF204-2BA DNA
6GK5204-2AA00-2YF2
6GK5204-0BA00-2YF2
R1 devices
S2
Network 1+2
MRP Ring
(optional)
Unrestricted | © Siemens 2023 | DI FA | 23.02.2023
S1
Configuration examples S7-1500H with R1 Redundancy
Combination of R1 and S1/S2 devices on ring structures
In order to connect the Y-switch to MRP
rings, additional switches are required.
Backup PLC
Primary PLC
Primary PLC
Backup PLC
To increase availability, the Y-Switch can
also be designed redundantly
"Redundant DNA".
In this case, an MRP ring must be used on
the S1/S2 side.
R1
R1
Switch
Switch
Switch
Y-Switch
Y-Switch
S2
MRP Ring
(optional)
S1
Y-Switch
MRP Ring (mandatory)
Single Y-Switch with MRP Ring
Unrestricted | © Siemens 2023 | DI FA | 23.02.2023
Redundant Y-Switch with MRP Ring
Configuration examples S7-1500H with R1 Redundancy
IO devices that are connected to only one CPU
In some cases, it is sufficient if S1/S2 devices are connected to only one of the two CPUs.
Examples of this are switches that transmit diagnostic data to the controller via PROFINET.
Behavior in case of CPU 2 failure
CPU 1
CPU 1
CPU 2
CPU 2
Fault
IO-Device 3
IO-Device 3
Only connected
to CPU 1
IO-Device 1
IO-Device 2
Connected to
both CPUs via
R1
Unrestricted | © Siemens 2023 | DI FA | 23.02.2023
IO-Device 1
Only connected
to CPU 2
IO-Device 2
A failure of the connected
CPU also leads to the
failure of the IO device!
Configuration examples S7-1500H with R1 Redundancy
IO devices that are connected to only one CPU - Configuration
Even if devices are connected to only one CPU they must be mapped to both CPUs
Operating mode must
be changed from "S2"
to "S1" 1)
Assignment must be
set to both CPUs
1) If
the operating mode is not adjusted, the switch is detected as
failed by the disconnected CPU and a corresponding bus error
and alarm is generated.
Unrestricted | © Siemens 2023 | DI FA | 23.02.2023
Assignment to only
CPU 1 leads to an error
during translation!
Connection of subordinate
components
Unrestricted | © Siemens 2023 | DI FA | 23.02.2023
Network configuration with S7-1500 R/H
Connection of subordinate controllers
Primary
Backup
H-Sync
S1
Option 2:
Via PN/PN Coupler
 Bumpless
switching
S2
Unrestricted | © Siemens 2023 | DI FA | 23.02.2023
Open User Communication
Option 1:
Connection as iDevice in switched
S1 mode
Not bumpless
currently only possible via GSD
Option 3:
Open user communication
between H-System and
subordinate controller
 With short interrupt
Terms:
Bumpless:
When switching the H-system, the
outputs remain at the last value. The
switching time is very short.
Network configuration with S7-1500 R/H
Connection of PROFIBUS DP slaves
Primary
Backup
Option 3:
Open user communication
between H-System and
subordinate controller 1)
 With short interrupt
H-Sync
Open User Communication
Option 1:
Connection as iDevice in switched S1
mode
Not bumpless
currently only possible via GSD
S1
PROFIBUS
Option 2:
Via PN/PN Coupler
 Bumpless
switching
S2
PROFIBUS
PROFIBUS
Note: IE/PB Link and IE/PB LINK HA are currently not supported
Unrestricted | © Siemens 2023 | DI FA | 23.02.2023
R1 network configuration with S7-1500 H
Connection of subordinate controllers
Backup PLC
Primary PLC
Network 1
Network 2
Option 2:
Via PN/PN Coupler
 Bumpless
switching
R1
S1
Y-Switch
Option 1: Connection as iDevice in
switched S1 mode
Not bumpless / only via GSD
Unrestricted | © Siemens 2023 | DI FA | 23.02.2023
S2
Option 3:
Open user communication
between H-System and
subordinate controller 1)
 With short interrupt
R1 network configuration with S7-1500 H
Connection of PROFIBUS DP slaves
Backup PLC
Primary PLC
Network 1
Network 2
Option 2:
Via PN/PN Coupler
 Bumpless
switching
R1
Option 3:
Open user communication
between H-System and
subordinate controller 1)
 With short interrupt
S2
S1
Y-Switch
Option 1: Connection as iDevice in
switched S1 mode
Not bumpless / only via GSD
Unrestricted | © Siemens 2023 | DI FA | 23.02.2023
PROFIBUS
PROFIBUS
PROFIBUS
Safety for
Redundant Systems
SIMATIC S7-1500 Redundant Systems
Unrestricted | © Siemens 2023 | DI FA | 23.02.2023
Safety for Redundant Systems
Realize Safety Applications with redundant Controller
High Availability + Failsafe = CPU 1518HF
•
•
•
•
•
Engineering ab STEP 7 Professional V17 und STEP 7 Safety
Safety programming as with non-redundant fail-safe PLC
Supported PROFIsafe Communication
Supports flexible F-Link (safe controller/controller communication)
Fail-over scenario without stop the safety program
Fast Commissioning Mode
• The Fast Commissioning Mode in deactiviated safety mode allows short
turnaround times:
• Faster compile time of the F program
• In this mode, the F program can also be loaded in the System State
RUN
• To change back to the safety mode, a STOP-RUN transition is
required
Unrestricted | © Siemens 2023 | DI FA | 23.02.2023
Safety for Redundant Systems
Realize Safety Applications with redundant Controller
High availability + Fail-safe = CPU 1518HF
Both S2 and R1 configurations are supported
New
Unrestricted | © Siemens 2023 | DI FA | 23.02.2023
Network configuration with S7-1500 HF
Safety Devices
Direct integration of fail-safe devices with SIMATIC CPU 1518HF
Primary
Backup
H-Sync
Safety Application
runs on CPU 1518HF
Direct connection of
PROFIsafe IO devices
Safe CPU-CPU
communication via
Flexible F-Link
Unrestricted | © Siemens 2023 | DI FA | 23.02.2023
Network configuration with S7-1500 R
Safety Devices
Connection of fail-safe devices via a subordinate F-controller
Primary
Backup
R-System (Non Safety) with
connected peripherals
(Not safe) Communication
between R and F controllers
via iDevice or Open User
Communication
Safety Application
runs in a separate
F-Controller
Unrestricted | © Siemens 2023 | DI FA | 23.02.2023
Network configuration with S7-1500 R
Safety Devices
Connection of fail-safe devices by a subordinate F-controller with PN/PN coupler
Primary
Backup
R-System (Non Safety) with
connected peripherals
(Not safe) Communication
between R and F controllers
via PN/PN couplers
Optional
Media redundancy (MRP ring)
increases availability in the
event of network interruptions
Safety Application
runs in a separate
F-Controller
Unrestricted | © Siemens 2023 | DI FA | 23.02.2023
Optional
Use of a second PN/PN coupler to
avoid
„Single Point of Failure“
MRP Ring
Notes for
Application
SIMATIC S7-1500 Redundant Systems
Unrestricted | © Siemens 2023 | DI FA | 23.02.2023
Load project
Load program
SIMATIC S7-1500 Redundant Systems
Unrestricted | © Siemens 2023 | DI FA | 23.02.2023
Load project in S7-1500R/H
Procedure with changes to the hardware configuration
Changes to the hardware configuration can only be loaded in the STOP state of a CPU.
To minimize downtime, the following procedure is recommended:
CPU 1
stop
2
RUN
CPU 1
CPU 1
4 start
(Primary)
STOP
SYNCUP
(with old
project)
(New project will be
transferred)
RUN
(Backup)
SYNCUP
Project is
Transfer automatically
CPU 2
RUN
STOP
(Backup)
(with new project)
Startup
RUN
RUN
(with new project)
(Primary)
3
1
Stop CPU 2
and load new project 1)
Previous project is active
CPU 2
start
DownTime
New project is active
1) Using the "Load into Backup CPU" function from the project tree of the TIA Portal
Unrestricted | © Siemens 2023 | DI FA | 23.02.2023
Load project in S7-1500R/H
Rollback to previous project status
With a similar approach, a quick "rollback" to the original status of a project planning can also be realized.
This can be useful if a program change is not successful.
CPU 1
stop
CPU 1
CPU 1
5 start
2
RUN
STOP
(Primary)
(with old project)
Run-up
CPU 2
STOP
(Backup)
(with new project)
Run-up
SYNCUP
RUN
STOP
(with new
project)
(Old project is
transferred)
1
3
4
6
Stop CPU 2
and load new project
CPU 2
start
CPU 2
stop
CPU 2
start
Previous project is active
Unrestricted | © Siemens 2023 | DI FA | 23.02.2023
Down-Time
New project
is active
RUN
(Primary)
SYNCUP
Project is
Transfer automatically
Testing phase
RUN
RUN
(With old project)
Down-Time
RUN
(Backup)
Rollback: Old project is activated
Load program in S7-1500R/H
Procedure without changes to the hardware configuration
If only the program of the CPU has been changed, this can be loaded in the RUN-Redundant state
CPU 1
Load
CPU 1
RUN
(Primary)
RUN
(Primary)
Program will be
automatically synchronized
CPU 2
RUN
(Backup)
Previous program is
active
Unrestricted | © Siemens 2023 | DI FA | 23.02.2023
RUN
(Backup)
New program
is active
Hardware extensions in RUN
with IO-Link
SIMATIC S7-1500 Redundant Systems
Unrestricted | © Siemens 2023 | DI FA | 23.02.2023
Hardware extensions in RUN with IO-Link
Applications
IO-Link for the extension of the hardware of a plant in the RUN
By using IO-Link, it is possible to carry out plant expansions without interrupting operation.
What is IO-Link?
• IO-Link is a standardized point-to-point IO technology (IEC 61131-9)
to communicate digitally with sensors and actuators.
• IO-Link devices are offered by most sensor manufacturers
• Siemens has IO-Link masters for the complete ET 200 family in its portfolio
•
•
•
•
•
AND 200SP
AND 200MP
AND 200eco PN
AND 200AL
AND 200pro
The following use cases can be solved with IO-Link
More information about IO-Link?
1.
2.
3.
See https://www.siemens.com/io-link
or https://io-link.com/
Add new sensors or actuators
Change the type of a sensor / actuator
Configure measuring point (e.g. adjust measuring range)
Unrestricted | © Siemens 2023 | DI FA | 23.02.2023
Hardware extensions in RUN with IO-Link
Functionality
With IO-Link, the actuators/sensors are configured directly via the IO-Link master.
The CPU or the RH system is not involved.
Sequence of HW configuration with conventional actuators/sensors
Primary
Procedure of the hardware configuration with IO-Link
Primary
Backup
Backup
1
1
2
CPU data is changed
currently only possible in
STOP state
Sensor
1. TIA Portal project is loaded into the PLC
2. PLC sends the data to the ET 200
Unrestricted | © Siemens 2023 | DI FA | 23.02.2023
Sensor
Data is only changed in the
IO-Link devices
 Also in condition
RUN-Solo / RUN-Redundant
possible
1. S7-PCT Tool loads the data into the IO-Link master
2. The IO-Link master configures the IO-Link devices
Hardware enhancements in RUN (CiR) with IO-Link
Procedure – Add new measuring point
1.
Construction
Hardware Extension
Program Extension
Commissioning phase
System im STOP
Production phase
System in RUN-Redundant
Production phase
System in RUN-Redundant
Reserve IO-Link master modules into a
Install ET 200 station
Perform TIA HW configuration
Load TIA Portal Project
2.
3.
1.
2.
3.
Advantage:
An IO-Link port can be used universally for all
channel types.:
• Digital input
• Digital output
• IO-Link (Analog Values)
 Only one assembly type for all applications
•
•
ET 200SP: CM 4xIO-Link, 6ES7137-6BD00-0BA0
ET 200MP: CM 8xIO-Link, 6ES7547-1JF00-0AB0
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4.
Connect the sensor to the IO-Link
master
Start the IO-Link configuration tool "S7PCT" from the TIA Portal
Insert and parameterize IO-Link
sensor/actuator in PCT
Load IO-Link Master
 Process values of the IO-Link device
are exchanged
1.
2.
Use a corresponding PLC tag (symbol)
in the TIA Portal and in the PLC
program
Load the supplemented PLC program
into the R/H system
 The program evaluates the data of the
new measuring point
Connection of a sensor / actuator
Example: ET 200SP
Conventional
With IO-Link
Four different module types are required
DI
DQ RTD AI
Only 1 module type is required
CM IOL
The connection is selected via S7-PCT
 In RUN-redundant state
of the R/H system possible
Proximity switch
24 VDC
Proximity switch
24 VDC
Contactor
24 VDC
Unrestricted | © Siemens 2023 | DI FA | 23.02.2023
TempSensor
PT 100
Flow
TempSensor
Flow
4..20mA
Contactor
24 VDC
Programming
Recommendations
SIMATIC S7-1500 Redundant Systems
Unrestricted | © Siemens 2023 | DI FA | 23.02.2023
Programming recommendations SIMATIC S7-1500 R/H (I)
1) Set maximum cycle time
The maximum cycle time should be set as large as the process allows.
This can shorten the time for the SYNCUP, as the transition to RUN-redundant only takes place when the actual cycle time is <80% of the
set maximum cycle time.
Recommendation:
0ms
Max cycle time parameter
Maximum cycle time of the program
Dead time when
switching
300ms with R-CPU
50ms for H-CPU
60%
Reserve
40%
2) Set minimum cycle time as high as possible
By increasing the minimum cycle time to the minimum value required for the process, the system load due to synchronization is reduced.
This also shortens the SYNCUP phase and leads to higher performance in communication.
Unrestricted | © Siemens 2023 | DI FA | 23.02.2023
Programming recommendations SIMATIC S7-1500 R/H (II)
3) Avoid direct peripheral access
Each direct peripheral access is synchronized in the system state RUN-Redundant and leads to a higher cycle time.
Recommendation: In the RH system, the inputs and outputs of the IO devices should only be accessed via the process image or the
subprocess images.
4) Reduce communication during the SYNCUP phase
If possible, the communication load should be kept low during a SYNCUP phase. This will speed up the SYNCUP process. This can be
done programmatically via the SFC "GET_DIAG".
5) Reduce cyclic interrupts during the SYNCUP phase
If cyclic interrupts are used intensively in the program and it is tolerable to reduce the call frequency during the SYNCUP phase, then the
sync load can be reduced by calling the system function "SFC SET_CINT". This measure also helps to shorten the SYNCUP time. In
normal state (RUN-Solo or RUN-Redundant) the alarm times can then be changed back to the original state.
Unrestricted | © Siemens 2023 | DI FA | 23.02.2023
Programming recommendations SIMATIC S7-1500 R/H (III)
6) Use of the WAIT function in the system state SYNCUP
If a longer cycle time is tolerable in the SYNCUP system state, the SYNCUP process can be accelerated by calling the system function
"WAIT" at the end of OB1. This is possible because the WAIT function on the backup PLC is used to catch up.
Primary PLC
Cycle time of the program in normal
operation
Programmed latency
in SYNCUP state
Backup PLC
Cycle time of the program in normal
operation
Backup PLC uses the
time to catch up in
SYNCUP
Cycle time of the program in the system state SYNCUP
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Specific functions
for R/H controllers
SIMATIC S7-1500 Redundant Systems
Unrestricted | © Siemens 2023 | DI FA | 23.02.2023
RH_CTRL Instruction
Switch CPU programmatically
Extensions of the RH_CTRL instruction
•
•
•
Request SYNCUP: If the system is in the RUN-Solo state, the SYNCUP can be
restarted by calling this function to bring the system back into the redundant state.
Stop Primary-PLC: When running redundantly, the primary PLC is stopped and the
backup PLC runs in RUN solo mode.
If the SYNCUP is then requested again (mode 7), the system works with swapped
roles (primary/backup) redundant.
Stop backup PLC: When running redundantly, the backup PLC is stopped and the
primary PLC continues to run in RUN solo mode.
Primary
STOP
Backup
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Primary
RH_CTRL
Mode 7
RH_CTRL
Mode 8
RUN-Redundant
Backup
Primary
RUN-Solo
RUN-Redundant
Mode
Function
3
Lock SYNCUP
4
Share SYNCUP
7
Request SYNCUP
8
Stop Primary-PLC
9
Stop Backup PLC
10
Check if SYNCUP is locked
New
Switched S1
Adjustable switching time for the "Switched S1" function
Switching process for S1 devices
1
Primary
2
3
Primary
Backup
X
Single AR
S1
S1
5
Primary
Primary
X
X
Single AR
Operation
4
X
Single AR
X
Connection in the device
still available
S1
Connection
degraded
X
Primary
S1
Single AR
X
New connection
Device not yet active
S1
Device Startup
completed
1) System in redundant operation, IO data is exchanged
2) After fail-over: IO Device holds the existing connection until the expiration of the Watchdog-Time.
As long as no further connection is possible.
3) IO device is ready for a new connection to the controller
4) The new connection is established, the IO device start-up begins
5) IO data is exchanged again
AR = Application Relation (connection between controller and device)
Unrestricted | © Siemens 2023 | DI FA | 23.02.2023
Switched S1
Adjustable switching time for the "Switched S1" function
Previous time behavior (with FW version 2.8)
Waiting time before switching
(Not adjustable)
Activation of the new AR
IO-Device specific
start-up time
New time behavior (with FW version 2.9)
Watchdog-Time
(individually adjustable for
each device)
Activation of
the new AR
(Optimized)
IO-Device specific
start-up time
Example measurement with CPU 1517H and iDevice (short device startup time)
FW V2.8
FW V2.9
IO data active again after
AR = Application Relation (connection between controller and device)
Unrestricted | © Siemens 2023 | DI FA | 23.02.2023
3 seconds
0.6 seconds
Reporting loss of redundancy
OB72 reports loss of redundancy during synchronization
 If a sync line fails, the maintenance LED on the controller lights up
and the H-System continues to work in redundant mode.
 The failure of a sync line is reported from firmware V2.9 by calling the
OB72 (redundancy loss).
 This can be used to report a request to restore the sync line.
Redundancy
loss on
H-Sync 2!
Primary
OB72
Backup
H-Sync 1
H-Sync 2
Process underway
Unrestricted | © Siemens 2023 | DI FA | 23.02.2023
Reporting of peripheral redundancy errors
OB70 reports loss of peripheral redundancy
New
In the H system 1), the OB 70 is called if in the system state RUN-Redundant on a R1/S2 device
redundancy loss or a redundancy return event.
 Redundancy Loss: An AR of two ARs of an R1/S2 device fails
 Redundancy Return: The second AR of an R1/S2 device is rebuilt
Example scenarios for the OB 70 call:
OB 70
OB 70
OB 86
OB 70
RUNredundant
RUNredundant
OB 70
H-Sync
H-Sync
H-Sync
H-Sync
OB 70
RUNredundant
RUNredundant
Network 1
Two ARs fail
An AR fails
1) (CPU 1517H / CPU 1518HF with firmware V3.0)
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An AR fails
Network 2
Network 1
An AR fails
Network 2
Security at R/H
SIMATIC S7-1500 Redundant Systems
Unrestricted | © Siemens 2023 | DI FA | 23.02.2023
Security Enhancements
Protection of configuration data / Secure communication to HMI and TIA Portal
Extensions from firmware V2.9 and
from TIA Portal V17
TIA Portal
V17
WinCC
1
3
Protection of configuration data
2 Secure communication between
controllers and TIA Portal V17
2
1
3 Secure communication between
controllers and HMI
3
Unrestricted | © Siemens 2023 | DI FA | 23.02.2023
Protection of configuration data
Properties
Configuration data protection can be activated/deactivated via the TIA Portal.
 The protection password is not stored in the project but stored independently of the project data in the
CPU. It is not readable and must therefore be stored in a safe place.
 If protection of the configuration data is activated, special features must therefore be taken into account
during the initial commissioning and replacement of a controller.  see next slides
Unrestricted | © Siemens 2023 | DI FA | 23.02.2023
Special features when activating password protection of the configuration data
Initial commissioning of an RH system
Step 1) Load the configuration and
set the password
Step 2) Set password in CPU 2
Alternative 1:
TIA Portal
TIA Portal
1x
1x
Alternative 2:
Special password
Memory Card
Step 3) Start RH System 
Synchronizing data
TIA Portal
Start RH System
First Download
SYNCUP
CPU 1
CPU 2
CPU 1
CPU 2
CPU 1
Without this step, the SYNCUP
process will fail!
Certificate with private key for PG/HMI communication
Unrestricted | © Siemens 2023 | DI FA | 23.02.2023
Password to protect configuration data
CPU 2
Special features when activating password protection of the configuration data
Replacing an R/H CPU
Event: A CPU fails and needs to be
replaced
Step 1) Change CPU and reset
password
Alternative 1:
TIA Portal / SAT
1x
Alternative 2:
Special password
Memory Card
3) Start the new CPU 
Synchronizing data
TIA Portal / SAT
Start CPU
SYNCUP
CPU 1
Defective CPU 2
CPU 1
New CPU 2
CPU 1
Without this step, the SYNCUP
process will fail!
Certificate with private key for PG/HMI communication
Unrestricted | © Siemens 2023 | DI FA | 23.02.2023
Password to protect configuration data
New CPU 2
Secure communication with HMI and TIA Portal
For controllers with firmware V2.9 or higher, secure communication is
used with
 TIA Portal from V17
 WinCC Runtime from V17
 Basic Panels 2nd Generation, Comfort Panel 1st Generation, Mobile Panels
 WinCC Unified from V17, Unified Comfort Panels
 WinCC OA from V3.18 Patch 4
 WinCC from V7.5 SP2 Update 4
 In order to be able to communicate with other HMI devices,
deselect the option shown below.
Unrestricted | © Siemens 2023 | DI FA | 23.02.2023
Feature Comparison /
Restrictions
SIMATIC S7-1500 Redundant Systems
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Functional comparison with S7-1500 and S7-400H
Communications
OPC UA / Webserver
Redundant communication
System-IP address
Redundant I/Os
Technology Objects
IRT, Isochrone Mode, MRPD
Hardware enhancements in RUN
S7-1500 R/H
S7-1500
S7-400H
Open User Communication;
S7 communication as server
(Secure) Open User
Communication;
S7 communication;
Configured connections
Open device
communication;
S7 communication;
Configured connections
No
Yes
No
Via LComRed Library
No
Yes
Yes
Not required
No
Via LRedIO Library
Via LRedIO Library
Yes
Counting, measuring, PID,
BasicPos
Yes
No
No
Yes
No
With IO-Link
With IO-Link
With switching (H-CiR)
See slide section
Firmware Update in RUN
No
No
Yes
DHCP with DNS
No
Yes
No
Unrestricted | © Siemens 2023 | DI FA | 23.02.2023
Configuration Restrictions for S7-1500R/H
Central connection of Modules
IO, CM/CP, System Power Supply
PROFINET network structure
Operation of the RH system as
Shared Device or iDevice
Operation of PROFIBUS devices
Unrestricted | © Siemens 2023 | DI FA | 23.02.2023
S7-1500 R/H
S7-1500
S7-400H
No
Yes
Yes
any
any
No
Yes
No
Via Coupling-PLC
Yes
Yes
New
S7-1500H: any
S7-1500R: MRP Ring
What's New with Firmware
V3.0
(TIA Portal V18)
SIMATIC S7-1500 Redundant Systems
Unrestricted | © Siemens 2023 | DI FA | 23.02.2023
SIMATIC S7-1500 Redundant Systems
What's New with Firmware Version 3.0
New Features / Improvements
System redundancy R1 for S7-1500H and ET 200SP
Flexible network topologies with S7-1500H
Maximum distance between H-CPUs now possible up to 40 km
Support in STEP 7 CFC (TIA Portal V18)
New OB 70 "Peripheral Redundancy Error"
Extensions RH_CTRL SYNCUP Status
New support for SIMATIC S7-1500 standard functions
CREATE_DB, DELETE_DB,
READ_DBL and WRIT_DBL
ReadFromArrayDBL and WriteToArrayDBL
Unrestricted | © Siemens 2023 | DI FA | 23.02.2023
SIMATIC S7-1500H
System redundancy R1 for S7-1500H and ET 200SP
S7-1500H
System Redundancy R1
• Increased availability
• Seamless switching in the event of an ET 200 SP interface
module failure (as well as ET200 SP HA or ET 200 iSP)
• High robustness due to two networks (ring or line)
• Fault tolerance: CPU, PROFINET Interruption, InterfaceModule and Subnet
AND 200SP
Network #1
Unrestricted | © Siemens 2023 | DI FA | 23.02.2023
Network #2
SIMATIC S7-1500H
More flexibility in network structures
In addition to the construction of an MRP ring, any other structures are possible. For example
• Line Topology
• Separated Ring
• Hybrid Topology
Simple MRP ring (since V15.1)
•
•
Line Topology
Easier to integrate into existing network structures
High flexibility in assembly
Separated Ring
R1 Line + Y-Switch
SIMATIC S7-1500H
Wide range fiber optic modules up to 40km




New sync modules for CPU 1517H and CPU 1518HF
Distance between H-CPUs: Minimum 8 km – Maximum 40 km
Application for large-scale structures (tunnel systems)
Requires TIA Portal V18 and CPU firmware V3.0
Article
Fiber Optic
Type
Length of fiber
optic cable
6ES7960-1CB00-0AA5
Multimode
10m
6ES7960-1FB00-0AA5
Single Mode
2 meters to
10km
6ES7960-1FE00-0AA5
Single Mode
8 km to
40km
New
Attention: When using the 40km sync module
6ES7960-1FE00-0AA5 a maximum ambient temperature of 55°C applies
Unrestricted | © Siemens 2023 | DI FA | 23.02.2023
Innovated Hardware for R CPUs
Technical comparison
CPU 1513R-1 PN
CPU 1515R-2 PN
New
New
Article
6ES7 513-1RL00-0AB0
6ES7 513-1RM03-0AB0
6ES7 515-2RM00-0AB0
6ES7 515-2RN03-0AB0
Installable firmware
Up to V2.9
From V3.0
Up to V2.9
From V3.0
Firmware compatible with
V2.6, V2.8, V2.9
V2.6, V2.8, V2.9, V3.0
V2.6, V2.8, V2.9
V2.6, V2.8, V2.9, V3.0
Display
Part of the front flap
Part of the CPU
Part of the front flap
Part of the CPU
Program memory
300 kByte
600 kByte
500 kByte
1 Mbyte
Memory
1.5 Mbyte
2.5 Mbyte
3 Mbyte
4.5 Mbyte
Processing time for bit operations
80 ns
50 ns
60 ns
20 ns
Operating temperature range
0°C... 60°C
-30°C... 60°C
0°C... 60°C
-30°C... 60°C
Unrestricted | © Siemens 2023 | DI FA | 23.02.2023
Innovated Hardware for R CPUs
Compatibility
The new R-CPUs are spare parts compatible with the existing R-CPUs
 Memory cards from existing CPUs can continue to be used 1:1 in the new CPUs
 New R CPUs can also be loaded with older TIA Portal versions. Configure the latest FW version there
Attention:
 In an R/H system, both CPUs must have the same article number and firmware version
 If an R CPU fails, the same type must be replaced
Unrestricted | © Siemens 2023 | DI FA | 23.02.2023
Supplements
SIMATIC S7-1500 Redundant Systems
Unrestricted | © Siemens 2023 | DI FA | 23.02.2023
Support of S7-1500 R/H in the SIMATIC Automation Tool (SAT)
 As of version 4.0 SP3 of the SIMATIC Automation Tool, redundant
controllers (S7-1500 R and S7-1500 H) are also supported.
 This allows e.g. firmware updates or program updates to be carried
out easily
 Information and download under the following link:
https://support.industry.siemens.com/cs/ww/en/view/98161300
Primary
Backup
SIMATIC Automation Tool
Unrestricted | © Siemens 2023 | DI FA | 23.02.2023
TIA Portal Add-In
Calculation of the watchdog time over a AddIn
To connect a PROFINET device to a redundant S7-1500 R/H system, it is necessary to set the correct
watchdog time for each device. The SIMATIC S7-1500 R/H AddIn determines the correct factor and updates
it in the settings
Available at https://support.industry.siemens.com/cs/ww/en/view/109769093
Unrestricted | © Siemens 2023 | DI FA | 23.02.2023
Application Example
Connection of redundant I/O in the user program
In this application example, a possibility is shown how
I/O can be redundantly connected to a SIMATIC S71500 controller with blocks of the TIA Portal.
Download: https://support.industry.siemens.com/cs/ww/en/view/109767576
Unrestricted | © Siemens 2023 | DI FA | 23.02.2023
Application Example
Diagnosis of the operating status of a SIMATIC S7-1500 R/H system using FB
A function block is available for download for extended diagnostics of the SIMATIC S7-1500 R/H system.
Advantages
 Prefabricated diagnostic block for SIMATIC S7-1500 R/H systems
 Simple connection of different hardware addresses for extensive diagnostics
 Integrated self-diagnosis function (in addition to the standard diagnostic functions) of the SIMATIC S7-1500 R/H
system for early detection and reporting of faults before they affect the process
Download: https://support.industry.siemens.com/cs/ww/en/view/109763768
Unrestricted | © Siemens 2023 | DI FA | 23.02.2023
Communication Functions
Telecontrol and substation control technology with SIMATIC S7-1500R/H
Component
Version
Protocols
SIOS
TIM 1531 IRC
From V2.1
• SINAUT ST7
• DNP3
• IEC 60870-5
101, 104
https://support.industry.siemens.c
om/cs/ww/en/view/109774204
SIPLUS RIC Library for
SIMATIC S7-1500
From V1.7
• IEC 60870-5
101,102,103, 104
https://support.industry.siemens.c
om/cs/ww/en/view/109422039
• IEC 61850 MMS
https://support.industry.siemens.c
om/cs/ww/en/pv/9LA1110-6PC102BC8/pi?dl=en
IEC 61850 MMS Client AS
LIBRARY
Unrestricted | © Siemens 2023 | DI FA | 23.02.2023
Communication Functions
Redundant communication
Component
Version
Protocols
SIOS
SIMATIC Modbus/TCP
Red S7-1200/S7-1500
Modbus/TCP
https://support.industry.siem
ens.com/cs/bd/en/ps/6AV66
76-6MB40-0AX0
Redundant Open User
Communication
Various
https://support.industry.siem
ens.com/cs/ww/en/view/109
763719
Unrestricted | © Siemens 2023 | DI FA | 23.02.2023
Hint
Redundant power supply
SITOP Redundancy Module RED1200
• Redundant design in the event of power failure
• Stable DC voltage due to redundant switching of two
same power supplies
• Redundant design in the event of a power failure
• Feeding of power supplies from different supplies
• Flexible use
• Redundant power supply setup for
DC voltages from 12 to 48 V
Unrestricted | © Siemens 2023 | DI FA | 23.02.2023
Details
Manual
Ordering Information
SIMATIC S7-1500 Redundant Systems
Unrestricted | © Siemens 2023 | DI FA | 23.02.2023
Ordering Information
SIMATIC CPU S7-1500 R
• CPU 1513R-1 PN
New
• CPU 1515R-2 PN
New
6ES7 513-1RL00-0AB0
6ES7 513-1RM03-0AB0 (V3.0)
6ES7 515-2RM00-0AB0
6ES7515-2RN03-0AB0 (V3.0)
SIMATIC CPU S7-1500 H
• CPU 1517H-3 PN
• CPU 1518HF-4 PN
6ES7 517-3HP00-0AB0
6ES7 518-4JP00-0AB0
At distances of up to 10 / 40 km between
SIMATIC S7-1500 H controllers:
• MLFB Module: 6ES7 960-1FB00-0AA5 (10km)
New
6ES7 960-1FE00-0AA5 (40km)
• Single mode Fiber optic cable
LC/LC duplex crossed 9/125μ
SIMATIC S7-1500 H Bundle
(2 SIMATIC CPU 1517-3 PN, 4 sync modules up to 10m and 2 sync cables 1m)
At distances of up to 10m between SIMATIC S7-1500 H
controllers: Use of synchronization modules for fiber
optic cables up to 10 m
•
•
•
•
MLFB Module: 6ES7 960-1CB00-0AA5
MLFB Fiber Optic Cable 1m: 6ES7 960-1BB00-5AA5
MLFB fiber optic cable 2m: 6ES7 960-1BC00-5AA5
MLFB Fiber Optic Cable 10m: 6ES7 960-1CB00-5AA5
Unrestricted | © Siemens 2023 | DI FA | 23.02.2023
• 6ES7 500-0HP00-0AB0
SIMATIC S7-1500 HF Bundle
(2 SIMATIC CPU 1518-4 PN, 4 sync modules up to 10m and 2 sync cables 1m)
• 6ES7 500-0JP00-0AB0
Disclaimer
© Siemens 2023
Subject to changes and errors. The information given in this document
only contains general descriptions and/or performance features which
may not always specifically reflect those described, or which may
undergo modification in the course of further development of the
products. The requested performance features are binding only when
they are expressly agreed upon in the concluded contract.
All product designations may be trademarks or other rights of
Siemens AG, its affiliated companies or other companies whose use by
third parties for their own purposes could violate the rights of the
respective owner.
Unrestricted | © Siemens 2023 | DI FA | 23.02.2023
Contact
Publisher: Siemens 2023
Unrestricted | © Siemens 2023 | DI FA | 23.02.2023