PROFINET System Redundancy with SINAMICS G220 and SIMATIC S7-410

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1. Introduction

1.1. Overview

The SINAMICS G220 family converters support PROFINET S2 system redundancy, ensuring continuous operation during controller defects or replacements, thereby reducing downtimes. This requires an S7-410 fault-tolerant system (H system), consisting of primary and backup CPUs that synchronize via fiber optics. If one CPU fails, the other takes over automatically.

1.2. Principle of operation

S2 system redundancy enhances reliability and fault tolerance by using two identical components in parallel. If one fails, the other assumes its function. This example demonstrates S2 system redundancy with a SINAMICS G220 operating as a PROFINET device on a fault-tolerant system without additional hardware.

Schematic diagram: A fault-tolerant system with two CPUs connected via fiber optics to a SINAMICS G220 drive.

Advantages:

• No plant downtime during controller failure.
• Hot-swappable components during operation.
• Configuration changes possible during operation.
• Automatic synchronization after component replacement.

Limitations of SINAMICS:

• PROFINET-IRT is not supported.
• No simultaneous operation of Shared Device and system redundancy.
• Maximum of 2 cyclic PROFINET connections.
• System redundancy only via the PROFINET X150 interface.
• Setpoint data remains valid when switching controllers.

Limitations on the engineering system:

Startdrive does not support direct drive configuration as a client on a redundant system. The SINAMICS G220 must be integrated via a GSDML file.

Limitations of the S7-410 fault-tolerant system:

Details can be found in the system manual "SIMATIC PCS 7 Process Control System CPU 410 Process Automation V8".

Required knowledge:

Basic knowledge of PCS 7 and SINAMICS G220 is required.

1.3. Components used:

Components can be obtained from the Siemens Industry Mall.

Application example components:

• Documentation: 109932875_S2_Systemredundancy_S7-410H_G220_DOC_V10_en.pdf
• Example project: 109932875_S2_Systemredundancy_S7-410H_G220_PROJ_V10.zip

2. Engineering

2.1. Hardware setup

The following images show the hardware setup and wiring:

• S7-410H (1): Mount the redundant system on one or two mounting rails. Connect the two CPUs with fiber-optic cables to two synchronization modules per CPU. Set up the PROFINET ring via the CPUs' X8 P1 R and X8 P2 R PROFINET interface.
• Power supply (2): The load current power supply (PM) supplies system power (PS) and core modules (CPU) with DC 24V. SIMATIC series devices are recommended for peripheral power supplies.
• Synchronization modules (S7-410H only) (3): Create two redundancy connections between H CPUs using fiber-optic cables and a total of four synchronization modules (two per CPU).
• Fiber-optic cables (S7-410H only) (4): Connect the two synchronization modules for each CPU with a pair of fiber-optic cables.

2.2. Topology

The following topology is used to integrate the SINAMICS G220 into the system via PROFINET:

Diagram Description: A diagram shows two SIMATIC S7 CPU 410-5H units (CPU1 and CPU2) connected via PROFINET interfaces (X8 P1, X8 P2) and fiber optics. Both CPUs are connected to a SINAMICS G220 drive via its PROFINET interface (X150 P1, P2).

2.3. Configuration

2.3.1. Configuration of the SIMATIC H system

Follow these steps to configure the SIMATIC S7 H system in PCS 7:

1. Create a new PCS 7 project using the PCS 7 Wizard. Select an AS410-2H or enter the part number of your fault-tolerant S7-410H.
2. Specify the number of hierarchy levels for your project and select whether an OS should be created.
3. Name the project and exit the wizard.
4. Assign the IP address for the first controller of the S7-410 H system. Open the hardware configuration (HW Config) and the properties of the X8 PROFINET interface of the first SIMATIC S7 controller.
5. In the "General > Interface" tab, open the PROFINET interface properties.
6. Enter the desired IP address (e.g., 192.168.1.1). Create a new subnet, give it a descriptive name, and assign it to the IP address.
7. Assign the IP address for the second controller of the S7-410 H system by opening HW Config and the properties of the X8 PROFINET interface of the second SIMATIC S7 controller.
8. In the "General > Interface" tab, enter the IP address (e.g., 192.168.1.2), assign the subnet, and change the device name.
9. Configure the MRP ring by selecting "Manager (Auto)" role under "Media redundancy" in the X8 interfaces properties.

2.3.2. Configuration of the SINAMICS G220 drive

The SINAMICS G220 drive is integrated using a GSDML file. The GSDML file can be downloaded from the article "SINAMICS G220 PROFINET GSDML" (https://support.industry.siemens.com/cs/ww/en/view/109901084). This example assumes basic configuration of the drive is complete.

Install the GSDML file:

1. Download and extract the GSDML file.
2. Open SIMATIC Manager and the multiproject.
3. Open the HW Config of the CPU.
4. In HW Config, navigate to "Options > Install GSD File...".
5. Browse to the extracted folder, select the GSDML file, and install it.

Configure the G220 hardware:

1. Drag the GSDML for the SINAMICS G220 from the "Standard" hardware catalog under "PROFINET IO > Drives > SINAMICS" into the HW Config.
2. Drag and drop the standard telegram (e.g., telegram 20) into slot 1.3 of the "DRIVE" module.
3. Open the G220 properties, modify the device name (e.g., "G220"), and assign an IP address (e.g., 192.168.1.3).
4. Switch to the "Media redundancy" tab and assign the role "Client". Adjust the "watchdog time" to be greater than 200 (e.g., 202.000 ms) as MRP is configured.

ATTENTION: Improper MRP ring configuration can lead to accidents and system damage due to the watchdog time. If this is unacceptable, consider S2 redundancy without an MRP ring. Ensure all safety precautions are taken and consult experts if needed.

2.3.3. Symbol table

Create symbolic names for input and output tags in the symbol table. Standard telegram type 20 uses specific output and input words:

Save the symbol table, then open and compile the HW Config.

2.4. CFC engineering

Preface: This example uses the "Drive" template from the Advanced Process Library (APL) for quick drive integration. The template includes blocks like "FbDrive" and "MotSpdCL" with necessary connections. Interlock blocks ("Interlock", "Permit", "Protect") are also included and can be deleted if not needed. Connect the "PZDIn1" input of "FbDrive" to the first input word "ZSW1" of the frequency converter and set the telegram type. Other signal connections are handled by the compiler.

This application example provides a simple, standardized solution for a quick start.

Drive system parameterization is not part of this example.

2.4.1. Configuration

1. Switch to SIMATIC Manager.
2. Open the menu: "File > Open...".
3. Go to the "Libraries" tab, select "PCS 7 AP Library V91", and confirm with "OK".
4. In the "PCS 7 AP Library V91", select the "Templates" folder, highlight the "Drive" template, right-click, and select "Copy".
5. In your master data library, go to "Process Tag Types", right-click, and "Paste" the copied template.
6. Copy the template from your master data library into your plant hierarchy and assign a plant designation.

Configure the MotSpdCL block:

1. Open the CFC.
2. Open the object properties of the "MotSpdCL" block.
3. Assign a meaningful name and description to your drive.
4. Go to the "I/Os" tab.
5. In the "Identifier" column, assign texts for proper display in the OS faceplate:
• UserAna1.Value: Torque
• UserAna2.Value: Power
• AV_Out.Value: Current
6. Optionally, set "IdleTime" to 0 if not needed. Optionally, delete "Interlock", "Permit", and "Protect" blocks if not required.

ATTENTION: Improper project engineering and operation can lead to accidents and system damage. Ensure proper integration of protection mechanisms and parameterize blocks and drives correctly. Program structure and parameterization may differ from this example. Failure to do so can result in accidents and plant damage. For more information, refer to the PCS 7 Advanced Process Library Manual (https://support.industry.siemens.com/cs/ww/en/view/109812806).

Interconnect FbDrive:

1. In the CFC chart, select the "PZDIn1" input of the "FbDrive" block. Right-click and select "Interconnection to Address...".
2. Select the first input word of the G220 (e.g., "IW 512_G220"). Other words are connected automatically during compilation.
3. Set the "telegram" parameter to "20".

For more information about FbDrive, see the PCS 7 Advanced Process Library manual (https://support.industry.siemens.com/cs/ww/en/view/109812806).

2.4.2. Process value scaling and units

Setpoint speed "STW2" and actual speed "ZSW2" are transmitted as integers (0-16384). PCS 7 scales raw values to process values in the "FbDrive" block. Scaling can be done in several places within CFC:

Values PZDIn2, PZDIn2Scale, and PZDIn2Unit are transmitted to the MotSpdCL block via "SpeedLink", "Speedscale", and "SpeedUnit" connectors.

For pump and fan applications with G220, values in percent or revolutions per minute are recommended.

Units of measurement:

Units of measurement in PCS 7 are coded per IEC 611582 standard. Refer to the APL manual for a complete list (https://support.industry.siemens.com/cs/ww/en/view/109812806/156301357579).

Compiling and downloading to the PLC:

1. In the CFC chart, select "Compile".
2. Select "Entire program" and check "Generate module drivers".
3. Download to the PLC.
4. Close the CFC.

3. Downloading and operating the OS

Compiling the OS: Compiling the OS automatically generates the motor symbol and corresponding faceplates.

1. Compile the OS.
2. Open the WinCC application.
3. Configure the computer name using "Computer".
4. Use the "OS-Project Editor" to configure the OS layout.
5. Download the OS.

Monitoring and control: The SINAMICS G220 is monitored and controlled via the MotSpdCL faceplate. The faceplate displays motor status and measured values like Readback, Torque, Power, and Motor current.

Start the drive:

1. Start the OS runtime.
2. Switch to the screen with the block icon.
3. Set a setpoint and start the motor using the Forward command.

4. Appendix

4.1. Service and support

SiePortal: An integrated platform for product selection, purchasing, and support, combining Industry Mall and Online Support Portal (SIOS). It offers "Products & Services" and "Support" sections. "mySieportal" manages personal data and orders. Access SiePortal at sieportal.siemens.com.

Technical Support: Siemens Industry Technical Support provides fast, competent support for technical queries with tailored offers, from basic support to individual contracts. Contact via web form: support.industry.siemens.com/cs/my/src.

SITRAIN – Digital Industry Academy: Offers globally available training courses with practical experience and innovative learning methods. More information at siemens.com/sitrain.

Industry Online Support app: Available for iOS and Android for optimum support on the go.

4.2. Links and literature:

• [1] Siemens Industry Online Support: https://support.industry.siemens.com
• [2] Link to the article page of the application example: https://support.industry.siemens.com/cs/ww/en/view/109932875
• [3] Manual: SIMATIC PCS 7 Process Control System CPU 410 Process Automation V8: https://support.industry.siemens.com/cs/ww/en/view/109826184
• [4] Download: SINAMICS G220 PROFINET GSDML: https://support.industry.siemens.com/cs/ww/en/view/109901084

4.3. Change documentation:

Version: V1.0

Date: 03/2023

Change: First edition