Applications & Tools. Setup and Configuration of a Redundancy via PRP and HSR SCALANCE X204 RNA, CP RNA, SOFTNET-IE RNA

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1 Setup and Configuration of a Redundancy via PRP and HSR SCALANCE X204, CP 443-1, SOFTNET-IE Application Description September 2013 Applications & Tools Answers for industry.

2 Warranty and Liability Warranty and Liability Note The Application Examples are not binding and do not claim to be complete regarding the circuits shown, equipping and any eventuality. The application examples do not represent customer-specific solutions. You are responsible for ensuring that the described products are used correctly. These Application Examples do not relieve you of your responsibility to use safe practices in application, installation, operation and maintenance. When using these application examples, you recognize that we cannot be made liable for any damage/claims beyond the liability clause described. We reserve the right to make changes to these Application Examples at any time and without prior notice. If there are any deviations between the recommendations provided in this application example and other Siemens publications e.g. catalogs the contents of the other documents have priority. Copyright Siemens AG 2013 All rights reserved Caution We do not accept any liability for the information contained in this document. Any claims against us based on whatever legal reason resulting from the use of the examples, information, programs, engineering and performance data etc., described in this application example will be excluded. Such an exclusion will not apply in the case of mandatory liability, e.g. under the German Product Liability Act ( Produkthaftungsgesetz ), in case of intent, gross negligence, or injury of life, body or health, guarantee for the quality of a product, fraudulent concealment of a deficiency or breach of a condition which goes to the root of the contract ( wesentliche Vertragspflichten ). The damages for a breach of a substantial contractual obligation are, however, limited to the foreseeable damage, typical for the type of contract, except in the event of intent or gross negligence or injury to life, body or health. The above provisions do not imply a change of the burden of proof to your detriment. Any form of duplication or distribution of these application examples or excerpts hereof is prohibited without the expressed consent of Siemens Industry Sector. The functions and solutions described in this entry are mainly limited to the realization of the automation task. Please furthermore take into account that corresponding protective measures have to be taken in the context of industrial security when connecting your equipment to other parts of the plant, the enterprise network or the Internet. Further information can be found under the Entry ID Siemens Industry Online Support This document is an article from the Siemens Industry Online Support. The following link takes you directly to the download page of this document: V10, Entry ID:

3 Table of Contents Copyright Siemens AG 2013 All rights reserved Table of Contents Warranty and Liability Task Overview Automation task Solution Approach with network redundancy Approach via media redundancy Description of the core functionality Realizing a redundancy Demonstration of the redundancy Diagnosing the redundancy Hardware and software components Validity Components used Alternative solutions Basics of (bumpless) Redundancy The redundancy protocol PRP Description Setting up a redundancy network with PRP Communication with PRP Modifying the Ethernet data packet The redundancy protocol HSR Description Setting up a redundancy network with HSR Communication with HSR Modifying the Ethernet data packet Combination of PRP and HSR Description Setting up a redundancy HSR-PRP connection The SIMATIC NET product portfolio for Diagnostic options Overview Statistic displays SOFTNET-IE diagnostic Configuration and Settings Configuring the CP Configuring the SOFTNET-IE Configuring the SCALANCE X204 (HSR) Installation Hardware installation Software installation Standard software Application software Starting the Application V10, Entry ID:

4 Table of Contents 6.1 Requirements Addressing the modules Overview of IP addresses Assigning the IP address Loading the controllers Operating the Application Requirements Demonstrating the redundancy Diagnostic at PRP Diagnostic at HSR Related Literature Bibliography Internet links History Copyright Siemens AG 2013 All rights reserved V10, Entry ID:

5 1 Task 1 Task 1.1 Overview Introduction The enhanced level of automation of industrial plants in order to raise productivity and quality increases the dependency on the availability of automation systems at the same. Failure of an automation system can cause high costs due to production failure and downtime caused by, for example, the failure of a CPU or of the network connection, e.g. by wire break. To counteract here, the implementation of a redundancy process which (almost) guarantees one hundred percent plant availability, even in the event of an error, is very important. There are numerous redundancy options with various approaches and implementations. What mechanism is used is mainly determined by the application. 1.2 Automation task Copyright Siemens AG 2013 All rights reserved General If Ethernet is used in automation, specific protocols and appropriate hardware have to ensure the availability. Time and security critical applications in plants (e.g. in energy distribution, power plant and ship automation, tunnel construction) do not tolerate any downtime. The implementation of a redundancy without changeover (bumpless) has highest priority here. The automation task consists in allowing bumpless redundancy for a sophisticated industrial application. V10, Entry ID:

6 1 Task Overview The graphic below shows the principle of the automation task: Figure 1-1 Control level Redundant connection Failsave, industrial plant network Copyright Siemens AG 2013 All rights reserved Production cell A Description and requirements Production cell B To guarantee full network functionality despite the failure of components or the connection, an automation plant is to be equipped and configured with a redundancy process. This is to prevent that a single fault brings the plant to a halt and ensures that the communication remains intact. In all redundantly-designed systems monitoring has an important role. A failure means the loss of redundancy and has to be detected, localized and removed, before a second failure occurs. This is why various diagnostic options have to be implemented in the automation plant. The requirements for the automation task are as follows: In the event of a failure of a component or network connection, data communication has to continue interruption-free. The application has to continue to operate without restriction in the event of an error, The network must not be hindered or overloaded by double data packets or loop formation. Transparency, compatibility and investment security must be guaranteed by the use of standardized protocols. In the event of an error, the cause of the error has to be detected and localized quickly. V10, Entry ID:

7 2 Solution 2 Solution To implement the automation task and to fulfill the mentioned requirements, this application provides two approaches: approach with network redundancy approach with media redundancy 2.1 Approach with network redundancy Schematic layout The following figure gives a schematic overview of the most important components of the solution: Figure 2-1 PG with SOFTNET-IE V8.2 Control level Copyright Siemens AG 2013 All rights reserved Redundant, LAN A industrial plant network LAN B SCALANCE X204 (PRP) SCALANCE X204 EEC (PRP) Production cell A S7-300 Production cell B Production cell C S7-400 with CP Structure A redundant network (; Redundant Network Access) is setup by two separate network topologies. Core elements are the connecting components: SIMATIC S7-400 with a CP Software package SIMATIC NET SOFTNET-IE SCALANCE X204 EEC (PRP) SCALANCE X204 (PRP) V10, Entry ID:

8 2 Solution All these devices are provided with two interfaces for connecting the two independent networks (LAN A and LAN B). Terminal devices or production cells that do not support the redundancy process (in this example the S7-300 station) can be connected behind a SCALANCE X The redundant, parallel network structure is on the basis of the standardized PRP (Parallel Redundancy Protocol) mechanism in the IEC Advantages / customer benefits Very high plant availability due to parallel data transfer via separate network structures. Application also in time-critical applications due to bumpless switchover. High flexibility in network setup since network structures can be designed as line, tree, star and ring. Possible integration into network management systems. Fast commissioning without mandatory configuration. Copyright Siemens AG 2013 All rights reserved V10, Entry ID:

9 2 Solution 2.2 Approach via media redundancy Schematic layout The following figure gives a schematic overview of the most important components of the solution: Figure 2-2 Control level PG SCALANCE X204 (HSR) Production cell B SCALANCE X204 (HSR) S7-400 Copyright Siemens AG 2013 All rights reserved Production cell A S7-300 SCALANCE X204 (HSR) Redundant, industrial plant network Production cell C SCALANCE X204 EEC(HSR) Structure A redundant communication structure in the shape of a ring topology is setup. Nodes of the redundancy are the following components: SCALANCE X204 EEC (HSR) SCALANCE X204 (HSR) All these devices are provided with two interfaces to connect network segments to the ring structure. The redundant ring structure is on the basis of the standardized HSR (Highavailability Seamless Redundancy Protocol) mechanism in the IEC V10, Entry ID:

10 2 Solution Advantages / customer benefits Very high plant availability due to parallel data transfer in ring-shaped network structures. Application also in time-critical applications due to bumpless switchover. Possible integration into network management systems. Fast commissioning without mandatory configuration. 2.3 Description of the core functionality Realizing a redundancy Copyright Siemens AG 2013 All rights reserved The core function in this application is the (Redundant Network Access) concept. at Siemens Industry stands for hardware and software for the realization of redundancy solutions. It includes the standardized redundancy processes PRP and HSR in IEC These processes are protocols for compensating cable/module failures in the network. The big advantage of PRP and HSR is the interruption-free switchover which avoids any switchover time in the event of an error and thus offers the highestpossible availability. Basis for this is the double transmission of frames in two directions. In fault-free operation the receiver thus receives two identical data packets. The redundancy protocol ensures that it only uses the first data packet and rejects the second. If only one packet is received, the receiver knows that a failure has occurred on a different path and responds accordingly Demonstration of the redundancy To demonstrate the redundancy function this application includes a small example scenario. A S7 communication is setup between the two controllers (S7-300 and S7-400) via which data is exchanged. This includes the current time which the S7-300 station sends to the partner station (S7-400). In order to demonstrate that this data exchange is also guaranteed in the event of an error, a network error is simulated by removing a connecting cable Diagnosing the redundancy The application furthermore describes how the redundancy nodes (partly after according configuration) (can) respond to the detection of the error. Error display via LEDs (for hardware components) Statistic display in web-based management of the components Visualization through redundancy status display (for software components) Network information via the Simple Network Management Protocol (SNMP) V10, Entry ID:

11 2 Solution 2.4 Hardware and software components Validity This application is valid for STEP 7 V5.5 SP3 S7-300 S Components used The application was set up with the following components. The first column illustrates which components are required for what approach. Copyright Siemens AG 2013 All rights reserved Hardware components Table 2-1 PRP, HSR PRP HSR Component No. Order number Note CPU PN/DP 1 6ES7416-3ER05-0AB0 From firmware V5.3.2 PS A 1 6ES7407-0KA00-0AA0 PS 307 5A 1 6ES7307-1BA01-0AA0 CPU PN/DP 1 6ES7317-2EK14-0AB0 PC 1 Configuration computer Industrial Ethernet patch cable 9 CP GK7443-1EX20-0XE0 Requires STEP 7 V5.5 SP2 and CPU with firmware from V5.3.2 onward SCALANCE X204 (PRP) 1 6GK5204-0BA00-2KB2 SCALANCE X204 EEC (PRP) 1 6GK5204-0BS00-3LA3 Field PG M3 1 6ES7715- Serves as PC station for the SOFTNET-IE software SCALANCE XB GK5008-0BA00-1AB2 Or a different switch; it has to be able to process frames up to 1532 byte (oversize frames). SCALANCE X204 (HSR) 3 6GK5204-0BA00-2MB2 SCALANCE X204 EEC (HSR) 1 6GK5204-0BS00-2NA3 V10, Entry ID:

12 2 Solution Software components Table 2-2 PRP, HSR PRP Component No. Order number Note STEP 7 V ES7810-4C The current service pack (SP 3; version 07/2013) can be found here: ens.com/ww/view/en/ HSP1097 SOFTNET-IE V GK1711-1EW08-2AA0 The current STEP 7 Hardware Support Packages (HSPs as of: 06/2013) can be found here: Requires CP 1612 A or two gigabit Ethernet interfaces Copyright Siemens AG 2013 All rights reserved Sample files and projects The following list includes all files and projects that are used in this example. Table 2-3 Component Note CODE_v10.zip This zip file contains the user program DOKU_v10_en.pdf This document. V10, Entry ID:

13 2 Solution 2.5 Alternative solutions Copyright Siemens AG 2013 All rights reserved Table 2-4 To increase the availability in communication networks, several redundancy options are available. Specific protocols provide a loop-free network topology and the detection of communication interruptions. In practice, neither perfect network topology nor the perfect media redundancy protocol which cover all application areas and requirements exist. Which topology and protocol is the most suitable for the automation network is always also dependent on additional factors such as: the physical installation specifications. the requirements of the application to the switchover time. the number of network nodes. the requirements to the data transmission (real time/standard Ethernet). The most common protocols are: Protocol Abbr. Reference Category Link aggregation LAG IEEE 802.1ad Spanning Tree Protocol STP IEEE 802.1d Rapid Spanning Tree Protocol RSTP IEEE 802.1d-2004 Multiple Spanning Tree Protocol MSTP IEEE 802.1s High Speed Redundancy Protocol HRP SIEMENS proprietary Standby connection SIEMENS proprietary Media Redundancy Protocol MRP IEC Media Redundancy for Planned Duplication MRPD IEC Redundant paths Ring topology with redundancy manager Parallel Redundancy Protocol PRP IEC Dual network design High Availability Seamless Redundancy HSR IEC Ring topology Note An overview and short description of these redundancy protocols can be found in the Siemens Industry Online Support under entryid: V10, Entry ID:

14 3 Basics of (bumpless) Redundancy 3 Basics of (bumpless) Redundancy Sophisticated industrial applications demand a bumpless changeover in the event of an error. One approach for the realization of such a process is to transmit each data packet several times at the same time via different paths that are independent from each other. The receiver uses the first received data packet and eliminates the duplicate that arrives later. The standard IEC even specifies two such protocols: The "Parallel Redundancy Protocol" (PRP). The High-availability Seamless Redundancy (HSR). 3.1 The redundancy protocol PRP Description Copyright Siemens AG 2013 All rights reserved PRP belongs to the category of network redundancy and is based on two independent networks of any topology (LAN A, LAN B). As compared with other redundancy processes PRP is implemented in the terminal devices. The protocol is realized in a software layer that is imported above the security layer (link layer). The terminal devices have each at least two separate network connections that are each connected to independent networks. The PRP protocol is a redundancy solution on layer 2. One component appears on both networks with the same MAC address (Media Access Control), so that all protocols here can be used for the network management without changes. The detection of the frame duplicate is performed via an additional trailer at the end of the Ethernet data packet. Figure 3-1 PRP terminal device PRP terminal device LAN A LAN B PRP terminal device PRP terminal device PRP terminal device In order to ensure high availability in the event of an error, the redundancy nodes send their data packets via LAN A and LAN B. V10, Entry ID:

15 3 Basics of (bumpless) Redundancy PRP network Setting up a redundancy network with PRP The topology of a PRP network consists of two fully independent Ethernet subnetworks. The two networks (LAN A or LAN B) can either have identical structure or they can differ in topology or performance. Note The structures should at least be similar since the duplicate filter is undone if the difference is too extreme due to too big a time difference. A PRP network can be setup with PRP-capable terminal devices as well as with standard components. The following graphic shows how a PRP network is to be setup with the mentioned components. Figure 3-2 DAN P SAN DAN P Copyright Siemens AG 2013 All rights reserved SAN Terminal device (DAN P) LAN A LAN B RedBox DAN P SAN A terminal device with PRP functionality is called "Double Attached Node for PRP" (DAN P) and has each a connection to each of the two independent networks (LAN A or LAN B). In the SIMATIC NET product range, for example, the following modules are PRPcapable: CP PC station with SOFTNET-IE PRP-capable SIPROTEC (EN100 module with LC connections and application version from V4.1x onward) protection devices SCALANCE X204 (EEC) (PRP) RuggedCom RS950G V10, Entry ID:

16 3 Basics of (bumpless) Redundancy Note Each data packet that is transmitted via the PRP mechanisms is given an identification that specifies whether it transmits via LAN A or LAN B. Observe the continuously correct connection of the PRP ports of the nodes to LAN A or to LAN B. A data packet with the identification "LAN A" also has to be received at the appropriate port at the receiver. Standard component (SAN) Standard components with an individual network interface are called "Single Attached Node" (SAN) and can be directly connected to one of the two networks. In this case, the device does not have a redundant path in the event of a failure and does not benefit from the network redundancy. However, a SAN can also be connected to a "Redundancy box" (RedBox). SANs do not have to support the PRP functionality. Copyright Siemens AG 2013 All rights reserved System connection (RedBox) A redundancy box (RedBox) makes it possible to connect one or several SANs to the two networks and takes on the PRP functions in place of all the SANs connected to it. From the SIMATIC NET product range, for example, the following modules act as RedBox: SCALANCE X204 (EEC) (PRP) RuggedCom RS950G V10, Entry ID:

17 3 Basics of (bumpless) Redundancy Communication with PRP The specification of PRP provides that two terminal devices are connected to each other via two independent networks (LAN A and LAN B). Each terminal device is represented in the two networks with the same MAC and IP address. Figure 3-3 Application Application Network Transport layer Network layer Transport layer Network layer Redundancy Tx PRP Rx Tx PRP Rx Ethernet Port A Tx Rx Port B Tx Rx Port A Tx Rx Port B Tx Rx Copyright Siemens AG 2013 All rights reserved Sending LAN A LAN B A PRP-capable terminal device doubles each frame to be sent at the PRP interface. The two duplicates are sent to the communication partner via the two ports of the PRP interface via two separate networks LAN A and LAN B. If a SAN is connected with a RedBox, the RedBox performs the PRP functions in place of the SANs: It doubles the frame to be transmitted and sends it via LAN A and LAN B to the communication partner. The RedBox therefore works as a type of redundancy proxy for every type of standard component. Receiving Correspondingly, the two duplicates are received by a PRP-capable terminal device via LAN A and LAN B to the two ports of the PRP interface. The PRP unit passes the first arriving packet on to the application layer and discards the second (identical) packet. The interface for the application is therefore identical to any other Ethernet interface. If the receiver is a standard component connected through a RedBox, the RedBox takes on the duplicate detection in its place and only passes on the first received frame to the addressee. The second frame is discarded. V10, Entry ID:

18 3 Basics of (bumpless) Redundancy Special case with SAN A SAN that is connected without RedBox can communicate with all DAN Ps and with SANs of the same network (either LAN A or LAN B) in a PRP network. SAN has no connection to the nodes of the other network. If a SAN is also to communicate with the node of the other network, a RedBox is required. Note The first frame of an unknown node is discarded in PRP mode and remains unreplied. This behavior has to be taken into consideration for services that generally do not initiate frame repetitions, such as: Firmware loading Network searches Ping Modifying the Ethernet data packet Copyright Siemens AG 2013 All rights reserved The detection of duplicates is performed by a Redundancy Control Trailers (RCT) which is inserted in each data packet with the help of the DAN P or RedBox. The identification field consists of the following parameters: A sequence number (16 bit) An identification for the LAN (4 bit) 0xA for LAN A 0xB for LAN B The length of the user load (12 bit) The RCT is inserted at the end of the data packet. Thus, the entire data traffic can also be read without restriction for the SANs, although they do not support PRP; they interpret the trailer as insignificant filling bits (padding). NOTICE Due to the additional trailer the size of the Ethernet packet increases to 1532 byte (Standard Ethernet: 1518 byte) Make sure that the standard components used, can process frames with an excessive length of up to 1532 byte (oversize frames). Note An overview of the compatible SIMATIC NET components can be found in the operating instruction of the SCALANCE X204 (PRP) and CP (see chapter 8.1). V10, Entry ID:

19 3 Basics of (bumpless) Redundancy 3.2 The redundancy protocol HSR Description HSR is defined in the same specification as PRP. HSR belongs to the category of media redundancy and is designed for the use in ring topologies. HSR is a redundancy protocol which is implemented in the terminal devices. The protocol is realized in a software layer that is integrated above the security layer (link layer). The terminal devices have each at least two network connections that are connected to a ring. The detection of the frame duplicate is not performed by a trailer as is the case for PRP but by expanding the Ethernet header (HSR tag). Figure 3-4 HSR Terminal device HSR Terminal device Copyright Siemens AG 2013 All rights reserved HSR Terminal device HSR Terminal device HSR Terminal device To ensure the high availability in the event of an error, the redundancy nodes sent a data packet in clockwise direction and an identical one in counter-clockwise direction. V10, Entry ID:

20 3 Basics of (bumpless) Redundancy HSR network Setting up a redundancy network with HSR The ring structure is used as HSR network topology. It can be setup with HSRcapable terminal devices as well as with standard components via a ballast (RedBox). HSR also permits a redundant design of the ring and / or a connection to the PRP network. The following graphic shows how a HSR network is to be setup with the mentioned components. Figure 3-5 DAN H DAN H Copyright Siemens AG 2013 All rights reserved SAN Terminal device (DAN H) RedBox DAN H A terminal device with HSR functionality is called "Double Attached Node for HSR" (DAN H) and includes at least two integrated network interfaces (ring ports) for the connection to a ring. Some devices furthermore have one (or several) internal port(s). In the SIMATIC NET product range, for example, the following modules are HSRcapable: SCALANCE X204 (EEC) (HSR) Standard component (SAN) Standard components with an individual network interface are called "Single Attached Node" (SAN) and can only be connected to the ring via a "redundancy box" (RedBox). SANs do not have to support the HSR functionality. V10, Entry ID:

21 3 Basics of (bumpless) Redundancy System connection (RedBox) With the help of the redundancy box, one or several SANs are integrated into the HSR network. The RedBox takes on the HSR functions in place of all its connected SANs. The RedBox furthermore enables the connection of PRP networks and the HSR ring. The connection of two HSR rings via two redundant paths is performed via quad boxes. These HSR terminal devices have at least four integrated ring ports. From the SIMATIC NET product range, for example, the following module acts as RedBox: SCALANCE X204 (EEC) (HSR) Note The connection of a HSR ring with the remaining network requires the configuration of the ports via the web-based management Communication with HSR Copyright Siemens AG 2013 All rights reserved The specification of HSR provides that all terminal devices are connected via a ring. Figure 3-6 Network Redundancy Application Transport layer Network layer Tx HSR Rx Application Transport layer Tx Network layer HSR Rx Ethernet Port 1 Tx Rx Port 2 Port 1 Port 2 Tx Rx Tx Rx Tx Rx LAN Sending A HRS-capable terminal device doubles each frame to be sent at the HRS interface. The two duplicates are sent via the ring ports to the communication partner as follows: One frame in clockwise direction One frame in counter-clockwise direction If a SAN is connected with a RedBox, the RedBox performs the HSR function in place of the SANs: It doubles the frame to be sent and accordingly sends it via the ring to the communication partner. The RedBox therefore works as a type of redundancy proxy for every type of standard component. V10, Entry ID:

22 3 Basics of (bumpless) Redundancy Receiving Note The two duplicates are received by a HSR-capable terminal device via the two ring ports. The HSR unit passes on the first arriving packet to the application layer and discards the second (identical) packet. The interface for the application is therefore identical to any other Ethernet interface. If the receiver is a standard component connected through a RedBox, the RedBox takes on the duplicate detection in its place and only passes on the first received frame to the addressee. The second frame is discarded. Due to sending the frames twice in both directions, effectively only 50% of the bandwidth of the network is available for data traffic Copyright Siemens AG 2013 All rights reserved Special case with SAN In contrast to PRP, SAN cannot be integrated into a HSR network without RedBox. The ring cannot be closed if one SAN misses the second network interface; as a result the ring would therefore be open. The HSR header furthermore cuts off the network traffic. Whilst SANs for PRP can classify the RCT as insignificant, this is not possible for a HSR tag. Due to its position in the data packet it is always interpreted as valid layer 2 information by SAN. Therefore it is not possible to read out the user data correctly. If a SAN is to participate in the network, a RedBox is required Modifying the Ethernet data packet To detect the duplicates, the DAN H devices or RedBox expand the Ethernet header in the data packet by a HSR tag. The identification field consists of the following parameters: A sequence number (16 bit) An identification for the port (4 bit) The length of the user load (12 bit) The positioning of the HSR tag right at the start of the data packet has the advantage that the duplicate detection for each individual data packet is performed straight after receiving the HSR tag in each device. Waiting for the full receipt of the data packets as is the case for PRP is not necessary. The HSR terminal devices already start with the passing on of the data packet at the second ring port, as soon as the HSR information has been fully read in and the duplicate detection has been performed (compare also cut-through switching). Only data packets that are directed to itself are passed on by the HSR terminal device to the application and are removed from the network. Multicast or broadcast packets are passed on along the ring by each node and are additionally forwarded to the application. Note In order to prevent a permanent circulating of multicast or broadcast packets in the ring, they are removed after one passage through the ring. V10, Entry ID:

23 3 Basics of (bumpless) Redundancy 3.3 Combination of PRP and HSR Description With the help of the redundancy box, a connection of the PRP network and a HSR ring can be realized. The SCALANCE X204 (HSR) can also be used as coupler between a PRP network and HSR ring. The two standard Ethernet ports are available for connection to the two networks (LAN A or LAN B) of the PRP network, whilst the two ring ports can be used as usual for the setup of the HSR ring topology. In order to make this possible the coupling mode between HSR and the remaining network in the web-based management of the SCALANCE X204 (HSR) has to be setup Setting up a redundancy HSR-PRP connection The following graphic shows a redundancy connection of a HSR rings with a PRP network. Figure 3-7 Copyright Siemens AG 2013 All rights reserved LAN A LAN B DAN P RedBox SAN PRP network Redundant network connection DAN P RedBox HSR ring SAN RedBox DAN H DAN H This connection is designed redundantly, as described by standard IEC In the SIMATIC NET product range, for example, the following modules can be used as coupler: SCALANCE X204 (EEC) (HSR) V10, Entry ID:

24 3 Basics of (bumpless) Redundancy Two SCALANCE X-204 HSR devices are required for the redundant connection. Both devices are connected with the PRP network LAN A, as well as with LAN B. If a connector fails, full communication is still guaranteed. The SANs are excluded from this, they are connected with the decoupled PRP network without the RedBox. Note The transmission between the HSR ring and the PRP network can also be nonredundant. Only one single SCALANCE X-200 device is used. This device is connected with the PRP network LAN A and with LAN B. This type of connection is not recommended since the communication between HSR and PRP nodes is interrupted if the connector fails. 3.4 The SIMATIC NET product portfolio for Copyright Siemens AG 2013 All rights reserved Overview SIMATIC NET offers components in its product portfolio that are predestined for the use of time and security critical applications by supporting the protocols PRP and HSR. The information includes: SCALANCE X204 (EEC) (PRP) SCALANCE X204 (EEC) (HSR) SCALANCE X204 EEC (combversion) CP PC station with SOFTNET-IE RuggedCom RS950G PRP-capable SIPROTEC (EN100 module with LC connections and application version from V4.1x onward) protection devices (For more information refer to The first five components are briefly described below. Note Detailed information on the modules can be found in the respective device manuals (see chapter 8.1). V10, Entry ID:

25 3 Basics of (bumpless) Redundancy SCALANCE X204 (EEC) Figure 3-8 Copyright Siemens AG 2013 All rights reserved The SCALANCE X204 is offered in three variants: with PRP functionality with HSR functionality with configurable PRP or HSR functionality Regarding the connectors, these variants hardly differ: both modules have four ports which have the following properties, depending on protocol: SCALANCE X204 (PRP) two standard Ethernet ports P1 and P2 (switch) two independent PRP ports to connect to LAN A or LAN B SCALANCE X204 (HSR) two standard Ethernet/PRP ports: P1/A and P2/B two ring ports: HSR 1 or HSR 2 Note The SCALANCE X204 (HSR) can also be used as coupler between a PRP network and HSR ring. The two standard Ethernet ports are available for the connection to the two networks (LAN A or LAN B) of the PRP network and the two ring ports can be used as usual for the setup of the HSR ring topology. The SCALANCE X204 and the SCALANCE X204 EEC have the same function, with the following exceptions: the environmental conditions, the input voltage ranges the option to be able to use the optical (SFP) modules in the case of SCALANCE X204 EEC. V10, Entry ID:

26 3 Basics of (bumpless) Redundancy CP Figure 3-9 Copyright Siemens AG 2013 All rights reserved Note The CP has two network interfaces: Interface 1: One standard Ethernet port as an alternative to the PRP ports Interface 2: two independent PRP ports to connect to LAN A or LAN B. The interfaces can only be operated alternatively. A parallel use of the two interfaces is not possible. Enabling is performed in the configuration with STEP 7 (refer also to chapter 4.1). The following graphic shows the CP connection variants: Figure 3-10 CP CP CP Industrial Ethernet LAN A Industrial Ethernet Industrial Ethernet LAN B Table 3-1 No. Description 1. Connection to port X1P1 of the Ethernet interface (ISO transport) 2. Connection of the interface to a PRP network 3. Connection to port X2P1 of the interface (ISO transport / ISO-on-TCP / TCP) V10, Entry ID:

27 3 Basics of (bumpless) Redundancy SOFTNET-IE Figure 3-11 Copyright Siemens AG 2013 All rights reserved RuggedCom RS950G The SOFTNET-IE network access software for the operation in PRP networks assumes the following: Two free Ethernet network cards in PC/ PG CP 1612A or Gigabit Ethernet network cards Administrator rights for the installation Per PC and product exactly one software license Figure 3-12 The RuggedCom RS950G is a three-port switch with the following port properties: One standard Ethernet port P1 Two independent PRP ports to connect to LAN A or LAN B The ports are provided twice and can be either connected via copper (RJ45) or optically (SFP). V10, Entry ID:

28 3 Basics of (bumpless) Redundancy 3.5 Diagnostic options Overview Copyright Siemens AG 2013 All rights reserved In order to receive indications for faults in the redundancy network, the SIMATIC NET components offer various options. Which ones they are, are shown by the table below: Table 3-2 Component SCALANCE X204 CP Diagnostic options LED display Fault tracing by web-based management (WBM) Error reporting by (SMTP) SNMP traps Syslog SNMP V1, V2, V3 (incl. PRP-MIB IEC62439 (IEC MIB)) Statistics display LED display Diagnostics with STEP 7 Diagnostic of communication with the special diagnostic NCM Web diagnostic SNMP (incl. PRP-MIB IEC62439 (IEC MIB)) IP double address identification Statistics display SOFTNET-IE SNMP (incl. PRP-MIB IEC62439 (IEC MIB)) SOFTNET-IE diagnostic tool for setting up a plant monitoring checking the redundancy status of the system statistics display RuggedCom RS950G LED display Fault tracing by web-based management (WBM) Note Detailed information on the diagnostic options can be found in the respective device manuals (see chapter 8.1). V10, Entry ID:

29 3 Basics of (bumpless) Redundancy Statistic displays The statistic displays in -capable devices give information on the number of frames in the PRP network or the HSR ring. Copyright Siemens AG 2013 All rights reserved Devices with PRP functionality The SCALANCE X204, CP and SOFTNET-IE perform the following measurements: number of valid, received frames (identification LAN A ) at PRP port A (LAN A) number of valid, received frames (identification LAN B ) at PRP port B (LAN B) number of incorrect, received frames (identification LAN A ) at PRP port B (LAN B) number of incorrect, received frames (identification LAN B ) at PRP port A (LAN A) The number of incorrect received frames always has to be zero ( 0 ). Otherwise a networking error is pending on the PRP ports A or B. Figure 3-13 Devices with HSR functionality The SCALANCE X204 (HSR) performs the following measurements: Number of valid received HSR frames at port HSR 1. Number of valid received HSR frames at port HSR 2. Number of valid, received PRP frames (identification LAN A ) at port P1/A. Number of valid, received PRP frames (identification LAN B ) at port P2/B. Number of faulty, received PRP frames (identification LAN A ) at port P2/B (error). Number of faulty, received PRP frames (identification LAN B ) at port P1/A (error). Number of received frames with independent source MAC address (error). Number of valid received PRP or standard frames at port HSR 1 (error). Number of valid received PRP or standard frames at port HSR 2 (error). Number of valid received HSR frames at port P1/A (error). Number of valid received HSR frames at port P2/B (error). V10, Entry ID:

30 3 Basics of (bumpless) Redundancy Measurements that are identified by (error) always have to supply ( 0 ). Otherwise a networking error at the HSR ports is pending. Figure 3-14 Copyright Siemens AG 2013 All rights reserved V10, Entry ID:

31 3 Basics of (bumpless) Redundancy SOFTNET-IE diagnostic Via an individual diagnostic tool the SOFTNET-IE software offers the option to: set up a plant, monitor it, Menu overview check the redundancy status of the system. In the overview all existing virtual adapters (see chapter 4.2) are listed with the following details: name of the virtual Ethernet adapter network name of the virtual Ethernet adapter Link status Figure 3-15 Copyright Siemens AG 2013 All rights reserved V10, Entry ID:

32 3 Basics of (bumpless) Redundancy Adapter menu For each configured adapter an individual button for polling more information, such as, statistics and connected devices will appear. The Statistics window provides the following details: name of the real Ethernet adapter network name of the real Ethernet adapter display of the connection status (connected/ not connected) sent PRP frames in this LAN received PRP frames from this LAN number of received faulty PRP frames at the LAN frames that, according to their identification were received at the wrong LAN. number of generated control frames Figure 3-16 Copyright Siemens AG 2013 All rights reserved V10, Entry ID:

33 3 Basics of (bumpless) Redundancy The Node table window gives an overview of the PRP nodes (PRP-capable terminal devices and standard components). Each node in the table consists of two rows. The first row stands for LAN A and the second row for LAN B. General information is only provided in the first row of the node (MAC address, type etc.). Figure 3-17 Copyright Siemens AG 2013 All rights reserved Additionally to the information in the table, the window also includes the following details and buttons: Number of nodes to which contact existed within a certain time period. Number of maximum stored nodes in the node table. V10, Entry ID:

34 3 Basics of (bumpless) Redundancy The Settings window makes it possible to configure parameters. These are: IP address of the virtual adapter Subnet mask of the virtual adapter Multicast address of the protocol Time in which the control frames are sent Enabling the Transparent reception function. This option has the effect that the RCT border of frames is not to removed before they are forwarded to the application Statistics refresh rate Language settings Note Start the diagnostic with administrator rights in order to be able to use the settings without restrictions. Figure 3-18 Copyright Siemens AG 2013 All rights reserved Note Detailed information on the SOFTNET-IE diagnostic can be found in the respective device manual (see chapter 8.1). V10, Entry ID:

35 4 Configuration and Settings 4 Configuration and Settings 4.1 Configuring the CP Note This chapter is for information purposes only. All the required settings for this application are already integrated in the STEP 7 project. Copyright Siemens AG 2013 All rights reserved Setting the active interface The CP has the following interfaces: Ethernet interface; e.g. for connecting a PG / PCs or a higher-level company network. interface (design with two ports); they can be operated as follows: PRP mode with the two ports as redundancy solution Port 1 as single port of the interface (port 2 is disabled). The Ethernet interface or the interface can only be enabled alternatively. A parallel use of the two interfaces is not possible. Enabling is performed in the configuration with STEP 7. Figure 4-1 V10, Entry ID:

36 4 Configuration and Settings Enabling SNMP The CP enables data polling on the interface via SNMP in version V1. It provides the contents of certain MIB objects according to standard MIB-II (RFC 1213), PRP MIB IEC62439 (IEC MIB) and automation MIB. If SNMP is required for, e.g. diagnostic purposes, this has to be enabled in the properties of the CP. Figure 4-2 Copyright Siemens AG 2013 All rights reserved Enabling PRP If CP acts as DAN P node the PRP function has to be explicitly enabled in the properties of the interface of the CP. Figure 4-3 V10, Entry ID:

37 4 Configuration and Settings 4.2 Configuring the SOFTNET-IE For the operation of the SOFTNET-IE on the PG you require at least two free Ethernet network cards to connect to the LAN A as well as the LAN B of the PRP network administrator rights. The assignment of network cards (adapters) to the SOFTNET-IE protocol is performed via the configuration. Figure 4-4 Copyright Siemens AG 2013 All rights reserved The two adapters selected are joined to a virtual adapter through the SOFTNET-IE software. After completing the configuration, only the virtual adapter appears in the network connection overview of Windows instead of the two network cards provided for the PRP. Note Detailed information on the SOFTNET-IE configuration can be found in the respective device manual (see chapter 8.1). V10, Entry ID:

38 4 Configuration and Settings 4.3 Configuring the SCALANCE X204 (HSR) The SCALANCE X204 (HSR) can also be used as coupler between a PRP network and HSR ring. In this case, the two standard Ethernet ports are available for the connection to the two networks (LAN A or LAN B) of the PRP network and the two ring ports can be used as usual for setting up the HSR ring topology. In order to make this possible the coupling mode between HSR and the remaining network in the web-based management of the SCALANCE X204 (HSR) has to be setup. Figure 4-5 Copyright Siemens AG 2013 All rights reserved The following modes can be selected. Table 4-1 Mode HSR SAN Mode Non Redundant HSR PRP coupling Redundant HSR PRP coupling, LAN A Redundant HSR PRP coupling, LAN B Description The HSR ring is connected with the standard Ethernet terminal devices or the network segments (default setting). Setting for non-redundant HSR<>PRP coupling. P1/A is connected with LAN A, P2/B with LAN B of a PRP network. Setting for redundant HSR<->PRP coupling. P1/A is connected with LAN A of a PRP network. P2/B is open and must not be used. Setting for redundant HSR<->PRP coupling. P1/B is connected with LAN B of a PRP network. P1/A is open and must not be used. Note Since a pure HSR network without redundant coupling has been established in this application example, the default setting can be kept. V10, Entry ID:

39 5 Installation 5 Installation 5.1 Hardware installation Solution via PRP The figure below shows the hardware setup of the application with the PRP network redundancy. Figure 5-1 S7-400 mit CP SCALANCE XB005 SCALANCE X204 (PRP) CPU PN/DP LAN A 24V 24V 24V Copyright Siemens AG 2013 All rights reserved SCALANCE X204 EEC (PRP) 24V 24V SCALANCE XB005 LAN B 24V PG with SOFTNET-IE V8.2 Configuration computer Connect all SIMATIC components each to a 24V power supply. After completing commissioning (according to chapter 6) connect all PRP nodes via their LAN A port with the first SCALANCE XB005 and via the LAN B port with the second SCALANCE XB005. Connect the S7-300 via the integrated CPU interface with port P1 of the SCALANCE X204 (PRP). Use the standard Ethernet cable for this purpose. Note Observe the continuously correct connection of the PRP ports of the nodes to LAN A or to LAN B. A data packet with the identification "LAN A" also has to be received at the appropriate port at the receiver. Try to set up the networks as symmetrical as possible. Redundancy faults in the network can be easier identified by the difference in number of received frames on the LANs (see statistic display of X204 and SOFTNET-IE ). V10, Entry ID:

40 5 Installation Note The installation guidelines for these components must always be observed. Solution via HSR The figure below shows the hardware setup of the use with media redundancy HSR. Figure 5-2 PG (Configuration computer) SCALANCE X204 EEC (HSR) SCALANCE X204 (HSR) CPU PN/DP 24V 24V 24V Copyright Siemens AG 2013 All rights reserved CPU PN/DP 24V SCALANCE X204 (HSR) 24V SCALANCE X204 (HSR) 24V Connect all SIMATIC components each to a 24V power supply. Connect all HSR nodes via their HSR ports to a ring topology. Connect the S7-300 and S7-400 via the integrated CPU interface with port P1 of the respective SCALANCE X204 (HSR). Use the standard Ethernet cable for this purpose. Note The installation guidelines for these components must always be observed. V10, Entry ID:

41 5 Installation 5.2 Software installation Standard software Overview The following table shows what software packets are required for which scenarios (PRP or HSR): Table 5-1 Scenario PRP and HSR PRP Software STEP 7 V5.5 SP3 HSP1097 SOFTNET-IE Development software Install the following software packages on you configuration computer. STEP 7 V5.5 SP 3 HSP1097 (only required for the PRP solution) Copyright Siemens AG 2013 All rights reserved SOFTNET-IE Note For the approach with network redundancy (PRP) the field PG incl. SOFTNET-IE is used. Install the following software package on your field PG. SOFTNET-IE Follow the instructions of the installation program. An installation instruction for the SOFTNET-IE can be found in its operating instructions (see chapter 8.1) Application software For each scenario, a sample program is available. Unzip the zipped CODE_v10.zip code folder from the download area into a folder your choice. In this folder, there are the STEP 7 project folders: _PRP.zip for implementing the PRP solution _HSR.zip for implementing the HSR solution V10, Entry ID:

42 6 Starting the Application 6 Starting the Application 6.1 Requirements Factory setting For fault-free commissioning of the application it is advisable to reset all SIMATIC components to the factory settings. After this process it can be guaranteed that no previous configuration exists in the modules. Note A detailed instruction for resetting can be found in the respective device manuals (see chapter 8.1). Creating the virtual adapter To be able to use the field PG as PRP node, the network cards used have to be configured accordingly. Copyright Siemens AG 2013 All rights reserved Note Opening STEP 7 project An instruction can be found in the SOFTNET-IE device manual (see chapter 8) as well as chapter 4.2. To commission the components the STEP 7 software is used, among other things. Open STEP 7 and retrieve the required project via File > Retrieve (see chapter 5.2.2). 6.2 Addressing the modules Overview of IP addresses PRP solution The following table shows what IP address is assigned to the components of the PRP solution. Table 6-1 Component CPU PN/DP CP SCALANCE X204 (PRP) SCALANCE X204 EEC (PRP) PG with SOFTNET-IE (Virtual adapter network interface) Configuration computer is used as subnet mask each time. IP address V10, Entry ID:

43 6 Starting the Application HSR solution The following table shows what IP address is assigned to the components of the HSR solution. Table 6-2 Component CPU PN/DP CPU PN/DP SCALANCE X204 (HSR) SCALANCE X204 EEC (HSR) Configuration computer is used as subnet mask each time Assigning the IP address IP address Copyright Siemens AG 2013 All rights reserved Configuration computer Table 6-3 Change the IP address of the PCs in the following way: No. Action Comments 1. For changing the network address, open the Internet protocol (TCP(IPv4) Properties via "Start > Control Panel > Network and Internet > Network Connections" Enter the IP address according to the figure. Close all dialog boxes by clicking OK. V10, Entry ID:

44 6 Starting the Application SOFTNET-IE Table 6-4 Change the IP address of the virtual SOFTNET-IE interface in the field PG as described below. No. Action Comments 1. For changing the network address, open the Internet protocol (TCP(IPv4) Properties via "Start > Control Panel > Network and Internet > Network Connections" Select the virtual adapter for the PRP communication. Enter the IP address according to the figure. Close all dialog boxes by clicking OK. Copyright Siemens AG 2013 All rights reserved SIMATIC components To address the SIMATIC components connect the configuration computer with the respective module via a standard Ethernet cable. The approach for changing the IP address is demonstrated on the example of the SCALANCE X204 (PRP). The addressing of the other modules is performed the same way. V10, Entry ID:

45 6 Starting the Application Table 6-5 No. Action Comments 1. The Ethernet nodes can be edited via the SIMATIC MANAGER. Open the respective dialog window via PLC > Edit Ethernet Node. Copyright Siemens AG 2013 All rights reserved 2. Search the network via the Browse button. V10, Entry ID:

46 6 Starting the Application No. Action Comments 3. The X204 is detected. Confirm the pre-selection with OK. Note: If several devices are found, verify the module to be addressed via the MAC address. Copyright Siemens AG 2013 All rights reserved 4. Select Use IP parameters and enter the respective IP address and subnet mask. Transfer the parameters via the Assign IP Configuration button into the module. Close the dialog box with OK. 5. Assign the required IP addresses to all SIMATIC components this way. V10, Entry ID:

47 6 Starting the Application 6.3 Loading the controllers Table 6-6 No. Action Comments 1. To load the controller, connect the PC with the respective CPU interface. Select the respective station and load the program into the CPU. 2. Repeat step 1 for the other controller. Copyright Siemens AG 2013 All rights reserved V10, Entry ID:

48 7 Operating the Application 7 Operating the Application 7.1 Requirements To test the redundancy, all components have to be networked according to the instruction of chapter 5.1. Pay attention to the correct interconnection of LAN A and LAN B or the ring. In order to be able to go online to the controllers with STEP 7, connect the PC (configuration computer) to a free LAN port of the SCALANCE X Demonstrating the redundancy Copyright Siemens AG 2013 All rights reserved Table 7-1 The STEP 7 project includes a small simulation program and is controlled via the included tag tables. For each communication partner a separate tag table exists (CONTROL). No. Action Comments 1. There is a CONTOL tag control in each of the module folders of the CPU. Open this element in the two stations. 2. Arrange the two tag tables next to each other with Windows > Arrange > Vertically or with the <SHIFT> + F3 shortcut key. 3. Select the tables successively and go online via the respective icon. 4. You can see the send area (S7-300 station) or receive area (S7-400 station) of the data exchange in row 6 and 7. V10, Entry ID:

49 7 Operating the Application No. Action Comments 5. The S7-300 sends the new values to S7-400 approx. every 10 sec. 6. Remove the network connection between the two devices in order to test the redundancy. 7. The data communication continued uninterrupted because of the dual network design. In this example, the network plug was removed from PRP port A of the CP for the PRP scenario. The ring was separated for the HSR scenario in this example. 7.3 Diagnostic at PRP Copyright Siemens AG 2013 All rights reserved Table 7-2 The missing network connection is detected by the PRP nodes and made visible by various mechanisms. No. Action Comments 1. In the online view of the S7-400 hardware configuration, the CP reports the missing link. 2. The value for the number of frames at port X2 P1 (LAN A), stagnates whilst the counter at port X2 P2 (LAN B) increases on the web-based statistics table of the CP The LED BUS2F at CP lights up red. V10, Entry ID:

50 7 Operating the Application No. Action Comments 4. The X204 reports the absence of the data packets in its log table of LAN A. 5. The value for the number of frames at port PRP A (LAN A), stagnates whilst the counter at port PRP A (LAN B) increases on the web-based statistics table of X The error LED lights up yellow. 7. In SOFTNET-IE fault is displayed by an exclamation mark. Copyright Siemens AG 2013 All rights reserved V10, Entry ID:

51 7 Operating the Application 7.4 Diagnostic at HSR Table 7-3 The open ring is detected by the HSR nodes and made visible by various mechanisms. No. Action Comments 1. The X204 reports a change of the port status in its log table. 2. On the web-based statistics table of the X204 the value for the number of frames at HSR 2 stagnates, whilst the counter at HSR 1 is increased. Copyright Siemens AG 2013 All rights reserved 3. The error LED lights up yellow. V10, Entry ID: