Redundant PROFIBUS DP network with S7-400H System and Ponto PO5063V5 Remote

Transcription

1 Application Note NAP102 Redundant PROFIBUS DP network with Altus Sistemas de Informática S.A. Página: 1

2 Contents 1 Description Introduction Reference Architecture PROFIBUS Project Access to the PO5063V5 Redundant Remote I/O PO5063V5 Operation Inputs and Outputs Transference Configuration Parameterization Diagnostics I/O Data Redundancy Data Structure Input Selection Process Output Copy Process Function for I/O Treatment Execution Time from I/O Treatment Function Diagnostics Revisions Altus Sistemas de Informática S.A. Página: 2

3 1 Description This document describes the utilization of the Altus redundant PROFIBUS remote and its integration with the S7-400H redundant system from Siemens communicating through PROFIBUS DP net. The main objective is to guide the implementation of this system. We recommend manuals and manufacturer support (Altus and Siemens) consulting for completely understanding of the equipment and the system. For different architectures besides described in this document we also recommend manufactures consulting. 2 Introduction The Ponto Series is a distributed control system with remote I/O. It has a flexible architecture that allows the access to remote modules via different fieldbuses. The I/O modules and fieldbuses head can communicate with Altus equipment and CPUs from another manufacturers. Therefore Altus Redundant PROFIBUS DP Head PO5063V5 module possess redundant characteristics that allows the simultaneous connection with two PROFIBUS DP nets. For that reasons the Redundant PROFIBUS DP Head PO5063V5 can be used to communicate with a redundant S7-400H system from Siemens. The steps to create the redundant system with Siemens S7-400H and Altus PO5063V5 are: Architecture definition PROFIBUS project Access to redundant remote I/O and diagnostics Application (interlocking, controlling and/or logic processing) This document uses a reference architecture, which is describe in the following section, to develop the applications. Altus Sistemas de Informática S.A. Página: 3

4 3 Reference Architecture The reference architecture is assembled with the following items: Redundant cluster with 2 S7-400H CPUs Redundant PROFIBUS DP net 2 PO5063V5 remotes Analog and digital modules from Ponto Series 1 ET200M (IM153-2) remote with SM322 module Step 7 programming software with support for S7-400H redundant system CPU 417-H CPU 417-H System S7-400H FIBER-OPTIC PROFIBUS DP Net A PROFIBUS DP Net B PO5063V5 Remote 04 PO5063V5 Remote 03 ET200M Remote 02 Altus Sistemas de Informática S.A. Página: 4

5 4 PROFIBUS Project The software SIMATIC STEP 7 from Siemens must be used to create a new project and configure the S7-400H redundant system. It will not be described the process for SIMATIC STEP 7 installation and license. It is considerate that the software is installed, configured and working properly. The software version used to develop the application is The next steps must be following to create the project system: Start the SIMATIC Manager software. Create a new project: File New Define a name for the project, ex: S7_Proj01. Select the S7_Pro01 folder and add the first net: Insert Subnet PROFIBUS. Altus Sistemas de Informática S.A. Página: 5

6 Repeat the previously step and create the second PROFIBUS net, because it is a redundant system. Add the redundant station H: Insert Station SIMATIC H Station Select the Hardware from SIMATIC H Station(1) and edit: Edit Open Object. In this moment another configuration software will open, HW Config. The hardware catalog can be opened: View Catalog. Altus Sistemas de Informática S.A. Página: 6

7 All the components to mount the station are available in the CATALOG. To mount the station H will be used the item SIMATIC 400 from CATALOG. Now it is necessary to mount the S7-400H redundant station, starting by the rack. Add the rack into station: Select rack UR2 moving the mouse to the project screen. Altus Sistemas de Informática S.A. Página: 7

8 Add the PS A power supply on Rack (0) Select and add the 417-4H V3.0 CPU on slot 3 rack (0). Add two synchronism sub modules from H system on slots IF1 and IF2 Altus Sistemas de Informática S.A. Página: 8

9 Add the PROFIBUS net created previously. Select the master PROFIBUS DP, slot X2 Add the net: Insert Master System. It will appear the screen to select the net, choose PROFIBUS (1) net. Altus Sistemas de Informática S.A. Página: 9

10 Press OK It will be show the PROFIBUS (1) net project connected to the master DP. Once rack 0 ready it is necessary to duplicate the system. Select rack 0 Copy: Edit Copy. Paste to the project: Edit Paste. Add PO5063V5 slave on PROFIBUS (1) net Altus Sistemas de Informática S.A. Página: 10

11 Configure slave with its modules, including the PO9100 redundant module. Duplicate slave on PROFIBUS (1) to PROFIBUS (2) net Select slave Copy: Edit Copy Altus Sistemas de Informática S.A. Página: 11

12 Select PROFIBUS (2) net Paste slave: Edit Paste Altus Sistemas de Informática S.A. Página: 12

13 5 Access to the PO5063V5 Redundant Remote I/O The access to the redundant remote I/O is the routine to bond the application data. This step will integrate the data from PO5063V5 module in one unique structure to facilitate the application. To implement this step it is necessary to observe the following items: PO5063V5 operation I/O Data Redundancy Diagnostic Redundancy 5.1 PO5063V5 Operation The remote PO5063V5 is composed by two identically modules (remote heads) and each modules is connected to the PROFIBUS net. Both heads and I/O modules are connected to the GBL serial bus (Altus propriety) with 12 Mbps. The modules change information through the GBL bus (head redundancy, inputs, outputs, parameterization, configuration and diagnostics). It exists a redundant hot standby mechanism between the remote heads. During usual operation one head is active and the other one is backup. During abnormal operation one of the heads can be unavailable and send a diagnostic signal. Position 1 Position 0 PO5063V5 Remote 04 net A PO2132 PO1112 net B GBL serial bus Inputs and Outputs Transference Each remote head receives the outputs coming from their master and send the inputs to the master through the PROFIBUS DP net (A or B). The active head communicate with the I/O modules writing the outputs sent by the master and reading the inputs that will transfer to the PROFIBUS master. Altus Sistemas de Informática S.A. Página: 13

14 The backup head receives a valid copy from the master outputs, but it ignores the data. The backup head also transmits to the master a copy from the inputs, but they are not actualized and must be ignore it. The active and backup heads also transmit to their corresponding master information about the status (active or step). With this information the master receives valid data from the active head and must to ignore the input data from the step head. Besides the input and output transferring cycle the PROFIBUS communication also uses some additional communication, like consistent configuration, parameterization and diagnostics Configuration During the power on of the remote or communication restart, the remote receives the configuration from the master. The remote checks the inputs and outputs modules installed on the bus crossing the information loaded in the application project with the physical configuration. The remote is not allowed to start the system if some module is installed on the bus and it is not declared in the master. Otherwise when modules are declared in the master and they are not installed on the bus, the user can choose between start or not to start the remote. The active head really executes the input and output module consistence. The backup head always indicates right configuration without consistence. However the backup head will execute the consistence procedure when assumes the active position (switchover) Parameterization Parameters are used to configure the behavior of the remote variables and its I/O modules. For example, if the channel from analog module permits the configuration in different modes you can set up the mode (4-20 ma, 0-10V, 0-20 ma, etc). The parameterization also occurs during the power on of the remote or communication restart. The active remote transmits the received parameters to the corresponding I/O modules. The step head just saved in the memory. If the step head assumes the position of the active head (switchover) the parameterization of the I/O modules will start again Diagnostics Diagnostics typically inform abnormal conditions (failures) or return to usual conditions. Both heads can transmit diagnostics to the master. In this case the master can consider all the diagnostics. The active head will send diagnostics from it self and the modules installed on the GBL bus. The step head only will send the diagnostic from it self. 5.2 I/O Data Redundancy Data Structure It is defines two main blocks in the CPU S7-400H for the I/O area that it will use from the application. Altus Sistemas de Informática S.A. Página: 14

15 DB_I block, with input operands I DB_Q block, with output operands Q Besides the two main blocks another four blocks are allocated automatically. DB_I_A block, with input operands I that are received from net A. The block has the same size and structure that DB_I block but with addition of remote status operand (operand RE). DB_I_B block, with input operands I that are received from net B. The block has the same size and structure that DB_I block but with addition of remote status operand (operand RE). DB_Q_A block, with output operands Q that are transmitted to net A. The block has the same size and structure that DB_Q block but with addition of the optionally switchover command (operand RS). DB_Q_B block, with output operands Q that are transmitted to net B. The block has the same size and structure that DB_Q block but with addition of the optionally switchover command (operand RS). Altus Sistemas de Informática S.A. Página: 15

16 5.2.2 Input Selection Process The CPU Siemens receives information from net A and B from each remote PO5063V5, but must to consider only the inputs from the active remote head. The following picture shows how to select the inputs from each remote PO5063V5. Inputs from remote head A Inputs from remote head B RE_A = 1 RE_A!= 1 another RE_B!= 1 RE_B = 1 condition RE_A RE_B Valid inputs considered in the application program The picture shows that the operand RE must to be consider for each remote head (RE_A for net A, RE_B for net B). When RE_X value is 1 indicates that the remote head x is active. Different values can indicate failures. When RE_A value is 1 and RE_B value is not 1, the inputs from remote head A must be considered When RE_B value is 1 e RE_A value is not 1, the inputs from remote head B must be considered In different cases the latest values from the inputs must be freeze. A diagnostic message will point the general failure. Altus Sistemas de Informática S.A. Página: 16

17 5.2.3 Output Copy Process The process to copy the outputs is really simple. The outputs from application must be copy for both remote outputs (net A and B). The operands RS can command a manual switchover. This is an optional command Function for I/O Treatment The processes described previously demand simple processing for copy and select. This process is embedded in a function that must be called from the main process (OB1). The function is generated automatically by the compilation and it will receives the following entries: The hardware configuration file generated from STEP First address of the operand I from the inputs block in the user application First address of the operand Q from the outputs block in the user application The function can be simple but the compilation will eliminate the task and it will reduce the possibility of error from function codification Execution Time from I/O Treatment Function The function for I/O treatment increases the cycle time of the CPU S7-400H. Tests with the CPU 6ES 417-4HL04-0AB0 presents the following information: TFB: fixed time for transference block treatment = 0.12 ms TB: transference time for a byte = ms NBT: number of transferred blocks NB: number of transferred data bytes The NBT value correspond NR * 3. The NR is the number of the remote PO5063V5. From the 3 blocks: One is used to transfer the inputs from active remote head to the user application inputs. Two are used to transfer the outputs from user application to the remote outputs. The NB values can be calculated adding the I/O data bytes. The execution time of the function is: NBT * TFB + NB * TB Altus Sistemas de Informática S.A. Página: 17

18 For example, considering a system with 20 remotes, with a total of 320 analog points (640 bytes) and 1600 digital points (200 bytes). The execution time will be approximately: 20 * 3 * ( ) * = 8.04 ms 5.3 Diagnostics The OB82 interruption is executed every time that occurs an I/O diagnostic. It will returns the address from the remote head that sends the diagnostic. With the address the function SFC13 can recover the diagnostic message that it was send by the remote head. 6 Revisions Revisão: A Data: 11/11/2004 Tradução: Jose Lozano Autoria: Gustavo Castro Aprovação: Luiz Francisco Gerbase Natureza das alterações: Primeira emissão do documento. Altus Sistemas de Informática S.A. Página: 18