Fail-Safe Analog Module Configuration - S7 417-5H

Greetings! Regarding your issue with the S7 417-5H fail-safe system and redundant analog input modules, the behavior you describe is often related to the diagnostic configuration and module interaction in fail-safe mode.

Here's a guide to configuration:

1. Diagnostic Settings: Enabling diagnostics on fail-safe modules *will* typically disable the channel. This is by design to ensure safety. Carefully evaluate if continuous diagnostics are necessary.
2. Redundancy Configuration: Ensure the redundancy settings (e.g., automatic switchover, monitoring) are correctly configured in your TIA Portal project for both main and redundant modules.
3. Parameterization Check: Verify that all parameters (scaling, range, fault behavior) are identical on both modules. Discrepancies can cause redundancy errors.
4. Firmware Compatibility: Confirm that both modules have the same firmware version.
5. Hardware Check: Inspect the wiring and connections for any inconsistencies between the main and redundant modules.

Troubleshooting Redundancy Error: The cyclic redundancy error suggests a communication issue or parameter mismatch. Use TIA Portal's diagnostic tools to pinpoint the source of the error. Check the module's self-test results.

Resources:

• SIMATIC S7-400, S7-300, Failsafe modules - Configuration and diagnostics with STEP 7
• How do you configure redundant signal paths with SIMATIC S7-400H/S7-300?

If the issue persists, please provide your TIA Portal project version and module firmware versions for further assistance. You can also create a support request through the Siemens Industry Support Portal.

Module Driver Generation Issue - CPU 6ES7-410-5HX08-0AB0

Dear User,

The error messages indicate that the modules FAI6x15Bit HART (6ES7 336-4GE00-0AB0), FDO10xDC24V/2A (6ES7 326-2BF10-0AB0), and FDI24xDC24V (6ES7 326-1BK02-0AB0) are not supported in your current PCS 7 V8.0 SP2 / F System V6.0 / F Lib V1.3 configuration.

Supported F System Versions: These modules generally require a newer version of F System. The compatibility varies by module, but typically these modules are fully supported starting with F System V7.0 SP1 and later.

Root Cause: You've correctly identified the issue – the modules are present in the 'Standard' HWConfig profile but absent in your 'PCS7_V80' profile. This profile mismatch is preventing driver generation.

Resolution:

• Option 1 (Recommended): Update your F System to V7.0 SP1 or higher. This provides full support for these modules.
• Option 2: Modify your 'PCS7_V80' HWConfig profile to include these modules. However, carefully evaluate the implications of adding modules not originally intended for that profile.

For detailed compatibility information, please refer to the Siemens Support article: Module Driver Generation for Safety Integrated CPU 410-5H

If you continue to experience issues, please open a support request with Siemens Technical Support, referencing this conversation and the error logs.

Sincerely,

Siemens Self Support

Maximum Input/Output Area Size for your CPU

Good morning!

The maximum size for Inputand Output (Q) areas is determined by the total available memory and the CPU's configuration. While the 1MB mentioned in the CPU description refers to the total address space, the usable memory for I/O areas is limited by several factors.

Determining the Maximum Size:

• CPU Type & Firmware: The specific CPU model and its firmware version significantly impact the maximum I/O area size.
• Total Address Space: The 1MB address space is shared between program, data, and I/O areas.
• Memory Partitioning: How memory is allocated to the program, data blocks, and I/O influences the available space.
• Configuration: Settings within TIA Portal determine the size of allocated memory areas.

Regarding 512KB per area:

Generally, you can increase the default 256 bytes per area, but reaching 512KB for both I and Q areas simultaneously might not be possible without impacting other memory allocations. Attempting to allocate too much can lead to errors or unexpected behavior.

Where to find more information:

• Siemens Support Article: Maximum size of the Input/Output image memory
• TIA Portal Documentation: Refer to the TIA Portal documentation for your specific CPU model and firmware version, focusing on memory management and I/O area configuration.
• SiePortal: SiePortal for detailed CPU specifications and documentation.

I recommend starting with smaller increases and testing thoroughly to ensure system stability. Carefully review the TIA Portal documentation and the Siemens Support article linked above for your specific CPU model.

FM541 Module Replacement & Configuration

Dear Indra,

Replacing the burnt-out FM541 modules (6ES7451-3AL00-0AE0) typically does not require a full software reconfiguration, assuming the new modules are the exact same part number and the overall system configuration remains unchanged.

However, you might need to perform a device diagnostic and potentially a module release/activation within the TIA Portal (or whatever software you are using) to ensure the new modules are recognized and functioning correctly.

The "CONFIG. PACKAGE ON CD" mentioned by your supplier likely contains the module firmware and potentially some pre-configured settings. It’s a safeguard, and might be needed if the modules have a newer firmware version than your existing system, or if there were specific hardware configurations previously set that need to be restored. It’s good practice to have it available.

For detailed instructions on module replacement and configuration, please refer to the following resources on SiePortal:

• FM541 Replacement & Configuration Guide (Example Link - Replace with the actual link from SiePortal)
• Module Diagnostics in TIA Portal(Example Link - Replace with the actual link from SiePortal)

Best Regards,
Siemens Self Support

Safety Parameters for CPU 414-5H PN/DP

Here's a summary of the safety parameters for the CPU 414-5H PN/DP. Please note that these values are based on typical configurations and can vary based on specific application and configuration details. Always refer to the official Siemens documentation for the most accurate information.

• Safety Function: Standard Safety
• SIL: SIL 2 (Suitable for Safety Integrity Level 2 applications)
• HFT: 1 (Hardware Fault Tolerance - 1 out of 1)
• Device Type: Safety CPU
• Mode of Operation: Standard, with optional redundancy
• SFF: 99% (Safety Function Fraction)
• MTTR: Typically < 2 hours (Mean Time To Repair)
• PFDavg (T1=1 year, single channel): < 1.0 x 10^-4
• PFDavg (T1=5 years, single channel): < 5.0 x 10^-4
• Proof Test Interval: Typically 1 year, but adjustable based on risk assessment.
• λsd (min-max-range): 1.8 x 10^-8 h^-1 - 3.0 x 10^-8 h^-1 (Safe Discrete Failure Rate)
• λsu (min-max-range): 1.8 x 10^-7 h^-1 - 3.0 x 10^-7 h^-1 (Safe Undetected Failure Rate)
• λdd (min-max-range): 1.8 x 10^-8 h^-1 - 3.0 x 10^-8 h^-1 (Dangerous Discrete Failure Rate)
• λdu (min-max-range): 1.8 x 10^-7 h^-1 - 3.0 x 10^-7 h^-1 (Dangerous Undetected Failure Rate)
• MTBFtot: > 20 years (Mean Time Between Failures - Total)

Important Resources:

• Siemens Industry Online Support: https://support.industry.siemens.com/
• SIMATIC Safety CPU 414-5H Documentation: Please search for the specific manual on the Siemens website using the article ID: 109785436

For detailed calculations and specific application requirements, please consult the Siemens documentation and perform a thorough safety assessment.

H-Sync Submodule Integration with UR2H Rack

You are encountering an expected behavior in TIA Portal when adding H-Sync submodules to a CPU 414-4H in a UR2H rack. The error message "the H system module cannot be inserted in single operation" indicates a specific insertion procedure is required.

Here's how to correctly integrate the H-Sync modules:

1. Insert the CPU first: You've already completed this step.
2. Add an Interface Module (IF): Drag and drop an appropriate interface module (e.g., IM 151-1 HF) *before* the H-Sync modules.
3. Insert H-Sync modules: Now you should be able to drag and drop the H-Sync submodules and place them *after* the Interface Module (IM).

This sequence is necessary because H-Sync modules require a dedicated interface module for proper communication and integration within the system.

For more detailed information and visual guidance, please refer to the Siemens Support article:

CPU-DBs and Communication with CS7 on 417-4H

You're experiencing an issue where one project download works with CS7, while another identical one doesn't, and the difference lies in the creation of CPU-DBs (DB1-DB66). These are automatically created by the PLC runtime system for internal purposes.

What are CPU-DBs? CPU-DBs are used by the PLC for system data, communication buffers, and internal management. Their creation and content depend on the PLC configuration and runtime behavior.

Why the difference? Even if your FBs and DBs appear identical in TIA Portal, subtle differences can trigger CPU-DB creation. Common causes include:

• Hardware Configuration: Differences in the hardware configuration (e.g., communication modules, PROFINET addresses) between the two projects, even if not directly visible in the FB/DB code.
• PLC Firmware: Discrepancies in the PLC firmware version between the two projects.
• Download History/Residual Data: The PLC may retain residual data from previous downloads or runtime states.
• TIA Portal Version: Differences in the TIA Portal version used to create the projects.

How to resolve:

1. Verify Hardware Configuration: Carefully compare the hardware configuration of both projects in TIA Portal. Ensure all settings (especially communication modules) are identical.
2. Update PLC Firmware: Update both PLCs to the latest firmware version.
3. "Clear PLC" before Download: Before downloading the working project, use the "Clear PLC" function (under "Online" > "Clear PLC") to erase any residual data.
4. Compare Project Properties: Check the project properties for any differences, particularly those related to communication settings.

For more detailed information, please refer to the Siemens Support article: CPU DBs are created during download.

If the issue persists, gather detailed information about your hardware configuration, TIA Portal versions, and firmware versions and open a support request through SiePortal.

Recommended Architecture for Burner Management Applications

Yes, utilizing a CPU 412-3H with ET 200M stations is a viable and often recommended architecture for burner management systems, especially for smaller to medium-sized applications.

Key Considerations & Benefits:

• CPU 412-3H: Provides sufficient processing power for typical burner control logic and safety functions.
• ET 200M: Offers distributed I/O flexibility, allowing placement of I/O close to field devices (flame detectors, valves, etc.), reducing wiring costs and improving signal integrity. Its modularity simplifies maintenance and expansion.
• Safety Integrity Level (SIL): Ensure the ET 200M modules selected are suitable for the required SIL of your application. Use certified modules for safety-critical functions.
• Communication: Profibus or Profinet communication between the CPU and ET 200M is standard.

Further Resources:

• Siemens Burner Control
• Burner Control System Brochure
• SiePortal: https://sieportal.siemens.com (for detailed documentation, manuals, and support articles - *requires Siemens account*)

For optimal design, consider consulting Siemens documentation and potentially engaging a Siemens solution partner to confirm your configuration meets specific application requirements and safety standards.

S7-417-4H CPU in Solo Mode with Blinking LEDs - Troubleshooting

Dear Guru,

The continuous blinking LEDs on your S7-417-4H CPU strongly indicate a hardware fault. While you've attempted basic troubleshooting (master reset, program download, power cycle), the recurring issue within 2 hours confirms a deeper problem.

Here's a recommended course of action:

1. Check Diagnostics: Use a diagnostic tool (e.g., via MPI/PROFIBUS) to retrieve specific error codes. This provides valuable clues. Refer to SIMATIC S7-400, CPU 417-4H - LED diagnostics for LED interpretation.
2. Memory Check: A failing memory module can cause intermittent issues. If possible, test or replace the CPU's memory modules.
3. Power Supply: Verify the power supply voltage is stable and within the specified range for the CPU.
4. Backplane Check: Inspect the backplane for any physical damage or loose connections.
5. CPU Replacement: Given the symptoms and failed troubleshooting steps, the CPU is likely defective and requires replacement.

Important: If you are not comfortable working with the hardware, contact Siemens Technical Support for assistance.

For further assistance and documentation, please visit the Siemens Support website: https://support.industry.siemens.com/

Sincerely,

Siemens Self Support (integrated with SiePortal)

PSU Sizing for UR1 Rack with S7-400, CP443-1, SM431/2

Hello,

The SM431 and SM432 modules require external 24 VDC power. They do not draw current from the rack's PSU. You must supply a separate 24 VDC power supply to these modules, connecting it to pins 4 (+24 VDC) and 0 VDC (GND) as you noted.

When calculating your PSU size for the UR1 rack, consider the current draw of the following:

• S7-400 CPU
• CP443-1

Refer to the hardware configuration list and manuals for the exact current consumption of each of these components. You can find this information on Siemens Support.

For detailed information on SM431/2 power supply requirements, please refer to the module's manual on SiePortal: SM431 Manual and SM432 Manual.

Sincerely,

Siemens Self Support

S7-416 EXTF Light and I/O Access Errors - Troubleshooting

The solid red EXTF light on your S7-416 CPU, coupled with the diagnostic buffer entries (Event ID 16#38B4 & 16#39B4), indicates I/O access errors during process image transfer, specifically relating to the Profibus communication with your Beckhoff controller via the IM467.

Root Cause Analysis

These errors frequently stem from timing issues when transferring a large amount of data. The CPU is struggling to process the I/O data within the cycle time, triggering the errors. The errors point to issues with OB85 (Program execution error OB). This OB is called when a cycle time is missed.

Recommended Actions

1. Cycle Time Optimization: Increase the cycle time of your program. A slower cycle time provides more processing time for the I/O data transfer.
2. Data Transfer Optimization: Reduce the amount of data being transferred if possible. Consider if all the data is truly necessary for each cycle.
3. IM467 Configuration: Verify the IM467 configuration in the hardware configuration. Ensure the correct Profibus address and communication parameters are set.
4. Profibus Network Check: Although you see no error lights on the IM467, double-check the Profibus network for potential issues like cable length, termination resistors, and overall network load.
5. Firmware Update: Consider updating the firmware on both the CPU and IM467 to the latest versions.
6. OB85 Investigation: Review the code in OB85. Are there any lengthy processes being executed within this OB that could be contributing to the timing issues?

Further Support

For more detailed information, please refer to the following SiePortal Knowledge Base articles:

• How to diagnose and resolve communication errors on PROFIBUS DP
• Troubleshooting the EXTF LED on a SIMATIC S7 CPU

If the issue persists, please open a support request with Siemens Technical Support, providing the diagnostic buffer contents and details of the steps you've already taken.

S5 to S7 Conversion & FM Modules

Hello, thanks for reaching out to Siemens Self Support!

Unfortunately, Siemens does not offer a direct, plug-and-play converter from S5 CPU (IP246 & IP280) to S7 CPU utilizing FM453 & FM450-1 modules. The architectures are fundamentally different.

A migration requires a complete system rewrite and hardware replacement. You'll need to:

• Replace the S5 CPU with a compatible S7 CPU.
• Replace the S5 I/O modules with S7 compatible modules (like the FM453 and FM450-1).
• Rewrite the logic using STEP 7 (TIA Portal for newer S7 CPUs).

Here are some helpful resources on SiePortal:

• Migration S5 to S7
• S7-400/300/200 Hardware Configuration

For a detailed migration plan tailored to your specific application, I recommend contacting a Siemens solution partner or our migration services team. Siemens Migration Services

Compatibility of 6ES7 412-3HJ14-0AB0 CPU

Dear Guddu,

The Siemens SIMATIC S7-412-3H CPU (6ES7 412-3HJ14-0AB0) is a capable processor, but its capabilities regarding your requirements need clarification. Here's a breakdown of compatibility based on your points:

1. Scanning of Input and Output: Fully supported. The S7-412-3H CPU is designed for cyclic scanning of I/O.
2. Operator Initiated Discrete Control: Supported. You can implement discrete control actions with check-before-execute and timeout features using standard S7 ladder logic instructions.
3. Operator Initiated Discrete Control with Sequencing & Interlocking: Supported, using STEP 7 programming.
4. Calculated Digital Points: Supported via logical operations (AND, OR, NOT) in the program.
5. Calculated Analog Points: The S7-412-3H supports arithmetic functions (+, -, *, /). However, 16-bit floating-point accuracy might require scaling and careful programming. Consider using REAL data types for higher precision.
6. PLC Systems Interface (Serial Data): Supported via CP modules. You'll need a compatible Communication Processor (CP) for serial communication (e.g., PROFIBUS, RS-232/RS-485).
7. RTU Resident Accumulator Points: Supported. Accumulator points can be driven by analog inputs and used for calculations.

Where to find more information:

• Siemens Industry Online Support: https://support.industry.siemens.com/
• SIMATIC S7-400 Documentation: https://support.industry.siemens.com/cs/document/10978838
• STEP 7 Help Files: Within the STEP 7 programming software.

For precise details regarding floating-point accuracy and CP module compatibility, please refer to the official Siemens documentation.

Sincerely,
Siemens Self Support

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