Siemens Simatic M7-400 Installation manual

Preface, Contents
SIMATIC
Product Overview
Installing the S7-400
S7-400 and M7-400
Programmable Controllers
Hardware and Installation
Installation Manual
Addressing the S7-400
Wiring the S7-400
Networking
Starting Up
Maintenance
Assembling the M7-400
1
2
3
4
5
6
7
8
Appendices
Assembling and Installing
Systems
A
Guidelines for Handling
Electrostatically-Sensitive
Devices (ESD)
B
Glossary, Index
This manual is part of the documentation
package with the order number
6ES7498-8AA03-8BA0
Edition 12/2002
A5E00069481-04
Safety Guidelines
This manual contains notices intended to ensure personal safety, as well as to protect the products and
connected equipment against damage. These notices are highlighted by the symbols shown below and
graded according to severity by the following texts:
!
!
!
Danger
indicates that death, severe personal injury or substantial property damage will result if proper precautions are not taken.
Warning
indicates that death, severe personal injury or substantial property damage can result if proper
precautions are not taken.
Caution
indicates that minor personal injury can result if proper precautions are not taken.
Caution
indicates that property damage can result if proper precautions are not taken.
Notice
draws your attention to particularly important information on the product, handling the product, or to a
particular part of the documentation.
Qualified Personnel
Only qualified personnel should be allowed to install and work on this equipment. Qualified persons
are defined as persons who are authorized to commission, to ground and to tag circuits, equipment, and
systems in accordance with established safety practices and standards.
Correct Usage
Note the following:
!
Warning
This device and its components may only be used for the applications described in the catalog or the
technical description, and only in connection with devices or components from other manufacturers
which have been approved or recommended by Siemens.
This product can only function correctly and safely if it is transported, stored, set up, and installed
correctly, and operated and maintained as recommended.
Trademarks
SIMATIC, SIMATIC HMI and SIMATIC NET are registered trademarks of SIEMENS AG.
Third parties using for their own purposes any other names in this document which refer to trademarks
might infringe upon the rights of the trademark owners.
Copyright W
Siemens AG 1999-2002 All rights reserved Disclaim of Liability
The reproduction, transmission or use of this document or its
contents is not permitted without express written authority.
Offenders will be liable for damages. All rights, including
rights created by patent grant or registration of a utility model
or design, are reserved.
We have checked the contents of this manual for agreement
with the hardware and software described. Since deviations
cannot be precluded entirely, we cannot guarantee full
agreement. However, the data in this manual are reviewed
regularly and any necessary corrections included in
subsequent editions. Suggestions for improvement are
welcomed.
Siemens AG
Bereich Automation and Drives
 Siemens AG 1999– 2002
Geschaeftsgebiet Industrial Automation Systems
Technical data subject to change.
Postfach 4848, D- 90327 Nuernberg
S7-400 and M7-400 Programmable Controllers Hardware and Installation
A5E00069480-02
Index-2
Siemens Aktiengesellschaft
A5E00069481-04
Preface
Purpose of the Manual
The information given in this manual makes it possible for you to:
• install and wire an S7-400 memory programmable controller
• configure an M7-400 automation computer for mechanical and electrical
installation
A description of the functions and technical specifications of the signal modules,
power supply modules and interface modules can be found in the reference
manual Module Specifications.
Required Basic Knowledge
General knowledge of the field of automation engineering is required in order to
understand the manual.
Target Group
This manual is aimed at people with the required qualifications to commission,
operate and maintain the products described.
Where is this Manual valid?
The manual is valid for the S7-400 and M7-400 programmable controllers.
Changes compared to the previous version
Section 2.5 and Appendix A have been updated since the previous edition of the
“Hardware and Installation” manual.
Note: You can recognize the previous edition of this ”Hardware and Installation”
manual by the number that appears in the footer: A5E00069480-03.
The number of the current edition is: A5E00069480-04.
S7-400 and M7-400 Programmable Controllers Hardware and Installation
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Preface
Certification
The SIMATIC S7-400 product range has the following certificates and approvals:
• Underwriters Laboratories, Inc.: UL 508 (Industrial Control Equipment)
• Canadian Standards Association: CSA C22.2 Nummer 142, tested (Process
Control Equipment)
• Factory Mutual Research: Approval Standard Class Number 3611.
You can find details on the certificates and approvals in the “Module Specifications”
manual.
CE Labeling
The SIMATIC S7-400 product range complies with the requirements and protection
objectives of the following EU directives:
• EC low voltage directive 73/23/EEC
• EC electromagnetic compatibility directive 89/336/EEC
C-Tick Mark
The SIMATIC S7-400 product range complies with the requirements of the
AS/NZS 2064 standard (Australia and New Zealand).
Standards
The SIMATIC S7-400 product range complies with the requirements and criteria of
the IEC 61131-2.
Place of this Documentation in the Information Environment
This manual is part of the documentation package for S7-400, M7-400.
System
S7-400/M7-400
Documentation Packages
• S7-400, M7-400 Programmable Controller;
Hardware and Installation
• S7-400, M7-400 Programmable Controllers; Module Specifications
• S7-400 Instruction List
• S7 400, CPU Data Programmable Controller
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S7-400 and M7-400 Programmable Controllers Hardware and Installation
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Preface
Finding Your Way
The manual offers the following access aids to make it easy for you to find specific
information quickly:
• At the beginning of the manual you will find a complete table of contents and
lists of the figures and tables contained in the manual.
• In each chapter you will find information in the left-hand margin on each page
that gives you an overview of the contents of the relevant section.
• After the appendices you will find a glossary containing definitions of important
terms and concepts that are used in the manual.
• At the end of the manual you will find a detailed index, allowing you to quickly
find the information you are looking for.
Specific Information for S7-400
You require the following manuals and manual packages in order to program and
commission an S7-400:
Manual/
Manual Package
Standard Software
for S7 and M7
Contents
• Installing and starting up STEP 7 on a programming device / PC
• Working with STEP 7 with the following contents:
STEP 7 Basic
Information
Managing projects and files
Configuring and assigning parameters to the S7-400 configuration
Assigning symbolic names for user programs
Creating and testing a user program in STL/LAD
Creating data blocks
Configuring the communication between two or more CPUs
Loading, storing and deleting user programs in the CPU / programming device
Monitoring and controlling user programs
Monitoring and controlling the CPU
• Guide for efficiently implementing the programming task with the programming
device / PC and STEP 7
• How the CPUs work (for example, memory concept, access to inputs and
outputs, addressing, blocks, data management)
•
•
•
•
•
Description of STEP 7 data management
Using data types of STEP 7
Using linear and structured programming
Using block call instructions
Using the debug and diagnostic functions of the CPUs in the user program
(for example, error OBs, status word)
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Preface
Manual/
Manual Package
Contents
STEP 7 Reference
Information
• Basic procedure for working with STL, LAD, or FBD (for example, structure of
Statement List (STL)
for S7-300 and
S7-400
•
•
•
•
•
•
Ladder Logic (LAD)
for S7-300 and
S7-400
Function Block
Diagram (FBD) for
S7-300 and S7-400
STL, LAD, or FBD, number formats, syntax)
Description of all instructions in STEP 7 (with program examples)
Description of the various addressing methods in STEP 7 (with examples)
Description of all functions integrated in the CPUs
Description of the internal registers in the CPU
Description of all system functions integrated in the CPUs
Description of all organization blocks integrated in the CPUs
System and
Standard Functions
Manual
PG 7xx
vi
• Description of the programming device hardware
• Connecting a programming device to various devices
• Starting up a programming device
S7-400 and M7-400 Programmable Controllers Hardware and Installation
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Preface
Specific Information for M7-400
This documentation package describes the hardware of the M7-400. You will need
the following additional documentation for programming and starting up an M7-400:
Documentation
Contents
System Software for
M7-300/400 Program Design
Programming Manual
Designing, writing and testing a C program
for M7 CPU/FM modules with the M7 SYS
programming package, using the M7 SYS
functions
System Software for
M7-300/400 System and
Standard Functions
Reference Manual
Detailed description of the M7 SYS functions
and data structures, listing of messages
types
System Software for
M7-300/400 Installation and
Operation
User Manual
Installing and configuring the operating
system and system software
Order No.
6ES7802-0FA14-0BA0
Recycling and Disposal
The S7-400 is environmentally friendly and can thus recyclable. Consult a certified
disposal agency for electronics junk to recycle and dispose of your old equipment
in an environmentally friendly manner.
Further Support
If you have any technical questions, please get in touch with your Siemens
representative or agent responsible.
http://www.siemens.de/partner
Training Centers
Siemens offers a number of training courses to familiarize you with the SIMATIC S7
automation system. Please contact your regional training center or our central
training center in D-90327 Nuremberg, Germany for details:
Telephone:
+49 (911) 895-3200.
Internet:
http://www.sitrain.com
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Preface
A&D Technical Support
Worldwide, available 24 hours a day:
Nuernberg
Johnson City
Beijing
Technical Support
Worldwide (Nuernberg)
Technical Support
24 hours a day, 365 days a year
Phone:
+49 (0) 180 5050-222
Fax:
+49 (0) 180 5050-223
E-Mail:
adsupport@
siemens.com
GMT:
+1:00
Europe / Africa (Nuernberg)
United States (Johnson City)
Asia / Australia (Beijing)
Authorization
Technical Support and
Authorization
Technical Support and
Authorization
Local time: Mon.-Fri. 8:00 to 17:00
Local time: Mon.-Fri. 8:00 to 17:00
Local time: Mon.-Fri. 8:00 to 17:00
Phone:
Fax:
+49 (0) 180 5050–222
+49 (0) 180 5050-223
Phone:
+1 (0) 423 262 2522
Phone:
+86 10 64 75 75 75
Fax:
+1 (0) 423 262 2289
Fax:
+86 10 64 74 74 74
adsupport@
siemens.com
+1:00
E-Mail:
simatic.hotline@
sea.siemens.com
E-Mail:
GMT:
–5:00
GMT:
adsupport.asia@
siemens.com
+8:00
E-Mail:
GMT:
The languages of the SIMATIC Hotlines and the authorization hotline are generally German and English.
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Preface
Service & Support on the Internet
In addition to our documentation, we offer our Know-how online on the internet at:
http://www.siemens.com/automation/service&support
where you will find the following:
• The newsletter, which constantly provides you with up–to–date information on
your products.
• The right documents via our Search function in Service & Support.
• A forum, where users and experts from all over the world exchange their
experiences.
• Your local representative for Automation & Drives via our representatives
database.
• Information on field service, repairs, spare parts and more under “Services”.
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Preface
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Contents
1
Product Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1
2
Installing the S7-400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1
2.1
Assembling an S7-400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2
2.2
Assembling the Central Rack (CR) and Expansion Rack (ER) . . . . . . . . .
2-6
2.3
Segmented CR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-8
2.4
Subdivided CR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-9
2.5
Mounting and Grounding the Racks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-10
2.6
Chassis Terminal Connection in the Non-Isolated Configuration . . . . . . . .
2-16
2.7
Methods of Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-19
2.8
Changing the Ventilation with the Cable Duct and Fan Subassembly . . . .
2-21
2.9
Installing the Fan Subassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-23
2.10
Installing the Cable Duct . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-25
2.11
Choosing and Setting up Cabinets with the S7-400 . . . . . . . . . . . . . . . . . . .
2-26
2.12
Rules for the Arrangement of Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-30
2.13
Fitting Memory Cards in the CPU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-31
2.14
Installing Modules in a Rack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-33
2.15
Marking the Modules with Slot Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-37
2.16
Methods of Expansion and Networking . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-38
2.17
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-39
Addressing the S7-400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1
3.1
Geographical and Logical Addresses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2
3.2
How to Determine the Default Address of a Module . . . . . . . . . . . . . . . . . .
3-4
3.3
How to Determine the Default Address of a Channel . . . . . . . . . . . . . . . . . .
3-6
3
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Contents
4
xii
Wiring the S7-400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1
4.1
Supplying Power to Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2
4.2
Choosing the Power Supply Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-3
4.3
Choosing the Load Current Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-4
4.4
Assembling an S7-400 with Process I/Os . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-5
4.5
Assembling an S7-400 with Grounded Reference Potential (M) . . . . . . . .
4-7
4.6
Assembling an S7-400 with Ungrounded Reference Potential
(Ungrounded Configuration) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-8
4.7
Assembling an S7-400 with Isolated Modules . . . . . . . . . . . . . . . . . . . . . . . .
4-10
4.8
Parallel Wiring of Digital S7-400 Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-12
4.9
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-13
4.10
Interference-Free Configuration for Local and Remote Connections . . . .
4-15
4.11
Wiring Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-17
4.12
Setting the VAC Power Supply Module to the Line Voltage . . . . . . . . . . . . .
4-18
4.13
Wiring the Power Supply Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-20
4.14
Wiring the Signal Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-24
4.15
Wiring the Front Connector, Crimp Snap-On Terminals . . . . . . . . . . . . . . . .
4-26
4.16
Wiring the Front Connector, Screw-Type Terminals . . . . . . . . . . . . . . . . . . .
4-27
4.17
Wiring the Front Connector, Spring-Type Terminals . . . . . . . . . . . . . . . . . . .
4-28
4.18
Fitting the Strain Relief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-30
4.19
Labeling a Front Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-31
4.20
Fitting the Front Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-35
4.21
Interconnecting the CR and ER(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-38
4.22
Setting the Fan Subassembly to the Line Voltage and Wiring It . . . . . . . . .
4-40
4.23
Routing Cables Using Cable Ducts or Fan Subassemblies . . . . . . . . . . . .
4-42
4.24
Routing Cables Using Fiber-Optic Cables . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-42
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5
6
7
Networking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1
5.1
Configuring a Network . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-2
5.2
Fundamentals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-3
5.3
Rules for Configuring a Network . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-7
5.4
Cable Lengths . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-15
5.5
PROFIBUS-DP Bus Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-18
5.6
Bus Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-19
5.7
RS 485 Repeater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-23
5.8
5.8.1
5.8.2
5.8.3
PROFIBUS-DP Network with Fiber-Optic Cables . . . . . . . . . . . . . . . . . . . . .
Fiber-Optic Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Simplex Connectors and Connector Adapter . . . . . . . . . . . . . . . . . . . . . . . .
Connecting a Fiber-Optic Cable to the PROFIBUS Device . . . . . . . . . . . . .
5-25
5-27
5-29
5-31
Starting Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-1
6.1
Recommended Procedure for First Startup . . . . . . . . . . . . . . . . . . . . . . . . . .
6-2
6.2
Checks Prior to Switching On for the First Time . . . . . . . . . . . . . . . . . . . . . .
6-3
6.3
Connecting a Programming Device (PG) to an S7-400 . . . . . . . . . . . . . . . .
6-5
6.4
Switching On an S7-400 for the First Time . . . . . . . . . . . . . . . . . . . . . . . . . .
6-6
6.5
Resetting the CPU with the Mode Selector Switch . . . . . . . . . . . . . . . . . . . .
6-7
6.6
Cold, Warm, and Hot Restarts with the Mode Selector Switch . . . . . . . . . .
6-10
6.7
Inserting a Memory Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-11
6.8
Inserting a Backup Battery (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-13
6.9
Starting Up a PROFIBUS-DP Subnet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-17
6.10
Installing Interface Submodules
(CPU 414-2, 414-3, 416-3, 417-4 and 417-4H) . . . . . . . . . . . . . . . . . . . . . . .
6-18
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-1
7.1
Replacing the Backup Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-2
7.2
Replacing a Power Supply Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-4
7.3
Replacing CPUs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-5
7.4
Replacing Digital or Analog Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-7
7.5
Changing the Fuses in the Digital Modules . . . . . . . . . . . . . . . . . . . . . . . . . .
7-9
7.6
Replacing Interface Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-11
7.7
Replacing the Fuse of the Fan Subassembly . . . . . . . . . . . . . . . . . . . . . . . .
7-13
7.8
Replacing Fans in the Fan Subassembly During Operation . . . . . . . . . . . .
7-14
7.9
Replacing the Filter Frame of the Fan Subassembly During Operation . .
7-16
7.10
Replacing the Power Supply PCB and Monitoring PCB
of the Fan Subassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-18
7.11
Replacing Memory Cards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-19
7.12
Replacing Interface Submodules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-22
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8
xiv
Assembling the M7-400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-1
8.1
Mechanical Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-2
8.2
Addressing the M7-400 Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-5
8.3
Electrical Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-6
8.4
8.4.1
8.4.2
8.4.3
8.4.4
8.4.5
8.4.6
8.4.7
8.4.8
Installing the M7-400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checklist for Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Module Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fitting Memory Cards in the CPU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing Interface Submodules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fitting the Short AT Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembling Expansion Modules on a Central Rack . . . . . . . . . . . . . . . . . . .
Installing a Module Assembly in the Rack . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inserting/Removing a Memory Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-8
8-9
8-10
8-11
8-13
8-15
8-17
8-24
8-28
8.5
Connecting a Module Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-29
8.6
Assembling an MPI Subnet or PROFIBUS-DP Subnet . . . . . . . . . . . . . . . .
8-30
8.7
8.7.1
8.7.2
8.7.3
8.7.4
8.7.5
8-32
8-33
8-36
8-39
8-40
8.7.6
8.7.7
Preparing for Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connecting the Operator Panels and I/O Devices . . . . . . . . . . . . . . . . . . . .
Connecting a Programming Device (PG) to the COM Interface . . . . . . . . .
Connecting a Programming Device (PG) to the M7-400 . . . . . . . . . . . . . . .
Connecting a Programming Device (PG) to Two or More Nodes . . . . . . . .
Connecting a Programming Device (PG)
to Ungrounded Nodes of an MPI Subnet . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starting Up a PROFIBUS-DP Subnet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking the Status and Error Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.8
8.8.1
8.8.2
8.8.3
8.8.4
Replacing Modules and Submodules/Cards . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing an Interface Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing the CPU or Expansion Modules of a Module Assembly . . . . . .
Replacing Memory Cards in a CPU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing a Short AT Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-46
8-47
8-49
8-54
8-56
8-43
8-44
8-45
S7-400 and M7-400 Programmable Controllers Hardware and Installation
A5E00069481-04
Contents
A
B
Assembling and Installing Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A-1
A.1
General Rules and Regulations for Operating the S7-400 . . . . . . . . . . . . .
A-2
A.2
Principles of System Installation for EMC . . . . . . . . . . . . . . . . . . . . . . . . . . .
A-5
A.3
Installation of Programmable Controllers for EMC . . . . . . . . . . . . . . . . . . . .
A-9
A.4
Examples of EMC-Compatible Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . .
A-10
A.5
Shielding Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A-13
A.6
Equipotential Bonding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A-15
A.7
Cabling Inside Buildings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A-17
A.8
Cabling Outside Buildings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A-19
A.9
A.9.1
A.9.2
A.9.3
A-20
A-21
A-23
A.9.4
Lightning Protection and Overvoltage Protection . . . . . . . . . . . . . . . . . . . . .
Lightning Protection Zone Concept . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rules for the Transition between Lightning Protection Zones 0 and 1 . . .
Rules for the Transitions between
Lightning Protection Zones 1 <-> 2 and Greater . . . . . . . . . . . . . . . . . . . . . .
Sample of a Surge Protection Circuit for Networked S7-400 PLCs . . . . . .
A.10
How to Protect Digital Output Modules against Inductive Surge . . . . . . . .
A-30
A.11
Safety of Electronic Control Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A-32
A.12
Interference-Free Connection of Monitors . . . . . . . . . . . . . . . . . . . . . . . . . . .
A-34
Guidelines for Handling Electrostatically-Sensitive Devices (ESD) . . . . . . . . . .
B-1
B.1
What is ESD? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
B-2
B.2
Electrostatic Charging of Persons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
B-3
B.3
General Protective Measures Against Electrostatic Discharge Damage .
B-4
A-25
A-28
Glossary
Index
S7-400 and M7-400 Programmable Controllers Hardware and Installation
A5E00069481-04
xv
Contents
Figures
2-1
2-2
2-3
2-4
2-5
2-6
2-7
2-8
2-9
4-1
4-2
4-3
4-4
4-5
4-6
4-7
4-8
4-9
4-10
4-11
4-12
4-13
4-14
4-15
4-16
4-17
4-18
4-19
4-20
4-21
4-22
4-23
4-24
4-25
5-1
5-2
5-3
5-4
5-5
5-6
5-7
5-8
5-9
5-10
5-11
5-12
5-13
5-14
xvi
Rack Fitted with Modules in the S7-400 System . . . . . . . . . . . . . . . . . . . . .
Max. Cabinet Ambient Temperature as a Function
of Power Dissipation of Equipment in the Cabinet . . . . . . . . . . . . . . . . . . . .
Fitting Memory Cards in the CPUs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Memory Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing the Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Attaching the Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Screwing the Modules in Place . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inserting the Key in the CPU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fitting a Slot Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operating the S7-400 from a Grounded Supply . . . . . . . . . . . . . . . . . . . . . .
An S7-400 Configured with Grounded Reference Potential . . . . . . . . . . . .
An S7-400 Configured with Ungrounded Reference Potential . . . . . . . . . .
Simplified Representation of Configuration with Isolated Modules . . . . . . .
Parallel Wiring of a Digital Output with Different Rated Load Voltages . . .
Parallel Wiring of a Digital Output with Identical Rated Load Voltages . . .
Grounded connection load voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shielding and Grounding the Connecting Cable for
a Remote Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Setting the voltage selector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disconnecting power supply connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wiring the power supply connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Plugging the power supply connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Preparing to wire the front connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wiring a Front Connector with Crimp Snap-On Terminals . . . . . . . . . . . . . .
Wiring a Front Connector with Screw-Type Terminals . . . . . . . . . . . . . . . . .
Wiring a Front Connector with Spring-Type Terminals . . . . . . . . . . . . . . . . .
Principle of the spring contact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fitting a Strain Relief (Viewed from Below) . . . . . . . . . . . . . . . . . . . . . . . . . .
Fitting the Labels on the Front Connector . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fitting a Label in the Front Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Attaching the Front Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Screwing On the Front Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Plugging a Connecting Cable into a Send IM . . . . . . . . . . . . . . . . . . . . . . . .
Connection Between a Send IM and Two Receive IMs . . . . . . . . . . . . . . . .
Wiring the Fan Subassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Communication between Programming Device/Operator Panel
and a Module without MPI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Data Exchange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Terminating resistor on bus connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Terminating resistor on RS 485 repeater . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Terminating resistor on MPI network . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Example of an MPI network . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Example of a PROFIBUS DP network . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Example with CPU 414-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Programming device access beyond network limits . . . . . . . . . . . . . . . . . . .
Configuration of an MPI network . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bu s connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Strip bus cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inserting cores into the screw termninal blocks . . . . . . . . . . . . . . . . . . . . . .
Switch on terminating resistant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2
2-28
2-32
2-32
2-34
2-35
2-35
2-36
2-37
4-6
4-7
4-8
4-11
4-12
4-12
4-14
4-16
4-19
4-20
4-22
4-23
4-25
4-26
4-27
4-28
4-29
4-30
4-31
4-32
4-36
4-37
4-38
4-39
4-41
5-5
5-6
5-9
5-9
5-10
5-11
5-12
5-13
5-14
5-17
5-19
5-20
5-21
5-22
S7-400 and M7-400 Programmable Controllers Hardware and Installation
A5E00069481-04
Contents
5-15
5-16
5-17
6-1
6-2
6-3
7-1
7-2
7-3
8-1
8-2
8-3
8-4
8-5
8-6
8-7
8-8
8-9
8-10
8-11
8-12
8-13
8-14
8-15
8-16
8-17
8-18
8-19
8-20
8-21
8-22
8-23
8-24
8-25
8-26
8-27
8-28
8-29
8-30
Turning back braided shield over cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Optical PROFIBUS-DP Network with Nodes
that have an Integrated Fiber-Optic Cable Interface . . . . . . . . . . . . . . . . . .
Simplex Connectors and a Special Connector Adapter
for the IM 153-2 FO and IM 467 FO (installed) . . . . . . . . . . . . . . . . . . . . . . .
Connecting PG to an S7-400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inserting a Memory Card in a CPU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inserting Interface Submodules in the CPU . . . . . . . . . . . . . . . . . . . . . . . . . .
Fitting Memory Cards in the CPUs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Memory Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inserting an Interface Submodule in a CPU . . . . . . . . . . . . . . . . . . . . . . . . .
Fitting Memory Cards in the CPUs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.3 V Memory Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inserting an Interface Submodule in an Expansion Module . . . . . . . . . . . .
Fitting an AT Card in the ATM 478 AT Adapter Module . . . . . . . . . . . . . . . .
Locations of the Expansion Socket and Plug . . . . . . . . . . . . . . . . . . . . . . . .
EXM 478 Expansion Module Fitted with Connecting Clips . . . . . . . . . . . . .
Removing the Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Interconnecting a CPU and Expansion Modules . . . . . . . . . . . . . . . . . . . . .
Module Assembly Comprising CPU and Expansion Modules . . . . . . . . . . .
Connecting Clip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Securing the Modules with Connecting Clips (Schematic Diagram) . . . . .
Attaching a Module Assembly Comprising CPU and Expansion Modules
and Swinging it into Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Screwing the Modules On . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inserting the Key in the CPU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inserting a Memory Card in a CPU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Example of a Configuration with the CPU in an MPI Subnet
and PROFIBUS-DP Subnet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connecting a Programming Device to the M7-400 . . . . . . . . . . . . . . . . . . . .
Connecting a Programming Device to Two or More M7-400s . . . . . . . . . .
Connecting a Programming Device to an M7-400 Subnet . . . . . . . . . . . . .
Ungrounded Operation of the M7-400 Network . . . . . . . . . . . . . . . . . . . . . .
Removing an Interface Submodule from the Card Slot
of an Expansion Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing the Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Unscrewing Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Swinging a Module Assembly Out and Lifting it Up and Out . . . . . . . . . . . .
Module Assembly Comprising CPU and Expansion Modules . . . . . . . . . . .
Removing the Connecting Clips from the Module to be Replaced . . . . . . .
Separating the Modules, for Example When the
Mass Storage Module is to be Replaced . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing Memory Cards from the CPUs . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.3 V Memory Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing an AT Card from the ATM 478 AT Adapter Module . . . . . . . . . .
S7-400 and M7-400 Programmable Controllers Hardware and Installation
A5E00069481-04
5-24
5-26
5-30
6-5
6-12
6-19
7-20
7-21
7-23
8-12
8-12
8-14
8-16
8-18
8-19
8-20
8-21
8-22
8-23
8-23
8-25
8-26
8-27
8-28
8-31
8-39
8-41
8-42
8-43
8-48
8-49
8-50
8-51
8-51
8-52
8-53
8-55
8-55
8-57
xvii
Contents
A-1
A-2
A-3
A-4
A-5
A-6
A-7
A-8
A-9
A-10
A-11
B-1
xviii
The Possible Routes for Electromagnetic Interference . . . . . . . . . . . . . . . .
Example of Cabinet Installation for EMC . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wall Mounting an S7-400 for EMC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mounting Cable Shields . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Routing Equipotential Bonding Conductor and Signal Line . . . . . . . . . . . . .
Lightning Protection Zones of a Building . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sample Circuitry for Networked S7-400 PLCs . . . . . . . . . . . . . . . . . . . . . . .
Relay Contact for EMERGENCY OFF in the Output Circuit . . . . . . . . . . . .
Suppression for DC-Operated Coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Suppression with AC-Operated Coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shielding and Grounding with a Great Distance between Monitor
and Programmable Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrostatic Voltages which can Build up on a Person . . . . . . . . . . . . . . . .
A-5
A-10
A-12
A-14
A-16
A-22
A-28
A-30
A-31
A-31
A-36
B-3
S7-400 and M7-400 Programmable Controllers Hardware and Installation
A5E00069481-04
Contents
Tables
2-1
2-2
2-3
4-1
4-2
4-3
4-4
5-1
5-2
5-3
5-4
5-5
5-6
5-7
6-1
6-2
8-1
8-2
8-3
8-5
8-6
8-7
8-8
8-9
8-10
A-1
A-2
A-3
A-4
A-5
A-6
Types of Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Modules in the different racks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Accessories for Modules and Racks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
VDE Specifications for Assembling a Programmable Controller . . . . . . . .
Methods of Protective Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Grounded connection load voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front connector coding elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Permitted Cable Length of a Segment in an MPI Network . . . . . . . . . . . . .
Permitted Cable Length of a Segment in the PROFIBUS-DP Network
Depending on the Transmisson Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lengths of Spur Lines per Segment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Features of the Fiber-Optic Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Order Numbers - Fiber-Optic Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Order Numbers - Simplex connectors and connector adapters . . . . . . . .
Permissible Cable Lengths on the Optical PROFIBUS-DP Network
(Partyline Topology) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checklist to be Used Before Switching On for the First Time . . . . . . . . . .
Setting the Battery Monitoring Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sequence in the Module Subassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Possible Applications of the M7-400 Modules . . . . . . . . . . . . . . . . . . . . . . . .
Dimensions of Modules in the M7-400 System . . . . . . . . . . . . . . . . . . . . . . .
Accessories for Modules and Racks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maximum Cable Lengths for Operator Panels and I/O Devices . . . . . . . . .
Null Modem Cable for Connecting a CPU via IF to the COM Interface
of a Programming Device with 9-pin Sub. D Male Connector . . . . . . . . . .
Null Modem Cable for Connecting a CPU via IF to the COM Interface
of a Programming Device with 25-pin Sub. D Male Connector . . . . . . . . . .
Pin Assignments of the Cable for Connecting a CPU via IF
to the COM Interface of a Programming Device
with 9-pin Sub. D Male Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pin Assignments of the Cable for Connecting a CPU via IF
to the COM Interface of a Programming Device with 25-pin
Sub. D Female Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Key for Example 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cabling Inside Buildings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
High-Voltage Protection of Cables with the Help
of Surge Protection Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Low-Voltage Protection Components
for Lightning Protection Zones 1 <–> 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Surge Protection Components for Lightning Protection Zones 2 <–> 3 . .
Example of a Circuit Conforming to Lightning Protection Requirements
(Legend to Figure A-7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
S7-400 and M7-400 Programmable Controllers Hardware and Installation
A5E00069481-04
2-27
2-30
2-39
4-5
4-13
4-14
4-35
5-15
5-15
5-16
5-27
5-29
5-30
5-31
6-3
6-5
8-3
8-3
8-4
8-10
8-35
8-36
8-37
8-38
8-38
A-11
A-17
A-23
A-26
A-27
A-29
xix
Contents
xx
S7-400 and M7-400 Programmable Controllers Hardware and Installation
A5E00069481-04
Product Overview
1
Overview of the S7-400
The S7-400 is a programmable controller. Almost any automation task can be
implemented with a suitable choice of S7-400 components.
S7-400 modules have a block design for swing-mounting in a rack. Expansion
racks are available to extend the system.
In this chapter, we show you the most important components with which you can
assemble an S7-400.
Features of the S7-400
The S7-400 programmable controller combines all the advantages of the previous
system with those of a new system and new software. These are:
• A graded CPU platform
• Upwardly-compatible CPUs
• Enclosed modules of rugged design
• Convenient terminal system for the signal modules
• Compact modules with a high component density
• Optimum communication and networking facilities
• Convenient incorporation of operator interface systems
• Software parameter assignment for all modules
• Extensive choice of slots
• Operation without fans
• Multicomputing in the non-segmented rack
S7-400 and M7-400 Programmable Controllers Hardware and Installation
A5E00069481-04
1-1
Product Overview
Overview of the M7-400
The SIMATIC S7 programmable controller is extended by the SIMATIC M7
automation computer with its AT-compatible computer functionality. This enables
the SIMATIC user to make use of the open software world, either as an extension
to an S7 programmable controller or as a stand-alone M7 computer system. The
entire SIMATIC S7 range of I/O devices is available to the M7 user.
Features of the M7-400
The M7-400 automation computer is suitable for the following typical tasks:
• Process data acquisition
• Storage of large volumes of data
• Control of local process I/Os
• Communication
• Closed-loop control, positioning, counting
• Operator interface systems.
It offers the following features:
• Running of DOS/Windows software available on the market
• Free programming (high-level language)
• RMOS real-time multitasking operating system
– running of real time-capable software
– event-driven program processing
– multitasking
• A standard, short AT card can be plugged in
• Multicomputing in the non-segmented rack
• Full incorporation in S7-400 systems.
1-2
S7-400 and M7-400 Programmable Controllers Hardware and Installation
A5E00069481-04
Product Overview
Components of an S7-400
The most important components of the S7-400 and their functions are given in the
following tables:
Components
Function
Racks
(UR: Universal Rack)
(CR: Central Rack)
(ER: Expansion Rack)
... provide the mechanical and
electrical connections between
the S7-400 modules.
Power Supply Modules
(PS = Power Supply)
... convert the line voltage
(120/230 VAC or 24 VDC) to the
5 VDC and 24 VDC operating
voltages required to power the
S7-400.
Accessories:
Backup battery
CPUs
Central Processing Units (CPUs)
... execute the user program;
communicate via the multipoint
interface (MPI) with other CPUs
or with a programming device
(PG).
Memory cards
... store the user program and
parameters.
IF 964-DP interface module
... used to connect distributed
I/Os via PROFIBUS-DP
Signal Modules
(SM = Signal Module)
(digital input modules, digital
output modules, analog input
modules, analog output modules)
Accessories:
Front connector with three
different terminal systems
... match the different process
signal levels to the S7-400.
... form the interface between
PLC and process.
Interface modules
(IM = Interface Module)
Accessories:
Connecting cable
Terminator
... interconnect the individual
racks of an S7-400.
Cable ducts
...are used for routing cables and
as ventilation.
PROFIBUS bus cables
...connect CPUs to programming
devices.
S7-400 and M7-400 Programmable Controllers Hardware and Installation
A5E00069481-04
Illustration
1-3
Product Overview
Components
Function
PG cables
...connect a CPU to a
programming device.
PROFIBUS components
for example, PROFIBUS bus
terminal
... connect the S7-400 to other
S7-400 devices or programming
devices.
RS 485 repeaters
...amplify data signals on bus
lines and links bus segments.
Programming device (PG) or PC
with the STEP 7 software
package
...configures, programs, debugs,
and assigns parameters to the
S7-400.
Fan subassemblies
(for special areas of application)
...ventilates modules in special
cases; can be operated with or
without a filter.
Illustration
Additional components of the S7-400 such as communications processors, function
modules, etc., are described in separate manuals.
Components of an M7-400
The most important components of the M7-400 and their functions are given in the
following tables:
Components
Function
Central Processing Units (CPUs)
... function as AT-compatible
processing units; execute the
user program; communicate via
the MPI with other CPUs or with
a programming device / PC;
serve to accommodate two
interface submodules (IFs).
Accessories:
Memory Card
DRAM Cards
Application Modules (FMs)
Accessories:
Memory Card
DRAM Cards
On-Board Silicon Disk
1-4
Illustration
... are ISA-compatible processing
units to support the CPU.
(They are described in a
separate manual.)
S7-400 and M7-400 Programmable Controllers Hardware and Installation
A5E00069481-04
Product Overview
Components
Function
Expansion Modules (EXMs)
... serve to accommodate three
interface submodules (IFs).
AT Adapter Modules (ATMs)
... provide a slot for a 16-bit AT
module (up to 164 mm long).
Mass Storage Modules (MSMs)
... serve to store programs and
data on a hard disk (2.5”) or
floppy disk (3.5”).
Interface Submodules (IFs)
... for connecting I/O devices
such as VGA monitor, mouse,
keyboard, printer.
Illustration
Applicable Modules in the S7-400 Range
The following modules from the S7-400 range can be used with the M7-400:
• Power supply modules (PSs)
• Function modules (FMs)
• Signal modules (SMs)
• Interface modules (IMs)
• Fan subassemblies
Suitable I/O Devices
The following I/O devices can be connected via the appropriate interface
submodules:
• VGA monitor
• Keyboard
• Mouse
• Printer
• Sensors and actuators
• Distributed I/Os
S7-400 and M7-400 Programmable Controllers Hardware and Installation
A5E00069481-04
1-5
Product Overview
Connecting the M7-400 to a Programming Device / PC
For the remote setup of the M7-400, you can connect a programming device or PC
to the CPU of the M7-400 via a V.24 cable.
A PC/PG cable is used to connect a programming device or PC and CPU of the
M7-400 via the multipoint interface (MPI).
Location of Order Number and Product Version
The order number and product version are printed on every module of the
SIMATIC S7-400/M7-400. The firmware version is also printed on the CPUs. The
following figure shows their locations on a module.
For the product version, an X is entered instead of the valid number. The following
figure shows a module with Product Version 1.
Module designation
CPU 412Ć1
X 2
3 4
Type label
412Ć1XF03Ć0AB0
V 3.0.1
Product version
Abbreviated order number
(6ES7 ...)
Firmware version
(in CPUs)
Example of a Rating Plate
SIMATIC M7
6ES7 488Ć3AA00Ć0AB0
CPU 488Ć3
FM
SVP JM123456
APPROVED
CLASS 1 BE4 2
Made in Germany
Order no.
MAX. 1BC
X 2 3 4
5
6 7 8
T4
Product version
Approvals and marks
Module designation
1-6
S7-400 and M7-400 Programmable Controllers Hardware and Installation
A5E00069481-04
2
Installing the S7-400
Chapter Overview
Section
Description
Page
2.1
Assembling an S7-400
2-2
2.2
Assembling the Central Rack (CR) and Expansion Rack (ER)
2-6
2.3
Segmented CR
2-8
2.5
Mounting and Grounding the Racks
2-10
2.6
Chassis Terminal Connection in the Non-Isolated Configuration
2-16
2.7
Methods of Ventilation
2-19
2.8
Changing the Ventilation with the Cable Duct and Fan Subassembly
2-21
2.9
Installing the Fan Subassembly
2-23
2.10
Installing the Cable Duct
2-25
2.11
Choosing and Setting up Cabinets with the S7-400
2-26
2.12
Rules for the Arrangement of Modules
2-30
2.13
Fitting Memory Cards in the CPU
2-31
2.14
Installing Modules in a Rack
2-33
2.15
Marking the Modules with Slot Labels
2-37
2.16
Methods of Expansion and Networking
2-38
2.17
Accessories
2-39
S7-400 and M7-400 Programmable Controllers Hardware and Installation
A5E00069481-04
2-1
Installing the S7-400
2.1
Assembling an S7-400
Introduction
An S7-400 programmable controller consists of a central rack (CR) and one or
more expansion racks (ERs), as required. You use ERs when there are insufficient
slots in the CR for your application, or when you wish to operate signal modules
separated from the CR (e.g. in the immediate vicinity of your process).
When using ERs, you need interface modules (IMs) as well as the additional racks,
and additional power supply modules if necessary. When using interface modules,
you must always use the appropriate partners: you insert a send IM in the CR, and
the matching receive IM in each connected ER (see Reference Manual,
Chapter 7).
The M7-400 modules function similarly to the S7-400 modules and also use the
racks in the S7-400 range. Any differences in function or data can be found directly
at the relevant point or in Section 8.1 “Mechanical Configuration.”
Central Rack (CR) and Expansion Rack (ER)
The rack containing the CPU is known as the central rack (CR). The racks
containing modules in the system and connected to the CR are the expansion
racks (ERs).
Shown in Figure 2-1 is a rack with 18 slots configured as a CR.
PS
CPU
Figure 2-1
2-2
SMs
Rack Fitted with Modules in the S7-400 System
S7-400 and M7-400 Programmable Controllers Hardware and Installation
A5E00069481-04
Installing the S7-400
Connecting the CR and ER(s)
To connect one or more ERs to a CR, you must fit one or more send IMs in the CR.
The send IMs have two interfaces. You can connect one chain of up to four ERs to
each of the two interfaces of a send IM in the CR.
Different IMs are available for local connection and remote connection.
Connecting with a 5 V Supply
For a local connection with the IM 460-1 and IM 461-1, the 5 V supply voltage is
also transferred via the interface modules. There must therefore be no power
supply module inserted in an ER connected to an IM 460-1/IM 461-1.
Up to 5 A may flow through each of the two interfaces of an IM 460-1. This means
that each ER connected via an IM 460-1/461-1 can be powered with a maximum of
5 A at 5 V. For further details, see the Reference Manual, Chapter 7.
Overview of the Connections
Observe the connection rules at the end of this section.
Local Connection
Remote Connection
Send IM
460-0
460-1
460-3
460-4
Receive IM
461-0
461-1
461-3
461-4
4
1
4
4
Max. distance
5m
1.5 m
102.25 m
605 m
5 V transfer
No
Yes
No
No
–
5A
–
–
Yes
No
Yes
No
Max. number of connectable
EMs per chain
Max. current transfer per interface
Communication bus transmission
S7-400 and M7-400 Programmable Controllers Hardware and Installation
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2-3
Installing the S7-400
Ways of Connecting Central and Expansion Racks
Central rack CR
IM 460-4
IM 460-3
IM 460-1
IM 460-0
Expansion without 5 V local transfer
Expansion rack ER 1
Expansion rack ER 4
IM 461-0
IM 461-0
Chain length max. 3 m
Expansion with 5 V local transfer
Expansion rack ER 1
IM 461-1
Chain length max. 1.5 m
Remote expansion
Expansion rack ER 4
Expansion rack ER 1
IM 461-3
IM 461-3
Chain length max. 102.25 m
Expansion rack ER 4
Expansion rack ER 1
IM 461-4
IM 461-4
Chain length max. 605 m
2-4
S7-400 and M7-400 Programmable Controllers Hardware and Installation
A5E00069481-04
Installing the S7-400
Rules for Connection
When you connect a central rack to expansion racks, you must observe the
following rules:
• You can connect up to 21 ERs of the S7-400 to one CR.
• The ERs are assigned numbers to identify them. The rack number must be set
on the coding switch of the receive IM. Any rack number between 1 and 21 may
be assigned. Numbers must not be duplicated.
• You may insert up to six send IMs in one CR. However, only two send IMs with
5 V transfer are allowed in one CR.
• Each chain connected to the interface of a send IM can comprise up to four ERs
(without 5 V transfer) or one ER (with 5 V transfer).
• The exchange of data via the communication bus is limited to 7 racks, meaning
the CR and ER numbers 1 to 6.
• The maximum (total) cable lengths specified for the type of connection must not
be exceeded.
Type of Connection
Local connection with 5 V transfer via
IM 460-1 and IM 461-1
Local connection without 5 V transfer via
IM 460-0 and IM 461-0
Maximum (Total) Cable Length
1.5 m
5m
Remote connection via IM 460-3 and
IM 461-3
102.25 m
Remote connection via IM 460-4 and
IM 461-4
605 m
S7-400 and M7-400 Programmable Controllers Hardware and Installation
A5E00069481-04
2-5
Installing the S7-400
2.2
Assembling the Central Rack (CR) and Expansion Rack
(ER)
Function of the Racks
The racks of the S7-400 system form the basic framework which accepts the
individual modules. The modules exchange data and signals and are powered via
the backplane bus. The racks are designed for wall mounting, for mounting on rails,
and for installation in frames and cabinets.
Racks in the S7-400 System
Rack
No. of
Slots
Available
Buses
Application
Characteristics
UR1
18
UR2
9
I/O bus
Communication
bus
CR
or
ER
Rack for all module types in the S7-400
and as central rack for CPUs and their
expansion modules from the M7-400
range (see Section 8.1).
ER1
Racks for signal modules (SMs), receive
IMs, and all power supply modules.
The I/O bus has the following restrictions:
18
• Interrupts from modules have no
effect because no interrupt lines
exist.
Restricted I/O
bus
ER2
2-6
• Modules are not supplied with 24 V,
i.e. modules requiring 24 V cannot
be used (see technical data of the
modules).
• Modules are neither backed up by
9
the battery in the power supply
module nor by the voltage applied
externally to the CPU or receive IM
(EXT.BATT. socket).
CR2
18
I/O bus,
segmented
Communication
bus, continuous
CR3
4
I/O bus
Communication
bus
2*9
I/O bus,
segmented
Communication
bus, segmented
UR2-H
ERs
Segmented
CR
CR in standard
systems
Subdivided CR or
ER for compact installation of a fault–
tolerant system
Rack for all module types in the S7-400
except receive IMs and for the CPUs
and their expansion modules from the
M7-400 range (see Section 8.1).
The I/O bus is subdivided into 2 I/O bus
segments of 10 and 8 slots respectively.
Racks for all S7-400 module types except receive IMs. CPUs 41x-H only in
stand-alone operation.
Rack for all module types in the S7-400.
The I/O bus and communication bus are
divided into 2 bus segments, each with 9
slots.
S7-400 and M7-400 Programmable Controllers Hardware and Installation
A5E00069481-04
Installing the S7-400
Electrical Supply
The modules inserted in the rack are supplied with the required operating voltages
(5 V for logic, 24 V for interfaces) via the backplane bus and base connector, by the
power supply module fitted in the slot on the extreme left in the rack.
For local connections, ERs can also be supplied with power via the
IM 460-1 / IM 461-1 interface modules.
5 A may flow through each of the two interfaces of a send IM 460-1, meaning each
ER in a local connection can be supplied with up to 5 A.
I/O Bus
The I/O bus is a parallel backplane bus designed for the fast interchange of
I/O signals. Each rack has an I/O bus. Time-critical operations to access the
process data of the signal modules take place via the I/O bus.
Communication Bus (C Bus)
The communication bus (C bus) is a serial backplane bus designed for the fast
exchange of large volumes of data parallel to the I/O signals. Except for racks ER1
and ER2, each rack has a communication bus.
Rack with I/O Bus and Communication Bus
The following figure shows a rack with an I/O bus and a communication bus. The
I/O bus connector and communication bus connector can be seen at each slot.
When the rack is delivered, these connectors are protected by a cover.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
I/O bus connector
Communication
bus connector
S7-400 and M7-400 Programmable Controllers Hardware and Installation
A5E00069481-04
2-7
Installing the S7-400
2.3
Segmented CR
Properties
The “segmented” characteristic relates to the configuration of the CR. In the
(non-segmented) CR the I/O bus is continuous and interconnects all 18 or 9 slots;
in the segmented CR, however, the I/O bus consists of two I/O bus segments.
A segmented CR has the following important characteristics:
• The communication bus is continuous (global), whilst the I/O bus is divided into
two I/O bus segments of 10 and 8 slots respectively.
• One CPU can be inserted per local bus segment.
• The two CPUs in a segmented CR may be in different operating states.
• The two CPUs can communicate with each other via the communication bus.
• All the modules inserted in a segmented CR are powered by the power supply
module at slot 1.
• Both segments have a common backup battery.
The following figure shows a segmented CR with divided I/O bus and continuous
communication bus.
1
11
SEG1
SEG2
1
2
3
4
SEG1
SEG1
SEG1
SEG1
5
SEG1
6
SEG1
7
SEG1
I/O bus
Segment 1
8
SEG1
9
SEG1
10
SEG1
11
SEG2
12
SEG2
13
SEG2
14
SEG2
15
SEG2
16
SEG2
17
SEG2
18
SEG2
I/O bus
Segment 2
Communication bus
2-8
S7-400 and M7-400 Programmable Controllers Hardware and Installation
A5E00069481-04
Installing the S7-400
2.4
Subdivided CR
Characteristics
The ”subdivided” characteristic relates to the configuration of the CR. In the
(non-divided) CR the I/O bus and communication bus are continuous and
interconnect all the slots; in the subdivided CR, however, the I/O bus and
communication bus consist of two segments each. The UR2-H rack used here
functions as two electrically isolated UR2 racks on the same rack profile.
A subdivided CR has the following important characteristics:
• The communication bus and I/O bus are subdivided into two segments with 9
slots each.
• Each segment represents a self-contained CR.
The following figure shows a divided CR with a divided I/O bus and communication
bus.
Division I
Division II
1
2
3
4
5
6
7
8
9
1
2
3
4
5
6
7
8
9
1
2
3
4
5
6
7
8
9
1
2
3
4
5
6
7
8
9
I/O bus
Segment 1
Communication bus
Segment 1
S7-400 and M7-400 Programmable Controllers Hardware and Installation
A5E00069481-04
I/O bus
Segment 2
Communication bus
Segment 2
2-9
Installing the S7-400
2.5
Mounting and Grounding the Racks
Important Notes on Installation
The S7-400 racks are designed for wall mounting, mounting on rails, and for
installation in frames and cabinets. Their mounting dimensions comply with
DIN 41 494.
According to the UL/CSA and the EU Directive 73/23/EEC (low-voltage directive),
installation in a cabinet, a casing, or a closed operations room is necessary in order
to fulfil the requirements for electrical safety (see Reference Manual, Chapter 1).
In principle, the M7-400 is mounted like an S7-400 except that preassembly is
required (see Section 8.4 “Installing the M7-400”).
Step 1: Retaining Distances Between Devices
You must observe the minimum distances between the rack and neighboring
devices. You need these minimum clearances during installation and operation.
• For fitting and removing modules
• For fitting and disconnecting the module front connectors
• To ensure the air flow required for cooling the modules during operation
The following figure shows the minimum space you must provide for a rack.
40 mm
1
2
3
4
5
6
7
8
9
10
11
14 15
16
17 18
20 mm
20 mm
352 mm
12 13
*
22 mm
522.5 mm (18 slots)
297.5 mm ( 9 slots)
172.5 mm (4 slots)
* 40 mm facilitates the mounting of a fan subassembly
Mounting depth, fitted: max. 237 mm
2-10
S7-400 and M7-400 Programmable Controllers Hardware and Installation
A5E00069481-04
Installing the S7-400
Space Required When Using Cable Channels and Fan Subassemblies
A cable duct or fan subassembly must be installed in the 19-inch pitch immediately
below the rack. Additional space for cable routing must be provided on both sides.
The following figure shows how much space you need to allow for when using a
cable duct or fan subassembly.
1
2
3
4
5
6
7
8
9 10 11 12 13 14 15 16 17 18
440 mm
Cable duct/fan subassembly
522.5 mm (with cable duct)
542.5 mm (with fan subassembly)
Mounting depth, fitted: max. 237 mm
19-inch reference level
Dimensions of the Racks
The following figure shows the dimensions for racks with 18, 9 and 4 slots and the
positions of cutouts for screw mounting.
The cutouts are arranged according to the 19-inch standard.
S7-400 and M7-400 Programmable Controllers Hardware and Installation
A5E00069481-04
2-11
Installing the S7-400
60 mm
1
2
3
4
5
6
7
8
9
10
11
12
13
14 15
16
6
7
9
17
18
290 mm 190 mm
40 mm
465 mm
482.5 mm
1
2
3
4
1
2
3
4
1
2
3
4
5
8
290 mm 190 mm
Depth = 27.5 mm without modules
Depth = 237.0 mm with modules
40 mm
115 mm
240 mm
132.5 mm
257.5 mm
Step 2: Mounting the Rack
Screw the rack to the base.
Is the base material a grounded metal plate or a grounded equipment plate?
If so: Establish a low-impedance connection between rack and base material.
With painted and anodized metals, for example, use a suitable contact agent or
special contact washers.
If not: No special measures are required.
2-12
S7-400 and M7-400 Programmable Controllers Hardware and Installation
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Installing the S7-400
Mounting Screws
You have a choice of the following types of screw for securing a rack:
Screw Type
Explanation
M6 cylinder-head screw to
ISO 1207/ISO 1580 (DIN 84/DIN 85)
M6 hex. screw to ISO 4017 (DIN 4017)
Choose the screw length according to your
assembly.
You also need “6.4” washers to ISO 7092
(DIN 433).
Step 3: Connecting the Rack to the Chassis Ground
Connect the rack to the chassis ground. A threaded bolt is provided for this
purpose on the bottom left of the rack.
Minimum cross-section of the conductor to the chassis ground: 10 mm2.
If the S7-400 is mounted on a mobile rack, you must provide a flexible conductor to
the chassis ground.
Note
Always ensure that there is a low-impedance connection to the chassis ground
(see the figure below). You achieve this with the shortest possible, low-resistance
conductor with a large surface to establish large-area contact.
M6 threaded bolt
Contact washer
Terminal
Plain washer
M6 nut
To chassis
ground
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2-13
Installing the S7-400
Step 4: Mounting Additional Racks
If you assemble an S7-400 with two or more racks, you must allow additional
clearance between the individual racks or install a fan subassembly or cable duct.
The figure below shows the clearance you must allow between two racks of the
S7-400 during installation.
1
2
3
4
5
6
7
8
9 10 11 12 13 14 15 16 17 18
1
2
3
4
5
6
7
8
9 10 11 12 13 14 15 16 17 18
110 mm
2-14
S7-400 and M7-400 Programmable Controllers Hardware and Installation
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Installing the S7-400
The figure below shows how much space you must allow for when assembling an
S7-400 from two racks with a cable duct or fan subassembly. This requirement is
increased by a height of 400 mm for each additional rack with a cable duct or fan
subassembly.
1
2
3
4
5
6
7
8
9 10 11 12 13 14 15 16 17 18
Cable duct/fan subassembly
840 mm
1
2
3
4
5
6
7
8
9 10 11 12 13 14 15 16 17 18
Cable duct/fan subassembly
Mounting depth, fitted: max. 237 mm
19-inch reference level
Note
A minimum clearance as shown in the above figure between rack and cable duct
or fan subassembly must not be provided, but is essential between two adjacent
racks and between racks and other equipment.
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2-15
Installing the S7-400
2.6
Chassis Terminal Connection in the Non-Isolated
Configuration
Reference Point
The racks offer the option of connecting the 24-V load voltage ground in the
non-isolated configuration to the 5-V ground (reference potential M, logic ground).
Connect the chassis ground to the reference point for non-isolated modules. The
reference point is metallically connected to the reference potential M.
Note
The position of the reference point on the racks was changed in 10/99.
The following figure shows the position of the reference point on a rack up
until 10/99.
1
2
3
4
5
6
7
Reference point
Chassis ground terminal
Connecting to the Reference Point until 10/99
For the connection to the reference point, use a cable lug for M4, a suitable spring
washer (for example, strain washer to DIN 6796) and an M4 x 6 cylinder-head
screw.
2-16
S7-400 and M7-400 Programmable Controllers Hardware and Installation
A5E00069481-04
Installing the S7-400
Note
Do not use any cyclinder-head screws longer than 6 mm for the connection to the
reference point. Otherwise, you may create an undesired connection between the
reference point and the rack profile behind it and therefore the connection for the
chassis ground.
The following figure shows the position of the reference point on a rack up
after 10/99.
1
2
3
4
5
6
7
Metallic connection, undo
from above in the case of
ungrounded configuration
Load voltage ground connection (reference point)
Chassis ground terminal
The following figure shows the ground connection to the reference point.
Threaded hole
Terminal
Spring washer
M4 screw
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2-17
Installing the S7-400
Connection to the Reference Point After 10/99
For the connection to the reference point, use a cable lug for M4, a suitable spring
lock washer (for example, clamping washer to DIN 6796) and the cylinder-head
screw supplied.
Ungrounded configuration: Undo the fixing screws of the metallic connection on
the rack. Tilt the connection downwards. For the connection to the reference point,
use the original M4 x 8 supplied. Use the tilted metallic connection as a washer.
Grounded configuration: Leave the metallic connection on the rack. For the
connection to the reference point, use the original M4 x 8.
Ungrounded configuration
Grounded configuration
Rack
Metallic connection
Reference point
Connection
Connection
Spring lock washer
Spring lock washer
Original screw with spring lock washer
M4 x 8
Original screw with spring lock washer
M4 x 8
Note
Do not use any cylinder-head screws that are longer than 6 mm for the connection
to the reference point. Otherwise, you may create an undesired connection between the reference point and the rack profile behind it and therefore the connection for the chassis ground. For this reason as well, leave the metallic connection
on the rack and use it as a washer in an ungrounded configuration.
2-18
S7-400 and M7-400 Programmable Controllers Hardware and Installation
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Installing the S7-400
2.7
Methods of Ventilation
Methods of Ventilation
Under extreme ambient conditions, particularly when operating the S7-400
modules in cabinets, you can use the cable duct or fan subassembly to optimize
ventilation.
There are two methods of supplying air to the modules. You draw in air either from
the back or from below. The cable duct and fan subassembly can be converted for
this purpose.
The following figure shows the ventilation when air is drawn in from the back.
Wall
ÇÇ
ÇÇ
ÇÇ
ÇÇ
ÇÇ
ÇÇ
ÇÇ
ÇÇ
ÇÇ
ÇÇ
ÇÇ
ÇÇ
ÇÇ
ÇÇ
ÇÇ
ÇÇ
ÇÇ
ÇÇ
ÇÇ
ÇÇ
ÇÇ
ÇÇ
ÇÇ
Exhaust air
Modules
Cable duct or fan
subassembly
Exhaust air
Modules
Supply air
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2-19
Installing the S7-400
The following figure shows the ventilation when air is drawn in from the bottom.
Wall
2-20
Ç
Ç
Ç
Ç
Ç
Ç
Ç
Ç
Ç
Ç
Ç
Ç
Ç
Ç
Ç
Ç
Ç
Ç
Ç
Ç
Ç
Ç
Exhaust air
Modules
Cable duct or fan
subassembly
Modules
Supply air
S7-400 and M7-400 Programmable Controllers Hardware and Installation
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Installing the S7-400
2.8
Changing the Ventilation with the Cable Duct and Fan
Subassembly
Changing the Ventilation
At the base of the cable duct and the fan subassembly, there is a cover that you
can move in order to change the air duct. To do this, proceed as follows:
1. Using a screwdriver, make a quarter turn counter-clockwise to open the two
quick-release locks at the front of the cable duct or fan subassembly.
2. Grasp the base with both hands; press it gently downward and pull it fully out of
the cable duct or fan subassembly.
3. The cover is secured to the base with snap catches. Press the cover from
below, close to the snap catches, and remove the cover.
4. At approximately right angles to the base, insert the cover in the snap hinges at
the rear edge of the base.
5. Slide the base in again and push it up.
6. Use a screwdriver to make a quarter turn clockwise and close the two
quick-release locks.
The following figure shows both methods of selecting the ventilation by
appropriately fitting the cover in the base of the cable duct or fan subassembly.
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A5E00069481-04
2-21
Installing the S7-400
Cover
Delivered state:
Cover fitted at bottom
(supply air from the rear)
Base
Quick-release locks
Snap catches
Cover
Cover fitted at back
(supply air from below)
Base
Snap hinges
State When Shipped
The cover is fitted in the base of the cable duct or fan subassembly. Air is supplied
from the back.
Filter Mat (Optional)
To filter the air supply, you can fit a filter mat for the cable duct and fan
subassembly. The filter mat is optional and is not part of the cable duct or fan
subassembly.
Like the cover, the filter mat can be inserted flat in the base or at its rear edge in
the corresponding snap hinges or quick-release locks.
2-22
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Installing the S7-400
2.9
Installing the Fan Subassembly
Procedure
1. Remove the left cover from the fan subassembly.
Using a 17 mm open-ended wrench, slacken the quick-release lock a quarter
turn.
Pull out the left cover of the fan subassembly. To do this, move the left cover
parallel to the fan subassembly in order to avoid damaging the plug-in contact
on the other side.
The following figure shows you how to remove the left cover.
Snap-in mechanism
of dummy covers
Plug-in contact
Back of cable
routing
Direction for
pulling off
Left cover
Quick-release lock
Note
Provide the fan subassembly with dummy plates beneath free slots, this will
ensure optimum ventilation.
The fan subassembly is supplied with 18 dummy plates, arranged as 2 units, each
with 9 individual dummy plates. By breaking at one of the rupture joints, you can
split up the individual plates as required.
2. Remove the dummy plates which are not required by slackening the snap-in
mechanisms of the covers and pulling them off.
3. Break off as many dummy plates as required.
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A5E00069481-04
2-23
Installing the S7-400
4. Attach the dummy plates to the free slots:
– Place the dummy plates on the rear wall of the cable routing,
– Push the dummy plates back so that the noses of the dummy plates will fit
into the cutouts provided,
– Push the dummy plates in until the snap-in mechanism engages in the
openings on the back of the cable routing.
5. Then install the fan assembly in the 19-inch pitch directly under the rack or
between two racks. Use M6 size screws for mounting.
The following figure shows how to mount the fan subassembly between two
racks.
9
10
11
12
13
14 15
16
17
18
Blanking
cover
9
10
11
12
13
14 15
16
17
18
19-inch
reference level
6. Refit the left cover.
7. Secure the left cover with the quick-release lock.
Monitoring the Fan Subassembly
To monitor the functioning of the fan subassembly via your program, connect the
outputs to a digital module.
Further details on the monitoring concept can be found in the Reference Manual,
Chapter 9.
2-24
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Installing the S7-400
2.10
Installing the Cable Duct
Procedure
1. Install the cable duct in the 19-inch pitch directly under the rack or between two
racks. Use M6 size screws for mounting.
The following figure shows how to mount the cable duct between two racks.
9
10
11
12
13
14 15
16
17
18
9
10
11
12
13
14 15
16
17
18
19-inch reference level
S7-400 and M7-400 Programmable Controllers Hardware and Installation
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2-25
Installing the S7-400
2.11
Choosing and Setting up Cabinets with the S7-400
Why Cabinets are Required
With larger installations and in an environment subject to interference or pollution,
you can install the S7-400 in cabinets. The requirements of UL/CSA are met, for
example, by an installation in cabinets.
Types and Dimensions of Cabinets
Observe the following criteria when selecting cabinet types and their dimensions:
• Ambient conditions at the point of installation of the cabinet
• Required clearances for the racks
• Total power dissipation of components contained by the cabinet
The ambient conditions at the point of installation of the cabinet (temperature,
humidity, dust, effects of chemicals, explosion hazard) govern the required degree
of protection of the cabinet (IP xx). Further information on degrees of protection
can be found in IEC 529 and DIN 40050.
2-26
S7-400 and M7-400 Programmable Controllers Hardware and Installation
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Installing the S7-400
Table 2-1 provides an overview of the most common types of cabinet. You will also
find the principle of heat removal, as well as the estimated, maximum achievable
power loss removal and the degree of protection.
Table 2-1
Types of Cabinet
Open Cabinets
Closed Cabinets
Through-ventilatio
n by natural
convection
Increased
through-ventilation
Natural convection
Forced circulation
using fan
subassembly,
enhanced natural
convection
Forced circulation
using heat
exchanger,
external ventilation
inside and outside
Heat removal
primarily by natural
thermal
convection, small
portion via the
cabinet wall
Increased heat
removal through
increased air
movement
Heat removal only
through the
cabinet wall; only
low power
dissipation
permissible. Heat
accumulation
usually occurs in
the top of the
cabinet.
Heat removal only
through the
cabinet wall.
Forced ventilation
of the internal air
results in improved
heat removal and
prevention of heat
accumulation.
Heat removal
through exchange
between heated
internal air and
cold external air.
The increased
surface of the
folded-area
sectional wall of
the heat
exchanger and
forced circulation
of internal and
external air permit
good heat output.
Degree of
protection IP 20
Degree of
protection IP 20
Degree of
protection IP 54
Degree of
protection IP 54
Degree of
protection IP 54
Typical removable power dissipation under the following boundary conditions:
• Cabinet size 2200 x 600 x 600 mm
• Difference between external and internal temperature of the cabinet: 20° C (for other temperature
differences, you must refer to the temperature characteristics of the cabinet manufacturer)
up to 700 W
up to 2700 W
(1400 W with very
fine filter)
up to 260 W
up to 360 W
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up to 1700 W
2-27
Installing the S7-400
Removable Power Dissipation from Cabinets (Example)
The removable power dissipation from a cabinet is governed by the type of cabinet,
its ambient temperature, and the arrangement of equipment in the cabinet.
Figure 2-2 shows a diagram with guide values for the permissible ambient
temperature of a cabinet measuring 600 x 600 x 2000 mm as a function of power
dissipation. These values only apply if you observe the specified installation
dimensions and clearances for racks. Further information can be found in Siemens
catalogs NV21 and ET1.
Ambient temperature in °C
60
50
1
40
2
30
3
20
200
400
600
800
1000
1200
1400 W
Power dissipation
Figure 2-2
Max. Cabinet Ambient Temperature as a Function of Power Dissipation of
Equipment in the Cabinet
Legend for Figure 2-2:
1. Closed cabinet with heat exchanger;
heat exchanger size 11/6 (920 x 460 x 111 mm)
2. Cabinet with through-ventilation by natural convection
3. Closed cabinet with natural convection and forced circulation by equipment fans
!
Warning
Modules can be damaged.
Modules can be damaged by subjecting them to excessively high ambient
temperature.
In the case of modules with hard drives, in particular, ensure that they are not
subjected to an excessively high ambient temperature.
2-28
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Installing the S7-400
Example for Determining the Type of Cabinet
The following example clarifies the maximum ambient temperature which is
permissible for a particular power dissipation with various types of cabinet.
The following equipment configuration is to be installed in a cabinet:
1 central rack
150 W
2 expansion racks of 150 W power dissipation each
300 W
1 load current power supply under full load
200 W
Total power dissipation
650 W
From Figure 2-2, with a total power dissipation of 650 W, the ambient temperatures
obtained are as follows:
Type of Cabinet
Max. Permissible Ambient
Temperature
Closed, with natural convection and forced circulation
(Curve 3)
(no operation possible)
Open, with through-ventilation (Curve 2)
approx. 38° C
Closed, with heat exchanger (Curve 1)
approx. 45° C
Dimensions of Cabinet
To determine the dimensions of a cabinet suitable for assembling an S7-400, you
must take the following into account:
• Space requirement of the racks
• Minimum clearances between racks and cabinet walls
• Minimum clearances between racks
• Space requirement of cable ducts or fan subassemblies
• Locations of rails
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2-29
Installing the S7-400
2.12
Rules for the Arrangement of Modules
Rules for S7-400 and M7-400
Given in this section are the rules you must observe when arranging modules in
the S7-400. The rules for M7-400 modules can be found in Section 8.1 “Mechanical
Configuration”.
Arrangement of Modules
You need observe only two rules for the arrangement of modules in a rack:
• In all racks, the power supply module must always be inserted on the extreme
left (beginning with slot 1). In the UR2-H from slot 1 in both segments.
• The receive IM in the ER must always be inserted on the extreme right. In the
UR2-H at slot 9 once per segment.
Note
Establish whether there are additional regulations applying to all modules not
described in this manual.
The following table shows which modules can be used in the different racks:
Table 2-2
Modules in the different racks
Racks
Modules
UR1, UR2
UR2-H as
CR
UR1, UR2
as ER
UR2-H
as ER*
Power Supply Modules
CPUs
Send IMs
Receive IMs
Signal Modules
*
Racks
CR2,
CR3
ER1, ER2
No IM 463–2, no adapter module, no power supply module along with the IM 461-1.
Space Requirement of the Racks
In the S7-400 system, there are modules occupying one, two, or three slots (width
25, 50, or 75 mm). Refer to the technical specifications of the module under the
keyword “dimensions” to see how many slots a module occupies.
The mounting depth of a rack fitted with modules is 237 mm maximum.
2-30
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Installing the S7-400
2.13
Fitting Memory Cards in the CPU
Memory Expansion
With the CPU 417-4 and CPU 417-4 H you can expand the work memory with
memory submodules.
The following points are important:
1. If only one submodule is inserted, l must be in slot 1.
2. You may only insert a second submodule if a 4 Mbyte-submodule is inserted in
slot 1.
The following combinations are then possible:
Slot 1
Slot 2
2 Mbytes
-
4 Mbytes
-
4 Mbytes
2 Mbytes
4 Mbytes
4 Mbytes
Note
Only use the memory cards intended for the particular CPU.
!
Warning
The modules can be damaged.
Failure to observe ESD guidelines can result in damage to both the CPU and
memory cards.
Observe the ESD guidelines when fitting memory cards.
Fitting Memory Cards in the CPU
Proceed as follows:
1. Remove the cover from the left side of the CPU by loosening the three screws.
2. Push the first memory card down through an angle of approximately 45o into
slot 1 (see Figure 2-3). Note the cutout at the front of the card (polarity reversal
protection).
3. Push the memory card down until the tabs in the slot slide into the
corresponding cutouts on the side of the card. Make sure that the metal flag at
the end of the card lies on the metal edge of the module.
4. If necessary, insert the second memory card in slot 2 in the same way (see
Figure 2-3).
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Installing the S7-400
5. Fit the cover on the upper left side of the CPU by securing it with three screws.
Note
The connectors to accept the memory cards are coded (see Figure 2-4). Do not
apply force when fitting the memory cards.
Lightly press the guide supports out to remove the memory cards
(see Figure 2-4).
Slot 1
Slot 2
Figure 2-3
Fitting Memory Cards in the CPUs
Copper flag
Memory card
Cutout
Cutout
Guide support
Polarity
reversal
protection
Guide support
Slots 1 and 2
2-32
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Installing the S7-400
Figure 2-4
Memory Card
2.14
Installing Modules in a Rack
Introduction
All modules are installed in a rack using the same procedure.
!
Caution
Modules and racks can be damaged.
If you use force when installing modules in a rack, these components may be
damaged.
Carefully follow the steps described below for the installation sequence.
Tool
The tool needed to install the modules is a cylindrical screwdriver with 3.5 mm
blade width.
Installation Sequence
To install modules in a rack, follow the steps outlined below:
1. Remove the dummy plates from the slots at which you intend to insert modules.
Grasp the dummy plate at the points marked and pull it forward and off.
With double and triple-width modules, you must remove the dummy plates from
all the slots to be covered by the relevant module.
2. Remove the cover, if applicable, from the module (see Figure 2-5).
3. Disconnect the power supply connector at the power supply module.
4. Attach the first module and swing it downwards (see Figure 2-6).
If you feel a resistance when swinging the module down, raise it slightly and
then continue.
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Installing the S7-400
5. Tighten the module screws top and bottom with a torque of 0.8 to 1.1 Nm (see
Figure 2-7). Triple-width modules are secured with two screws at the top and at
the bottom.
6. Refit the module cover, if applicable.
7. Fit the remaining modules in the same way.
8. Insert the key into the keyswitch in the CPU when you have installed all the
modules (see Figure 2-8).
The individual steps for installation are explained in the following.
The method of removing modules is described in Chapter 7.
Removing the Cover
With modules which have a cover (for example, power supply modules and CPUs),
you remove this before installing the module in the rack. Proceed as follows:
1. Press the locking lever down (1).
2. Swing the cover forward and off (2).
(1)
(2)
Figure 2-5
2-34
Removing the Cover
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Installing the S7-400
Attaching the Modules
Attach the modules one by one (1) and swing them carefully downwards (2). If you
feel a resistance when swinging the module down, raise it slightly and then
continue.
(1)
(2)
Figure 2-6
Attaching the Modules
Screwing the Modules in Place
Tightening torque
0.8 to 1.1 Nm
Figure 2-7
Screwing the Modules in Place
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2-35
Installing the S7-400
Inserting the Keyswitch
You can insert the key in the CPU in the STOP position of the switch. You can
remove the key in the STOP or RUN settings.
Figure 2-8
2-36
Inserting the Key in the CPU
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Installing the S7-400
2.15
Marking the Modules with Slot Labels
Slot Number
Once the modules are installed, you should mark each one with its slot number to
avoid the risk of mixing up modules during operation. If modules do get mixed up,
you may have to reconfigure the assembly.
The slot number is printed on the rack.
Double-width modules occupy two slots and are assigned the consecutive slot
numbers of both slots.
Triple-width modules occupy three slots and are assigned the consecutive slot
numbers of these three slots.
Fitting Slot Labels
You use slot labels to mark a module with its slot number. The slot labels are
provided with the rack as a “number wheel”.
To fit the slot labels, follow the steps outlined below:
1. Hold the “number wheel” on the module and rotate it to the slot number for the
module inserted at this slot.
2. Use your finger to press the slot label into the module. The label will break away
from the “number wheel”.
Figure 2-9
Fitting a Slot Label
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Installing the S7-400
2.16
Methods of Expansion and Networking
Introduction
Apart from the structures mentioned in this chapter, other expansions are possible,
for example, by connecting distributed I/Os or by networking. The modules with
which you can connect an M7-400 to PROFIBUS DP can be found in Section 6.9
“Starting Up a PROFIBUS-DP Subnet.”
Distributed I/Os
When an S7-400 is configured with a distributed I/O system, the inputs/outputs
operate in a distributed local arrangement and are directly connected via
PROFIBUS DP to a CPU.
One of the master-capable CPUs of the S7-400 is used.
You can use the following devices, for example, as slaves, i.e. as local
inputs/outputs:
• ET 200M
• ET 200 U/B/C
• All DP standard slaves
Networking
Two or more S7-400s can be arranged in a network for communication via the
multipoint interface.
For networking the individual S7-400s, you must interconnect their CPUs with
PROFIBUS-DP bus cables. The S7-400 is connected to the communication
network via the multipoint interface (MPI) of the CPU via:
• Bus connectors
• A PROFIBUS-DP RS 485 bus terminal
See Chapter 7 for further details.
Other networking methods require special modules.
2-38
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Installing the S7-400
2.17
Accessories
Accessories
Some of the accessories needed for fitting the modules in the rack are provided in
the packaging of the modules and racks. The front connectors of the signal
modules must always be ordered separately. There are also optional accessories
for some modules.
The accessories for modules and racks are listed and briefly explained in
Table 2-3. A list of spare parts for SIMATIC S7 can be found in the Reference
Manual, Appendix C as well as in the current ST 70 catalog. The accessories for
installing the M7-400 can be found in Section 8.4.
Table 2-3
Accessories for Modules and Racks
Module
Rack (UR, CR,
ER)
Accessories
Supplied
Number wheel with
slot labels
Power Supply
Module (PS)
CPU
2 keys
1 or 2 backup batteries
-
Signal Module
(SM)
Accessories Not
Supplied
2 labels
Memory cards
-
Purpose of the Accessory
For identifying the modules with
slot labels
For central backup of RAM areas
in the CPU
To operate the mode selector of
the CPU
Load memories required for the
CPU
For labeling the inputs and
outputs on the front connector
Plate with pinout
To identify the pinout of the front
connectors
-
Front connector with
strain relief for screw,
crimp or spring-type
terminal
For wiring the SMs
-
Extraction tool (for
crimp terminals)
For rewiring SMs with a front
connector with crimp terminals
-
Crimp contacts
Crimping tool
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Installing the S7-400
2-40
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3
Addressing the S7-400
Chapter Overview
Section
Description
Page
3.1
Geographical and Logical Addresses
3-2
3.2
How to Determine the Default Address of a Module
3-4
3.3
How to Determine the Default Address of a Channel
3-6
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3-1
Addressing the S7-400
3.1
Geographical and Logical Addresses
Addresses
In order to control a process, you must address the channels (inputs and outputs)
of the signal modules from the user program. You must establish a unique
assignment between the (geographical) location of a channel and an address in the
user program. Information on addressing M7-400 modules can be found in
Section 8.2.
Geographical Addresses
The geographical address of a particular channel is permanently assigned. It is
governed by the physical location of the input or output. In particular, this depends
on the following basic conditions:
• In which rack (0 to 21) is the signal module fitted?
• At which slot (1 to 18 or 1 to 9) in this rack is the signal module inserted?
• Which channel (0 to 31) of this signal module is addressed?
Section 3.2 describes the method of establishing the geographical address of a
channel.
Logical Addresses
The logical address of a module and, therefore, of a channel is freely selectable. It
is used in the program to address (read or write to) a particular input or output. The
physical location of the relevant module need not be known during programming.
You establish the assignment between logical and geographical address with
STEP 7.
The Two Stages of Addressing
You perform the addressing of a channel, or the assignment between its location
and its address, in two stages:
• Determine the geographical address of the channel from its location in the
entire configuration.
• Assign a logical address to the geographical address under STEP 7. This
logical address is used for addressing the channel in the user program.
Note
If your S7-400 comprises only a CR without ER, you can also use default
addressing.
3-2
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Addressing the S7-400
Default Addressing
Under certain conditions, the CPU can handle the assignment between logical
address and geographical address for you (default addressing). The logical
addresses are then permanently assigned to the slots (default address). Distributed
I/Os are not taken into account.
Conditions for Default Addressing
The CPU assigns default addresses under the following conditions:
• If only signal modules are inserted
(no IM, CP, FM inserted; no expansion racks connected)
• If signal modules are used with their default settings (measuring ranges,
interrupt processing, etc.)
• If modules are inserted in STOP mode or during power off
(modules inserted in RUN mode will not be taken into account, nor during the
change from RUN STOP RUN)
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3-3
Addressing the S7-400
3.2
How to Determine the Default Address of a Module
Default Addressing
You determine the default address of a module from the number of the slot of the
module in the CR.
The algorithms used to calculate the default address are different for analog and
digital modules.
The following figure shows the numbering of slots in a rack with 18 slots. You can
also read off the slot numbers directly from the rack.
1
2
3
4
5
6 7
8
9 10 11 12 13 14 15 16 17 18
1
2
3
4
5
6
8
9
7
10
11
12
13
14
15
16
17
18
Default Addresses of Digital Modules
On the S7-400, the default addresses for digital modules start from 0 (First slot in
the central rack which is usually occupied by the power supply module) up to 68
(18th slot).
The algorithm used to calculate the default address of a digital module is:
Default address = (slot number - 1) x 4
Example
The default address of a digital module in the 12th slot is as follows:
Default address = (12 - 1) x 4 = 44
3-4
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Addressing the S7-400
Default Addresses of Analog Modules
On the S7-400, the default addresses for analog modules start from 512 (first slot
in the central rack which is usually occupied by the power supply module) up to
1600.
The algorithm used to calculate the default address of an analog module is:
Default address = (slot number - 1) x 64 + 512
Example
The default address of an analog module in the 6th slot is as follows:
Default address = (6 - 1) x 64 + 512 = 832
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3-5
Addressing the S7-400
3.3
How to Determine the Default Address of a Channel
Channel on a Digital Module
A channel on a digital module is addressed bit-wise. For a digital input module with
32 inputs, four bytes (starting with the default address of the module) are used to
address the inputs, and for a digital input module with 16 inputs, two bytes are
used. Bits 0 to 7 in these bytes are then reserved by the individual inputs (from top
to bottom).
This is clarified by the following figure with the example of a digital input module
with 32 channels at slot 12 (default address 44). With a digital output module, the
first character is a Q instead of an I.
Channel addresses
I 44.0
I 44.1
I 44.2
I 44.3
I 44.4
I 44.5
I 44.6
I 44.7
I 45.0
I 45.1
I 45.2
I 45.3
I 45.4
I 45.5
I 45.6
I 45.7
I 46.0
I 46.1
I 46.2
I 46.3
I 46.4
I 46.5
I 46.6
I 46.7
I 47.0
I 47.1
I 47.2
I 47.3
I 47.4
I 47.5
I 47.6
I 47.7
3-6
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Addressing the S7-400
Channel on an Analog Module
Channels on analog modules are addressed word-wise.
Starting with the default address of the module, which also represents the address
of the uppermost channel of the module, the addresses of the individual channels
(from top to bottom) increase by two bytes (= one word).
This is clarified by the following figure with the example of a digital input module
with 8 channels at slot 6 (default address 832). With an analog input module, the
first characters are IW instead of QW.
Channel addresses
QW 832
QW 834
QW 836
QW 838
QW 840
QW 842
QW 844
QW 846
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Addressing the S7-400
3-8
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4
Wiring the S7-400
Chapter Overview
Section
Description
Page
4.1
Supplying Power to Modules
4-2
4.2
Choosing the Power Supply Module
4-3
4.3
Choosing the Load Current Power Supply
4-4
4.4
Assembling an S7-400 with Process I/Os
4-5
4.5
Assembling an S7-400 with Grounded Reference Potential (M)
4-8
4.6
Assembling an S7-400 with Ungrounded Reference Potential
(Ungrounded Configuration)
4-9
4.7
Assembling an S7-400 with Isolated Modules
4-11
4.8
Parallel Wiring of Digital S7-400 Outputs
4-13
4.9
Grounding
4-14
4.10
Interference-Free Configuration for Local and
Remote Connections
4-16
4.11
Wiring Rules
4-18
4.12
Setting the VAC Power Supply Module to the Line Voltage
4-19
4.13
Wiring the Power Supply Module
4-21
4.14
Wiring the Signal Modules
4-25
4.15
Wiring the Front Connector, Crimp Snap-On Terminals
4-27
4.16
Wiring the Front Connector, Screw-Type Terminals
4-28
4.17
Wiring the Front Connector, Spring-Type Terminals
4-29
4.18
Fitting the Strain Relief
4-31
4.19
Labeling a Front Connector
4-32
4.20
Fitting the Front Connector
4-36
4.21
Interconnecting the CR and ER(s)
4-39
4.22
Setting the Fan Subassembly to the Line Voltage and Wiring It
4-41
4.23
Routing Cables Using Cable Ducts or Fan Subassemblies
4-43
4.24
Routing Cables Using Fiber-Optic Cables
4-43
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4-1
Wiring the S7-400
4.1
Supplying Power to Modules
Power Supply Modules and Load Current Power Supplies
The modules of the S7-400 system are supplied with all the required operating
voltages by a power supply module, via the backplane bus of the rack. Which
power supply module you use in a rack depends on your system requirements (line
voltage, current consumption of the modules used).
You must provide load voltages and currents via external load current power
supplies.
The following figure shows how the individual modules of the S7-400 are supplied
with current and voltage.
Operating voltages
S7-400
power supply
module
5 VDC and 24 VDC
via backplane bus
S7-400
modules (DC
or AC)
Load current via
front connector
Line voltage:
120/230 VAC
with supply
isolator
or 24 VDC
Load current power
supply
Note
The power supply modules must not be connected in parallel on their secondary
sides.
4-2
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Wiring the S7-400
4.2
Choosing the Power Supply Module
Estimating the Power Requirement
You should make an estimate of the power requirement for each rack of your
S7-400 system in order to select the appropriate power supply module for the rack.
Selection of the power supply for an M7-400 configuration is described separately
in Section 8.3 “Electrical Configuration.” Current consumption and power
dissipation of the individual modules can be found in the relevant data sheets.
Calculation Example
The following modules are to be fitted in a CR with 18 slots:
• 1 CPU 414-1
• 3 analog input modules SM 431, AI 16 x 16 bits
• 5 digital input modules SM 421;DI 32 x 24 VDC
• 6 digital input modules SM 422;DO 32 x 24 VDC/0.5A
• 1 send IM, IM 460-0
You can calculate Current Consumption I in this rack as follows, with the data from
the individual data sheets:
Module
Quantity
+5 VDC (Max. Current Consumption
Values)
I / Module
I Total
CPU 414-1
1
1800 mA
1800 mA
SM 431; AI 16 x 16 bits
3
700 mA
2100 mA
SM 421;DI 32 x 24 VDC
5
30 mA
150 mA
SM 422;DO 32 x 24 VDC/0.5A
6
200 mA
1200 mA
IM 460-0
1
140 mA
140 mA
Total
5390 mA
From the data in the table, you can see that you must install a power supply
module PS 407 10A (for connection to 120/230 VAC) or PS 405 10A (for
connection to 24 VDC) in the rack, to cover the current consumption calculated
here.
Note
If you wish to connect an ER to the CR via a send IM with current transfer, you
must also take the current consumption of this ER into account when choosing the
power supply module.
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4-3
Wiring the S7-400
4.3
Choosing the Load Current Power Supply
Choosing the Load Current Power Supply
The input and output circuits (load current circuits) as well as sensors and
actuators are powered by the load current power supply. Listed in the following are
the characteristics of the load current power supplies required in special
applications for choosing the load current power supplies.
Characteristics of
the Load Current
Power Supply
Safe isolation
Required for ...
Modules which must be
supplied with voltages
60 VDC or 25
VAC.
Remarks
The Siemens SITOP power load current
supplies have this characteristic.
24 VDC load circuits
Tolerances of the
output voltages:
20.4 V to 28.8 V
24 VDC load circuits
40.8 V to 57.6 V
48 VDC load circuits
51 V to 72 V
60 VDC load circuits
If the output voltage tolerances are
exceeded, you should provide an energy
storage capacitor. Rating: 200 µF per 1 A
load current (with bridge rectification).
Load Current Power Supplies
The DC load current power supply must meet the following requirements:
Only a safe, isolated extra-low voltage of 60 VDC may be used as the load
current supply. Isolation may be implemented according to the requirements of the
following, amongst other publications:
VDE 0100-410 / HD 384-4-41 S2 / IEC 60364-4-41
(as a functional extra-low voltage with isolation) or
VDE 0805 / EN 60950 / IEC 60950
(as a safety extra-low voltage SELV) or VDE 0106 Part 101.
4-4
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Wiring the S7-400
Determining the Load Current
The required load current is governed by the total current of all sensors and
actuators connected to the outputs.
During a short-circuit, a current of two to three times the rated output current flows
briefly at DC outputs before the switched electronic short-circuit protection
becomes effective. When selecting the load current power supply, therefore, you
must ensure that the increased short-circuit current is available. With unregulated
load current power supplies, this excess current is generally ensured. With
regulated load current power supplies, particularly at low output levels (up to 20 A),
you must ensure a suitable excess current.
4.4
Assembling an S7-400 with Process I/Os
Definition of a Grounded Supply (TN-S Network)
In grounded supplies, the neutral conductor of the system is grounded. A single
fault between a live conductor and ground or a grounded part of the installation
results in tripping of the protective devices.
Components and Protective Measures
Various components and protective measures are specified for assembling a full
installation. The types of components and whether the protective measures are
mandatory or recommended depends on the VDE specification applying to your
installation, VDE 0100 or VDE 0113. The following table relates to Figure 4-1.
S7-400 and M7-400 Programmable Controllers Hardware and Installation
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4-5
Wiring the S7-400
Table 4-1
VDE Specifications for Assembling a Programmable Controller
Compare ...
Ref. to
Figure
4-1
VDE 0100
VDE 0113
Disconnection element for control
system, sensors, and actuators
... Part 460:
Main switches
... Part 1:
Isolating switches
Short-circuit and overload protection:
in groups for sensors and actuators
... Part 725:
Single-pole
protection of
circuits
... Part 1:
• With
grounded
secondary
circuit:
single-pole
protection
• Otherwise:
all-pole
protection
Load current PS for AC power circuits
with more than five items of
electromagnetic apparatus
Isolation by
transformer is
recommended
Isolation by
transformer is
required
Rule: Grounding the Load Current Circuits
Load current circuits should be grounded.
Reliable functional safety is provided by the common reference potential (ground).
Provide a detachable connection to the protective ground conductor at the load
current power supply (Terminal L- or M) or on the isolating transformer
(Figure 4-1, ). In the event of faults in the power distribution, this will facilitate the
locating of ground faults.
4-6
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Wiring the S7-400
S7-400 in the Overall Installation
Shown in Figure 4-1 is the position of the S7-400 in the overall installation (load
current power supply and grounding concept) with supply from a TN-S system.
Note: The arrangement of supply terminals shown is not the actual arrangement; it
has been chosen for reasons of clarity.
L1
L2
L3
N
PE
Low-voltage distribution e.g. TN-S system (3 x 400 V)
Cabinet
Racks
PS
CPU
SM
L+
Data
M
L1
N
Signal modules
P
E
Ground bus in cabinet
AC
AC
AC
DC
Figure 4-1
Load circuit
24 to 230 VAC for AC modules
Load circuit 5 to 60 VDC for isolated DC modules
Operating the S7-400 from a Grounded Supply
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4-7
Wiring the S7-400
4.5
Assembling an S7-400 with Grounded Reference
Potential (M)
Application
You use an S7-400 with grounded reference potential in machines or industrial
plants.
Discharge of Interference Currents
When the S7-400 is configured with a grounded reference potential, any
interference currents are discharged to the chassis ground.
Terminal Connection Model
When delivered, the racks have a detachable metallic connection between the
internal reference potential M of the modules and the frame element of the racks.
Situated behind this connection is an RC network which is placed in the circuit for
the ungrounded configuration. This connection is located at the left edge of the
rack. The terminal for the chassis ground also has an electrical connection to the
frame element.
Shown in Figure 4-2 is an S7-400 configured with grounded reference potential. To
ground the reference potential M, you must connect the chassis ground terminal to
the chassis ground and you must not remove the jumper between reference
potential M and the frame element terminal on the rack.
RC network
Detachable
jumper
6.8 nF
10 MΩ
M
Frame element terminal
Metallic connection
Reference potential M
Chassis ground terminal
Figure 4-2
4-8
An S7-400 Configured with Grounded Reference Potential
S7-400 and M7-400 Programmable Controllers Hardware and Installation
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Wiring the S7-400
4.6
Assembling an S7-400 with Ungrounded Reference
Potential (Ungrounded Configuration)
Application
In large installations, it may be necessary to configure the S7-400 with an
ungrounded reference potential, for example, for ground fault monitoring. This is
the case in the chemical industry or in power plants, for example.
Discharge of Interference Currents
With the S7-400 in an ungrounded configuration, any interference currents are
discharged to the chassis ground via an RC network integrated in the rack.
Terminal Connection Model
Shown in Figure 4-3 is an S7-400 configured with ungrounded reference potential.
In this case you must remove the jumper between reference potential M and the
frame element terminal on the rack. The reference potential M of the S7-400 is
then connected via the RC network to the chassis ground terminal. When you
connect this terminal to the chassis ground, RF interference currents will be
discharged and static charges will be avoided.
RC network
Detached
jumper
6.8 nF
10 MΩ
M
Frame element terminal
Reference potential M
Chassis ground terminal
Figure 4-3
An S7-400 Configured with Ungrounded Reference Potential
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4-9
Wiring the S7-400
Power Supply Units
When using power supply units, ensure that the secondary winding is not
connected to the protective ground conductor.
Filtering the 24 VDC Supply
When you power the S7-400 from a battery with the ungrounded configuration, you
must provide interference suppression for the 24 VDC supply. Use a Siemens
power cable filter, such as the B84102-K40.
Insulation Monitoring
If a double fault could cause a hazardous state in the installation, you must provide
insulation monitoring.
Example of Ungrounded Operation
If you have configured an S7-400 with a local connection and you only wish to
ground the overall installation at the CR, you can operate the ERs in an
ungrounded configuration.
Note
If you connect an ER via a local connection with 5 V transfer, ungrounded
operation is mandatory for the ER.
Connecting a Programming Device with Ungrounded Configuration
To connect a programming device to an S7-400 in ungrounded configuration,
please observe the following note:
Note
To connect a programming device to an S7-400 in ungrounded configuration, you
must connect the programming device via an RS 485 repeater.
4-10
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Wiring the S7-400
4.7
Assembling an S7-400 with Isolated Modules
Definition
In a configuration with isolated modules, the reference potentials of the control
circuit (Minternal) and the load circuit (Mexternal) are isolated (see also Figure 4-4).
Application
Isolated modules are used for:
• All AC load circuits
• DC load circuits with a separate reference potential
Examples of load circuits with a separate reference potential:
– DC load circuits whose sensors have different reference potentials (for
example, when grounded sensors are used far from the programmable
controller and equipotential bonding is not possible).
– DC load circuits whose positive terminal (L+) is grounded (battery circuits).
Isolated Modules and Grounding Concept
You can use isolated modules, regardless of whether or not the reference potential
of the programmable controller is grounded.
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4-11
Wiring the S7-400
Configuration with Isolated Modules
Shown in Figure 4-4 are the potentials of an S7-400 configured with isolated input
and output modules.
Racks
PS
CPU
DI
DO
Uinternal
Data
Reference
potential M
L1
N
PE
Ground bus in cabinet
L+
L1
Mexternal
N
230 VAC load current PS
24 VDC load current PS
Figure 4-4
4-12
Simplified Representation of Configuration with Isolated Modules
S7-400 and M7-400 Programmable Controllers Hardware and Installation
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Wiring the S7-400
4.8
Parallel Wiring of Digital S7-400 Outputs
Parallel Wiring of a Digital Output with Different Rated Load Voltages
The parallel wiring of a digital output (rated load voltage 1L+) with another digital
output (rated load voltage 2L+) or a rated load voltage 3L+ is only possible using
series diodes.
1 L+
Figure 4-5
2 L+
3 L+
Parallel Wiring of a Digital Output with Different Rated Load Voltages
Parallel Wiring of a Digital Output with Identical Rated Load Voltages
If the L+ supplies of the digital output modules and the L+ voltage connected in
parallel to the output are always the same (difference < 0.5 V), there is no need to
use diodes, see figure 4-6.
L+
Figure 4-6
Parallel Wiring of a Digital Output with Identical Rated Load Voltages
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4-13
Wiring the S7-400
4.9
Grounding
Introduction
Grounding in accordance with regulations and conscientiously implemented is the
prerequisite for proper functioning of a programmable controller.
Each individual component of the S7-400 and of the controlled system must be
properly grounded.
Ground Connections
Low-resistance ground connections reduce the risk of electric shock in the event of
a short-circuit or faults in the system. Moreover, proper grounding (low-impedance
connections: large surface area, wide-area bonding) together with the effective
shielding of lines and devices reduces the effect of interference on the system and
the interference signal emissions.
Note
Always ensure that operating currents do not flow via ground.
Protective Ground
All equipment of Safety Class I and all large metal parts must be connected to the
protective ground. This is essential to ensure that the user of the installation is
reliably protected from electric shock.
Furthermore, this serves to discharge interference transferred via external power
supply cables, signal cables, or cables to I/O devices.
Shown in Table 4-2 are the grounding methods required for the individual
components.
Table 4-2
Methods of Protective Grounding
Device
4-14
Grounding Method
Cabinet/frame
Connection to central ground point, e.g. ground bus, via
cable with protective conductor quality
Racks
Connection to central ground point via cable with
10 mm2 min. cross-section, when racks are not installed in a
cabinet and not interconnected via large metal parts
Module
None; automatically grounded via backplane bus when fitted
I/O device
Grounded via power plug
Shields of connecting
cables
Connection to rack or central ground point (avoid ground
loops)
Sensors and actuators
Grounding according to specifications applying to the
system
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Wiring the S7-400
Connecting the Load Voltage Ground
Many output modules require an additional load voltage to switch the actuators.
Two different modes are possible for this load voltage:
• Non-isolated operation
• Floating operation
The following table shows how the load voltage ground is connected in the
individual modes.
Table 4-3
Grounded connection load voltage
Connection of Load Voltage
Mode
Non-isolated operation
• Grounded configuration
To the reference point of the rack; metallic connection
between frame element and chassis ground must be
fitted.
• Ungrounded configuration
To the reference point of the rack; metallic connection
between frame element and chassis ground must be
fitted.
Floating operation
• Grounded and ungrounded
configuration
Left open or to any point, but not to protective ground
or reference potential M of operating voltages
The following figure shows how the load voltage ground is connected for
non-isolated operation.
Metallic connection, remove for
ungrounded configuration
Ground terminal for
load voltage
Figure 4-7 Grounded connection load voltage
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4-15
Wiring the S7-400
4.10
Interference-Free Configuration for Local and Remote
Connections
Use only Approved Components
Note
If you use components which are not approved for setting up local and remote
connections, interference rejection may be impaired.
Interference-Free Configuration for Local Connections
If you connect the CR and ER via suitable interface modules (send IM and receive
IM), no particular shielding and grounding need be implemented. Ensure, however,
that
• All racks have a low-impedance connection to each other
• The racks in a grounded arrangement have a star grounding configuration
• The contact springs of the racks are clean and not bent and will therefore
ensure the discharge of interference currents.
4-16
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Wiring the S7-400
Interference-Free Configuration for Remote Connections
If you connect the CR and ER via suitable interface modules (send IM and receive
IM), normally no particular shielding and grounding need be implemented.
Special shielding and grounding may become necessary if you operate your
system in an environment with an extremely high level of interference. In that case,
observe the following points:
• In the cabinet, connect the cable shields to the shield bus immediately after
entry.
– Strip the outer cable insulation in the region of the shield bus without
damaging the braided shield.
– Ensure that the braided shield has the greatest possible contact area on the
shield bus, for example, with metal hose clamps surrounding the shield over
a large area.
• Connect the shield bus(es) over a large area to the frame or cabinet wall.
• Connect the shield bus(es) to the chassis ground.
In a remote connection, ensure that the VDE regulations for laying the protective
ground are not infringed.
Figure 4-8 shows the methods described here. If the permissible potential
difference between grounding points is exceeded, you must install an equipotential
bonding conductor (copper conductor with a cross-section of 16 mm2).
ER
CR
Send IM
Figure 4-8
Shield/
protective
ground bar
ÎÎ
ÎÎ
ÎÎ
<7V
Receive IM
Î
Î
Î
Shielding and Grounding the Connecting Cable for a Remote Connection
Special Cases
For remote connections, you must use precut/preassembled connecting cables of
fixed length. When the connecting cables are laid, therefore, there may be excess
lengths. These must be coiled with a bifilar winding and deposited.
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4-17
Wiring the S7-400
4.11
Wiring Rules
Lines and Tools
For wiring the S7-400 modules, there are some rules for the cables and for the tool
you use. Information on connecting an M7-400 module assembly can be found in
Section 8.5.
Rules for
... Power Supply
... Front Connectors
Crimp terminal
Screw-type
terminal
Spring-type terminal
Conductor
cross-sections:
Outer diameter:
3 to 9 mm
Flexible cond.
without wire end
ferrule
no
0.5 to 1.5 mm2
0.25 to 2.5 mm2
0.08 to 2.5 mm2
Flexible cond. with
wire end ferrule
230 VAC: flexible
sheathed cable
3 1.5 mm2
no
0.25 to 1.5 mm2
0.25 to 1.5 mm2
1*
24 VDC: flexible
sheathed cable
3 1.5 mm2 or
individual wires
1.5 mm2
No. of conductors
per terminal
1
1
1*
Stripping length of
single conductors
7 mm
5 mm
8 to 10 mm without 8 to 10 mm without
ferrule
ferrule
10 mm with ferrule 10 mm with ferrule
Wire end ferrules
230 VAC: with
insulating collar to
DIN 46228 E1,5-8
-
with or without
insulating collar to
DIN 46228 Part 1
or 4, Shape A,
normal version
with or without
insulating collar to
DIN 46228 Part 1 or
4, Shape A, normal
version
24 VDC: without
insulating collar to
DIN 46228, shape A,
short version
*
Blade width and
shape of the screw
driver
3.5 mm (cylindrical
shape)
-
3.5 mm (cylindrical
shape)
0.5 mm x 3.5 mm
DIN 5264
Tightening torque:
for connecting
conductors
0.6 to 0.8 Nm
-
0.6 to 0.8 Nm
-
You can also connect a combination of two conductors of up to 1.0 mm each to a screw-type
or spring-type terminal. You must use special wire end ferrules for this purpose. Two types
and manufacturers of such ferrules are given below:
• Phoenix TWIN
Type no. 32 00 81 0, for 2 x 1 mm2
• AMP
Order no. 966 144-4, for 2 x 1 mm2
4-18
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Wiring the S7-400
Note
You must use shielded cables for the analog modules (see Section 4.5).
4.12
Setting the VAC Power Supply Module to the
Line Voltage
Set the voltage selector with 6ES7 407-0DA00-0AA0 and 6ES7 407-0RA00-0AA0
An S7-400 with VAC power supply can be operated from either a 120 V or 230 V
line voltage.
Check whether the voltage selector switch is set to your line voltage. To set the
VAC power supply module to the correct line voltage, follow the steps outlined
below:
1. Open the cover of the power supply module.
2. Remove the window of the voltage selector switch by levering it off with a
screwdriver.
3. Set the voltage selector switch to your available line voltage.
4. Refit the window.
5. Close the cover.
The following figure shows how to set the voltage selector switch to the available
line voltage.
S7-400 and M7-400 Programmable Controllers Hardware and Installation
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4-19
Wiring the S7-400
Figure 4-9 Setting the voltage selector
4-20
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Wiring the S7-400
4.13
Wiring the Power Supply Module
Power Supply Connector
You use the power supply connector to connect a power supply module to your
supply. When delivered, the power supply connector is plugged into the power
supply module. There are two versions (AC and DC) of power supply connector.
The two versions are coded, meaning an AC connector can only be plugged into
an AC power supply module, and a DC connector can only be plugged into a DC
power supply module.
Disconnecting the Power Supply Connector
Before wiring, you must unplug the power supply connector from the power supply
module.
1. Open the cover of the power supply module.
2. Detach the connector by levering it off with a suitable tool, for example, a
screwdriver, at the opening provided (1).
3. Pull the connector forward and out of the power supply module (2).
(1)
(2)
Figure 4-10 Disconnecting power supply connector
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Wiring the S7-400
Wiring the Power Supply Connector
To wire the power supply connector, follow the steps outlined below:
!
Warning
There is a risk of personal injury.
If you wire the connector with voltage applied, you may suffer a shock and
personal injury.
Only wire the connector with power disconnected.
1. Switch off the line voltage at your VAC supply disconnector.
Note
The standby switch of the power supply module does not disconnect the power
supply module from the supply.
2. Are you using a flexible sheathed cable with outer insulation (with 230 VAC)?
If so: Strip the outer insulation over a length of 70 mm. Note that an overall
cable diameter of between 3 mm and 9 mm must be present under the strain
relief after connection.
If not: Wrap the cores with insulating tape so that an overall cable diameter of
between 3 mm and 9 mm will be present under the strain relief after connection.
As an alternative to insulating tape, you can use a shrink-on sleeve.
3. Shorten the two cores which are not needed for connection to protective ground
(PE) by 10 mm.
4. Strip the cores over a length of 7 mm.
5. Slacken the screw in the cover of the power supply connector and open the
connector.
4-22
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Wiring the S7-400
6. Slacken the screw of the strain relief and insert the cable.
7. Connect the cores according to the illustration on the cover of the power supply
connector. Connect the longer core to PE. Screw on the cores with a torque of
0.6 to 0.8 Nm.
Terminals
Cable
AC
L1
DC
L+
N
L–
PE
PE
Strain-relief assembly
Screw for the strainrelief assembly
Figure 4-11 Wiring the power supply connector
8. Tighten the screw of the strain relief, so that the cable is secured properly.
9. Close the power supply connector and screw on the cover.
!
Caution
The power supply module or power supply connector can be damaged.
If you plug in or disconnect the connector with voltage applied, the power supply
module or the connector may be damaged.
Only plug in or disconnect the power supply connector with power removed.
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Wiring the S7-400
Plugging In the Power Supply Connector
You can only plug in the connector when the power supply module is installed
(lower mounting screw tightened).
!
Caution
An AC power supply module with the order number 6ES7 407-0DA00-0AA0 or
6ES7 407-0RA00-0AA0 can be damaged.
If you set the voltage selector switch of an AC power supply module to 120 V and
connect the power supply module to a 230 V supply, a fault may develop on the
power supply module. In this case the warranty will be void.
Set the voltage selector switch of an AC power supply module to the available line
voltage.
To plug the wired power supply connector into the power supply module, follow the
steps outlined below:
1. Open the cover of the power supply module.
2. Insert the power supply connector into the guide groove in the module housing.
3. Slide the power supply connector into the power supply module as far as it will
travel.
4. Close the cover of the power supply module.
The following figure shows how to plug the power supply connector into the power
supply module.
Figure 4-12 Plugging the power supply connector
4-24
S7-400 and M7-400 Programmable Controllers Hardware and Installation
A5E00069481-04
Wiring the S7-400
4.14
Wiring the Signal Modules
Procedure
There are two steps for providing the connection between the signal modules of
your S7-400 and the sensors and actuators of your plant:
1. Wiring the front connector. This serves to connect the cables to and from the
sensors/actuators to the front connector.
2. Plugging the front connector into the module.
The Three Types of Front Connector
There are three types of front connector for signal modules in the S7-400 series:
• Front connector with crimp snap-on terminals
• Front connector with screw-type terminals
• Front connector with spring-type terminals.
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4-25
Wiring the S7-400
Preparing to Wire the Front Connector
1. Insert a screwdriver at the point marked on the bottom left of the front connector
and lever the lower corner of the cover off the front connector.
2. Open the cover completely.
3. Pull the opened cover forward at the bottom and swing it upwards and off.
Levering the cover off
Opening the cover
Pulling the cover off
Figure 4-13 Preparing to wire the front connector
4. Cut the wires to the right lengths so that no loops are created in the front
connector after wiring.
5. Isolate the wires according to the table in Section 4.11.
Note
The front connectors contain a jumper needed for functioning of some signal
modules. Do not remove this jumper.
4-26
S7-400 and M7-400 Programmable Controllers Hardware and Installation
A5E00069481-04
Wiring the S7-400
4.15
Wiring the Front Connector, Crimp Snap-On Terminals
Procedure
To wire the prepared front connector, follow the steps outlined below:
1. Strip the conductors over approx. 5 mm.
2. Crimp the contacts onto the conductors. You can use a crimping tool which can
be ordered as an accessory for your signal modules.
3. Insert the crimp contacts into the cutouts in the front connector. Start at the
bottom of the front connector.
The order number for crimp contacts can be found in Appendix C of the
Reference Manual.
ÂÂ
ÂÂ
Figure 4-14
Wiring a Front Connector with Crimp Snap-On Terminals
S7-400 and M7-400 Programmable Controllers Hardware and Installation
A5E00069481-04
4-27
Wiring the S7-400
4.16
Wiring the Front Connector, Screw-Type Terminals
Procedure
To wire the prepared front connector, follow the steps outlined below:
1. Are you using wire end ferrules?
If so: Strip the conductors over 10 mm. Press-fit the wire end ferrules onto the
conductors.
If not: Strip the conductors over 8 to 10 mm.
2. Position the cores. Start at the bottom of the front connector.
3. Screw the ends of the conductors onto the front connector with a tightening
torque of 0.6 to 0.8 Nm. Also tighten the unwired terminals.
0.6 ... 0.8 Nm
ÂÂÂ
ÂÂÂ
ÂÂÂ
Figure 4-15
4-28
Wiring a Front Connector with Screw-Type Terminals
S7-400 and M7-400 Programmable Controllers Hardware and Installation
A5E00069481-04
Wiring the S7-400
4.17
Wiring the Front Connector, Spring-Type Terminals
Procedure
To wire the prepared front connector, follow the steps outlined below:
1. Are you using wire end ferrules?
If so: Strip the conductors over 10 mm. Press-fit the wire end ferrules onto the
conductors.
If not: Strip the conductors over 8 to 10 mm.
2. Use a screwdriver (0.5 x 3.5 mm DIN 5264) to release the spring contact of the
first terminal. Start at the bottom of the front connector.
You can release the individual spring contacts at three points: from the front,
from the side or from the back (see Figure 4-16 ).
3. Push the first wire into the released spring contact and withdraw the
screwdriver.
4. Repeat steps 3 and 4 for all other wires.
ÂÂÂ
ÂÂÂ
Releasing
a spring contact
from the back
Releasing
a spring contact
from the front
Releasing
a spring contact
from the side
Figure 4-16
Wiring a Front Connector with Spring-Type Terminals
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4-29
Wiring the S7-400
Principle of the Spring Contact
The following figure shows the principle of spring contacts. Releasing and
engaging from the front is illustrated.
1. nsert the screwdriver
2. Insert the wire into the spring
contact as far as it will go
3. Withdraw the screwdriver: the wire
is trapped by the contact
Figure 4-17 Principle of the spring contact
4-30
S7-400 and M7-400 Programmable Controllers Hardware and Installation
A5E00069481-04
Wiring the S7-400
4.18
Fitting the Strain Relief
Cable Ties as Strain Relief
When you have wired the front connector, the cable tie provided should be fitted at
the bottom of the front connector as a strain relief for the connected cable.
There are three ways of fitting the strain relief, according to the thickness of the
cable. Three openings are provided at the bottom of the front connector.
Figure 4-18
Fitting a Strain Relief (Viewed from Below)
S7-400 and M7-400 Programmable Controllers Hardware and Installation
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4-31
Wiring the S7-400
4.19
Labeling a Front Connector
Labels and Terminal Diagram
Each signal module is provided with three labels: two blank labels and one printed
label showing the terminal diagram for inputs and outputs.
Figure 4-19 shows the locations for fitting the individual labels on the front
connector.
Label
in front connector
Terminal diagram
interior
Label
exterior
Figure 4-19
Fitting the Labels on the Front Connector
To label a front connector, follow the steps outlined below:
1. Enter the addresses of the individual channels on the two labels. Note the slot
numbers on the labels to record the assignment of front connector to module.
2. Place a label on the left of the opened front connector. The label has a
T-shaped blank in the middle with which you can fix the label onto the front
connector housing. Bend the blank slightly to one side and push it behind the
corresponding cutout of the front connector whilst sliding in the label
(see Figure 4-20).
3. Refit the cover on the front connector.
4. Slide the label with the terminal diagram of the inputs or outputs into the interior
of the cover of the front connector.
5. Slide a label externally into the cover of the front connector.
4-32
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Wiring the S7-400
Figure 4-20 shows details for fitting a label in the front connector.
Label with blank
Cutout in front connector
Figure 4-20
Fitting a Label in the Front Connector
Labeling Sheets
• Labeling sheets that can be printed by machine for the I/O modules of SIMATIC
S7-400, including FMs, are the prerequisite for professional, convenient labeling
of SIMATIC modules.
• The labeling strips are already perforated on DIN A4 sheets and can be easily
separated without the use of a tool. This makes them easy to use and ensures a
clean cut.
• The labeling sheets are single-color, tear-proof and dirt-resistant. They are
available in petrol, light beige, red, and yellow.
• SIMATIC S7-400 I/O modules can be easily labeled application-specifically by
machine using a standard laser printer in one of the following two ways:
– Using templates that can be downloaded free from the Internet
– Using the “S7-SmartLabel” add-on tool for SIMATIC STEP7
S7-400 and M7-400 Programmable Controllers Hardware and Installation
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4-33
Wiring the S7-400
Notes on Ordering Labeling Sheets for S7-400
Order Number
4-34
Description
6ES7492-2AX00-0AA0
SIMATIC S7-400, 10 A4 LABELING SHEETS, COLOR
PETROL, 4 LABELING STRIPS/SHEETS FOR SIGNAL
MODULES, MATERIAL: FOIL, PERFORATED FOR
PRINTING WITH A LASER PRINTER, 10 SHEETS PER
PACKAGE
6ES7492-2BX00-0AA0
SIMATIC S7-400, 10 A4 LABELING SHEETS, COLOR
LIGHT BEIGE, 4 LABELING STRIPS/SHEETS FOR SIGNAL
MODULES, MATERIAL: FOIL, PERFORATED FOR
PRINTING WITH A LASER PRINTER, 10 SHEETS PER
PACKAGE
6ES7492-2CX00-0AA0
SIMATIC S7-400, 10 A4 LABELING SHEETS, COLOR
YELLOW, 4 LABELING STRIPS/SHEETS FOR SIGNAL
MODULES, MATERIAL: FOIL, PERFORATED FOR
PRINTING WITH A LASER PRINTER, 10 SHEETS PER
PACKAGE
6ES7492-2DX00-0AA0
SIMATIC S7-400, 10 A4 LABELING SHEETS, COLOR RED,
4 LABELING STRIPS/SHEETS FOR SIGNAL MODULES,
MATERIAL: FOIL, PERFORATED FOR PRINTING WITH A
LASER PRINTER, 10 SHEETS PER PACKAGE
S7-400 and M7-400 Programmable Controllers Hardware and Installation
A5E00069481-04
Wiring the S7-400
How to Label S7-400 Modules
Method 1: Using Templates
1. Find the templates on the Internet
You can download the templates from the Internet free of charge. You can
search for the templates on the initial Customer Supports page (try entering the
keyword ”label”, for example).
2. Download
The download contains templates for the labeling of S7-400 modules.
The templates for S7-400 make the labeling strips available for the outside of
the front connector cover and the terminal diagrams for the inside of the front
connector cover.
3. How to Print the Labeling Sheets Using the Templates
The idea is to use the templates to print directly onto the foil sheets. You can
use a laser printer to label the foil sheets. Proceed as follows:
a) Select page layout view in WORD to enter the information in the form
templates.
b) Label the module by clicking in the text boxes and entering the
application-specific designation.
c) We recommend that you first print the label out on white paper and compare
the dimensions of the paper printout with those of the original labeling
sheets. Because there are differences between the different printers and
printer drivers and their accuracy, the dimensions may vary and adjustment
may be necessary. If the line and column spacing is not set correctly, you
can adjust the position of the entire template under
“Header>Graphics>Position” and “File>Page Setup>Margins”.
d) When some templates are printed, a message reporting that the margins are
outside of the print area appears. This message can be ignored.
e) Once you have printed the foil sheets, make sure that you fold the labeling
strips along the perforation before separating them. This will ensure that the
edges of the strips are even. You can then apply the labeling strips to the
corresponding module.
Method 2: Using the “S7-SmartLabel” Add-On Tool for SIMATIC STEP 7
You can initiate the labeling directly from the STEP 7 project. The basis for
application-specific labeling is the symbol table in STEP 7. You will find more
detailed information at http://www.s7-smartlabel.de/ .
S7-400 and M7-400 Programmable Controllers Hardware and Installation
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4-35
Wiring the S7-400
4.20
Fitting the Front Connector
Principle of a Coding Key
To reduce the risk of a wired front connector being plugged into the wrong type of
module after rewiring or module replacement, the signal modules have a coding
key for front connectors.
A coding key comprises two parts: one part is permanently connected to the
module; the second part is still connected to the first part when delivered
(see Figure 4-21).
When you plug in a front connector, the second part of the coding key engages in
the connector, becoming detached from the part connected to the signal module.
Both parts of the coding key are mating elements and a front connector with the
wrong mating element cannot be plugged into this signal module.
Front Connector Coding on the Signal Modules
Shown in the following table is the allocation between the different front connector
coding keys and individual signal modules.
Table 4-4
Front connector coding elements
Signal Modules
Color of Front Connector Coding Key
red
yellow
green
Digital inputs, outputs
> 60 VDC or > 50 VAC
1. Digital inputs, outputs
60 VDC or 50 VAC
Analog inputs, outputs
Plugging In the Front Connector
You can only plug in the connector when the power supply module is installed
(lower mounting screw tightened).
!
Caution
Modules can be damaged.
If, for example, you plug the front connector of a digital input module into a digital
output module, the module can be damaged. If, for example, you plug the front
connector of an analog input module into an analog output module, the module
can be damaged.
When plugging in the front connector, ensure that the module and front connector
are matched.
4-36
S7-400 and M7-400 Programmable Controllers Hardware and Installation
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Wiring the S7-400
To plug in the front connector, follow the steps outlined below:
1. Hold the front connector horizontally and engage the front connector with the
coding key. After an audible click, the front connector will engage with the mount
and can be swung upwards.
2. Swing the front connector upwards. The two parts of the coding key will then be
separated.
3. Screw the front connector on.
Coding key
2
1
Figure 4-21
Attaching the Front Connector
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4-37
Wiring the S7-400
Figure 4-22 shows how to screw on the front connector.
Figure 4-22
4-38
Screwing On the Front Connector
S7-400 and M7-400 Programmable Controllers Hardware and Installation
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Wiring the S7-400
4.21
Interconnecting the CR and ER(s)
Interconnecting the Interface Modules
When you assemble a programmable controller comprising a CR and one or more
ERs, you connect the racks via the connecting cables of the interface modules.
To interconnect the interface modules, follow the steps outlined below:
1. Ensure that all the connecting cables needed for the programmable controller
are ready. Allow for the maximum cable lengths permitted for your assembly
(see Chapter 2) and check that you have the correct cables
(see Reference Manual Module Specifications, Chapter 6).
2. Start with the send IM (the interface module in the central rack).
3. Open the cover of the send IM.
4. Plug the male connector of the first connecting cable into one of the female
connectors of the send IM and screw the connector on.
Figure 4-23
Plugging a Connecting Cable into a Send IM
5. If you wish to connect two chains with ERs to this send IM, plug the connector
of the second connecting cable into the other port of the send IM.
6. Close the cover of the send IM.
S7-400 and M7-400 Programmable Controllers Hardware and Installation
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4-39
Wiring the S7-400
7. Open the cover of the first receive IM (interface module in the ER).
8. Plug the free end of the connecting cable into the upper male connector
(receive interface) of the receive IM and screw the connector on.
9. Connect the remaining receive IMs by connecting one send interface (lower
female connector X2) to one receive interface (upper male connector X1) in
each case.
Send IM
Receive IM
Receive IM
Terminator
Figure 4-24
Connection Between a Send IM and Two Receive IMs
10.Plug the terminator into the lower female connector of the receive IM in the last
ER of the chain (see Reference Manual Module Specifications, Chapter 6).
4-40
S7-400 and M7-400 Programmable Controllers Hardware and Installation
A5E00069481-04
Wiring the S7-400
4.22
Setting the Fan Subassembly to the Line Voltage and
Wiring It
Setting the Fan Subassembly to the Line Voltage
Check whether the voltage selector switch in the fan subassembly is set to your
line voltage (see Figure 4-25).
Fuse
The fan subassembly has two standard fuses:
• A 250 mA slow blow fuse for the 120 V range
• A 160 mA slow blow fuse for the 230 V range.
The fuse for the 230 V range is fitted before delivery.
Note
If you change the voltage range, you must also fit the fuse for this voltage range in
the fan subassembly. Replacing the fuse is described in Chapter 7.
Wiring the Fan Subassembly
1. Strip the cores of the power cable and press-fit wire end ferrules to the cores.
2. Insert the cores in the power terminals of the fan subassembly. Use a suitable
screwdriver to release the spring contacts of the power terminals.
3. The small cover serves as a strain relief for the power cable. Choose one of the
three sizes provided to suit your cable cross-section.
4. Screw the strain relief on.
S7-400 and M7-400 Programmable Controllers Hardware and Installation
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4-41
Wiring the S7-400
Fit the small cover
as a strain relief
Power terminals
(spring contacts)
Voltage selector switch
Fuse cap
Figure 4-25
4-42
Wiring the Fan Subassembly
S7-400 and M7-400 Programmable Controllers Hardware and Installation
A5E00069481-04
Wiring the S7-400
4.23
Routing Cables Using Cable Ducts or Fan
Subassemblies
Cable Routing
Depending on the number of cables and plug-in lines merging at the particular
rack, the cross-section of the cable duct or fan subassembly may not be sufficient
to accept all cables.
You should therefore route half the cables toward each side via the cable duct or
fan subassembly.
Securing Cables
There are eyes for securing cables on both sides of the cable duct or fan
subassembly (see Reference Manual Module Specifications, Chapter 6). You can
secure the cables to these eyes with cable ties, for example.
Shield Contact
The cable duct and fan subassembly offer the facility of electrical contact for cable
shields. You can use the shield clamps provided
(see Reference Manual Module Specifications, Chapter 6).
To establish contact for the cable shields, strip the outer insulation in the region of
the shield clamp, and trap the cable shield under the shield clamp.
4.24
Routing Cables Using Fiber-Optic Cables
Cable Routing
Indoor fiber-optic cables (for example, for connecting synchronization submodules)
are permitted for use in buildings, cable ducts, and channel trunking.
The maximum strain load when assembling is 1000 N and during operation 150 N.
Bending Radius
When laying cables, you should maintain the following minimum bending radii:
• Next to connector: 55 mm
• Otherwise: 30 mm
S7-400 and M7-400 Programmable Controllers Hardware and Installation
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4-43
5
Networking
Chapter Overview
Section
Description
Page
5.1
Configuring a Network
5-2
5.2
Fundamentals
5-3
5.3
Rules for Configuring a Network
5-7
5.4
Cable Lengths
5-15
5.5
PROFIBUS-DP Bus Cables
5-18
5.6
Bus Connectors
5-19
5.7
RS 485 Repeater
5-23
5.8
PROFIBUS-DP Network with Fiber-Optic Cables
5-25
S7-400 and M7-400 Programmable Controllers Hardware and Installation
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5-1
Networking
5.1
Configuring a Network
Subnets
You can connect an S7-400 device to various subnets:
• Via a Simatic Net CP Ethernet to an Industrial Ethernet subnet
• Via a Simatic Net CP PROFIBUS to a PROFIBUS-DP subnet
• Via the integrated multipoint interface to an MPI subnet
• Via the integrated PROFIBUS-DP interface to a PROFIBUS-DP subnet
With the M7-400, an MPI or PROFIBUS-DP network can be configured in the same
way. Only the modules required for connection to the PROFIBUS-DP network are
different (see Section 8.7.6).
Same Configuration
We recommend you use the same bus components as for a PROFIBUS-DP
network configuration when configuring an MPI network. The same configuration
rules apply.
Multipoint Interface (MPI)
This interface of the CPU uses a Simatic S7-specific protocol for data exchange
with programming devices (via STEP 7), operator panels, and other S7 CPUs. The
bus structure corresponds to that of the PROFIBUS.
Configuring Communication
In order that the individual nodes of an MPI or PROFIBUS-DP network can
communicate with each other, you must assign MPI or PROFIBUS-DP addresses
to them. The Manual Configuring Hardware and Communication Connections
STEP 7 V 5.2 describes how to assign these addresses and what you must take
into account.
All the CPU-related data you need to know to configure communication can be
found in the Reference Manual CPU Data, Chapter 4.
5-2
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Networking
5.2
Fundamentals
Station = Node
Declaration: All the stations you connect in a network are referred to as nodes in
the following.
Segment
A segment is a bus cable between two terminating resistors. A segment can
contain up to 32 nodes. Furthermore, a segment is limited by the permissible cable
length according to the transmission rate.
Baud Rate
The baud rate (transmission rate) is the speed at which data is transmitted,
expressed in terms of bits per second.
• Baud rates of 19.2 kbps to 12 Mbps are possible for interfaces of the type
MPI/DP.
• Transmission rates of 9.6 kbps to 12 Mbps are possible for interfaces of the
type PROFIBUS-DP.
Note
If you change the parameter assignment of the MPI/DP interface transmission rate,
the new transmission rate remains set even after memory reset, voltage failure or
removing/inserting the CPU.
Connectable Nodes
MPI
Programming devices (PGs)
PROFIBUS DP
Programming devices (PGs)
Operator interfaces (SIMATIC-OP), Operator panels (OPs)*
WinCC
S7-400/M7-400
PROFIBUS-DP master
S7-300/M7-300
PROFIBUS-DP slaves
*
Not recommended in DP operation
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Number of Nodes
MPI
PROFIBUS DP
127
127 *
(default: 32)
of which:
1 PG port (reserved)
1 master (reserved)
1 PG port (reserved)
125 slaves or other masters
*
Observe the CPU-related maximum numbers in the Reference Manual CPU Data,
Chapter 4
MPI/PROFIBUS-DP Addresses
In order for all nodes to be able to communicate with one another, you must assign
them an address:
• In the MPI network, an MPI address
• A PROFIBUS-DP address in the PROFIBUS-DP network
Default MPI Addresses
The following table shows the default MPI address and the max. MPI address with
which the devices are shipped:
Node (Device)
Default MPI Address
Default Highest MPI
Address
Programming device
0
32
OP
1
32
CPU
2
32
Note
If you change the parameter assignment of the highest MPI address of the MPI/DP
interface, the new address remains set even after memory reset, voltage failure or
removing/inserting the CPU.
Rules for MPI Addresses
Observe the following rules before assigning MPI addresses:
• All MPI addresses in an MPI network must be different.
• The highest possible MPI address must be the highest actual MPI address
and must be set to the same value for all nodes. (Exception: connecting a
programming device to two or more nodes.)
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Communication from PG/OP to Module without MPI
If one of the programming devices or operator panels connected to a multipoint
interface (MPI) communicates with an S7-400 module which does not have an
MPI connection (for example, SIMATIC NET CPs, FM 456 etc.), this module can be
reached via the CPU to whose MPI the programming device or operator panel is
connected. In this case, the CPU simply acts as an intermediary for the transfer.
This type of connection between a programming device or operator panel and a
module only communicating via the communication bus occupies two connection
resources in the CPU.
CPU
CP or FM
PG or OP
C bus
MPI
One connection
resource occupied
Figure 5-1
Two connection resources
occupied in the CPU
S7-400
station
One connection
resource occupied
Communication between Programming Device/Operator Panel and a Module
without MPI
Maximum Number of Connections via MPI
When configuring the connections of a CPU 416 via MPI, remember to include the
PG connection in the maximum number of possible connections.
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Networking
PG Access
A CPU exchanges data with other systems using communication mechanisms, for
example with other programmable controllers, with operator interface stations (OP,
OS) or with programming devices (see Figure 5-2).
PLC
OS
PG
SIMATIC NET
CPU
MPI
PG
Figure 5-2
DP network
OS
PLC
PG
OS
Slave
Data Exchange
Process communication, including communication services for data exchange
between programmable controllers (PLC - PLC) and between programmable
controllers and operator interface stations (PLC - OS/OP), has priority in CPUs
over communication between programming devices and CPUs.
The CPUs have different characteristics. One of these characteristics is their
communication performance. If the communication resources of a CPU are
occupied completely by process communication, this can severely hamper access
to the CPU from the programming device.
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5.3
Rules for Configuring a Network
Rules
Observe the following rules for connecting the nodes of a network:
• Before you interconnect the individual nodes of the network, you must assign to
each node the MPI address and the highest MPI address or PROFIBUS-DP
address.
Tip: Mark the address of each node in a network on the housing. To do this, use
the adhesive labels enclosed with the CPU. You can then always see which
address is assigned to which node in your plant.
• Before you insert a new node in the network, you must switch off its supply
voltage.
• Connect all the nodes in the network in a row. In other words, include the fixed
programming devices and operator panels directly in the network.
Only use spur lines for connecting the programming devices / OPs to the
network which are needed for startup or maintenance.
• If you operate more than 32 nodes in a PROFIBUS-DP network, you must
connect the bus segments via RS 485 repeaters.
In a PROFIBUS-DP network, all bus segments together must have at least one
DP master and one DP slave.
• You connect ungrounded bus segments and grounded bus segments via
RS 485 repeaters (see Reference Manual CPU Data, Chapter 10).
• The maximum number of nodes per bus segment decreases with each
RS 485 repeater. This means that if there is an RS 485 repeater in a bus
segment, there may only be a maximum of 31 other nodes in a bus segment.
However, the number of RS 485 repeaters has no effect on the maximum
number of nodes on the bus.
Up to ten segments can be connected in series.
• Switch on the terminating resistor at the first and last node of a segment.
To ensure the bus operates without interference, you should not switch off these
nodes.
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Data Packets in the MPI Network
Observe the following feature in the MPI network:
Note
If you connect an additional CPU to the MPI network during operation, data may
be lost.
Remedy:
1. Disconnect power from the nodes to be connected.
2. Connect the nodes to the MPI network.
3. Switch on the nodes.
Recommendation for MPI Addresses
Reserve MPI address “0” for a service programming device and “1” for a service
OP, which will later be briefly connected to the MPI network as required. Thus you
assign different MPI addresses to the programming devices / OPs incorporated in
the MPI network.
Reserve MPI address “2” for a new CPU. You thus avoid the duplication of MPI
addresses after a CPU with a default setting has been installed in the MPI network
(for example, when replacing a CPU). Thus you assign an MPI address higher than
“2” to all CPUs in the MPI network.
Recommendation for PROFIBUS-DP Addresses
Reserve PROFIBUS-DP address “0” for a service programming device, which will
later be briefly connected to the PROFIBUS-DP network as required. Thus you
assign other PROFIBUS-DP addresses to all the programming devices
incorporated in the PROFIBUS-DP network.
Components
You connect the individual nodes via bus connectors and the PROFIBUS-DP bus
cable. Remember to provide a bus connector with PG female port for nodes into
which a programming device may be plugged if required.
Use RS 485 repeaters for the connection between segments and for extending the
cable.
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Terminating Resistor on the Bus Connector
Terminating
resistor
switched on
Terminating
resistor
switched off
on
off
on
off
Figure 5-3 Terminating resistor on bus connector
Terminating Resistor on the RS 485 Repeater
DC
24
V
L+ M PE M 5.2
A1 B1 A1 B1
ON
ON
SIEMENS
RS 485-REPEATER
A2 B2A2 B2
Terminating resistor
for bus segment 1
Terminating resistor
for bus segment 2
Figure 5-4 Terminating resistor on RS 485 repeater
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Example: Terminating Resistor in the MPI Network
The figure below shows where you have to connect the terminating resistor in a
possible configuration for an MPI network.
S7-400
PG
S7-400
S7-400
OP
RS 485
repeater
OP
S7-300
Spur line
Programming device
Terminating resistor switch on
Figure 5-5 Terminating resistor on MPI network
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Example of an MPI Network
S7-400**
S7-400
S7-400
S7-400
PG
OP**
2
1
3
4
5
S7-400
S7-400
OP
11
6
10
S7-300
OP
9
8
7
0
Programming device
* Only connected via spur line for startup/maintenance (with default MPI address)
** Connected to the MPI later on (with default MPI address)
0 ... x MPI address of nodes
Terminating resistor switch on
Figure 5-6 Example of an MPI network
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Networking
Example of a PROFIBUS-DP Network
S7-400 with
CPU 414-2-DP
as DP master
ET 200M
ET 200M
S5-95U
PG
1
2
ET 200B
OP
PG*
0
8
3
7
4
5
ET 200B
6
* Only connected via spur line for startup/maintenance (with default PROFIBUS-DP address = 0)
0 ... x PROFIBUS DP addresses of nodes
Terminating resistor switched on
Figure 5-7 Example of a PROFIBUS DP network
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Example Using a CPU 414-2
The figure below shows an example of a configuration with CPU 414-2 DP which is
integrated in an MPI network and simultaneously used as DP master in a
PROFIBUS-DP network.
In both networks, the node numbers can be assigned separately without conflicts
resulting.
S7-400
PG*
OP
S7-300
S7-300
S7-400 with
CPU 414-2 as
DP master
S7-400
ET 200M
ET 200M
OP
RS 485
repeater
S7-400
OP
S7-200
ET 200B
MPI network
PROFIBUS-DP
network
* Only connected via spur line for startup/maintenance
ET 200B
Terminating resistor switched on
Figure 5-8 Example with CPU 414-2
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Networking
Programming Device Access Beyond Network Limits (Routing)
You can access all modules beyond network limits using a programming device.
S7-400 with
CPU 416
Programming
device / PC 3
S7-400 with
CPU 417
MPI network 3
MPI network 1
S7-300 with
CPU 318
S7-300 with
CPU 318
Programming
device / PC 1
PROFIBUS-DP network 2
ET 200
Programming
device / PC 2
Figure 5-9 Programming device access beyond network limits
Requirements :
• Use STEP 7 from version 5.0 onwards
• Assign STEP 7 to a programming device or PC on the network (SIMATIC
Manager, Assign programming device/PC)
• The network limits are bridged by modules with routing capability.
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5.4
Cable Lengths
Segment in the MPI Network
In a segment of an MPI network, you can use cable lengths of up to 50 m. This
50 m applies from the first node to the last node in the segment.
Table 5-1
Permitted Cable Length of a Segment in an MPI Network
Transmission Rate
Maximum Cable Length of a Segment (in m)
187.5 Kbps
50
19.2 Kbps
50
12 Mbps
50
Segment in the PROFIBUS-DP Network
In a segment of a PROFIBUS-DP network, the cable length depends on the
transmission rate (see Table 5-2). These lengths only apply if you connect a CPU
to a PROFIBUS-DP network via an MPI interface configured as a DP interface.
Table 5-2
Permitted Cable Length of a Segment in the PROFIBUS-DP Network
Depending on the Transmisson Rate
Transmission Rate
Maximum Cable Length of a Segment (in m)
9.6 to 187.5 Kbps
1000
500 Kbps
400
1.5 Mbps
200
3 to 12 Mbps
100
Longer Cable Lengths
If you have to implement cable lengths which are longer than permissible in one
segment, you must use RS 485 repeaters. The maximum possible cable length
between two RS 485 repeaters is the same as the cable length of a segment (see
Tables 5-1 and 5-2). With these maximum cable lengths, however, note that no
other nodes may be situated between the two RS 485 repeaters. You can connect
up to ten RS 485 repeaters in series.
Note that you must count an RS 485 repeater as a node of the MPI network in the
total number of all nodes to be connected, even if it is not assigned its own
MPI number. The use of RS 485 repeaters reduces the number of nodes.
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Networking
Lengths of Spur Lines
If you do not fit the bus cable directly at the bus connector (for example, when
using a PROFIBUS-DP bus terminal), you must take into account the maximum
possible spur line length.
The following table gives the maximum lengths of spur lines allowed per bus
segment:
Table 5-3
Lengths of Spur Lines per Segment
Transmission Rate Maximum
Length of a
Spur Line
Number of Nodes per
Spur Line Length of ...
1.5 m and
1.6 m
3m
Maximum
Length of
Spur Lines
per Segment
9.6 to 93.75 kbps
3m
32
32
96 m
187.5 kbps
3m
32
25
75 m
500 kbps
3m
20
10
30 m
1.5 Mbps
3m
6
3
10 m
A spur line is not permissible with transmission rates greater than 1.5 Mbps.
To connect a programming device or PC, use the connecting cable for the
programming with theorder number 6ES7 901-4BD00-0XA0. You can use several
connecting cable with this order number for programming devices in one bus
configuration.
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Example
The figure below shows a possible configuration of an MPI network. This example
clarifies the maximum possible distances in an MPI network.
S7-400
S7-400
S7-400
OP
3
4
5
PG*
Programming
device*
7
6
RS 485repeater
max.
1000m
Spur line
0
max. 50m
S7-400
OP
11
S7-400
OP
10
RS 485repeater
9
8
max. 50m
Terminating resistor switched on
Programming device connected via spur line for maintenance
0 ... x MPI addresses of nodes
Figure 5-10 Configuration of an MPI network
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5.5
PROFIBUS-DP Bus Cables
PROFIBUS-DP Bus Cables
Siemens supply the following PROFIBUS-DP bus cables (see catalog ST 70):
PROFIBUS-DP bus cable
6XV1 830-0AH10
PROFIBUS-DP cable for burying in ground
6XV1 830-3AH10
PROFIBUS-DP trailing cable
6XV1 830-3BH10
PROFIBUS-DP bus cable with PE sheath (for foodstuffs and
luxury food industry)
6XV1 830-0BH10
PROFIBUS-DP bus cable festoons
6XV1 830-3CH10
Characteristics of the PROFIBUS-DP Bus Cable
The PROFIBUS-DP bus cable is a twisted, shielded pair with the following
characteristics:
Characteristics
Values
Impedance
approx. 135 to 160 Ω (f = 3 to 20 MHz)
Loop resistance
115 Ω/km
Working capacitance
30 nF/km
Attenuation
0.9 dB/100 m (f = 200 kHz)
Permissible core cross-section
0.3 mm2 to 0.5 mm2
Permissible cable diameter
8 mm 0.5 mm
Rules for Laying Cables
When you lay the PROFIBUS-DP bus cable, you should not:
• Twist it,
• Stretch it, or
• Compress it.
Furthermore, when installing the indoor bus cable, you must observe the following
basic conditions (dA = outer diameter of the cable):
Characteristics
5-18
Boundary
Conditions
Bending radius for single bend
80 mm (10dA)
Bending radius for repeated bends
160 mm (20dA)
Permissible temperature range for installation
- 5 C to + 50 C
Storage and stationary operating temperature range
- 30 C to + 65 C
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5.6
Bus Connectors
Purpose of the Bus Connector
The bus connector is used to connect the PROFIBUS-DP bus cable to the MPI or
PROFIBUS-DP interface. In this way, you establish the connection to other nodes.
There are two different bus connectors:
• Bus connector without PG connector
(6ES7 972-0BA20-0XA0)
• Bus connector with PG connector
(6ES7 972-0BB20-0XA0)
Appearance (6ES7 972-0B.20 ...)
Screws for
mounting on
station
9-pin sub. D male connector
for connection to MPI or
PROFIBUS-DP interface
Switch for
terminating
resistor
PG connector (only with
6ES7 972-0BB20-0XA0)
Housing screw
Clamp hinge for vertical
or 30° cable routing
Figure 5-11 Bu s connector
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Networking
Connecting Bus Cables to Bus Connectors (6ES7 972-0B.20 ...)
1. Strip the bus cable according to the following figure.
11
5.5
Without PG connector
2
13
6
2
13
2
8
2
5.5
5.5
A B
7
A B
A B
7.5
5.5
11
Angled outgoing cable unit
AB
With PG connector
Figure 5-12 Strip bus cable
2. Open the housing of the bus connector by slackening the housing screw and
swinging the cover upwards.
3. Slacken the clamp hinge cover.
4. The bus connector with order number 6ES7 972-0B.20 is supplied with an
angled outgoing cable unit and used as it is in the S7-400.
If the cable is to be routed vertically out of the housing:
– Slacken the left-hand screw on the clamp hinge,
– Raise the clamp hinge slightly, and
– Turn the clamp hinge inward.
– Screw the left-hand screw tight again.
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5. Insert the green and red cores in the screw terminal block as shown in the
following figure.
Ensure that the same cores are always connected to the same terminals A or B
(for example, green conductor always wired to terminal A, and red conductor to
terminal B).
Bus cable connection for first
and last station on the bus
Bus cable connection for all
other stations on the bus
A B A B
ÇÇ
A B A B
The bus cable can be
connected either right or left.
Figure 5-13 Inserting cores into the screw termninal blocks
6. Retighten the clamp hinge cover.
Ensure that the bare cable shield is under the shield clamp.
7. Tighten the screw terminals for the green and red cores.
8. Close the cover of the bus connector.
9. Screw the housing on.
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Networking
Connecting the Bus Connector
To connect the bus connector, proceed as follows:
1. Plug the bus connector into the module.
2. Screw the bus connector into the module.
3. If the bus connector, order no. 6ES7 972-0B.20-0XA0, is situated at the
beginning or end of a segment, you must switch on the terminating resistor.
Terminating
resistor
switched on
on
off
Terminating resistor
not switched on
on
off
Figure 5-14 Switch on terminating resistant
Ensure that power is always applied to the stations at which the terminating resistor
is situated, during startup and operation.
Removing the Bus Connector
With a looped-through bus cable you can remove the bus connector from the
PROFIBUS-DP interface at any time, without interrupting data traffic on the bus.
!
Warning
Interference to the data traffic on the bus is possible.
A bus segment must always be terminated with the terminating resistor at both
ends. This is not the case, for example, when the last slave with bus connector is
not under power. Since the bus connector is powered by the station, the
terminating resistor has no effect.
Ensure that the stations at which the terminating resistor is switched on are always
under power.
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5.7
RS 485 Repeater
Purpose of the RS 485 Repeater
The RS 485 repeater enhances data signals on bus cables and links bus
segments.
You need an RS 485 repeater when:
• More than 32 nodes are connected in the network,
• A grounded segment is to be connected to an ungrounded segment, or
• The maximum cable length of a segment is exceeded.
Description of the RS 485 Repeater
A detailed description and technical data of the RS 485 repeater can be found in
the Reference Manual Module Specifications, Chapter 10.
Assembly
You can install the RS 485 repeater on a 35 mm standard profile rail.
Wiring the Power Supply Unit
To wire the power supply unit of the RS 485 repeater, proceed as follows:
1. Slacken the screw for “M” and “PE”.
2. Strip the cable for the 24 VDC supply.
3. Connect the cable to terminals “L+” and “M” or “PE”.
Terminal “M5.2”
Terminal “M5.2” should not be wired because it is only needed during maintenance.
Terminal “M5.2” is the reference ground you require when measuring the voltage
between terminals “A1” and “B1”.
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Connecting the PROFIBUS-DP Bus Cable
Connect the PROFIBUS-DP bus cable to the RS 485 repeater as follows:
1. Cut the PROFIBUS-DP bus cable to the required length.
2. Strip the PROFIBUS-DP bus cable according to the following figure.
The braided shield must be turned back over the cable. This is essential so that
the shielding point can serve later for strain relief and as a securing element.
6XV1 830-3AH10
6XV1 830-0AH10
6XV1 830-3BH10
8.5
16
10
ÇÇ
ÇÇ
16
16
10
ÇÇ
ÇÇ
8.5
Braided shield must be turned back over cable
Figure 5-15 Turning back braided shield over cable
3. Connect the PROFIBUS-DP bus cable to the RS 485 repeater:
Connect the same cores (green/red for PROFIBUS-DP bus cable) to the same
terminal A or B (for example, green conductor always connected to terminal A
and red conductor to terminal B).
4. Tighten the shield clamps so that the bare shield makes contact under the
shield clamp.
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5.8
PROFIBUS-DP Network with Fiber-Optic Cables
Electrical/Optical Conversion
If you want to use the field bus for larger distances irrespective of the transmission
rate, or if the data traffic on the bus is not to be impaired by external interference
fields, use fiber-optic cables rather than copper cables.
There are two ways to convert electrical cables to fiber-optic cables:
• PROFIBUS nodes with a PROFIBUS-DP interface (RS 485) are connected to
the optical network via an Optical Bus Terminal (OBT) or via the Optical Link
Module (OLM).
• PROFIBUS nodes with an integrated fiber-optic cable interface (e.g. ET 200M
(IM 153-2 FO), S7-400 (IM 467 FO)) can be directly integrated in the optical
network.
How to set up optical networks with the Optical Link Module (OLM) is described in
detail in the SIMATIC NET PROFIBUS Networks manual. You will find below the
most important information on setting up an optical PROFIBUS-DP network with
PROFIBUS nodes that have an integrated fiber-optic cable interface.
Benefits and Areas of Application
Fiber-optic cables have the following advantages over electrical cables:
• Electrical isolation of the PROFIBUS-DP components
• Insensitivity to electromagnetic interference (EMC)
• No electromagnetic emission into the environment
• Thus no need for additional grounding and shielding measures
• No adherence to minimum clearances from other cables necessary for EMC
• No need for equipotential bonding conductors
• No need for lightning conductors
• Maximum permissible cable lengths independent of the transmission rate
• Easy installation of the fiber-optic cable connections of the PROFIBUS-DP
components by means of standard fiber-optic cable connectors (Simplex
connectors)
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Networking
Optical PROFIBUS-DP Network in Partyline Topology
The optical PROFIBUS-DP network with nodes that have an integrated fiber-optic
cable interface has a partyline topology. The PROFIBUS nodes are
interconnected in pairs by means of Duplex fiber-optic cables.
Up to 32 PROFIBUS nodes with a fiber-optic cable interface can be
series-connected in an optical PROFIBUS-DP network. If a PROFIBUS node fails,
as a result of the partyline topology none of the downstream DP slaves can be
accessed by the DP master.
Programming
device/PC/OP
S7-400 with IM 467 FO
ET 200M with Other field devices without
IM 153-2 FO fiber-optic cable interface
PROFIBUS
cable
Distances between 2
nodes:
Plastic fiber-optic cable up
to 50 m
PCF fiber-optic cable up to
300 m
Optical PROFIBUS-DP
OBT
Figure 5-16
OBT
Other
nodes
Optical PROFIBUS-DP Network with Nodes that have an Integrated Fiber-Optic Cable
Interface
Transmission Rate
The following transmission rates are possible when the optical PROFIBUS-DP
network is operated with a partyline topology:
9.6 kbps, 19.2 kbps, 45.45 kbps, 93.75 kbps, 187.5 kbps, 500 kbps, 1.5 Mbps and
12 Mbps
PROFIBUS Optical Bus Terminal (OBT)
A PROFIBUS node can be connected to the optical PROFIBUS-DP network via a
PROFIBUS Optical Bus Terminal (OBT) (6GK1 500-3AA00) without an integrated
fiber-optic cable interface (e.g. programming devices (PGs) or operator panels
(OPs), see Figure 5-16).
The programming device/PC is connected to the RS 485 interface of the OBT by
means of the PROFIBUS cable. The OBT is integrated in the optical
PROFIBUS-DP line by means of its fiber-optic cable interface.
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5.8.1
Fiber-Optic Cables
Features of the Fiber-Optic Cables
Use Siemens plastic and PCF fiber-optic cables with the following features:
Table 5-4
Features of the Fiber-Optic Cables
Description
Standard designation
Area of application
SIMATIC NET PROFIBUS
Plastic Fiber-Optic
Duplex Conductor
Plastic Fiber-Optic
Standard Cable
PCF Fiber-Optic
Standard Cable
I-VY2P 980/1000
150A
I-VY4Y2P 980/1000
60A
I-VY2K 200/230
10A17+8B20
Indoors with a low
mechanical load,
such as laboratory
test assemblies or in
cabinets:
Indoors:
Indoors:
Cable lengths up to
50 m
Cable lengths up to
300 m
Cable lengths up to
50 m
Fiber type
Step-index fiber
Core diameter
980 µm
200 µm
Core material
Polymethyl methacrylate (PMMA)
Quartz glass
1000 µm
230 µm
Cladding outer diameter
Cladding material
Fluorinated special polymer
Inner sheath
• Material
• Color
• Diameter
2.2
PVC
PA
-
Gray
Black and orange
(Without inner sheath)
0.01 mm
2.2 0.01 mm
Outer sheath
• Material
• Color
-
Number of fibers
PVC
Purple
2
Attenuation at
wavelength
Cable grip
PVC
Purple
230 dB/km
10 dB/km
660 nm
660 nm
-
Kevlar fibers
Kevlar fibers
50 N
100 N
500 N
Not suitable for
continuous tensile
load
Not suitable for
continuous tensile
load
100 N
(At cable grip only,
50 N at connector or
single conductor)
Maximum permissible tensile
force
• Short-term
• Continuous
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Networking
Table 5-4
Features of the Fiber-Optic Cables, continued
Description
SIMATIC NET PROFIBUS
Plastic Fiber-Optic
Duplex Conductor
Plastic Fiber-Optic
Standard Cable
PCF Fiber-Optic
Standard Cable
35 N/ 10 cm
100 N/ 10 cm
750 N/ 10 cm
30 mm
100 mm
75 mm
50 mm
(flat side only)
150 mm
75 mm
-30 _C to +70 C
-30 C to +70 C
-30 C to +70 C
0 C to +50 C
0 C to +50 C
-5 C to +50 C
-30 C to +70 C
-30 C to +70 C
-20 C to +70 C
Conditional 1)
Conditional 1)
Conditional 1)
• UV radiation
Not UV-resistant
Conditional 1)
Conditional 1)
Flame retardance
Flame retardant in accordance with the VW-1 flame test to UL 1581
Resistance to lateral pressure
per 10 cm cable length
(short-term)
Bend radii
• Single bend
(without tensile force)
• Multiple bends
(with tensile force)
Permissible environmental
conditions
• Transport/storage
temperature
• Laying temperature
• Operating temperature
Resistance against
• Mineral oil ASTM no. 2,
grease or water
External dimensions
2.2 4.4 mm
0.01 mm
Weight
1
7.8 kg/km
Diameter:
0.3 mm
7.8
65 kg/km
Diameter:
4.7
0.3 mm
22 kg/km
Please ask your Siemens contact about specific applications.
5-28
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Order Numbers
You can order the fiber-optic cables specified in Table 5-4 as follows.
Table 5-5
Order Numbers - Fiber-Optic Cables
Fiber-Optic Cables
Form
Order Number
50 m ring
6XV1821-2AN50
per meter
6XV1821-0AH10
I-VY4Y2P 980/1000 160A
50 m ring
6XV1821-0AN50
Robust round cable with 2 plastic fiber-optic cable conductors,
PVC outer sheath and PA inner sheath, without connectors,
100 m ring
6XV1821-0AT10
SIMATIC NET PROFIBUS PCF fiber-optic, standard cable
50 m
6XV1821-1CN50
I-VY2K 200/230 10A17 + 8B20
75 m
6XV1821-1CN75
PCF fiber-optic cable with 2 conductors, PVC outer sheath, fitted
with 4 Simplex connectors, whip length 30 cm each, for distances
up to 300 m
100 m
6XV1821-1CT10
150 m
6XV1821-1CT15
200 m
6XV1821-1CT20
250 m
6XV1821-1CT25
300 m
6XV1821-1CT30
SIMATIC NET PROFIBUS plastic fiber-optic,
duplex conductor
I-VY2P 980/1000 150A
Plastic fiber-optic cable with 2 conductors and a PVC sheath,
without connectors,
for use in environments with low mechanical stress (e.g. in a
cabinet or for test assemblies in the laboratory)
SIMATIC NET PROFIBUS plastic fiber-optic, standard cable
for use indoors
(Other lengths on request)
5.8.2
Simplex Connectors and Connector Adapter
Definition
Simplex connectors allow you to connect the fiber-optic cable to the integrated
fiber-optic cable interface on the PROFIBUS device. In some Siemens modules
(e.g. IM 153-2 FO, IM 467 FO) two Simplex connectors (one for the sender and
one for the receiver) are inserted in the module by means of a special connector
adapter.
Prerequisite
The PROFIBUS device must be equipped with a fiber-optic cable interface, such as
the ET 200M (IM153-2 FO) or the IM 467 FO for S7-400.
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Networking
Structure
Two Simplex connectors (a sender and a receiver) and a connector adapter with
the following attributes are required for a fiber-optic cable connection:
• IP 20 protection
• Transmission rates of 9.6 kbps to 12 Mbps
Connector adapter
Receiver
Sender
Simplex
connectors
Figure 5-17
Fiber-optic
cables
Simplex Connectors and a Special Connector Adapter for the IM 153-2 FO
and IM 467 FO (installed)
Order Numbers
You can order Simplex connectors and connector adapters as follows:
Table 5-6
Order Numbers - Simplex connectors and connector adapters
Accessories
SIMATIC NET PROFIBUS plastic fiber-optic Simplex
connector/polishing set
Order Number
6GK1901-0FB00-0AA0
100 Simplex connectors and 5 polishing sets for fitting
SIMATIC NET PROFIBUS plastic fiber-optic cables
with connectors
Connector adapters
6ES7195-1BE00-0XA0
Pack of 50 for fitting plastic Simplex connectors with
the IM 467 FO and the IM 153-2 FO
5-30
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5.8.3
Connecting a Fiber-Optic Cable to the PROFIBUS Device
Cable Lengths
With fiber-optic cables, the length of the cable segment does not depend on the
transmission rate.
Each bus node in the optical PROFIBUS-DP network has repeater functionality.
The distances specified below are the distances between two neighboring
PROFIBUS nodes in the partyline topology.
The maximum cable length between two PROFIBUS nodes depends on the type of
the fiber-optic cable used.
Table 5-7
Permissible Cable Lengths on the Optical PROFIBUS-DP Network (Partyline
Topology)
SIMATIC NET
PROFIBUS
Fiber-Optic Cable
Maximum cable
Lengths Between Two
Nodes (in m)
Projected for 1 Network
(= 32 nodes) (in m)
Plastic fiber-optic
duplex conductor
50
1.550
Plastic fiber-optic
standard cable
50
1.550
PCF fiber-optic
standard cable
300
9.300
Mixed Use of Plastic Fiber-Optic and PCF Fiber-Optic Cable
To gain the maximum benefit from the different cable lengths you can mix the
plastic and PCF fiber-optic cables.
For example, you can use plastic fiber-optic cable for connections between DP
slaves locally (distances 50 m) and PCF fiber-optic cable for the connection
between the DP master and the first DP slave in the partyline topology (distance
50 m).
Laying PCF Fiber-Optic Cable
You can order PCF fiber-optic cables fitted with 2x2 connectors in specific lengths
from Siemens.
Lengths and order numbers: See Table 5-5
Laying Plastic Fiber-Optic Cable
You can easily fit connectors to and install plastic fiber-optic cables yourself. Please
read the following information on how to do this and on the rules for laying the
cable.
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Networking
Installation Instructions for Plastic Fiber-Optic Cable (with Photos)
You will find detailed installation instructions and a series of photographs on fitting
plastic fiber-optic cables with Simplex connectors:
• In the appendix of the SIMATIC NET PROFIBUS Networks manual
• On the Internet
– German: http://www.ad.siemens.de/csi/net
– English: http://www.ad.siemens.de/csi_e/net
Click SEARCH on this page, enter the number “574203” under “Entry-ID” and
start the search function.
• Enclosed with the Simplex connector/polishing set
Title: Assembly instructions for SIMATIC NET PROFIBUS Plastic Fiber Optics with
Simplex connectors
Rules for Laying Cable
When you lay plastic fiber-optic cable, please adhere to the following rules:
• Use only the Siemens fiber-optic cables specified in Section 5.8.1
• Never exceed the maximum permissible stresses (tensile load, crushing, etc.) of
the cable you are using specified in Table 5-4. Impermissible crushing can
occur, for example, when screw clamps are used to fix the cable in place.
• Follow the steps specified in the installation instructions, and use only the tools
specified there. Grind and polish the fiber ends carefully.
Note
Polishing the fiber ends of the fiber-optic cable, as described in the installation
instructions, reduces attenuation by 2 dB.
• Grind and polish by pressing the connector only lightly against the abrasive
paper or polishing foil in order to prevent the connector fusing with the fiber.
• Ensure that you maintain the bend radii specified in Table 5-4 during grinding
and polishing, particularly when cables are supported for mechanical strain
relief. In this case, ensure an adequate whip length.
• Ensure that there are no loops when cables are cut to length. Under tensile
load, loops can cause kinks to form in the cable and thus damage it.
• Ensure that the outer and conductor sheathing of the cable and the fibers are
not damaged. Scoring and scratches can let light escape and thus lead to
higher attenuation values and line failure.
• Never insert dirty connectors or connectors with protruding fibers in the device
sockets. This can destroy the optical sending and receiving elements.
Installing the Connector Adapter
The installation of the cut fiber-optic cable with connector on the PROFIBUS
devices is module-specific, and it is therefore described in the manual for the
PROFIBUS device with an integrated fiber-optic cable interface.
5-32
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6
Starting Up
Chapter Overview
Section
Description
Page
6.1
Recommended Procedure for First Startup
6-2
6.2
Checks Prior to Switching On for the First Time
6-3
6.3
Connecting a Programming Device (PG) to an S7-400
6-5
6.4
Switching On an S7-400 for the First Time
6-6
6.5
Resetting the CPU with the Mode Selector Switch
6-7
6.6
Cold, Warm, and Hot Restarts with the Mode Selector Switch
6-10
6.7
Inserting a Memory Card
6-11
6.8
Inserting a Backup Battery (Option)
6-13
6.9
Starting Up a PROFIBUS-DP Subnet
6-17
6.10
Installing Interface Submodules
(CPU 414-2, 414-3, 416-3, 417-4 and 417-4H)
6-18
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6-1
Starting Up
6.1
Recommended Procedure for First Startup
Recommended Procedure
Due to the modular assembly and the many expansion options, an S7-400 can be
very extensive and complex. A first startup of an S7-400 with two or more racks
and all modules inserted is therefore not advisable. Instead, a startup in stages is
recommended.
When commissioning an H system, you should first start up each subsystem
separately, as described in this chapter, before connecting both subsystems
together to form a complete system.
The following procedure is recommended for the first startup of an S7-400:
1. Carry out the checks listed in Table 6-1.
2. First start the CR with the power supply module and CPU inserted (see
Section 6.4). If you are setting up your assembly in a segmented rack, you must
insert both CPUs at the beginning for the first startup.
Check the LED indicators on the two modules. The meanings of these LED
indicators can be found in the Reference Manual Module Specifications,
Chapters 3 and in the reference manual CPU Data.
3. Insert additional modules in the CR, one at a time, and start them up one at a
time.
4. If required, connect the CR to ERs by inserting one or more send IMs in the CR
and the matching receive IM in the ER.
In the case of ERs with their own power supply modules, switch them on first
and then the power supply module of the CR.
5. Insert additional modules in the ERs one at a time and start them up one after
the other.
How to Proceed in the Case of an Error
If an error occurs, you can proceed as follows:
– Check your system by means of the checklist in Section 6.2.
– Check the LED indicators on the modules. Meanings of these indicators can
be found in the chapters containing the descriptions of the relevant modules.
– If necessary, remove individual modules to locate faults.
6-2
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6.2
Checks Prior to Switching On for the First Time
Checks Prior to Switching On for the First Time
After installing and wiring your S7-400, it is advisable to check the steps carried out
so far, before switching on for the first time.
Table 6-1 contains a guide in the form of a checklist for your S7-400, and refers to
the chapters containing additional information on the subject.
Table 6-1
Checklist to be Used Before Switching On for the First Time
Points to be Checked
See
Installation
Manual
Chapter
Are the racks secured on the wall, in
the frame or cabinet?
2
Have the necessary clearances been
allowed?
2
Are cable ducts or fan subassemblies
correctly installed?
2
Is the ventilation in order?
2
See Reference
Manual
“Module
Specifications
” Chapter
See Reference
Manual “CPU
Data” Chapter
Racks
Grounding and Chassis Ground Concept
Is there a low-impedance connection
(large surface, large-area contact) to
the chassis ground?
2
On all racks, is the connection between reference ground and chassis
ground correct (metallic connection or
ungrounded operation?)
4
Are all grounds of the non-isolated
ded modules and the grounds of the
load current power supplies connected to the reference points?
2
Mounting and Wiring Modules
Are all modules correctly inserted and
screwed on?
2
Are all front connectors correctly wired, plugged into the right modules,
and screwed on?
4
Are any necessary cable ducts or fan
subassemblies fitted correctly?
2
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Starting Up
Table 6-1
Checklist to be Used Before Switching On for the First Time, continued
Module Settings
Is the CPU mode switch set to
STOP?
6
Are the numbers of the racks correctly set on the coding switches of
the receive IMs and not duplicated?
1
7
If measuring range modules are fitted
on the analog input modules, are they
correctly set?
5, 6
Have the rules for connection been
observed?
2
Have the correct cables been used
for connections to existing ERs?
2, 4
Is the last receive IM of each connection chain terminated with the right
terminator?
7
7
Power Supply Module
Is the power supply connector correctly wired?
4
On AC PS modules, is the voltage
selector switch set to the available
line voltage?
4
3
On fan subassemblies, is the voltage
selector switch set to the available
line voltage?
4
9
Are all power supply modules switched off (Standby switch set to
)?
3
Is the BATT INDIC switch for battery
monitoring correctly set
(see Table 6-2)?
3
Has the connection to the supply
been made?
Line Voltage
Is the available line voltage correct?
3
According to the backup concept, Table 6-2 shows how you must set the battery
monitoring switch on the different power supply modules.
6-4
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Starting Up
Table 6-2
Setting the Battery Monitoring Switch
...Then
If You ...
6.3
do not use battery monitoring,
set the BATT INDIC switch to OFF.
use battery monitoring with a single-width
power supply module,
set the BATT INDIC switch to BATT.
want to monitor a backup battery with a
double or triple-width power supply module,
set the BATT INDIC switch to 1BATT.
want to monitor two backup batteries with a
double or triple-width power supply module,
set the BATT INDIC switch to 2BATT.
Connecting a Programming Device (PG) to an S7-400
Connecting a Programming Device (PG) to an S7-400
You must connect the programming device via a connecting cable to the MPI of the
CPU. This allows access via the communication bus to all CPUs and
programmable modules.
S7-400
PG cable
Programming device
Figure 6-1 Connecting PG to an S7-400
Note
The programming device is not ungrounded. To operate the S7-400 in an
ungrounded configuration, you must connect the programming device via an
RS 485 repeater (see Reference Manual Module Specifications, Chapter 10).
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6-5
Starting Up
Communication between Programming Device and CPU
The following conditions apply when communicating between a programming
device and a CPU:
• You need a programming device with STEP 7.
• The CPU can communicate with the programming device in the following
modes: RUN-P, RUN, STOP, STARTUP, and HOLD.
Operator Control
A description of operator control of communication between CPUs and
programming devices can be found in the STEP 7 manuals.
6.4
Switching On an S7-400 for the First Time
Switching On an S7-400 for the First Time
First switch on the power cutout.
Then set the standby switch of the power supply module from the standby setting
to the I setting (output voltages at rated value).
Result:
• On the power supply module, the green 5 VDC and 24 VDC LEDs light up.
• On the CPU
– The yellow CRST LED lights up;
– The yellow STOP LED flashes for three seconds at 2 Hz. During this time the
CPU automatically executes a reset.
– The yellow STOP LED lights up after the automatic reset.
If the red BAF LED and one of the yellow LEDs (BATTF or BATT1F or BATT2F)
light up on the power supply module, check the backup battery/batteries, the
setting of the BATT INDIC switch, or read the section on controls and indicators of
the power supply modules in Chapter 3 of the Reference Manual, Module
Specifications.
Switching On an H System for the First Time
First switch on the master device and then the standby device. In each case,
proceed as described above.
6-6
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Starting Up
6.5
Resetting the CPU with the Mode Selector Switch
How to Carry Out a Memory Reset
When you reset a CPU, you place the memories of the CPU in a defined initial
state. The CPU also initializes its hardware parameters and some of the system
program parameters. If you have inserted a Flash card with a user program in the
CPU, the CPU transfers the user program and the system parameters stored on
the Flash card into the main memory after the memory reset.
When Should a CPU be Reset?
You must reset the CPU:
• Before transferring a new, complete user program to the CPU.
• When the CPU requests a reset. Your recognize this request by slow flashing of
the STOP LED at 0.5 Hz.
How to Perform a Memory Reset
There are two ways of resetting the CPU:
• Reset with the mode selector switch
• Reset from the programming device (see STEP 7)
Resetting the CPU with the mode selector is described in the following section.
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Starting Up
Resetting the CPU with the Mode Selector Switch
The mode selector switch is designed as a keyswitch. The following figure shows
the possible positions of the mode selector switch.
RUN-P
RUN
STOP
MRES
Proceed as follows to reset the CPU using the mode switch:
Case A: You want to transfer a new, complete user program to the CPU.
1. Turn the switch to the STOP setting.
Result: The STOP LED lights up.
2. Turn the switch to the MRES setting and keep it at this setting.
Result: The STOP LED is dark for one second, bright for one second, dark for
one second and then remains lit.
3. Turn the switch back to the STOP setting, then to the MRES setting again within
the next 3 seconds and back to STOP.
Result:The STOP LED flashes for at least 3 seconds at 2 Hz (reset is being
executed) and then remains lit.
Case B: The CPU requests a reset by slow flashing of the STOP LED at 0.5 Hz
(system reset request, for example, when a memory card has been removed or
inserted).
Turn the switch to the MRES setting and back to the STOP setting.
Result:The STOP LED flashes for at least 3 seconds at 2 Hz (reset is being
executed) and then remains lit.
6-8
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Starting Up
What Happens in the CPU During a Memory Reset
When you carry out a memory reset, the following process occurs in the CPU:
• The CPU deletes the entire user program from the main memory and load
memory (integrated RAM and, if applicable, RAM card).
• The CPU clears all counters, bit memory, and timers (except for the time of
day).
• The CPU tests its hardware.
• The CPU initializes its hardware and system program parameters, (internal
default settings in the CPU). Some programmed default settings will be taken
into account.
• If no Flash card is inserted, a reset CPU has a memory utilization level of 0. You
can read out the memory utilization level with STEP 7.
• If a Flash card is inserted, the CPU copies the user program and the system
parameters stored on the Flash card into the main memory after the reset.
What Remains Following the Memory Reset...
After the CPU has been reset, the following remains:
• The contents of the diagnostic buffer
The contents can be read out with the programming device using STEP 7.
• Parameters of the MPI (MPI address and highest MPI address). Note the
special cases in the following table.
• The time of day
• Status and value of the operating hours counter
Special Case MPI Parameters
The MPI parameters have a special function during a memory reset. The following
table describes which MPI parameters are valid following a memory reset.
Memory Reset ...
MPI Parameters ...
with Flash card inserted
... on the Flash card are valid.
without Flash card inserted
... are retained in the CPU and are valid.
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6-9
Starting Up
6.6
Cold, Warm, and Hot Restarts with the Mode Selector
Switch
Sequence of Events During a Cold Restart (CPU 417 and 417 H)
1. Turn the switch to the STOP setting.
Result: The STOP LED lights up.
2. Turn the switch to the RUN/RUNP setting.
Sequence of Events During a Warm Restart (CPU 417 and 417 H)
1. Turn the switch to the STOP setting.
Result: The STOP LED lights up.
2. Turn the switch to the MRES setting and keep it at this setting.
Result: The STOP LED is dark for one second, bright for one second, dark for
one second and then remains lit.
3. Turn the switch to the RUN/RUNP setting.
6-10
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Starting Up
6.7
Inserting a Memory Card
The Memory Card as Load Memory
You can insert a memory card in all CPUs of the S7-400. It is the load memory of
the CPU. Depending on the type of memory card, the user program is retained on
the memory card even when power is removed.
What Type of Memory Card Should You Use?
There are two types of memory card: RAM cards and Flash cards.
Whether you use a RAM card or a Flash card depends on how you intend to use
the memory card.
If You ...
only intend to expand the integrated load
memory of the CPU,
...Then
you should use a RAM card.
want to store your user program
you should use a Flash card.
permanently on the memory card, even with
power removed (without backup or outside
the CPU),
Further information on the memory cards can be found in the CPU Manual,
Chapter 1.
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6-11
Starting Up
Inserting a Memory Card
To insert a memory card, follow the steps outlined below:
1. Set the mode selector switch on the CPU to STOP.
2. Insert the memory card in the submodule slot of the CPU and push the memory
card in as far as it will go.
Note the position of the marker dot. You can only insert the memory card in the
card slot in the direction shown in Figure 6-2.
Result: The CPU requests a memory reset by slow flashing of the STOP LED
at 0.5 Hz.
3. Perform a memory reset on the CPU by turning the mode switch to the MRES
setting and back again to STOP.
Result: The STOP LED flashes for at least 3 seconds at 2 Hz (reset is being
executed) and then remains lit.
Marker dot
Figure 6-2
Inserting a Memory Card in a CPU
Note
If you insert or remove the memory card with the controller switched
on, the CPU requests a memory reset by slow flashing of the STOP
indicator at 0.5 Hz.
If you insert or remove the memory card with the controller switched
off, the CPU will execute an automatic reset after power on.
6-12
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Starting Up
6.8
Inserting a Backup Battery (Option)
Backup
Depending on the power supply module, you can use one or two backup batteries:
• To back up a user program and save it without loss in the event of a power
failure.
• For retentive storage of bit memory, timers, counters, and system data as well
as data in variable data blocks.
You can also provide this backup with an external battery (5 to 15 VDC). You
achieve this by connecting the external battery to the EXT. BATT. socket on the
CPU (see Reference Manual, CPU Data Section 1.2). You can also back up
modules in an expansion rack via the EXT. BATT socket on the receive IM.
Inserting a Backup Battery
To insert the backup battery (batteries) in the power supply module, proceed as
follows:
1. Discharge any static charge by touching a grounded metal part of the S7-400.
2. Open the cover of the power supply module.
3. Insert the backup battery/batteries in the battery compartment.
Ensure correct polarity of the battery.
4. Switch on battery monitoring with the BATT INDIC slide switch, as shown in the
following table.
If You ...
...Then
have a single-width power supply module,
set the BATT INDIC switch to BATT.
have a double or triple-width power supply
module and want to monitor a backup
battery,
set the BATT INDIC switch to 1BATT.
have a double or triple-width power supply
module and want to monitor both backup
batteries,
set the BATT INDIC switch to 2BATT.
5. Close the cover.
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6-13
Starting Up
The following figure shows how to insert a backup battery in the single-width power
supply module.
6-14
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Starting Up
The following figure shows how to insert two backup batteries in a double-width
power supply module.
!
Warning
Hazardous to persons and property, risk of pollutant emission.
A lithium battery can explode if treated incorrectly; improper disposal of old lithium
batteries can result in pollutant emission. The following instructions should
therefore be observed without fail:
• Do not throw new or discharged batteries into a fire and do not solder onto the
cell body (max. temperature 100° C). Do not recharge, there is a risk of
explosion. Do not open the battery, and only replace it with one of the same
type. Obtain the replacement via Siemens (see the Reference Manual, Module
specifications Chapter 11 for the order number). This will ensure that you have
a short-circuit protected type.
• Old batteries should be disposed of with battery manufacturers/recyclers if
possible, or as hazardous waste.
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6-15
Starting Up
Reducing the Passivation Layer
Lithium batteries (lithium/thionyl chloride) are used as backup batteries for the
S7-400. In lithium batteries of this technology, a passivation layer can develop after
storage for a very long time, and the immediate functional capability of the battery
may not be certain. This may result in an error message when the power supply
module is switched on.
The power supply modules of the S7-400 are capable of reducing the passivation
layer of the lithium battery with a defined load on the battery. This process may
take some minutes. When the passivation layer has been reduced and the lithium
battery has reached its rated voltage, the error message of the power supply
module can be acknowledged with the FMR button.
Since the storage time of the lithium battery is not usually known, we recommend
the following procedure:
• Insert the backup battery/batteries in the battery compartment.
• Acknowledge any battery error message of the power supply module with the
FMR button.
• If the battery error cannot be cleared, try again after a few minutes.
• If the battery error still cannot be cleared, remove the battery/batteries and
short-circuit it/them for one to three seconds maximum.
• Reinsert the battery/batteries and try to acknowledge with the FMR button
again.
• If the battery error message goes off, the battery/batteries is/are operational.
• If the battery error message does not go off, the battery/batteries is/are
discharged.
Removing a Backup Battery
Chapter 7 describes how to remove the backup battery (batteries).
6-16
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Starting Up
6.9
Starting Up a PROFIBUS-DP Subnet
Introduction
This section describes the procedure for starting up a PROFIBUS-DP subnet with
an S7-400 CPU as the DP master.
Requirements
Before you can start up the PROFIBUS-DP subnet, the following requirements
must be met:
• The PROFIBUS-DP subnet has been set up (see Chapter 5).
• With STEP 7, you have configured the PROFIBUS-DP subnet and assigned a
PROFIBUS-DP address and the address area to all nodes (see manual
Configuring Hardware and Communication Connections with STEP 7 V 5.1).
Note that for some DP slaves, address switches must also be set (see the
reference manuals for the particular DP slaves).
Starting Up
1. Use the programming device to load the configuration of the PROFIBUS-DP
subnet created under STEP 7 (preset configuration) in the CPU. This procedure
is described in the manual Configuring Hardware and Communication
Connections with STEP 7 V 5.1.
2. Switch on all DP slaves.
3. Switch the CPU from STOP to RUN.
Behavior of the CPU During Startup
During startup, the CPU compares the preset and actual configurations. You set
the duration of the test with STEP 7 in the “Startup” parameter block with the
“module time limits” parameter. (See also Reference Manual, Chapter 4, the
manual Configuring Hardware and Communication Connections with
STEP 7 V 5.2, and the STEP 7 online help).
If the preset configuration = actual configuration, the CPU goes to RUN.
If the preset configuration actual configuration, the CPU’s reaction depends on
the setting of the parameter for “Startup if preset configuration actual
configuration”:
Startup if Preset Config. Actual
Config. = Yes (Default)
CPU goes into RUN
Startup if Preset Config. Actual Config. = No
The CPU remains at STOP and, after the timeset in the “module time
limits” parameter, the BUSF LED flashes.
Flashing of the BUSF LED indicates that at least one slave will not
respond. In this case, check whether all slaves are switched on or
display the content of the diagnostic buffer
(see Configuring Hardware and Communication Connections with
STEP 7 V 5.2).
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Starting Up
6.10
Installing Interface Submodules
(CPU 414-2, 414-3, 416-3, 417-4 and 417-4H)
Available Interface Submodules
Note
Only use interface submodules that are explicitly released for use in S7-400
devices.
Installing Interface Submodules
!
Warning
The modules can be damaged.
When inserting or removing interface submodules with power applied, the CPU
and interface submodules can be damaged (exception: using synchronization
submodules in an H system).
Never insert or remove the interface submodules while power is being supplied
(exception: synchronization submodules). Always switch off the power supply
before inserting or removing interface submodules.
!
Caution
Danger of damage to persons and property.
Interface submodules contain electronically-sensitive components that may be
damaged if they are touched.
The surface temperatures on the components can reach up to 70o C and there is a
risk of burning.
For this reason, you should always hold the interface submodules on the longest
sides of the front panel.
Observe the ESD guidelines when installing interface submodules.
To fit an interface submodule in a card slot, follow the steps outlined below:
1. Undo the additional front plate with the IF 964-DP or IF 960 HF (synchronization
submodule).
2. Make all the required settings on the submodule (for example, setting the rack
number on a synchronization submodule).
3. Hold the interface submodule on the long sides of the front plate.
4. Insert the PCB end of the interface submodule in the lower and upper guides of
the card slot, as shown in Figure 6-3.
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Starting Up
5. Slowly push the interface submodule into the slot until the front plate rests on
the frame of the card slot.
6. Important! Secure the front plate with the two fitted, captive M2.5 x 10 slot-head
screws on the left frame of the card slot.
7. Attach the additional front plate for an IF 964-DP and for an IF 960 HF
(synchronization module).
Guide
rails
Figure 6-3
Inserting Interface Submodules in the CPU
Covering Unused Submodule Slots
On delivery, all the submodule slots are secured with a submodule cover. The
cover is attached to the frame of the card slot with screws.
Leave unused submodule slots secured.
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Starting Up
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7
Maintenance
Chapter Overview
Section
Description
Page
7.1
Replacing the Backup Battery
7-2
7.2
Replacing a Power Supply Module
7-4
7.3
Replacing CPUs
7-5
7.4
Replacing Digital or Analog Modules
7-7
7.5
Changing the Fuses in the Digital Modules
7-9
7.6
Replacing Interface Modules
7-11
7.7
Replacing the Fuse of the Fan Subassembly
7-13
7.8
Replacing Fans in the Fan Subassembly During Operation
7-14
7.9
Replacing the Filter Frame of the Fan Subassembly During Operation
7-16
7.10
Replacing the Power Supply PCB and Monitoring PCB of the Fan
Subassembly
7-18
7.11
Replacing Memory Cards
7-19
7.12
Replacing Interface Submodules
7-22
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7-1
Maintenance
7.1
Replacing the Backup Battery
Replacing the Backup Battery
1. Discharge any static charge by touching a grounded metal part of the S7-400.
2. Open the cover of the power supply module.
3. Using the loop(s), pull the backup battery/batteries out of the battery
compartment.
4. Insert the new backup battery/batteries in the battery compartment of the power
supply module.
Ensure correct polarity of the battery/batteries.
5. Switch on battery monitoring with the BATT INDIC slide switch.
If You ...
...Then
have a single-width power supply module,
set the BATT INDIC switch to
BATT.
have a double or triple-width power supply module
and want to monitor a backup battery,
set the BATT INDIC switch to
1BATT.
have a double or triple-width power supply module
and want to monitor both backup batteries,
set the BATT INDIC switch to
2BATT.
6. Press the FMR button.
7. Close the cover of the power supply module.
7-2
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Maintenance
Note
If you store the batteries for a long period, a passivation layer may form. Please
read Section 6.8, Inserting a Backup Battery.
Using Backup Batteries
You should change the backup battery once a year.
Observe the usual regulations/guidelines for disposing of lithium batteries in your
country.
Backup batteries should be stored in a cool, dry place.
Backup batteries can be stored for ten years. If they are stored for a longer period,
however, a passivation layer may form.
Rules for the Care of Backup Batteries
You must observe the following rules to avoid hazards in the care of backup
batteries:
!
Warning
The improper care of backup batteries can result in injury and damage.
Backup batteries can ignite or explode if they are heated or damaged.
Backup batteries must not be
• Recharged
• Heated
• Burned
• Drilled into
• Crushed
Store the backup batteries in a cool, dry place.
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7-3
Maintenance
7.2
Replacing a Power Supply Module
Slot Numbering
If you have provided the modules in your system with slot numbering, you must
remove the number from the old module when replacing it and apply the number to
the new module.
Removing the Module (Ignore Steps 1 and 2 When Using Redundant Power
Supply Modules)
1. Set the CPU mode switch to STOP.
When you replace the power supply module in an ER, the CR may remain in the
RUN state, depending on CPU programming. You can back up the data in the
ER via the EXT. BATT. socket of the receive IM.
2. If you wish to back up the data in the CPU, you can use the EXT. BATT. socket
of the CPU (see Reference Manual, Chapter 4).
3.
4.
5.
6.
7.
8.
9.
(0 V output voltages).
Set the standby switch of the power supply module to
Set the line disconnector to OFF.
Remove the cover.
Remove the backup battery/batteries if applicable.
Disconnect the power supply connector from the power supply module.
Loosen the mounting screws of the module.
Swing the module out.
Installing a New Module
1. Check the voltage selector switch.
2. Attach the new module of the same type and swing it downwards.
3. Screw the module on.
4. Check that the power disconnector is set to OFF and the standby switch to
.
5. Plug in the power supply connector at the power supply module.
6. Insert the backup battery/batteries, if applicable.
7. Close the cover.
8. Set the power disconnector to ON.
9. Set the standby switch of the power supply module to I (output voltages at rated
value).
10.Set the CPU mode switch to RUN if applicable.
How the S7-400 Behaves after Exchanging Modules
If an error occurs after replacing a module, you can read out the cause of the error
from the diagnostic buffer.
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Maintenance
7.3
Replacing CPUs
Slot Numbering
If you have provided the modules in your system with slot numbering, you must
remove the number from the old module when replacing it and apply the number to
the new module.
Saving the Data
Save the user program including configuration data.
Removing the Module
1. Set the CPU mode switch to STOP.
2. Set the standby switch of the power supply module to
(0 V output voltages).
3. Remove the cover of the CPU.
4. Disconnect the MPI connector, if applicable.
5. Disconnect the connector at the EXT. BATT. socket, if applicable.
6. Remove the memory card.
7. Loosen the mounting screws of the module.
8. Swing the module out.
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7-5
Maintenance
Installing a New Module
1. Attach the new module of the same type and swing it downwards.
2. Screw the module on.
3. If applicable, plug the connector for the external battery supply into the socket.
4. Set the CPU mode switch to STOP.
5. Insert the memory card.
6. Set the standby switch of the power supply module to I (output voltages at rated
value).
The remaining procedure depends on whether you use a Flash card and
whether or not you have configured your system for networking.
7. Proceed as follows to operate with a Flash card:
Transfer the user and configuration data.
Set the CPU mode switch to RUN.
Close the cover.
8. If your system is not configured for networking, proceed as follows:
Transfer the user and configuration data by means of the programming device,
via the programming device cable (see Section 6.3).
Set the CPU mode switch to RUN.
Close the cover.
9. If your system is configured for networking, proceed as follows:
Transfer the user and configuration data by means of the programming device,
via the programming device cable (see Section 6.3).
Set up your network by plugging in the MPI connector.
Set the CPU mode switch to RUN.
Close the cover.
How the S7-400 Behaves after Exchanging Modules
If an error occurs after replacing a module, you can read out the cause of the error
from the diagnostic buffer.
7-6
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Maintenance
7.4
Replacing Digital or Analog Modules
Slot Numbering
If you have provided the modules in your system with slot numbering, you must
remove the number from the old module when replacing it and apply the number to
the new module.
Installing a Module
1. You can replace analog and digital modules in RUN mode. You must have taken
the appropriate action in your STEP 7 program to ensure correct responses
from your system.
If you are not sure whether your program will react correctly, set the CPU mode
switch to STOP.
!
Warning
Improper handling of the front connectors can result in injury and damage.
If the front connector is removed and inserted during operation, hazardous
voltages of >25 VAC or >60 VDC may be present at the pins of the module.
When such voltages are present at the front connector, modules with power
applied may only be replaced by electrical specialists or trained personnel in such
a way that the pins of the module are not touched.
2. Loosen the mounting screw of the front connector and pull it off.
3. Loosen the mounting screws of the module.
4. Swing the module out.
Note
In order that the removal and insertion of digital or analog modules can be
detected by the CPU, a minimum time of two seconds must elapse between
removal and insertion.
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7-7
Maintenance
Removing the Front Connector Coding Key
Before fitting the front connector, you must remove (break off) the front part of the
coding key, because this part is already fitted in the wired front connector.
!
Caution
The module can be damaged.
If, for example, you insert a front connector of a digital module in an analog
module, the module may be damaged.
Only operate modules with their complete front connector coding key.
Installing a New Module
1. Attach the new module of the same type at the appropriate slot and swing it
downwards.
2. Screw the module on with both mounting screws.
3. Fit the front connector.
4. If you have set the CPU to STOP, you must now set it to RUN again.
5. After fitting, each programmable module will be reinitialized by the CPU with
parameters.
How the S7-400 Behaves after Exchanging Modules
If an error occurs after replacing a module, you can read out the cause of the error
from the diagnostic buffer.
Exchanging the Front Connector
1. Switch off all load power supplies for the module.
2. Loosen the screw of the front connector and pull it off.
3. Remove the labels from the front connector and insert them into the new front
connector.
4. Wire the new front connector.
5. Insert the front connector in the module.
6. Screw the front connector on.
7. Switch on the load voltage.
7-8
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Maintenance
7.5
Changing the Fuses in the Digital Modules
Modules with Fuses
The following modules have fuses which you can change yourself if they are
defective:
• Digital output module SM 422; DO 16 x AC 20-120 V/2A
(6ES7422-5EH00-0AB0)
• Digital output module SM 422;DO 8 x AC 120/230 V/5A
(6ES7422-1FF00-0AA0)
• Digital output module SM 422;DO 16 x AC 120/230 V/2A
(6ES7422-1FH00-0AA0)
Check the Plant
Correct the faults which led to the fuses blowing.
Changing the Fuses
To change the fuses in a digital module, you must remove the front connector from
the digital module and remove the module from the rack.
Warning
!
Improper handling of the digital modules can result in injury and damage.
Hazardous voltages of >25 VAC or >60 VDC may be present below the covers on
the right-hand side of the module.
Before you open these covers, ensure that either the front connector for the
module is removed or the module is disconnected from the voltage supply.
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7-9
Maintenance
!
Warning
Improper handling of the front connectors can result in injury and damage.
If the front connector is removed and inserted during operation, hazardous
voltages of >25 VAC or >60 VDC may be present at the pins of the module.
When such voltages are present at the front connector, modules with power
applied may only be replaced by electrical specialists or trained personnel in such
a way that the pins of the module are not touched.
To change the fuses, follow the steps outlined below:
1. You must have taken the appropriate action in your STEP 7 program to ensure
correct responses from your system.
If you are not sure whether your program will react correctly, set the CPU mode
switch to STOP.
2. Loosen the mounting screw of the front connector and pull it off.
3. Loosen the mounting screws of the module.
4. Swing the module out.
Note
In order that the removal and insertion of digital modules can be detected by the
CPU, a minimum time of two seconds must elapse between removal and insertion.
5. Remove the covers on the right-hand side of the module by levering them out
with a screwdriver.
6. Replace the defective fuses with new fuses of the same type.
7. Place the guides on the covers into the appropriate cutouts in the module
casing and close the covers until they click into place.
8. Attach the module onto its slot and swing it down.
9. Screw the module on with both mounting screws.
10.Fit the front connector.
11. If you have switched the CPU to STOP, you must now switch it to RUN again.
12.After fitting, each programmable module will be reinitialized by the CPU with
parameters.
How the S7-400 Behaves after Replacing the Fuse
If an error occurs after replacing a fuse, you can read out the cause of the error
from the diagnostic buffer.
7-10
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Maintenance
7.6
Replacing Interface Modules
Slot Numbering
If you have provided the modules in your system with slot numbering, you must
remove the number from the old module when replacing it and apply the number to
the new module.
Fitting and Removing Modules During Operation
Observe the following warning when fitting and removing the interface modules and
the corresponding connecting cables.
!
Caution
Data can be lost or corrupted.
If you remove or insert the interface modules and/or corresponding connecting
cables with power applied, data may be lost or corrupted.
Switch off the power supply modules of the CR and ERs on which you are working
before carrying out any actions.
Removing Modules / Exchanging Cables
1. If you wish to back up your data in the CPU, you can do this with a backup
battery or via an external battery supply at the CPU (see Reference Manual,
Chapter 4).
2. Set the CPU mode switch to STOP.
3. Set the standby switches of both power supply modules (in the CR and the ER)
to (0 V output voltages).
4. Remove the cover.
5. Disconnect the connecting cables.
6. Disconnect the terminator, if applicable.
7. Loosen the mounting screws of the module.
8. Swing the module out.
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7-11
Maintenance
Installing a New Module
1. Set the number of the rack at receive IMs.
2. Attach the new module of the same type and swing it downwards.
3. Screw the module on.
4. Fit the connecting cables.
5. Plug in the terminator, if applicable.
6. Secure the cover.
7. First switch on the power supply module in the ER.
8. Then switch on the power supply module in the CR.
9. Set the CPU mode switch to RUN mode.
How the S7-400 Behaves after Exchanging Modules
If an error occurs after replacing a module, you can read out the cause of the error
from the diagnostic buffer.
7-12
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Maintenance
7.7
Replacing the Fuse of the Fan Subassembly
Fuse Type
The fuse of the fan subassembly is a standard 5 x 20 mm cartridge fuse to DIN and
not a spare part.
Use the following fuse:
• 160 mA slow blow if the voltage selector switch is set to 230 V
• 250 mA slow blow if the voltage selector switch is set to 120 V
Replacing the Fuse
To replace the fuse of the module, follow the steps outlined below:
1. Disconnect the power cable of the fan subassembly from the supply.
2. Use a screwdriver to unscrew the fuse cap.
Voltage selector switch
Fuse cap
3. Remove the blown fuse from the fuse cap.
4. Insert the new fuse in the fuse cap and screw the cap into the fan subassembly.
5. Connect the power cable of the fan subassembly to the supply.
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7-13
Maintenance
7.8
Replacing Fans in the Fan Subassembly During
Operation
Removing the Fans
1. Use a screwdriver to make a quarter turn counter-clockwise and open the two
quick-release locks on the front of the fan subassembly.
ÄÄÄÄÄ
ÄÄÄÄÄÄ
ÄÄÄÄÄ
ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ
Fan 1
Fan 2
Fan 3
Base
Quick-release locks
Reset button
LEDs: F 1 = Fan 1
F 2 = Fan 2
F 3 = Fan 3
7-14
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A5E00069481-04
Maintenance
2. Grasp the base with both hands, press it down slightly and pull it fully out of the
fan subassembly.
3. Release the fan to be replaced by pressing the fan grip away from the housing
with your thumb.
Fan
Fan grip
Base
4. Pull out the fan to be replaced.
5. Slide the new fan in until it engages.
6. Slide the base in again and press it up.
7. Use a screwdriver to make a quarter turn clockwise and close the two
quick-release locks.
8. Use a pointed object to press the RESET button. The fault LED will go off and
the fan will start running.
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7-15
Maintenance
7.9
Replacing the Filter Frame of the Fan Subassembly
During Operation
Replacing the Filter Frame
1. Use a screwdriver to make a quarter turn counter-clockwise and open the two
quick-release locks on the front of the fan subassembly.
2. Grasp the base with both hands, press it down slightly, pull it first fully forward
and then up at an angle out of the fan subassembly.
3. The filter frame is secured either in the bottom of the base or at its rear edge
with snap hinges and snap catches. The individual filter mats are joined with the
filter frame.
Remove the filter frame as follows:
– The filter frame is fitted in the bottom of the base:
Near the snap catches, press against the filter frame from below and remove
the filter frame.
– The filter frame is secured at the rear edge of the base:
With the flat of your hand, press the filter frame away from the base of the
fan subassembly. This will release the filter frame from the snap hinges.
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Maintenance
Filter mat
Filter frame
Cover
Snap catches
Base with cover and filter
frame (optionally fitted at
bottom or rear)
Snap hinges
Quick-release locks
4. Fit the new filter frame:
– Fitting the filter frame at the bottom of the base:
Insert the filter frame in the snap hinges at the base cutout and engage it
with the snap catches.
– Fitting the filter frame at the rear edge of the base:
At about a right angle to the base, insert the filter frame in the snap hinges at
the rear edge of the base.
5. Slide the base in again and press it up.
6. Use a screwdriver to make a quarter turn clockwise and close the two
quick-release locks.
7. Replacing the filter frame will not trigger an interrupt. There is therefore no need
to press the RESET button.
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Maintenance
7.10
Replacing the Power Supply PCB and Monitoring PCB
of the Fan Subassembly
Exchanging the Mother Board
1. Disconnect the power cable of the fan subassembly from the supply.
2. Use a screwdriver to make a quarter turn counter-clockwise and open the two
quick-release locks on the front of the fan subassembly.
3. Remove the base of the fan subassembly (see Section 7.9).
Shown in the following figure is a front view of the fan subassembly. You can also
see the locations of the printed-circuit boards (PCBs).
ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ
Fan 1
Quick-release
lock
Power supply
PCB
Fan 2
Monitoring
PCB
Fan 3
Quick-release
lock
Reset
button
4. Pull the faulty PCB forward and out of the fan subassembly.
5. Slide the new PCB in until it engages.
6. Slide the base in again and press it up.
7. Use a screwdriver to make a quarter turn clockwise and close the two
quick-release locks.
8. Connect the power cable of the fan subassembly to the supply.
9. Use a pointed object to press the RESET button. The fans will start running.
!
Caution
Electronic components can be damaged.
If you do not observe the ESD guidelines when handling printed-circuit boards with
electronic components, the components can be damaged by a static discharge.
Observe the ESD guidelines (see Appendix).
7-18
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Maintenance
7.11
Replacing Memory Cards
Memory Expansion
The CPU 417-4 and CPU 417-4 H memory modules are expandable. Take note of
the following rules for the expansion procedure:
1. If you are inserting only one module, it has to be inserted on slot 1.
2. A second module may only be inserted if a module of 4 Mbytes is inserted on
slot 1.
The following combinations are thus possible:
Slot 1
Slot 2
2 Mbytes
–
4 Mbytes
–
4 Mbytes
2 Mbytes
4 Mbytes
4 Mbytes
In order to be able to replace memory cards in a central processing unit, you have
to remove the CPU from the rack (see section 7.3).
!
Warning
The modules can be damaged.
Failure to observe ESD guidelines can result in damage to both the CPU and
memory cards.
Observe the ESD guidelines when fitting memory cards.
Only use the memory cards intended for the particular CPU.
Fitting Memory Cards in the CPU
Proceed as follows:
1. Remove the cover from the left side of the CPU by loosening the three screws.
2. Push the first memory card down through an angle of approximately 45o into
slot 1 (see Figure 7-1). Note the cutout at the front of the card (polarity reversal
protection).
3. Push the memory card down until the tabs in the slot slide into the
corresponding cutouts on the side of the card. Make sure that the metal flag at
the end of the card lies on the metal edge of the module.
4. If necessary, insert the second memory card in slot 2 in the same way (see
Figure 7-1).
5. Fit the cover on the upper left side of the CPU by securing it with three screws.
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Maintenance
6. If necessary, insert the second memory card in slot 2 in the same way.
7. Fit the cover on the upper left side of the CPU by securing it with three screws.
Slot 1
Slot 2
Figure 7-1
7-20
Fitting Memory Cards in the CPUs
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Maintenance
Note
The connectors to accept the memory cards are coded (see Figure 7-2). Do not
apply force when fitting the memory cards.
Lightly press the guide supports out to remove the memory cards
(see Figure 7-2).
Copper flag
Memory card
Cutout
Cutout
Guide support
Polarity
reversal
protection
Guide support
Slots 1 and 2
Figure 7-2
Memory Card
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7-21
Maintenance
7.12
Replacing Interface Submodules
Available Interface Submodules
Note
Only use interface submodules that are explicitly released for use in S7-400
devices.
Installing Interface Submodules
!
Warning
The modules can be damaged.
When inserting or removing interface submodules with power applied, the CPU
and interface submodules can be damaged (exception: using synchronization
submodules in an H system).
Never insert or remove the interface submodules while power is being supplied
(exception: synchronization submodules). Always switch off the power supply
before inserting or removing interface submodules.
!
7-22
Caution
Danger of damage to persons and property.
Interface submodules contain electronically-sensitive components that may be
damaged if they are touched.
The surface temperatures on the components can reach up to 70o C and there is a
risk of burning.
For this reason, you should always hold the interface submodules on the longest
sides of the front panel.
Observe the ESD guidelines when installing interface submodules.
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Maintenance
You can replace an interface submodule with another one without having to remove
the associated CPU from the rack. Follow the steps outlined below:
1. Switch the CPU to STOP.
2. Disconnect the CPU module from the network (unless it is a synchronization
submodule).
3. Loosen the screws of the sub-D-connector and remove all connectors.
4. Loosen the two captive slot-head screws which secure the front plate of the
interface submodule to the left frame of the card slot so that the screws can be
removed by 6 mm.
5. Carefully remove the interface submodule from the guide support of the card
slot (see figure 7-3). Hold the interface module on the long sides of the front
plate.
Guide
rails
Figure 7-3
Inserting an Interface Submodule in a CPU
Installing Interface Submodules
In order to install an interface submodule, proceed in reverse order. For further
information, see section 6.10 ”Installing Interface Submodules”.
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7-23
Maintenance
7-24
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8
Assembling the M7-400
This Chapter
The assembling of an M7-400 automation computer is largely identical to that of an
S7-400 programmable controller. Most of the instructions in the S7-400 chapters
can therefore be applied to the M7-400. Wherever details relate specifically to the
M7-400, these are pointed out to you at the beginning of each S7-400 chapter with
a cross-reference to the corresponding M7-400 section.
The headings of the second-digit sections of this chapter are largely the same as
those of the corresponding S7-400 chapter to guide you through the text.
Chapter Overview
Section
Description
Page
8.1
Mechanical Configuration
8-2
8.2
Addressing the M7-400 Modules
8-5
8.3
Electrical Configuration
8-6
8.4
Installing the M7-400
8-8
8.5
Connecting a Module Assembly
8-29
8.6
Assembling an MPI Subnet or PROFIBUS-DP Subnet
8-30
8.7
Preparing for Operation
8-32
8.8
Replacing Modules and Submodules/Cards
8-46
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8-1
Assembling the M7-400
8.1
Mechanical Configuration
Introduction
Explained in this section are the rules you must observe for arranging modules in
the M7-400 automation computer.
All other information which is important for the mechanical configuration applies
both to the S7-400 and the M7-400, and is described in Chapter 2.
Rules for the Arrangement of Modules
You must observe the following rules for the arrangement of modules in a rack:
• The power supply module must be inserted in slot 1 in all racks.
• The receive IM in the expansion rack must always be inserted on the extreme
right.
• A module assembly comprising CPU and expansion units must be configured in
a particular sequence. Shown in Table 8-1 are the possible configurations of a
module assembly with a specified sequence for the expansion units.
8-2
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Assembling the M7-400
Table 8-1
Sequence in the Module Subassembly
CPU
Slot
Slot
Slot
Slot n and n + 1 for Double-Width
CPUs
n+2
n+3
n+4
EXM 478
-
-
EXM 478
EXM 478
-
EXM 478
EXM 478
EXM 478
EXM 478
EXM 478
ATM 478
EXM 478
ATM 478
ATM 478
EXM 478
ATM 478
-
ATM 478
-
-
ATM 478
ATM 478
-
CPU 486-3, CPU 488-3
ATM 478
ATM 478
ATM 478
MSM 478
-
-
EXM 478
MSM 478
-
EXM 478
EXM 478
MSM 478
EXM 478
MSM 478
ATM 478
MSM 478
ATM 478
ATM 478
MSM 478
ATM 478
-
Note
Establish whether there are additional regulations applying to all modules not
described in this manual.
Table 8-2 shows which modules can be used in the different racks.
Table 8-2
Possible Applications of the M7-400 Modules
Racks
Modules
UR1, UR2
as
Central
Rack
Central Processing Units (CPUs)
Expansion Module (EXM)
*
AT Adapter Module (ATM)
*
Mass Storage Module (MSM)
*
*
UR1, UR2
as
Expansion
Rack
CR2
ER1, ER2
-
-
-
*
-
-
*
-
-
*
-
Can only be inserted in conjunction with the CPU.
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8-3
Assembling the M7-400
Dimensions of Modules in the M7-400
There are modules of 25 mm and 50 mm in width in the M7-400 system.
Table 8-3 contains a summary of dimensions of the modules used in the M7-400.
Table 8-3
Dimensions of Modules in the M7-400 System
Slots
Occupied
Module
Height
CPU 486-3 (incl. mode switch)
CPU 488-3 (incl. mode switch)
Mass Storage Module
MSM 478
AT Adapter Module
ATM 478
219 mm
(236.5 mm)
2
Expansion Module
EXM 478
Depth (Depth
when Fitted)
290 mm
210 mm
(227.5 mm)
1
230 mm*
(247.5 mm*)
* The mounting depth is governed by the installed AT card and its connector.
8-4
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Assembling the M7-400
8.2
Addressing the M7-400 Modules
Which Modules Can Be Reached Via a Start Address?
Out of the M7-400 modules, only the application modules can be addressed
directly via an address.
The EXM 478 expansion module, ATM 478 AT adapter module and MSM 478
mass storage module cannot be accessed via the S7-400 backplane bus.
Communication between these modules and the CPU is exclusively via the
ISA bus.
Addressing Application Modules
In contrast to the signal modules which have a default address at least in the
central rack, the application modules have no default address.
This means that you must configure the addresses for the application modules in
STEP 7. The procedure can be found in the manual Configuring Hardware and
Communication Connections with STEP 7 V 5.1.
Addressing Interface Submodules
Addresses of interface submodules, which are operated in a module assembly with
an application module, are only visible locally for the corresponding application
module. The CPU can only address the interface submodules that are installed in
the same rack or an expansion rack belonging to the CPU and that can be reached
via the ISA bus. The addresses of these interface submodules must be configured
via STEP 7. There are no default addresses.
Local access of the CPU to interface submodules allocated to an application
module is not directly possible.
However, the interface submodules can be accessed indirectly via programmed
communication between CPU and application module (see also System Software
for M7-300 and M7-400, Program Design Programming Manual).
Addressing for Operation in the Segmented Rack
If you assemble M7 modules in a CR2 rack with a divided I/O bus (segmented
rack), the same applies to addressing of the application modules and interface
submodules as in a non-segmented rack.
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8-5
Assembling the M7-400
8.3
Electrical Configuration
Introduction
This section contains the important information you need for the electrical
configuration of an M7-400. You will learn:
• How to calculate the current consumption of an M7-400, based on a
configuration example, and how to select the required power supply module.
• The additional facilities for expansion with PROFIBUS DP.
All other important information for the electrical configuration applies both to the
S7-400 and to the M7-400 modules and is described in Chapter 4.
Choosing the Power Supply Module
This section uses an example to show how you can estimate the current
consumption of a rack. You should make this estimate for each rack of your
M7-400 system, in order to select the appropriate power supply module for the
rack.
Current consumption and power dissipation of the individual modules can be found
in the relevant data sheets.
Calculation Example
The following modules are to be fitted in a CR with 18 slots:
• 1 CPU 488-3
• 1 interface submodule IF 962-VGA
• 1 interface submodule IF 962-COM
• 1 expansion module EXM 478
• 2 interface submodules IF 961-DIO
• 1 interface submodule IF 961-AIO
• 1 mass storage module MSM 478
• 1 AT adapter module ATM 478
• 1 short AT module (LAN)
• 3 analog input modules SM 431, AI 16 x 16 bits
• 3 digital input modules SM 421, DI 32 x 34 VDC
• 3 digital output modules SM 422, DO 32 x 34 VDC
• 1 send IM
8-6
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Assembling the M7-400
With the details from the individual data sheets, you can calculate Current
Consumption I in this rack as follows:
Table 8-4
Calculation Example for Power Supply Module
Module
Slots
Occupied
+5 VDC
(Max. Current Consumption Values)
I / Module
I Total
4500 mA
4500 mA
IF 962-VGA
600 mA
600 mA
IF 962-COM
100 mA
100 mA
200 mA
200 mA
IF 961-DIO
85 mA
170 mA
IF 961-AIO
85 mA
85 mA
CPU 488-3
EXM 478
2
1
MSM 478
1
1000 mA
1000 mA
ATM 478
1
120 mA
120 mA
1400 mA
1400 mA
Short AT Module (LAN)
SM 431; AI 16 x 16 bits
3
700 mA
2.100 mA
SM 421; DI 32 x 34 VDC
3
30 mA
90 mA
SM 422; DO 32 x 34 VDC
3
200 mA
600 mA
IM 460-0
1
110 mA
110 mA
Total
15
10075 mA
From the data in Table 8-4, you see that to cover the current consumption
calculated here, you must install a power supply module PS 407 20A (for a
120/230 VAC supply) or PS 405 20A (for a 24 VDC supply) in the rack.
Note
If you wish to connect an expansion rack to the central rack via a send IM with
current transfer, you must take into account the current consumption of this
expansion rack when choosing the power supply module.
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8-7
Assembling the M7-400
8.4
Installing the M7-400
Introduction
This section contains the important information you need for installing the M7-400.
You will learn:
• The sequence for installation from a checklist
• Which module accessories were already provided and which ones you can
order as options
• How to install the DRAM memory cards of the main memory in the CPU
• How to insert an interface submodule in a CPU or expansion module
• How to insert a short AT card in an AT adapter module
• How to fit expansion modules on a CPU
• How to install a module assembly in a rack
All other important information for installation applies both to S7-400 and M7-400
modules and is described in Chapter 5.
8-8
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Assembling the M7-400
8.4.1
Checklist for Installation
Checklist for Installation
This section explains the procedure in stages for installing the M7-400. You should
proceed as follows:
1. Install the rack and remove the dummy plates from the required slots
(Chapter 5).
2. Remove, if applicable, the cover of the module and refit it after wiring.
3. Check that the power supply on the rack is correctly rated (page 8-7).
4. Insert the power supply module in the first slot of the rack (Chapter 5).
5. Fit the required MEM 478 memory cards in the CPU (page 8-11).
6. Insert the interface submodules in the card slots of the CPU or EXM 478
expansion modules (page 8-13).
7. If you intend to use an ATM 478 AT adapter module, you must fit the short
AT card in the ATM 478 before the next step (page 8-15).
8. If applicable, assemble the CPU with expansion modules to create a complete
module assembly outside the rack (page 8-17).
9. Attach the preassembled module(s) or module assembly to the rack and screw
it on (page 8-24).
10.Insert the memory card, if applicable, in the memory card slot of the CPU
(page 8-28).
11. Fit and wire the required S7-400 modules (Chapters 5 and 6).
12.Mark the installed modules with a slot number (Chapter 5).
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8-9
Assembling the M7-400
8.4.2
Module Accessories
Introduction
The module packaging contains the basic accessories you need to install the
M7-400 modules in the rack. There are optional accessories for some modules.
Accessories
The accessories for the modules are listed and briefly explained in Table 8-5. A list
of spare parts for the SIMATIC M7-400 can be found in the Reference Manual,
Chapter 11.
Table 8-5
Accessories for Modules and Racks
Module
CPUs
Accessories Provided
(Basic Accessories)
Accessories not
Provided
Purpose of the Accessory
2 keys
-
The key serves to actuate the
mode switch for the CPU.
-
Memory card
For storing the user program with
power removed from the CPU.
-
MEM 478
Main memory size is defined by
inserting the MEM 478 (DRAM or
flash EPROM) memory cards.
Expansion
Modules
(EXM 478)
2 connecting clips
2 module covers
(fitted)
12 module covers To cover unused card slots; two
module covers are already fitted
with screws
All Expansion
Modules
2 connecting clips
-
8-10
per expansion unit.
To secure the modules in a
module assembly, top and
bottom.
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Assembling the M7-400
8.4.3
Fitting Memory Cards in the CPU
Introduction
For the CPUs of the M7-400 automation computer, the MEM 478 memory cards
are supplied separately. Before the module with its expansion modules is inserted
in the rack, the memory cards must be fitted.
Note
With a CPU, a DRAM memory card of the same size must be inserted at Slot 1
and Slot 2.
Only use the memory cards intended for the particular CPU.
!
Warning
The modules can be damaged.
Failure to observe ESD guidelines can result in damage to both the CPU and
memory cards.
Observe the ESD guidelines when fitting memory cards.
Fitting Memory Cards in the CPU
To install a memory submodule in a slot on the central rack, proceed as follows:
1. Remove the cover from the upper left side of the CPU by loosening the three
screws.
2. Insert the first DRAM memory card of the required size at an angle of about 45°
into Slot 1 as far as it will go (see Figure 8-1).
3. Press the protruding side of the DRAM memory card toward the PCB until the
memory card engages with the two lateral retaining springs (see Figure 8-1).
4. Insert the second DRAM memory card of the same size in the same way into
Slot 2 (see Figure 8-1).
5. Fit the cover on the upper left side of the CPU by securing it with three screws.
Note
The connectors to accept the memory cards are coded (see Figure 8-2).
Do not apply force when fitting the memory cards.
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8-11
Assembling the M7-400
3
4
4
2
Slot 1
Slot 2
Figure 8-1
Fitting Memory Cards in the CPUs
3.3 V DRAM memory card
(for main memory)
Recess
Slots 1 and 2
Figure 8-2
8-12
3.3 V Memory Card
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Assembling the M7-400
8.4.4
Installing Interface Submodules
Installing Interface Submodules
The following modules have card slots to accept interface submodules:
• CPU 486-3, two card slots
• CPU 488-3, two card slots
• EXM 478 expansion module, three card slots.
!
!
Warning
The modules can be damaged.
When inserting or removing interface submodules with power applied, the CPU
and expansion modules as well as the interface submodules can be damaged.
Never insert or remove interface submodules with power applied. Always switch
off the power supply before inserting or removing interface submodules.
Caution
Damage to persons and property may occur.
Interface submodules contain electonically-sensitve components that may be
damaged if they are touched.
The surface temperatures on the components can reach up to 70o C and there is a
risk of burning.
For this reason, you should always hold the interface submodules on the longest
sides of the front panel.
Observe the ESD guidelines when installing the interface submodules.
To fit an interface submodule in a card slot of the CPU or expansion module, follow
the steps outlined below:
1. Hold the interface submodule on the long sides of the front plate.
2. Insert the PCB end of the interface submodule in the lower and upper guides of
the card slot, as shown in Figure 8-3.
3. Slowly push the interface submodule into the slot until the front plate rests on
the frame of the card slot.
4. Secure the front plate with the two fitted, captive M2.5 x 10 slot-head screws on
the left frame of the card slot.
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8-13
Assembling the M7-400
Guides
Frame of card slot with
mounting hole
EXM 478
Figure 8-3
Inserting an Interface Submodule in an Expansion Module
Covering Unused Submodule Slots
On delivery, only the upper submodule slot is open in the central and expansion
racks. All other card slots are covered. The cover is secured to the frame of the
card slot with screws.
Loosen the screws and remove the cover to insert more than one interface
submodule in an expansion module.
8-14
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Assembling the M7-400
8.4.5
Fitting the Short AT Card
Installing the AT Card
A short AT card can be used with the AT adapter module ATM 478. Only short
AT cards with a slot in the mounting bracket can be fitted (see also the chapter on
M7-400 expansion in the Reference Manual).
To assemble an AT card in an AT adapter module ATM 478, proceed as follows:
!
Warning
The modules can be damaged.
When inserting or removing the AT card with power applied and without observing
the ESD guidelines, the CPU, AT adapter modules and AT card can be damaged.
Never insert or remove the AT card with power applied. Always switch off the
power supply before inserting or removing the AT card. Observe the
ESD guidelines.
1. If the ATM 478 AT adapter module is installed in the rack, you must remove the
module assembly and remove the ATM 478 AT adapter module from this
assembly.
2. Remove the cover from the upper left side of the ATM 478 (see Figure 8-4).
3. Remove the mounting bracket for the AT module from the upper front of the
ATM 478 (see Figure 8-4).
4. Insert the AT card into the slot from the front (see Figure 8-4).
5. Press the AT card through the side opening and at the front downward into the
ISA bus connector until it engages. Ensure that the support plate of the AT card
slides under the metal spring on the front of the ATM 478 (see Figure 8-4).
6. Fit the mounting bracket over the angled part of the support plate of the AT card
and screw it onto the support plate of the AT card and to the ATM 478.
7. Fit the cover on the upper left side of the ATM 478.
S7-400 and M7-400 Programmable Controllers Hardware and Installation
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8-15
Assembling the M7-400
5
6
5
2
7
3
5
4
Figure 8-4
8-16
Fitting an AT Card in the ATM 478 AT Adapter Module
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Assembling the M7-400
8.4.6
Assembling Expansion Modules on a Central Rack
Introduction
Before installing the M7-400 in the rack, you must preassemble the programmable
modules with all the required expansion modules.
This section contains the information you need to create a module assembly using
a central rack with expansion modules such as the EXM 478 expansion module,
ATM 478 AT adapter module, and MSM 478 mass storage module.
Order of Assembly
Proceed in the following order when assembling:
1. Remove the connector and socket covers from modules.
2. Remove the connecting clips fitted at the top and bottom of the module.
3. Remove module covers.
4. Position the modules on a level surface and plug them into each other.
5. Use connecting clips top and bottom to interconnect the modules.
The individual stages for installing an expansion assembly are explained below.
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8-17
Assembling the M7-400
Removing the Connector and Socket Covers
On the right-hand side of a central rack, there is a 120-pin socket for connecting
expansion racks to the ISA bus (see Figure 8-5). This socket is protected by a
screw-mounted metal cover.
The EXM 478, ATM 478, and MSM 478 expansion modules contain
• The matching plug on the left side,
• An expansion socket on the right side so that other expansion modules can be
plugged in.
Remove the transport protection from the expansion plugs and unscrew the metal
covers from the module expansion sockets which are to accept other expansion
modules.
e. g. CPU 488-3
e. g. EXM 478
Expansion plug
Expansion
socket
Figure 8-5
8-18
Locations of the Expansion Socket and Plug
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Assembling the M7-400
Removing the Connecting Clips
Connecting clips are fitted at the top and bottom of expansion modules. Pull these
off upward and downward respectively.
Figure 8-6
EXM 478 Expansion Module Fitted with Connecting Clips
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8-19
Assembling the M7-400
Removing the Cover
For modules with a cover (for example, CPUs), remove these before fitting the
modules together.
Proceed as follows:
1. Press the locking lever down (1).
2. Swing the cover forward and off (2).
Figure 8-7 shows how to remove the cover.
(1)
(2)
Figure 8-7
8-20
Removing the Cover
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Assembling the M7-400
Interconnecting Modules
Take the CPU and first expansion module, position them on a level surface and
press them carefully together so that all pins of the expansion module plug are
precisely inserted into the CPU socket.
Then plug the other modules successively into the assembled group (see
Figure 8-8).
e. g. CPU 488-3
e. g. EXM 478
e. g. MSM 478
e. g. ATM 478
1.
2.
3.
Level surface
Figure 8-8
Interconnecting a CPU and Expansion Modules
Note
Note that there are rules on the number of connectable expansion modules and on
the sequence of the modules following the CPU. These rules are listed in the
Reference Manual under the chapter on M7-400 expansion.
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8-21
Assembling the M7-400
This completes all the expansion on the ISA bus of the CPU (see Figure 8-9).
Level surface
Figure 8-9
!
Module Assembly Comprising CPU and Expansion Modules
Warning
The connector pins can be damaged.
If the modules are not exactly lined up for interconnecting, the pins can be
damaged.
Line up the modules precisely when interconnecting.
Latching Modules with Connecting Terminals
Latch the interconnected modules with the two enclosed connecting terminals
(Figure 8-10), in order to protect them against being shifted or becoming skewed.
To do this, proceed as follows:
1. As shown in Figure 8-11, slide a connecting clip from above between the two
modules to be secured until the bent clip ends touch the housing cover of the
modules.
2. Align the connecting clips so that each bent clip end is situated over a grid hole
of the module housing cover. Here, the first bent terminal end should be over
the fifth notch space, counting from the back of the modules.
8-22
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Assembling the M7-400
3. Press the connecting clip on its two 90° ends downward until it engages.
Figure 8-11 shows a connecting clip in its final position.
4. Carry out steps 1 to 3 similarly on the bottom of the modules to be secured.
Clip end bent
90°
Bent clip end
Figure 8-10
Connecting Clip
Fifth grid hole
Figure 8-11
Securing the Modules with Connecting Clips (Schematic Diagram)
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8-23
Assembling the M7-400
8.4.7
Installing a Module Assembly in the Rack
Introduction
The installation of an M7-400 CPU together with modules from the S7-400 series in
a rack is carried out as described in Chapter 5. If the M7-400 central rack has
expansion racks, this must be preassembled with its expansion racks into a module
group (see also Section 8.4.6 ”Assembling Expansion Modules on a Central
Rack”). The installation of such a module group in the rack is the subject of this
section.
Tool
The tool needed to install the module assembly is a cylindrical screwdriver with
3.5 mm blade width.
Installation Sequence
To install modules in a rack, follow the steps outlined below:
1. Remove the dummy plates from the slots of the rack at which you wish to insert
the module assembly. Grasp the dummy plate at the points marked and pull it
forward and off.
2. Disconnect the power supply module from the supply.
3. Attach the module assembly and swing it downward (see Figure 8-12).
4. Screw on the modules of the module assembly top and bottom with a torque of
0.8 to 1.1 Nm (see Figure 8-13).
5. Fit the remaining modules.
6. Insert the key of the CPU mode switch when you have fitted all modules (see
Figure 8-14).
7. Refit the module covers after wiring.
Described in the following section are the most important stages in installing a
module assembly.
Removal of the modules is described in Section 8.8 from page 8-46 onward.
8-24
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Assembling the M7-400
Attaching the Module Assembly
Attach the module assembly (1) and swing it downwards (2). Figure 8-12 shows
how to attach a module assembly onto a rack and swing it into position.
Note
Do not push the module assembly down whilst swinging it into position.
1
2
Figure 8-12
Attaching a Module Assembly Comprising CPU and Expansion Modules and Swinging it into
Position
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8-25
Assembling the M7-400
Screwing On the Modules
Figure 8-13 shows how to screw on the modules.
Tightening torque
0.8 to 1.1 Nm
Figure 8-13
8-26
Screwing the Modules On
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Assembling the M7-400
Inserting the Mode Selector Switch
Figure 8-14 shows how to insert the key in the CPU at the STOP position of the
switch. You can remove the key at the STOP or RUN settings.
Figure 8-14
Inserting the Key in the CPU
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8-27
Assembling the M7-400
8.4.8
Inserting/Removing a Memory Card
Purpose of the Memory Card
You can do the following with a memory card:
• Store the operating system, user programs, and data (similarly to using a floppy
disk),
• Transport the programs and data stored on the memory card,
• Retain the programs and data, even during Power Off.
Inserting/Removing the Memory Card
A memory card should only be inserted or removed when no access to the memory
card is taking place, meaning the “SD” indicator on the CPU must be OFF. Figure
8-15 shows how to insert a memory card in a CPU.
!
Warning
Data can be lost by inserting and removing the memory card.
If a write operation onto the memory card is taking place during insertion or
removal of the card, data consistency cannot be guaranteed.
If you are not sure whether write operations onto the memory card are taking
place, only change it with power removed.
Figure 8-15
8-28
Inserting a Memory Card in a CPU
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Assembling the M7-400
8.5
Connecting a Module Assembly
Introduction
The individual modules and interface submodules of a module assembly can be
connected via commercially-available cables and connectors.
Requirements
The connector housings and cables must meet the following requirements:
• Connector housing
The height of the connector housing should not be more than 43 mm, the width
up to 19 mm. It must have a 45° side outlet for the cable. These requirements
are met by the connector housings of cables and lines listed in the chapter on
spare parts and accessories in the Reference Manual.
• Cables
You should only use cables that are shielded using a braided screen. The shield
must be connected to the housing ground with low resistance.
Components to be Connected
A module assembly can comprise the following components to be connected:
• CPU with MPI and interface submodules
• EXM expansion module with interface submodules
• ATM AT adapter module with short AT card
• Mass storage module with parallel interface
Connecting the CPU
Connecting the MPI for particular applications is explained in Chapter 5,
“Networking.”
Connecting Interface Submodules (IFs)
The interface submodules are equipped with subminiature D female or male
connectors. To connect devices to the interface submodules, you must fabricate
cables with the appropriate mating connectors or obtain preassembled,
commercially available cables.
The pin assignments of the subminiature D connectors can be found in the
description of the relevant interface submodule in the chapter on interface
submodules of the Reference Manual.
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Assembling the M7-400
Connecting Mass Storage Modules (MSM)
Pin assignments of the parallel interface of the MSM 478 mass storage module can
be found in the chapter on M7-400 expansion of the Reference Manual.
Connecting the Short AT Card
The interface pin assignments of short AT cards which you intend to use can be
found in the corresponding documentation.
8.6
Assembling an MPI Subnet or PROFIBUS-DP Subnet
2 Subnets
With the M7-400, you can
• Assemble an MPI subnet via the MPI;
• Assemble a PROFIBUS-DP subnet with an M7-400 master.
Chapter 7 explains how to assemble one of these subnets and what you must take
into account.
Note Relating to the M7-400
To be able to connect an M7-400 to a PROFIBUS-DP subnet as the master, it is
necessary to plug an IF 964-DP interface submodule either directly into the
CPU 486-3/CPU 488-3, or into an EXM 478 expansion module belonging to the
CPU.
Example of Operation in 2 Subnets
Shown in Figure 8-16 is an example of a configuration with M7-400 CPU,
integrated in an MPI subnet, and simultaneously acting as DP master in a
PROFIBUS-DP subnet.
8-30
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Assembling the M7-400
Programming
device*
S5-95U
M7-400
S5-95U
M7-400
S5-95U
M7-400 with
CPU as DP
master
M7-400
ET 200M
ET 200M
OP 25
M7-400
RS 485
repeater
ET 200B
ET 200B
ET 200B
ET 200B
OP 25
MPI subnet
PROFIBUS-DP
subnet
* Only connected via spur line for startup/maintenance
Terminating resistance switched on
Figure 8-16
Example of a Configuration with the CPU in an MPI Subnet and PROFIBUS-DP Subnet
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8-31
Assembling the M7-400
8.7
Preparing for Operation
Contents
Listed briefly in this section is information on the steps required for preparing an
M7-400 for operation:
You will learn the following:
• A checklist with the order in which preparations must be made
• How to connect operator panels and I/O devices
• How to connect a programming device via the COM interface
• How to connect a programming device via the MPI to a single M7-400, to two or
more nodes in a network or to ungrounded nodes
• How to check the status and error display by switching on for the first time
All other information which is important for preparing for operation applies (except
for the reset) both to the S7-400 and M7-400 modules and is described in
Chapter 8.
Checklist for Preparing for Operation:
You should proceed as follows:
1. Ensure that the power supply is switched off.
2. Insert the backup batteries in the power supply module (see Chapter 8).
3. Set the key of the mode switch to STOP.
4. Connect the required operator panels and I/O devices (see page 8-33).
5. Switch on the I/O devices.
6. Switch on the power supply of the rack.
7. Set the key of the mode switch to RUN.
8. Check that the status and error indicators are correct (see page 8-45).
Steps for Complete Commissioning
Carry out the following steps in order to completely commission an M7-400 device:
1. Configure your M7-400 with the S7 software.
2. Transfer the operating system; if applicable, execute BIOS setup.
3. Load the user software from the programming device/PC to the CPU, test it, and
start it.
A description of the BIOS setup for your CPU can be found in the chapter on CPUs
for the M7-400 in the Reference Manual. For other activities, refer to the M7-SYS
User Manual.
8-32
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Assembling the M7-400
8.7.1
Connecting the Operator Panels and I/O Devices
Introduction
The operator panels and I/O devices which can be connected to your M7-400
depend on its configuration.
Extensive information on all connection options of the M7-400 can be found in the
appropriate sections of the technical data.
To prepare for operation, you need either a PC/programming device or the M7-400
configuration with monitor, keyboard, expansion module, and mass storage module
as well as interface submodules.
For reasons of noise immunity of the entire system, we recommend that you use
the standard connecting cables available from Siemens for connecting the
I/O devices.
Note
If the monitor cable and connecting cables between the CPU and the keyboard or
printer, etc. are laid parallel to high-voltage lines, screen interference and
interruptions in the M7-400 complete system may occur.
You should not lay the monitor cable and connecting cables between the M7-400
and the keyboard or printer, etc. parallel to high-voltage lines.
If necessary, install a separate cable rack with a minimum clearance of 50 cm from
the power cables.
Connecting the VGA Monitor Locally
To be able to connect a VGA monitor locally to the central rack, you must insert an
interface submodule IF 962-VGA in the submodule slot of the central rack or in one
of the corresponding expansion racks. Connect the monitor to the 15-pin
high-density subminiature D female connector of the IF 962-VGA interface
submodule (up to 2.5 m).
Connecting the Keyboard
Connect the keyboard to the 6-pin mini-round socket of the interface submodule
IF 962-VGA.
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Assembling the M7-400
Notes for Setting Up Monitors
Please observe the following notes when setting up monitors:
• Ensure that the clearance between two monitors in asynchronous operation is
at least 15 cm, otherwise video interference may occur.
Exception: Monitors with a mu-metal shield.
• Provide sufficient space between the monitor and extraneous magnetic sources.
• Do not set up the monitors in steel shelving or on steel benches. Magnetization
of the surrounding sheet steel can result in false colors or video shifting.
• Avoid setting up monitors in the vicinity of transformers, radio transmitters,
magnets, and power cables.
• The effects of extraneous magnetic fields can be attenuated by using a
mu-metal shield.
Special Conditions when Using Office Monitors
Additionally, you should observe the following notes when setting up office
monitors:
• Office monitors with an internal metallized plastic housing should not be used in
an environment subject to electromagnetic interference, because the internal
metal surface cannot subsequently be connected to the external ground bus.
The required isolation of the electronic ground from the housing ground of the
monitors - essential for an environment subject to electromagnetic interference is not possible with most office monitors.
• You can only use such monitors in conjunction with conventional VGA cables.
For this reason, only restricted connection to the M7-400 is possible, because
you can only cover short distances with these cables.
Connecting Printers
You can connect printers with a serial or parallel port.
• A printer with a parallel port should be connected with the appropriate
connecting cable to the IF 962-LPT interface submodule.
• A printer with a serial port should be connected with the appropriate connecting
cable to the IF 962-COM interface submodule.
We recommend you use a Siemens printer.
Note
Only a connecting cable with the shield grounded at both ends should be used
between an M7-400 component and a printer.
8-34
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Assembling the M7-400
Connecting a Mouse
Connect the mouse to the IF 962-COM interface submodule.
Maximum Cable Length
The following table shows you where the maximum cable lengths of the connecting
cables of the individual devices are. A requirement is a hardware configuration with
interference immunity.
Table 8-6
Maximum Cable Lengths for Operator Panels and I/O Devices
Device
Maximum Length
Keyboard
• via IF 962-VGA
2.5 m
Monitor
• via IF 962-VGA
2.5 m
Printer
• via IF 962-LPT parallel port
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3.0 m
8-35
Assembling the M7-400
8.7.2
Connecting a Programming Device (PG) to the COM Interface
Introduction
To operate your M7-400 without monitor and keyboard, you need a programming
device or PC for initial settings in the BIOS Setup.
This section explains how to connect a programming device via the COM1
interface of an IF 962-COM interface submodule to your M7-400. However, it is
also possible to connect a programming device via the MPI of the M7-400 CPU. In
this case, please refer to Sections 8.7.3 to 8.7.5.
Connecting the M7-400 to a Programming Device
Connect the 9-pin subminiature D connector of the COM1 interface of the interface
submodule fitted in your CPU to the connector of a free COM interface of your
programming device. The following types of connection are possible:
• Connection without using control cables
• Connection using control cables
Connecting with Control Cables
When the interface control cables are used for data traffic via the COM1 interface,
you need a null modem cable.
This may be necessary when, for example, you enter a console redirection in the
AUTOEXEC.BAT of your CPU:
:
CTTY COM1
:
If the free COM interface of your programming device has a 9-pin subminiature
D connector, you can use Table 8-7 below for the pin assignments of the null
modem cable.
This cable can also be obtained preassembled (see V.24 cables in the chapter on
spare parts and accessories of the Reference Manual).
Table 8-7
8-36
Null Modem Cable for Connecting a CPU via IF to the COM Interface of a
Programming Device with 9-pin Sub. D Male Connector
Signal
Pin
E1 / GND
U
M5 / DCD
Connection
Pin
Signal
connected to
U
E1 / GND
1
-
1
M5 / DCD
D2 / RxD
2
connected to
3
D1 / TxD
D1 / TxD
3
connected to
2
D2 / RxD
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Assembling the M7-400
Table 8-7
Null Modem Cable for Connecting a CPU via IF to the COM Interface of a
Programming Device with 9-pin Sub. D Male Connector, continued
Signal
Pin
S1 / DTR
4
E2 / GND
Pin
Signal
connected to
6
M1 / DSR
5
connected to
5
E2 / GND
M1 / DSR
6
connected to
4
S1 / DTR
S2 / RTS
7
connected to
8
M2 / CTS
M2 / CTS
8
connected to
7
S2 / RTS
M3 / RI
9
-
9
M3 / RI
9-pin sub.
D female conn.
(COM1 for IF)
Connection
Pin U = housing (shield)
Length: 10 m max.
9-pin sub.
D female conn.
(COMx for
programming
device)
If the free COM interface of your programming device has a 25-pin subminiature
D connector, you can use Table 8-8 below for the pin assignments of the null
modem cable.
Table 8-8
Null Modem Cable for Connecting a CPU via IF to the COM Interface of a
Programming Device with 25-pin Sub. D Male Connector
Signal
Pin
Connection
Pin
Signal
E1 / GND
U
connected to
U
E1 / GND
M5 / DCD
1
-
8
M5 / DCD
D2 / RxD
2
connected to
2
D2 / RxD
D1 / TxD
3
connected to
3
D1 / TxD
S1 / DTR
4
connected to
6
M1 / DSR
E2 / GND
5
connected to
7
E2 / GND
M1 / DSR
6
connected to
20
S1 / DTR
S2 / RTS
7
connected to
5
M5 / CTS
M2 / CTS
8
connected to
4
S2 / RTS
M3 / RI
9
-
22
M3 / RI
9-pin sub.
D female conn.
(COM1 for IF)
Pin U = housing (shield)
Length: 10 m max.
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25-pin sub.
D male conn.
(COMx for
programming
device)
8-37
Assembling the M7-400
Connecting without Control Cables
If the data traffic via the COM interface is to be controlled exclusively via the data
lines, a connecting cable as described below is sufficient for connecting your CPU
to a programming device.
If the free COM interface of your programming device has a 9-pin subminiature
D male connector, you can use Table 8-9 below for the pin assignments of the
connecting cable.
Table 8-9
Pin Assignments of the Cable for Connecting a CPU via IF to the COM
Interface of a Programming Device with 9-pin Sub. D Male Connector
Pin
Signal
Connection
Pin
Signal
E1 / GND
U
U
E1 / GND
D2 / RxD
2
2
D2 / RxD
D1 / TxD
3
3
D1 / TxD
E2 / GND
5
5
E2 / GND
9-pin sub.
D female conn.
Pin U = housing (shield)
(COM1 for IF)
Length: 10 m max.
9-pin sub.
D female conn.
(COMx for
programming
device)
If the free COM interface of your programming device has a 25-pin subminiature
D female connector, you can use Table 8-10 below for the pin assignments of the
connecting cable.
Table 8-10 Pin Assignments of the Cable for Connecting a CPU via IF to the COM
Interface of a Programming Device with 25-pin Sub. D Female Connector
Signal
Pin
Pin
Signal
E1 / GND
U
U
E1 / GND
D2 / RxD
2
2
D1 / TxD
D1 / TxD
3
3
D2 / RxD
E2 / GND
5
7
E2 / GND
9-pin sub.
D female conn.
(COM1 for IF)
8-38
Connection
Pin U = housing (shield)
Length: 10 m max.
25-pin sub.
D male conn.
(COMx for PG)
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Assembling the M7-400
8.7.3
Connecting a Programming Device (PG) to the M7-400
Connecting a Programming Device (PG) to the M7-400
You can connect the programming device via a preassembled programming device
cable to the MPI of the CPU.
Alternatively, you can fabricate the connecting cable with the PROFIBUS-DP bus
cable and bus connectors (see Chapter 5).
Shown in Figure 8-17 are the components for connecting a programming device to
the M7-400.
M7-400
PG cable
Programming
device
Figure 8-17
Connecting a Programming Device to the M7-400
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8-39
Assembling the M7-400
8.7.4
Connecting a Programming Device (PG) to Two or More Nodes
Two Arrangements
To connect a programming device to two or more nodes, you must distinguish
between two arrangements:
• A programming device permanently installed in the MPI subnet
• A programming device connected for startup and maintenance
Depending on this, you connect the programming device to the other nodes as
follows (see also Chapter 5).
Arrangement
8-40
Connection
Programming device permanently installed
in the network
Directly incorporated in the MPI subnet
Programming device connected for startup
or maintenance
Programming device connected via spur
cable to a node
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Assembling the M7-400
Permanently-Installed Programming Device in the MPI Subnet
The programming device permanently installed in the MPI subnet should be
connected directly via bus connectors to the other nodes of the MPI subnet,
according to the rules in Chapter 5.
Figure 8-18 shows an M7-400 subnet with two M7-400s. They are interconnected
via bus connectors.
M7-400
Programming
device
PROFIBUS-DP bus cable
M7-400
PROFIBUS-DP bus cable
Figure 8-18
Connecting a Programming Device to Two or More M7-400s
Connecting a Programming Device for Servicing
If no stationary programming device is present, we recommend the following:
To connect a programming device to an MPI subnet with “unknown” node
addresses for servicing, set the following address on the service programming
device:
• MPI address: 0
• Highest MPI address: 126.
Then determine, via M7 Configuration, the highest MPI address in the MPI subnet
and adjust the highest MPI address in the programming device to that of the
MPI subnet.
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8-41
Assembling the M7-400
Programming Device for Commissioning or Servicing
For commissioning or servicing purposes, connect the programming device via a
spur line to a node on the MPI subnet. The bus connector of this node must have a
programming device socket for this (see also Chapter 5).
Figure 8-19 shows a network with two M7-400s, to which a programming device is
connected.
Programmin
g device
M7-400
PG cable = spur line
M7-400
PROFIBUS-DP bus cable
Figure 8-19
8-42
Connecting a Programming Device to an M7-400 Subnet
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Assembling the M7-400
8.7.5
Connecting a Programming Device (PG) to Ungrounded Nodes
of an MPI Subnet
Connecting a Programming Device to Ungrounded Nodes
If you configure the nodes of an MPI subnet or an M7-400 as ungrounded devices
(see Chapter 4), you should only connect an ungrounded programming device to
the MPI subnet or M7-400 device.
Connecting a Grounded Programming Device to the MPI
You want to operate the nodes as ungrounded devices (see Chapter 4). However,
the MPI at the programming device is grounded. To be able to operate the nodes
without grounding, you must connect an RS 485 repeater between the nodes and
programming device. The ungrounded nodes must be connected to bus segment 2
if the programming device is connected to bus segment 1 (terminals A1 B1) or the
programming device/OP interface (see Reference Manual, Chapter 10).
Figure 8-20 shows the RS 485 repeater as an interface between a grounded and
an ungrounded node of an MPI subnet.
Bus Segment 1
Grounded signals
M7-400
Programming
device
Bus Segment 2
Grounded signals
Figure 8-20
Ungrounded Operation of the M7-400 Network
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8-43
Assembling the M7-400
8.7.6
Starting Up a PROFIBUS-DP Subnet
This Chapter
This section contains the procedures for starting up a PROFIBUS-DP subnet with a
CPU 486-3 or CPU 488-3 as the DP master.
Requirements
Before you can start up the PROFIBUS-DP subnet, the following requirements
must be met:
• The PROFIBUS-DP subnet has been set up (see Chapter 7).
• The M7 system software is installed (see M7-SYS User Manual).
• The central rack is fitted with an interface submodule IF 964-DP. The interface
submodule is connected to the PROFIBUS-DP subnet.
• With STEP 7, you have configured the PROFIBUS-DP subnet and assigned a
PROFIBUS address and the address area to all nodes (see the manual
Configuring Hardware and Communication Connections STEP 7 V 5.2). Note
that for some DP slaves, address switches must also be set (see the reference
manuals for the particular DP slaves).
Starting Up
To start up the PROFIBUS-DP subnet, follow the steps outlined below:
1. Use the programming device to load the configuration of the PROFIBUS-DP
subnet (preset configuration) created with STEP 7 into the CPU. This procedure
is described in the manual Configuring Hardware and Communication
Connections STEP 7 V 5.2.
2. Switch on all DP slaves.
3. Switch the CPU from STOP to RUN.
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Assembling the M7-400
Behavior of the CPU During Startup
During startup, the CPU compares the preset and actual configurations. You set
the duration of the test with STEP 7 in the “Startup” parameter block with the
“module time limits” parameter.
If the preset configuration = actual configuration, the CPU goes to RUN.
If the preset configuration actual configuration, the reaction of the CPU depends
on the setting of the parameter for “Startup if preset configuration actual
configuration”:
Starting if Preset Actual Config. = No
Starting if Preset
Actual
Config. = Yes (Default)
CPU goes into RUN
CPU remains in STOP.
In this case, check whether all slaves are switched on or
display the content of the diagnostic buffer (see
Configuring Hardware and Communication Connections
with STEP 7 V 5.2).
To set the parameters in the “Startup” parameter block, see the M7-SYS User
Manual, the Configuring Hardware and Communication Connections with
STEP 7 V 5.2 manual, and the online help of STEP 7.
8.7.7
Checking the Status and Error Indicators
Switching On an M7-400 for the First Time
When the supply voltage is switched on, all status and error indicators of the CPU
of your M7-400 light up briefly. If the mode switch is set to STOP, the STOP
status/error indicator lights up after switching on. Otherwise the module boots up.
In the event of a fault, the INTF indicator lights up.
If this is not the case with your modules, please consult your Siemens contact at a
maintenance and repair center or call the SIMATIC hotline.
This completes preparations for operation as covered in this manual.
The remaining stages, such as installing the operating system and the user
program, can be found in the “M7-SYS” User Manual.
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8-45
Assembling the M7-400
8.8
Replacing Modules and Submodules/Cards
Contents
This section explains
• How to replace interface submodules,
• How to replace CPUs or expansion modules of a module assembly,
• How to replace memory cards,
• How to replace a short AT card.
All other important information for replacing modules applies both to the S7-400
and the M7-400 modules and is described in Chapter 7.
Tool
To replace modules and submodules/cards, you need a cylindrical screwdriver with
3.5 mm blade width.
8-46
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Assembling the M7-400
8.8.1
Replacing an Interface Module
Removing an Interface Submodule
You can replace an interface submodule without needing to remove the
corresponding CPU or expansion module from the rack. Proceed according to the
following sequence:
!
Warning
The modules can be damaged.
When inserting or removing interface submodules with power applied, the CPU
and expansion modules as well as the interface submodules can be damaged.
Never insert or remove interface submodules with power applied. Before inserting
or removing interface submodules, always disconnect the power supply from the
AC supply. Observe the ESD guidelines.
!
Caution
There is a risk of personal injury and damage to property.
Interface modules contain electrostatically sensitive components that may be irreparably damaged if touched.
The surface temperature of the components can reach as high as 70° C, which
means there is a risk of you burning yourself. You should therefore always hold the
interface modules by the long sides of the front plate.
Always adhere to the guidelines for electrostatically sensitive components (ESD)
when installing the interface modules.
1. Switch the CPU and all function modules in your M7-400 to STOP with the
mode switch.
2. Switch off the load voltage for the modules.
3. Disconnect the automation computer from the supply.
4. Loosen the screws of the subminiature D connectors and disconnect all
connectors.
5. Loosen the two captive slot-head screws which secure the front plate of the
interface submodule to the left frame of the card slot, until the front plate can be
pulled out about 6 mm.
6. Carefully withdraw the interface submodule from the guide of the card slot (see
Figure 8-21).
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8-47
Assembling the M7-400
!
Warning
The interface submodules can be damaged.
If you replace two or more interface submodules simultaneously and interchange
their front connectors, the interface submodules can be damaged.
Mark the front connectors so that they are assigned to the corresponding interface
submodules.
Guides
Frame of card slot with
mounting hole
EXM 478
Figure 8-21
Removing an Interface Submodule from the Card Slot of an Expansion
Module
Fitting an Interface Submodule
Fit the new interface submodule in the reverse order. Further information can be
found in Section 8.4.4, “Installing Interface Submodules” from page 8-13.
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Assembling the M7-400
8.8.2
Replacing the CPU or Expansion Modules of a Module
Assembly
Removing a Module
To remove a module from a module assembly, follow the steps outlined below:
1. Switch the CPU and all function modules in your M7-400 to STOP with the
mode switch.
2. Switch off the load voltage for the modules.
3. Disconnect the automation computer from the supply.
4. Remove the covers from the modules, if applicable. Figure 8-22 shows how to
remove the cover.
– Press the locking lever down (1).
– Swing the cover forward and off (2).
(1)
(2)
Figure 8-22
Removing the Cover
5. Disconnect the interface connections at the module assembly, including all
interface submodules.
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Assembling the M7-400
6. Loosen the mounting screws of all modules in the module assembly.
Figure 8-23 shows the locations of mounting screws on a module.
Figure 8-23
Unscrewing Modules
7. Ensure that all the mounting screws of the module assembly are undone.
8. Swing the module assembly forward out of the bus connectors and lift it upward
and out of the guides of the rack (Figure 8-24).
8-50
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2
1
Figure 8-24
Swinging a Module Assembly Out and Lifting it Up and Out
9. Place the module assembly on a level surface (Figure 8-25).
Level surface
Figure 8-25
Module Assembly Comprising CPU and Expansion Modules
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Assembling the M7-400
10.Remove the connecting clips, top and bottom, from the module to be replaced
(as shown in Figure 8-26).
Figure 8-26
Removing the Connecting Clips from the Module to be Replaced
11. Carefully withdraw the adjacent modules from the module to be replaced. The
modules to be separated should be held above the bus connector and pulled
apart at the side walls of the modules, so that the ISA bus connection is
disconnected (Figure 8-27).
!
Warning
The connector pins can be damaged.
If you misalign the modules when pulling them apart, the connector pins may be
damaged.
Pull the modules apart carefully without misaligning them.
8-52
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1.
2.
Level surface
Figure 8-27
Separating the Modules, for Example When the Mass Storage Module is to be Replaced
Fitting a Module
Fit the new module in the reverse order. Further details can be found in
Section 8.4.6, “Fitting Expansion Modules to a CPU” and Section 8.4.7, “Installing a
Module Assembly in the Rack” on pages 8-17 and 8-24.
Reactions of the M7-400 After Replacing a Module
After replacing a module, the CPU goes to the RUN state if there are no errors. If
the CPU remains in the STOP state, you can use STEP 7 to display the cause of
the error (see manual Configuring Hardware and Communication Connections with
STEP 7 V 5.1). If the cause of the error is not displayed, check the BIOS Setup or
reinstall the system software if necessary.
Note
If a data medium such as the on-board silicon disk, memory card, or hard disk has
been replaced with the module replacement, it may be necessary to reinstall the
operating system, user programs, etc. (see the corresponding sections in the
M7-SYS User Manual).
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Assembling the M7-400
8.8.3
Replacing Memory Cards in a CPU
Introduction
To be able to replace MEM 478 memory cards in a CPU, you must remove the
module assembly from the rack (see Section 8.8.2, page 8-49). It is not necessary
to disassemble the module assembly because the CPU is always situated on the
left end of the assembly, and the slot for the memory cards is therefore accessible.
Note
With both CPUs, a DRAM card of the same size must be inserted in each of
Slots 1 and 2.
Only use the memory cards intended for the particular CPU.
!
Warning
The modules can be damaged.
Failure to observe ESD guidelines can result in damage to both the CPU and
memory cards.
Observe the ESD guidelines when replacing memory cards.
Replacing Memory Cards for Main Memory and OSD
To remove a memory card from a CPU slot, follow the steps outlined below:
1. Remove the cover from the upper left side of the CPU by loosening the three
screws.
2. Press both lateral retaining springs to release the lock of the desired memory
card. The card is raised at an angle of 45° (see Figure 8-28).
3. Remove the memory card from the connector (see Figure 8-28).
4. Push the new memory card at an angle of about 45° into the free connector as
far as it will go (see Figure 8-28).
5. Press the new memory card on the protruding side in the direction of the PCB
until it engages with the two retaining springs (see Figure 8-28).
6. Fit the cover on the upper left side of the CPU by securing it with three screws.
8-54
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4
3
Slot 1
2
5
Figure 8-28
Slot 2
Removing Memory Cards from the CPUs
Note
The connectors to accept the memory cards are coded (see Figure 8-29).
Do not apply force when fitting the memory cards.
3.3 V DRAM memory card
(for main memory)
Recess
Slots 1 and 2
Figure 8-29
3.3 V Memory Card
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Assembling the M7-400
8.8.4
Replacing a Short AT Card
Removing an AT Card
Before you can replace a short AT card, you must remove the module assembly
and remove the ATM 478 AT adapter module from the assembly (see
Section 8.8.2, from page 8-49).
!
Warning
The modules can be damaged.
If the AT card is inserted or removed with power applied and without observing the
ESD guidelines, the CPU, AT adapter module, and the AT card can be damaged.
Never insert or remove the AT card with power applied. Always switch off the
power supply before inserting or removing the AT card. Observe the ESD
guidelines.
To remove a short AT card, follow the steps outlined below (see Figure 8-30):
1. Remove the cover from the upper left side of the ATM 478.
2. Unscrew the fixing bracket from the support plate of the AT card and from the
ATM 478 and remove it.
3. Remove the AT card from the side opening and from the front panel upwards
out of the plug-in contact.
4. Pull the AT card out of the slot from the front.
Fitting an AT Card
Fit the new AT card in the AT adapter in the reverse order (see Section 8.4.5
“Fitting the Short AT Card”, page 8-15).
Then refit the AT adapter module in the module assembly and install the latter in
the rack (see Section 8.4.6 “Assembling Expansion Modules on a Central Rack”
and Section 8.4.7 “Installing a Module Assembly in the Rack” on pages 8-17 and
8-24).
8-56
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3
2
3
1
3
4
Figure 8-30
Removing an AT Card from the ATM 478 AT Adapter Module
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8-58
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A
Chapter Overview
Section
Description
Page
A.1
General Rules and Regulations for Operating the S7-400
A-2
A.2
Principles of System Installation for EMC
A-5
A.3
Installation of Programmable Controllers for EMC
A-9
A.4
Examples of EMC-Compatible Assembly
A-10
A.5
Shielding Cables
A-13
A.6
Equipotential Bonding
A-15
A.7
Cabling Inside Buildings
A-17
A.8
Cabling Outside Buildings
A-19
A.9
Lightning Protection und Overvoltage Protection
A-20
A.9.1
Lightning Protection Zone Concept
A-21
A.9.2
Rules for the Transition between Lightning Protection Zones 0 and 1
A-23
A.9.3
Rules for the Transitions between Lightning Protection Zones 1 <-> 2
and Greater
A-25
A.9.4
Sample of a Surge Protection Circuit for Networked S7-400 PLCs
A-28
A.10
How to Protect Digital Output Modules against Inductive Surge
A-30
A.11
Safety of Electronic Control Equipment
A-32
A.12
Interference-Free Connection of Monitors
A-34
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Assembling and Installing Systems
A.1
General Rules and Regulations for Operating
the S7-400
General Basic Rules
On account of the many possible applications of the S7-400, this chapter can only
cover the basic rules for the electrical configuration. You must at least comply with
these basic rules to ensure fault-free operation of the S7-400. The M7-400
modules operate similarly to the S7-400 modules. Differences in operation or data
can be found at the appropriate point or in Section 8.3 “Electrical Configuration.”
Specific Application
Observe the safety and accident prevention regulations applying to specific
applications, for example, the Machine Protection Guidelines.
EMERGENCY OFF Devices
EMERGENCY OFF devices complying with IEC 60204-1 (which corresponds to
VDE 0113-1) must remain effective in all operating modes of the plant or system.
Reactions of the Plant after Certain Events
The following table shows how you must respond to the reactions of a plant to
certain events.
Event
A-2
Requirement
Failure of the operating or
supply voltage of the S7-400
Hazardous operating states must not occur.
Tripping of the Emergency
Off device
Hazardous operating states must not occur.
Restoration of the operating
or supply voltage of the
S7-400
Hazardous operating states must not occur. No
uncontrolled or undefined restart of the system must occur.
Restart after release of the
Emergency Off device
Hazardous operating states must not occur. No
uncontrolled or undefined restart of the system must occur.
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120/230 VAC Supply
The following table shows which points you must observe when connecting the
S7-400 to a 120/230 VAC supply.
With ...
... You Must Ensure ...
buildings
that suitable external lightning protection measures are
provided.
supply cables and signal
lines
that suitable internal and external lightning protection
measures are provided.
stationary equipment and
systems without all-pole
disconnector
that a supply disconnector (switch) is installed in the
building.
load power supplies and
power supply modules
that the set line voltage range corresponds to the local line
voltage.
all circuits of the S7-400
that fluctuations of line voltage from the rated value are
within permissible tolerances (see Technical Data of the
modules).
residual-current devices
(RCDs)
that the RCD is suitable for the total discharge currents of
the power supply module.
24 VDC Supply
The following table shows the points you must observe when connecting the
S7-400 to a 24 VDC supply.
With ...
... You Must Ensure ...
buildings
that suitable external lightning protection measures are
provided.
24 VDC supply cables and
signal lines
that suitable internal and external lightning protection
measures are provided.
24 V supply
that the supply voltage produced is an isolated extra-low
voltage.
load power supplies
that only isolated load current power supplies are used.
Protection Against External Electrical Effects
The following table shows what you must observe for protection against external
electrical effects.
With ...
... You Must Ensure ...
all plants and systems in
which the S7-400 is
installed
that the plant and all system sections are properly
connected to protective ground to discharge
electromagnetic interference.
connecting cables and
signal lines
that all cables are correctly routed and connected.
signal lines
that an open circuit in a signal line does not place the
equipment in an undefined state.
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Assembling and Installing Systems
Protection Against Other Electrical Effects
The following table shows the other external effects against which you must
provide protection.
Protection against ...
A-4
... by Means of ...
inadvertent actuation of
operator controls
a suitable arrangement or covering of keyboard and
operator controls or a recessed arrangement of operator
controls.
splashing and surging water
suitable protective devices or installation in waterproof
housings.
direct solar radiation
suitable shading or installation in appropriately sheltered
locations.
mechanical damage
suitable demarcation, protective devices, or installation in
rugged housings.
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A.2
Principles of System Installation for EMC
Definition: EMC
EMC (electromagnetic compatibility) describes the capability of electrical apparatus
to operate without faults in a given electromagnetic environment, without being
affected by the environment and without affecting it in an unacceptable manner.
Introduction
Although the S7-400 and its components were developed for operation in an
industrial environment and meet high EMC requirements, you should carry out
EMC planning before installing your control system, taking possible interference
sources into account and incorporating them in your observations.
Possible Effects of Interference
Electromagnetic interference can affect the programmable controller in different
ways:
• Electromagnetic fields which directly affect the system
• Interference picked up via bus signals (PROFIBUS DP, etc.)
• Interference acting via the process wiring
• Interference reaching the system via the power supply and/or protective ground
Figure A-1 shows the possible routes for electromagnetic interference.
Electromagnetic
fields
Bus signal
Process wiring
Protective ground
Figure A-1
Power supply module
The Possible Routes for Electromagnetic Interference
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Assembling and Installing Systems
Coupling Mechanisms
Interference can reach the programmable controller via four different coupling
mechanisms, depending on the transmission medium (conducted or
non-conducted) and distance between interference source and the equipment.
Coupling Mechanism
Direct Coupling
Cause
Direct or metallic coupling always
occurs when two circuits have a
common conductor.
Typical Interference Sources
• Switched devices (supply affected
by inverters and external power
supply units)
• Motors being started
• Different potentials of component
cases with a common power
supply
• Static discharges
Capacitive Coupling
Capacitive or electrical coupling
occurs between conductors which are
at different potentials.
• Interference pickup via parallel
signal cables
• Static discharge of the operator
The degree of coupling is proportional • Contactors
to the voltage variation as a function
of time.
Inductive Coupling
Radiated Interference
A-6
Inductive or magnetic coupling occurs
between two conductor loops through
which current is flowing. Interference
voltages are induced by the magnetic
fluxes associated with the currents.
The degree of coupling is proportional
to the current variation as a function of
time.
• Transformers, motors, electric
There is a radiation path when a
conductor is subjected to an
electromagnetic wave. Impinging of
the wave results in induced currents
and voltages.
• Local transmitters (for example,
welders
• Parallel AC supply cables
• Cables with switched currents
• Signal cables with a high
frequency
• Unconnected coils
two-way radios)
• Spark gaps (spark plugs,
collectors of electric motors,
welders)
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Five Basic Rules for Ensuring Electromagnetic Compatibility
In many cases, you can ensure electromagnetic compatibility by observing the
following five basic rules:
Rule 1: Large Area Grounding
When installing the programmable controllers, provide large-area good quality
grounding of the inactive metal parts (see Section A.3).
• Make a large-area low-impedance connection of all inactive metal parts to
chassis ground.
• For screw connections on painted or anodized metal parts, either use special
contact washers or remove the insulating protective layers from the contact
points.
• If possible, do not use aluminum parts for grounding. Aluminum oxidizes easily
and is therefore less suitable for grounding.
• Make a central connection between chassis ground and the ground/protective
ground conductor system.
Rule 2: Correct Cable Routing
Ensure proper routing of lines when wiring (see Sections A.7 and A.8).
• Arrange the cabling in line groups (AC power cables, power supply cables,
signal lines, data lines).
• Always install AC power cables and signal or data lines in separate ducts or
bunches.
• Route the signal and data lines as closely as possible to grounded surfaces
such as cabinet elements, metal bars and cabinet panels.
Rule 3: Secure Cable Shields
Ensure that cable shields are properly secured (see Section 4.9).
• Only use shielded data lines. The shield must have a large-area connection to
ground at each end.
• Analog lines must always be shielded. For the transfer of signals with low
amplitudes, it may be advisable to connect the shield to ground at only one end.
• Provide the line shields with a large-area connection to a shield/protective
ground bar immediately after the cabinet inlet, and secure the shields with cable
clamps. Route the grounded shield as far as the module without interruption, but
do not ground it there again.
• There must be a low-impedance connection between shield/protective ground
bar and cabinet/housing.
• Use metal or metallized connector cases for shielded data lines.
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Assembling and Installing Systems
Rule 4: Special EMC Measures
Employ special EMC measures for particular applications (see Section 4.11).
• Fit suppressors to all inductors which are not controlled by S7-400 modules.
• Use incandescent bulbs or suppressed fluorescent lamps in the immediate
vicinity of your controller for illuminating cabinets or housings.
Rule 5: Standard Reference Potential
Create a standard reference potential; ground all electrical apparatus if possible
(see Sections 4.10 and 4.12).
• Install equipotential bonding conductors of sufficient rating when potential
differences exist or are expected between sections of your system.
• Use specific grounding measures. Grounding the control system is a protective
and functional measure.
• Connect the system sections and cabinets containing central racks and
expansion racks to the grounding/protective ground system in a star
configuration. This prevents the formation of ground loops.
See also
Cable shielding, page A-13
Cabling outside buildings, page A-19
Cabling inside buildings, page A-17
Mounting of programmable controllers for EMC, page A-9
A-8
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A.3
Installation of Programmable Controllers for EMC
Introduction
Measures for suppressing interference are often only applied when the control
system is already operational, and the proper reception of a useful signal is found
to be impaired.
The cause of such interference is often due to insufficient reference potentials
which can be attributed to errors during assembly. This section tells you how to
avoid such errors.
Inactive Metal Parts
Inactive parts are all the conductive parts which are electrically isolated from active
parts by basic insulation, and can only develop a potential in the event of a fault.
Grounding of Inactive Metal Parts During Installation
When installing the S7-400, ensure large-area grounding of all inactive metal parts.
Properly implemented chassis grounding creates a standard reference potential for
the control system, and reduces the effects of picked-up interference.
The chassis ground provides the electrical interconnection between all inactive
parts. The entirety of all interconnected inactive parts is known as the chassis
ground.
Even in the event of a fault, the chassis ground must not develop a dangerous
touch potential. It must therefore be connected to the protective ground conductor
via an adequate conductor cross-section. To prevent ground loops, locally
separated ground elements such as cabinets, structural and machine parts must
always be connected to the protective ground system in star configuration.
Ensure the following when chassis grounding:
• Connect the inactive metal parts with the same degree of care as the active
parts.
• Ensure low-impedance connections between metal parts, for example, with
large-area good quality contact.
• With painted or anodized metal parts, the insulating protective layer must be
penetrated or removed at the contact point. Use special contact washers or
scratch the layer off fully at the contact point.
• Protect the connection points from corrosion, for example, with suitable grease.
• Use flexible grounding strips to connect movable grounded parts such as
cabinet doors. The grounding strips should be short and have a large surface,
because the surface is decisive in providing a path to ground for high-frequency
interference.
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Assembling and Installing Systems
A.4
Examples of EMC-Compatible Assembly
Introduction
Below you will find two examples of configurations for programmable controllers for
EMC.
Example 1: Cabinet Configuration for EMC
Figure A-2 shows a cabinet installation in which the measures described above
(grounding of inactive metal parts and connection of cable shields) have been
applied. However, this example only applies to grounded operation. Observe the
points marked in the figure when installing your system.
2
1
3
4
5
6
7
8
Figure A-2
A-10
Example of Cabinet Installation for EMC
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Assembling and Installing Systems
Key for example 1
The numbers in the following list refer to the numbers in Figure A-2.
Table A-1
No.
Key for Example 1
Key
Meaning
1
Grounding strips
If there are no large-area metal-to-metal connections, you must interconnectinactive metal parts
such as cabinet doors or support plates via grounding strips or to ground. Use short grounding strips
with a large surface.
2
Supporting bars
Connect the supporting bars and the cabinet housing over a large area (metal-to-metal connection).
3
Secure the rack
There must be a large-area metal-to-metal connection between supporting barand rack.
4
Signal lines
Use cable clamps on the protective ground bar or an
additional shield bus forlarge-area connection of the
shield of signal lines.
5
Cable clamp
The cable clamp must surround the braided shield
over a large area and ensuregood quality contact.
6
Shielding bus
Provide a large-area connection between the shield
bus and supporting bars(metal-to-metal connection).
The cable shields are connected to the shield bus.
7
Protective ground
bar
Provide a large-area connection between the protective ground bar and supporting bars(metal-to-metal
connection). Connect the protective ground bar to
the protective conductor system via a separate conductor (minimum cross-section 10 mm2).
8
Conductor to the
Provide a large-area connection between the conprotective conductor ductor and the protective conductor system (grounsystem (grounding
ding point).
point)
Example 2: Wall Mounting for EMC
If you operate your S7-400 in a low-interference environment in which the
permissible ambient conditions are complied with (see Reference Manual,
Chapter 1), you can mount your S7-400 in frames or on the wall.
Picked-up interference must be given a path to large metal surfaces. You should
therefore secure standard mounting channels, shield, and protective ground bars to
metal structural elements. For wall mounting in particular, installation on reference
potential surfaces made of sheet steel has proved advantageous.
Provide a shield bus for connecting the cable shields if you install shielded cables.
The shield bus can simultaneously serve as the protective ground bar.
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Assembling and Installing Systems
Ensure the following for frame and wall mounting:
• Use special contact washers with painted and anodized metal parts, or remove
the insulating protective layers.
• Provide large-area, low-impedance metal-to-metal connections when securing
the shield/protective ground bar.
• Cover the AC supply conductors in a shockproof arrangement.
Figure A-3 shows an example of wall mounting for EMC
Figure A-3
A-12
Wall Mounting an S7-400 for EMC
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Assembling and Installing Systems
A.5
Shielding Cables
Purpose of the Shielding
A cable is shielded to attenuate the effects of magnetic, electrical, and
electromagnetic interference on this cable.
Principle of Operation
Interference currents on cable shields are discharged to ground via the shield bus
which is electrically connected to the housing. To prevent these interference
currents themselves from becoming an interference source, a low-impedance
connection to the protective ground conductor is particularly important.
Suitable Cables
If possible, only use cables with a braided shield. The coverage density of the
shield should be at least 80%. Avoid cables with a foil shield because the foil can
be easily damaged by tensile and compressive stress at the securing points; this
can reduce the shielding effect.
Grounding the Cable Shields
Generally, you should always connect both ends of the shield to the chassis ground
(that is, at the beginning and end of the cable). Grounding the shields at both ends
is essential to achieve a good degree of suppression of interference in the higher
frequency region.
In exceptional cases, you can connect only one end of the shield to the chassis
ground (for example, at the beginning or end of the cable). However, you only
achieve attenuation of lower frequencies. Single-ended connection of the shield
may be advantageous when
• An equipotential bonding conductor cannot be laid
• Analog signals of a few mA or mA are transmitted
• Foil shields (static shields) are used.
For data cables in serial communication, only use metallic or metallized
connectors. Secure the shield of the data cable to the connector housing. Do not
connect the shield to Pin 1 of the connector.
For stationary operation, you should strip the shielded cable without damaging the
shield and connect it to the shield/protective ground bar.
Note
In the event of potential differences between grounding points, a circulating current
may flow via the shield connected at both ends. In this case, install an additional
equipotential bonding conductor (see Section A.6).
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Assembling and Installing Systems
Handling the Shields
Observe the following points with regard to the shield:
• Only use cable clamps made of metal to secure braided shields. The clamps
must surround the shield over a large area and provide good contact.
• Connect the shield to a shield bus immediately after entry of the cable into the
cabinet. Route the shield to the module but do not connect it there again to the
chassis ground or the shield bus.
• For installation other than in cabinets (for example, wall mounting), you can
provide contact between the cable shields and the cable duct.
Shown in the figure A-4 are some methods of securing shielded cables with cable
clamps.
Figure A-4
A-14
Mounting Cable Shields
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A.6
Equipotential Bonding
Potential Differences
Potential differences can occur between separate system components, leading to
high transient currents; for example, if cable shields are fitted on both sides and
grounded at different system components.
Potential differences can be caused by different electrical supplies.
!
Caution
This can result in damage.
Cable shields are not suitable for equipotential bonding.
Use the prescribed cables exclusively (e.g. those with a 16 mm2 cross-section).
Ensure also that the cable cross-section is adequate when installing MPI/DP networks, since otherwise the interface hardware may be damaged or even destroyed.
Equipotential Bonding Conductor
You must reduce the potential differences by laying equipotential bonding
conductors to ensure that the electronic components used function correctly.
Observe the following points for installing an equipotential bonding conductor:
• The lower the impedance of the equipotential bonding conductor, the higher the
efficiency of the equipotential bonding.
• Where two sections of an installation are interconnected via shielded signal
lines whose shields are connected to the ground/protective conductor at both
ends, the impedance of the additional equipotential bonding conductor must not
exceed 10% of the shield impedance.
• The cross-section of an equipotential bonding conductor must be rated for the
maximum circulating current. In practice, equipotential bonding conductors with
a cross-section of 16 mm2 have proved to be effective.
• Use equipotential bonding conductors made of copper or zinc-plated steel.
Provide a large-area contact between the cables and the ground/protective
conductor and protect them from corrosion.
• Lay the equipotential bonding conductor in such a way that the surface between
the conductor and the signal lines is as small as possible. (see Figure A-5).
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Assembling and Installing Systems
Figure A-5
A-16
Routing Equipotential Bonding Conductor and Signal Line
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A.7
Cabling Inside Buildings
Introduction
Inside buildings, clearances must be observed between groups of different cables
to achieve the necessary electromagnetic compatibility (EMC). Table A-2 provides
you with information on the general rules governing clearances to enable you to
choose the right cables.
How to Read the Table
If you want to know how two lines of different types should be laid, proceed as
follows:
1. Look up the type of the first cable in column 1 (Cables for ...).
2. Look up the type of the second cable in the corresponding field in column 2
(and Cables for ...).
3. Read off the guidelines to be observed from column 3 (Run ...).
Table A-2
Cabling Inside Buildings
Connect Cables for ...
and Cables for ...
LAN signals, shielded
(SINEC L1, PROFIBUS DP)
Data signals, shielded
(programming devices, operator
panels, printers, counter inputs,
etc.)
Analog signals, shielded
DC voltage
(60 V), unshielded
Process signals
(25 V), shielded
AC voltage
(25 V), unshielded
Monitors (coaxial cable)
LAN signals, shielded
(SINEC L1, PROFIBUS DP)
Data signals, shielded
(programming devices, operator
panels, printers, counter inputs,
etc.)
Analog signals, shielded
DC voltage
(60 V), unshielded
Process signals
(25 V), shielded
AC voltage
(25 V), unshielded
Monitors (coaxial cable)
Run ...
in common bundles or cable
ducts
DC voltage
in separate bundles or cable
(60 V and400 V), unshielded ducts (no minimum clearance
necessary)
AC voltage
(25 V and400 V),
unshielded
DC and AC voltages
(400 V), unshielded
S7-400 and M7-400 Programmable Controllers Hardware and Installation
A5E00069481-04
Inside cabinets:
in separate bundles or cable
ducts (no minimum clearance
necessary)
Outside cabinets:
on separate cable racks with a
clearance of at least 10 cm
(3.93 in.)
A-17
Assembling and Installing Systems
Table A-2
Cabling Inside Buildings, continued
Connect Cables for ...
DC voltage
(60 V and400 V), unshielded
AC voltage
(25 V and400 V), unshielded
and Cables for ...
LAN signals, shielded
(SINEC L1, PROFIBUS DP)
Data signals, shielded
(programming devices, operator
panels, printers, counter inputs,
etc.)
Analog signals, shielded
DC voltage
(60 V), unshielded
Process signals
(25 V), shielded
AC voltage
(25 V), unshielded
Monitors (coaxial cable)
Run ...
in separate bundles or cable
ducts (no minimum clearance
necessary)
DC voltage
in common bundles or cable
(60 V and400 V), unshielded ducts
AC voltage
(25 V and400 V), unshielded
DC and AC voltages
(400 V), unshielded
DC and AC voltages
(400 V), unshielded
Inside cabinets:
in separate bundles or cable
ducts (no minimum clearance
necessary)
Outside cabinets:
on separate cable racks with a
clearance of at least 10 cm (3.93
in.)
LAN signals, shielded
(SINEC L1, PROFIBUS DP)
Data signals, shielded
(programming devices, operator
panels, printers, counter inputs,
etc.)
Analog signals, shielded
DC voltage
(60 V), unshielded
Process signals
(25 V), shielded
AC voltage
(25 V), unshielded
Monitors (coaxial cable)
Inside cabinets:
in separate bundles or cable
ducts (no minimum clearance
necessary)
Outside cabinets:
on separate cable racks with a
clearance of at least 10 cm (3.93
in.)
DC voltage
(60 V and400 V), unshielded
AC voltage
(25 V and400 V), unshielded
DC and AC voltages
(400 V), unshielded
DC and AC voltages
(400 V), unshielded
in common bundles or cable
ducts
ETHERNET
ETHERNET
in common bundles or cable
ducts
Others
in separate bundles or cable
ducts with a clearance of at least
50 cm (19.65 in.)
A-18
S7-400 and M7-400 Programmable Controllers Hardware and Installation
A5E00069481-04
Assembling and Installing Systems
A.8
Cabling Outside Buildings
Rules for EMC
When installing cables outside buildings, the same EMC rules apply as for inside
buildings. The following also applies:
• Run cables on metallic cable supports (racks, trays etc.).
• Establish a metallic connection between the joints in the cable supports
• Ground the cable supports
• If necessary, provide adequate equipotential bonding between the various items
of equipment connected.
• Take the necessary (internal and external) lightning protection and grounding
measures applying to your particular application (see below).
Rules for Lightning Protection Outside Buildings
Lay your cables either:
• In metallic conduits grounded at both ends, or
• In concrete cable ducts with continuous end-to-end armoring
Overvoltage Protection Devices
An individual appraisal of the entire plant is necessary before initiating any lightning
protection measures (see Section A.9).
Further Information on Lightning Protection
You will find further information in the following sections.
S7-400 and M7-400 Programmable Controllers Hardware and Installation
A5E00069481-04
A-19
Assembling and Installing Systems
A.9
Lightning Protection and Overvoltage Protection
Overview
Failures are very often the result of overvoltages caused by:
• Atmospheric discharge or
• Electrostatic discharge.
First of all, we want to introduce you to the lightning protection zone concept, on
which the protection against overvoltage is based.
At the end of this section, you will find rules for the transitions between the
individual lightning protection zones.
Note
This section can only provide information on the protection of a programmable
logic controller against overvoltages.
However, a complete protection against overvoltage is guaranteed only if the
whole surrounding building is designed to provide protection against overvoltages.
This refers especially to constructional measures for the building already in the
planning phase.
If you wish to obtain detailed information on overvoltage protection, we therefore
recommend you to address your Siemens contact or a company specialized in
lightning protection.
A-20
S7-400 and M7-400 Programmable Controllers Hardware and Installation
A5E00069481-04
Assembling and Installing Systems
A.9.1
Lightning Protection Zone Concept
Principle of the Lightning Protection Zone Concept According to IEC 61312-1/DIN
VDE 0185 T103
The principle of the lightning protection zone concept states that the volume to be
protected, for example, a manufacturing hall, is subdivided into lightning protection
zones in accordance with EMC guidelines (see Figure A-6).
The individual lightning protection zones are constituted by the following measures:
The external lightning protection of the building (field side)
Lightning protection
zone 0
The shielding of buildings
Lightning protection
zone 1
The shielding of rooms
Lightning protection
zone 2
The shielding of devices
Lightning protection
zone 3
Effects of a Lightning Strike
Direct lightning strikes occur in lightning protection zone 0. The lightning strike
creates high-energy electromagnetic fields which can be reduced or removed from
one lightning protection zone to the next by suitable lightning protection
elements/measures.
Surges
In lightning protection zones 1 and higher, surges can result from switching
operations and interference.
S7-400 and M7-400 Programmable Controllers Hardware and Installation
A5E00069481-04
A-21
Assembling and Installing Systems
Diagram of the Lightning Protection Zones
The following diagram illustrates a lightning protection zone concept for a detached
building.
Lightning Protection Zone 0, Field Side
Building
Shield
External
Lightning
Protection
(Steel
Reinforcement)
Lightning Protection Zone 1
Room Shield
Lightning Protection
Zone 2
EnergyTechnical
Cable
(Steel
Reinforcement)
Lightning
Device Shield
Protection
(Metal Housing)
Zone 3
Device
NonElectrical
Cable
(Metal)
Metal
Component
Internal
Cable
Information-Technical Cable
Lightning Protection
Equipotential Bonding
Local
Equipotential Bonding
Galvanic
Connection
Figure A-6
Lightning Protection Zones of a Building
Principle of Transitions between the Lightning Protection Zones
At the transition points between the lightning protection zones, you must take
measures to prevent surges being conducted further.
The lightning protection zone concept also states that all lines at the transitions
between the lightning protection zones that can carry lightning stroke current must
be included in the lightning protection equipotential bonding.
Lines that can carry lightning stroke current include:
• Metal pipelines (for example, water, gas and heat)
• Power cables (for example, line voltage, 24 V supply)
• Data cables (for example, bus cable).
A-22
S7-400 and M7-400 Programmable Controllers Hardware and Installation
A5E00069481-04
Assembling and Installing Systems
A.9.2
Rules for the Transition between Lightning Protection Zones
0 and 1
Rule for the Transition 0 <-> 1 (Lightning Protection Equipotential Bonding)
The following measures are suitable for lightning protection equipotential bonding
at the transition between lightning protection zone 0 <-> 1:
• Use grounded, spiralled, current-conducting metal strips or metal braiding, for
example, NYCY or A2Y(K)Y, as a cable shield at the start and end
• Lay the cables in one of the following ways:
– in continuous metal pipes that are grounded at the start and end
– in ducts of armored concrete with continuous armoring
– on closed metal cable racks grounded at the start and end
• Use fiber-optic cables instead of lightning stroke current-carrying cables.
Additional Measures
If you cannot take the measures listed above, you must install a high-voltage
protector at transition 0 <->1 with a relevant lightning conductor. Table A-3 contains
the components you can use for high-voltage protection of your plant.
Table A-3
Ser.
No.
1
High-Voltage Protection of Cables with the Help of Surge Protection Equipment
Cables for ...
... equip transition point 0 <–> 1
with:
Order No.
3-phase TN-C system
1 piece
of
DEHNbloc/3 lightning conductor
phase L1/L2/L3 to PEN
900 110*
5SD7 031
3-phase TN-S system
1 piece
of
DEHNbloc/3 lightning conductor
phase L1/L2/L3 to PE
900 110*
5SD7 031
1 piece
of
DEHNbloc/1 lightning conductor
N to PE
900 111*
5SD7 032
1 piece
of
DEHNbloc/3 lightning conductor
phase L1/L2/L3 toN
900 110*
5SD7 031
1 piece
of
DEHNgap B/n N-PE lightning conductor
N to PE
900 130*
3-phase TT system
AC TN-S system
2 pieces DEHNbloc/1 lightning conof
ductor
phase L1 + N to PE
S7-400 and M7-400 Programmable Controllers Hardware and Installation
A5E00069481-04
900 111*
5SD7 032
A-23
Assembling and Installing Systems
Table A-3
Ser.
No.
High-Voltage Protection of Cables with the Help of Surge Protection Equipment, continued
Cables for ...
... equip transition point 0 <–> 1
with:
Order No.
AC TN-C system
1 piece
of
DEHNbloc/1 lightning conductor
phase L to PEN
900 111*
5SD7 032
AC TT system
1 piece
of
DEHNbloc/1 lightning conductor
phase to N
900 111*
5SD7 032
1 piece
of
DEHNgap B/n N-PE lightning conductor
N to PE
900 130*
2
24 VDC Power Supply
1 piece
of
Blitzductor VT lightning con- 918 402*
ductor,
type A D 24 V –
3
MPI bus cable, RS 485, RS 232
(V.24)
1 piece
of
Blitzductor CT lightning con- 919 506* and
ductor, type B
919 510*
4
Inputs/outputs of digital modules
24 V
5
24 VDC power supply module
6
Inputs/outputs of digital modules and 2 pieces DEHNbloc/1 lightning con120/230 VAC power supply
of
ductor
7
Inputs/outputs of analog modules up
to 12 V +/–
*
DEHNrail 24 FML
1 piece
of
1 piece
of
You can order these components directly at:
A-24
901 104*
Blitzductor VT lightning con- 918 402*
ductor,
900 111*
type AD 24 V –
5SD7 032
900 111*
5SD7 032
Blitzductor CT lightning con- 919 506* and
ductor,
919 510*
type B
DEHN + SÖHNE
GmbH + Co. KG
Elektrotechnische Fabrik
Hans-Dehn-Str. 1
D-92318 Neumarkt
S7-400 and M7-400 Programmable Controllers Hardware and Installation
A5E00069481-04
Assembling and Installing Systems
A.9.3
Rules for the Transitions between Lightning Protection
Zones 1 <-> 2 and Greater
Rules for Transitions 1 <-> 2 and Above (Local Equipotential Bonding)
for all lightning protection zone transitions 1
<-> 2 and greater:
• Set up local equipotential bonding at each subsequent lightning protection zone
transition.
• Include all cables (also metal pipelines, for example) in the local equipotential
bonding at all subsequent lightning protection zone transitions.
• Include all metal installations located within the lightning protection zone in the
local equipotential bonding (for example, metal part within lightning protection
zone 2 at transition 1 <-> 2).
Additional Measures
We recommend you ensure low-voltage protection for the following elements
• for all lightning protection zone transitions 1 <-> 2 and greater
and
• for all cables that run within a lightning protection zone and are longer than
100 m.
Lightning Protection Element for the 24 VDC Supply
You should only use the lightning conductor KT, type 24 VAD SIMATIC for the
24 VDC power supply of the S7-400. All other surge protection components do not
meet the required tolerance range of 20.4 V to 28.8 V of the S7-400’s power
supply.
Lightning Protection Element for Signal Modules
You can use standard overvoltage protection components for the digital I/O
modules. However, please note that these only permit a maximum of
1.15 VNom = 27.6 V for 24 VDC nominal voltage. If the tolerance of your 24 VDC
power supply is higher, use the surge protection components for 30 VDC nominal
voltage.
You can also use the VT lightning conductor, Type AD 24 V SIMATIC. However,
this can result in the following restrictions:
• Digital inputs: An increased input current can flow in the case of negative input
voltages.
• Digital outputs: Dropout time of contactors can increase significantly.
S7-400 and M7-400 Programmable Controllers Hardware and Installation
A5E00069481-04
A-25
Assembling and Installing Systems
Low-Voltage Protection Elements for 1<–> 2
For the transition points between lightning protection zones 1 <–> 2 we
recommend the surge protection components listed in table A-4
Table A-4
Ser.
No.
1
Low-Voltage Protection Components for Lightning Protection Zones 1 <–> 2
Cables for ...
... equip transition point 1 <–> 2 with:
Order No.
3-phase TN-C system
3 pieces
of
DEHNguard 275 surge arresters
900 600*
5SD7 030
3-phase TN-S system
4 pieces
of
DEHNguard 275 surge arresters
900 600*
5SD7 030
3-phase TT system
3 pieces
of
DEHNguard 275 surge arresters
phase L1/L2/L3 to N
900 600*
5SD7 030
1 piece of DEHNgap C N-PE surge N to PE
900 131*
AC TN-S system
2 pieces
of
DEHNguard 275 surge arresters
900 600*
5SD7 030
AC TN-C system
1 piece of DEHNguard 275 surge arresters
900 600*
5SD7 030
AC TT system
1 piece of DEHNguard 275 surge arresters
phase L to N
900 600*
5SD7 030
1 piece of DEHNgap C, N-PE surge arrester, 900 131*
N to PE
2
24 VDC Power Supply
3
Bus cable
•
MPI RS 485
•
RS 232 (V.24)
1 piece of Blitzductor VT lightning conductor, 918 402*
type AD 24 V
•
Blitzductor CT surge arrester,
type MD/HF
919 506* and
919 570*
1 piece of •
per conductor pair
surge arrester Blitzductor CT
type ME 15 V
919 506* and
919 522*
4
Inputs of digital modules 24
VDC
1 piece of Low-voltage surge arrester,
type FDK 2 60 V
919 993*
5
Outputs of digital modules 24
VDC
1 piece of Low-voltage surge arrester
FDK 2D5 24
919 991*
6
Inputs/outputs of digital
modules
2 pieces
of
7
*
•
120 VAC
•
230 VAC
Inputs of analog modules up
to 12 V +/–
•
DEHNguard 150
900 603*
•
DEHNguard 275
900 600*
1 piece of Surge arrester
Blitzductor CT type MD 12 V
You can order these components directly at:
A-26
Surge arresters
919 506* and
919 541*
DEHN + SÖHNE
GmbH + Co. KG
Elektrotechnische Fabrik
Hans-Dehn-Str. 1
D-92318 Neumarkt
S7-400 and M7-400 Programmable Controllers Hardware and Installation
A5E00069481-04
Assembling and Installing Systems
Low-Voltage Protection Elements for 2<–> 3
For the transition points between lightning protection zones 2 <–> 3 we
recommend the surge protection components listed in the table below. This
low-voltage protection must be used in S7-400 for CE compliance.
Table A-5
Cables for ...
Ser.
No.
1
Surge Protection Components for Lightning Protection Zones 2 <–> 3
... .. equip transition point
2 <–> 3 with:
3-phase TN-C-System
3 pieces
of
DEHNguard 275 surge arresters
900 600*
5SD7 030
3-phase TN-S system
4 pieces
of
DEHNguard 275 surge arresters
900 600*
5SD7 030
3-phase TT system
3 pieces
of
DEHNguard 275 surge arresters phase 900 600*
L1/L2/L3 to N
5SD7 030
1 piece of DEHNgap C N-PE surge N to PE
900 131*
AC TN-S system
2 pieces
of
DEHNguard 275 surge arresters
900 600*
5SD7 030
AC TN-C system
1 piece of DEHNguard 275 surge arresters
900 600*
5SD7 030
AC TT system
1 piece of DEHNguard 275 surge arresters phase 900 600*
L to N
5SD7 030
1 piece of DEHNgap C N-PE surge N to PE
2
24 VDC Power Supply
3
Bus cable
4
•
MPI RS 485
•
RS 232 (V.24)
900 131*
1 piece of Blitzductor VT lightning conductor, type 918 402*
AD 24 V
•
Blitzductor CT surge arrester, type
MD/HF
919 506* and
919 570*
1 piece of •
per conductor pair low-voltage protection FDK 2 12 V
919 995*
Inputs of digital modules
•
24 VDC
1 piece of Low-voltage surge arrester,
type FDK 2 60 V on insulated rail
2 pieces
of
•
120 VAC
•
230 VAC
919 993*
Surge arresters
•
DEHNrail 120 FML
901 101*
•
DEHNrail 230 FML
901 100*
1 piece of Low-voltage protection FDK 2 D 5 24
919 991*
5
Outputs of digital modules 24 VDC
6
Outputs of analog modu- 1 piece of Low-voltage protection,
les up to 12 V +/–
type FDK 2 12 V on insulated rail connected with M– of the power supply for
the modules.
*
Order No.
You can order these components directly at:
919 995*
DEHN + SÖHNE
GmbH + Co. KG
Elektrotechnische Fabrik
Hans-Dehn-Str. 1
D-92318 Neumarkt
S7-400 and M7-400 Programmable Controllers Hardware and Installation
A5E00069481-04
A-27
Assembling and Installing Systems
A.9.4
Sample of a Surge Protection Circuit for Networked S7-400
PLCs
Sample Circuit
The sample in the figure A-7 shows you how install an effective surge protection for
2 networked S7-400 PLCs:
L1 L2 L3 NPE
Lightning-protection 0, field side zone
Lightning-protection zone 1
Switchgear cubicle1
Lightning-protection zone 2
SV
CPU
MPI
SM
Switchgear cubicle 2
Lightning-protection zone 2
SV
CPU
MPI
SM
PE 10 mm2
PE 10 mm2
Figure A-7 Sample Circuitry for Networked S7-400 PLCs
A-28
S7-400 and M7-400 Programmable Controllers Hardware and Installation
A5E00069481-04
Assembling and Installing Systems
Components in figure A-7
The table A-6 explains consecutive numbers in the figure A-7:
Table A-6
Ser. No.
from figure A-7
Example of a Circuit Conforming to Lightning Protection Requirements (Legend to Figure A-7)
Components
Description
1
Lightning arrestor, depending on
the mains system, e.g. TN-S system:
1 piece DEHNbloc/3,
order number: 900 110* and
1 piece DEHNbloc/1,
order number: 900 111*
High-voltage protection against direct
lightning strike and surge voltage as of
transition 0 <–> 1
2
surge arrestors,
2 pieces DEHNguard 275;
order number: 900 600*
High-voltage surge protection at transition 1 <–> 2
3
Surge arrestor,
Blitzductor CT type MD/HF,
order number: 919 506* and
919 570*
Low-voltage surge protection for RS 485
interfaces at transition 1 <–> 2
4
Digital input modules:
FDK 2 D 60 V, order number:
919 993*
Low-voltage surge protection, signal modules I/O at transition 1 <–> 2
Digital output modules:
FDK 2 D 5 24 V, order number:
919 991*
Analog modules:
MD 12 V Blitzductor CT,
order number: 919 506 and
919 541
*
5
Bus cable shielding mounting de- Discharge of interference current
vice with EMC spring clamp on
the basic unit of Blitzductor CT;
order No.: 919 508*
6
Cable for equipotential bonding
16 mm
7
Blitzductor CT, type B for building High-voltage surge protection for RS 485
transitions;
interfaces at transition 0 <–> 1
order number: 919 506* and
919 510*
Standardization of reference potentials
You can order these components directly at:
S7-400 and M7-400 Programmable Controllers Hardware and Installation
A5E00069481-04
DEHN + SÖHNE
GmbH + Co. KG
Elektrotechnische Fabrik
Hans-Dehn-Str. 1
D-92318 Neumarkt
A-29
Assembling and Installing Systems
A.10
How to Protect Digital Output Modules against
Inductive Surge
Inductive Surge Voltage
Overvoltage occurs when inductive devices are switched off. Examples are relay
coils and contactors
Integrated Surge Arrester
S7-400 digital output modules are equipped with an integrated surge arrester
Additional Overvoltage Protection
Inductive devices require additional surge arresters only in following cases:
• If SIMATIC output circuits can be switched off by additionally installed contacts
(e.g. relay contacts).
• If the inductive loads are not controlled by SIMATIC modules.
Note: Consult the supplier of the inductors for the ratings of surge suppression
devices.
Example
Figure A-8 shows an output circuit that requires additional surge arresters.
Contact in output circuit
Inductivitys requires a circuiting
(see Figures A-9 and A-10)
Figure A-8
A-30
Relay Contact for EMERGENCY OFF in the Output Circuit
S7-400 and M7-400 Programmable Controllers Hardware and Installation
A5E00069481-04
Assembling and Installing Systems
Suppression for DC-Operated Coils
DC-operated coils are interconnected to diodes or Zener diodes.
With diode
With Zener diode
+
+
-
-
Figure A-9
Suppression for DC-Operated Coils
Suppression with Diodes / Zener Diodes
Suppression with diodes or Zener diodes exhibits the following characteristics:
• Switching overvoltages can be avoided entirely. A Zener diode has a higher
turn-off voltage.
• High turn-off delay (6 to 9 times higher than without suppressor circuits)
The Zener diode switches off more quickly than a diode circuit.
Suppression with AC-Operated Coils
AC-operated coils are suppressed with varistors or RC elements.
With varistor
With RC element
~
~
~
~
Figure A-10
Suppression with AC-Operated Coils
Suppression with a varistor exhibits the following characteristics:
• The amplitude of the switching overvoltage is limited but not attenuated.
• The steepness of the surge voltage remains the same.
• Low turn-off delay.
Suppression with an RC element exhibits the following characteristics:
• The amplitude and steepness of the switching overvoltage are reduced.
• Low turn-off delay.
S7-400 and M7-400 Programmable Controllers Hardware and Installation
A5E00069481-04
A-31
Assembling and Installing Systems
A.11
Safety of Electronic Control Equipment
Intoduction
The notes below apply independent of the type or manufacturer of the electronic
control.
Reliability
Maximum reliability of SIMATIC devices and components is achieved by
implementing extensive and cost-effective measures during development and
manufacture:
• Use of high-quality components;
• Worst-case design of all circuits;
• Systematic and computer-aided testing of all components;
• Birm-in of all large-scale integrated circuits (e.g. processors, memory, etc.);
• Measures preventing static charge when handling MOS ICs;
• Visual checks at different stages of manufacture;
• Continuous heat-run test at elevated ambient temperature ove a period of
several days;
• Careful computer-controlled final testing;
• Statistical evaluation of all returned systems and components to enable the
immediate initiation of suitable corrective measures;
• Monitoring of major control compoments, using on-line tests (watchdog for the
CPU, etc.).
These measures are referred to in safety technology as basic measures. They
prevent or rectify a large proportion of possible faults.
A-32
S7-400 and M7-400 Programmable Controllers Hardware and Installation
A5E00069481-04
Assembling and Installing Systems
Risks
In all cases where the occurrenced of failures can failures can result in material
damage or injury to persons, special measures must be taken to enhance the
safety of the installation - and therefore also of the situation. System-specific and
special regulations exist for such applications. They must be observed on installing
the control system (e.g. VDEE 0116 for burner control systems).
For electronic control equipment with a safety function, the measures that habe to
be taken to prevent or rectify faults are based on the risks involved in the
installation. As of a certain degree of hazard the basic measures mentioned above
are no longer sufficient. That is, additional measures (e.g. redundant
configurations, tests, checksums, etc.) must be implemented and certified for the
control equipment (DIN VDE 0801). The prototype of the fail-safe PLC S5-95F was
tested by TÜV (German Institute for Technological Suirveillance), BIA and G EM III;
several certificates have been granted. Thus, it is suitable in the same way as the
previously tested fail-safe PLC S5-115F to control and monitor safety-relevant
system areas.
Splitting the group into safety-relevant areas and areas which are not
savety-relevant
Most plants contain equipment performing safety-relevant operations (e.g.
EMERGENCY-OFF switch, protective gates, two-hand controls). To avoid the need
to examine the entire controller from the aspect of safety, the controller is usually
divided into an area that is saftey-relevant and an area that is not
safety-relevant. In the non-safety-related area, no special demands are placed on
the safety of the control equipment because any failure in the electronics will have
no effect on the safety of the installation. In the safety-relevant area, however, it is
only allowed to operate controllers or circuits compliant with corresponding
regulations.
The following divisions are common in practical situations:
• For control equipment with few safety-related functions (e.g. machine controls)
The conventional PLC is responsible for machine control, whereas
safety-related functions are implemented with a fail-safe mini PLC (e.g.
S5-95F).
• For controllers with balanced areas (e.g. chemical installations, cable cars)
In this case also, the area that is not safety-relevant is controlled with a
standard PLC, whereas a tested fail-safe controller (S7-400F, S7-400FH,
S5-115F, or multiple S5–95F) controls the safety-relevant areas.
The entire installation is implemented with a fail-safe control system.
• For control equipment with mainly safety-relevant functions (e.g. burner control
systems)
The entire control system is implemented with fail-safe technology
S7-400 and M7-400 Programmable Controllers Hardware and Installation
A5E00069481-04
A-33
Assembling and Installing Systems
Important Information
Even when electronic control equipment has been configured for maximum design
safety – e.g. with a multi-channel structure – it is imperative conform with
instructions given in the operating manual. Incorrect handling can render measures
intended to prevent dangerous faults ineffective, or generate additional sources of
danger.
A.12
Interference-Free Connection of Monitors
Introduction
You can use operator interfaces with monitor ports from the COROS product family.
The layout of apparatus and the interference content of the environment
significantly affect the interference-free connection of monitors to a programmable
controller. The choice of monitor and video cables is governed by whether the
monitor and programmable controller are to be operated under low-interference
conditions or under industrial conditions.
Operation under Low-Interference Conditions
Where a monitor and the programmable controller operate in a low-interference
environment and there is only a short distance between monitor and programmable
controller, they are at almost the same ground potentials. Interference and
disturbance by ground loops are therefore not expected.
In these cases, you can use either TTL or analog signals to drive the monitor.
Digital cables or single-shielded coaxial cables can be used to transmit the video
signals. Note that the braided shield of the coaxial cable serves as the return
conductor and must not be connected to the shield bus. The monitor and
communications processor (CP) are interconnected without additional shielding
and grounding.
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Assembling and Installing Systems
Operation under Industrial Conditions
Where the monitor and programmable controller are operated under harsh
industrial conditions or there is a great distance between monitor and
programmable controller, the apparatus may be at different ground potentials; this,
in turn, can result in interference and disturbances caused by ground loops.
In these cases, double-shielded coaxial cable (triaxial cable) must be used to
transmit the video signals. The inner braided shield of this cable serves as the
return conductor and must not be connected to the shield bus. The outer braided
shield serves to discharge interference currents and must be incorporated in
shielding and grounding measures.
To avoid ground loops, the electronics ground and housing ground of the monitor
must be separate. This requirement is considered to be met when one of the
following conditions is fulfilled:
• Electronic and housing grounds of the monitor are isolated from each other.
• Electronic and housing grounds of the monitor are interconnected via a
voltage-dependent resistor (VDR) fitted by the manufacturer of the monitor.
Shielding and Grounding under Industrial Conditions
If the monitor and programmable controller are operated under harsh industrial
conditions, you must observe the following:
On the side of the programmable controller:
• Connect the cable shields in the cabinet to the shield bus immediately after
cabinet entry. The following points are important:
– Strip the video cables without damaging the conductors.
– Secure the outer braided shield with the largest possible area to the shield
bus of the programmable controller (for example, with metal hose clamps
which surround the shield, or with cable clamps).
• Provide large-area contact between the shield buses and the frame or cabinet
wall.
• Connect the shield bus to the ground point of the cabinet.
On the side of the monitor:
• Isolate the electronic ground and housing ground from each other. Proceed as
follows:
– Remove the jumper on the monitor to separate the two grounds.
– Fit touch protection to the video sockets, because when the grounds have
been separated, a dangerous touch voltage of more than 40 V may be
present at the sockets.
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A-35
Assembling and Installing Systems
!
Caution
There is a risk of personal injury.
Dangerous touch voltages may be present at the video sockets of the monitor.
Fit suitable touch protection to the sockets.
• Connect the ground clamp of the monitor to the chassis ground.
• Connect the cable shields to the ground clamp of the monitor as follows:
Proceed as follows:
– Strip the outer cable insulation of the video cables in the region of the ground
clamp of the monitor, without damaging the braided shield.
– Secure the outer braided shield over a large area to the ground clamp of the
monitor.
Figure A-11 shows a simplified representation of shielding and grounding for
monitor and S7-400.
CR
Monitor with
separate
electronic
ground and
housing
ground
CP
Ó
Ó
Ó
Figure A-11
A-36
Shield bus
Outer shield
connected
to ground
clamp
Shielding and Grounding with a Great Distance between Monitor and Programmable
Controller
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Guidelines for Handling
Electrostatically-Sensitive Devices (ESD)
B
Chapter Overview
Section
Description
Page
B.1
What is ESD?
B-2
B.2
Electrostatic Charging of Persons
B-3
B.3
General Protective Measures Against Electrostatic Discharge Damage
B-4
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B-1
Guidelines for Handling Electrostatically-Sensitive Devices (ESD)
B.1
What is ESD?
Definition:
All electronic modules are equipped with large-scale integrated ICs or components.
Due to their design, these electronic elements are very sensitive to overvoltages
and thus to any electrostatic discharge.
These Electrostatically-Sensitive Devices are commonly referred to by the
abbreviation ESD.
Electrostatically-sensitive devices are labeled with the following symbol:
!
B-2
Caution
Electrostatically-sensitive devices are subject to voltages that are far below the
voltage values that can still be perceived by human beings. These voltages are
present if you touch a component or the electrical connections of a module without
previously being electrostatically discharged. In most cases, the damage caused
by an overvoltage is not immediately noticeable and results in total damage only
after a prolonged period of operation.
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Guidelines for Handling Electrostatically-Sensitive Devices (ESD)
B.2
Electrostatic Charging of Persons
Charging
Every person with a non-conductive connection to the electrical potential of its
surroundings can be charged electrostatically.
Figure B-1 shows you the maximum values for electrostatic voltages which can
build up on a person coming into contact with the materials indicated in the figure.
These values are in conformity with the specifications of IEC 61000-4-2.
Voltage in kV
(kV
) 16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
1
Synthetic material
2
Wool
3 Antistatic material, for
example, wood or concrete
1
2
3
5 10 20 30 40 50 60 70 80 90 100
Figure B-1
Relative air
humidity in %
Electrostatic Voltages which can Build up on a Person
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B-3
Guidelines for Handling Electrostatically-Sensitive Devices (ESD)
B.3
General Protective Measures Against Electrostatic
Discharge Damage
Ensure Sufficient Grounding
Make sure that the personnel, working surfaces, and packaging are sufficiently
grounded when handling electrostatically-sensitive devices. You thus avoid
electrostatic charging.
Avoid Direct Contact
You should touch electrostatically-sensitive devices only if it is unavoidable
(for example, during maintenance work). Hold modules without touching the pins of
components or printed conductors. In this way, the discharged energy cannot affect
the sensitive devices.
If you have to carry out measurements on a module, you must discharge your body
before you start the measurement by touching grounded metallic parts. Use
grounded measuring devices only.
B-4
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Glossary
A
Accumulator (ACCU)
The accumulators are registers in the CPU and are a buffer for load, transfer and
comparison, math and conversion instructions.
Address
An address is the identifier for a specific area of memory on which an instruction
acts.
Examples: Input I 12.1; Memory Word MW24; Data Block DB3.
Analog Module
Analog modules convert analog process variables (for example, temperature) into
digital values that can be processed in the CPU or they convert digital values into
analog manipulated variables.
Application Module
Application modules are function modules from the M7 range.
AT Adapter Module
The ATM 478 AT adapter module provides a slot for a short AT card.
B
Backup Battery
The backup battery ensures that the user program in the CPU is not lost in the
event of a power failure and that defined data areas, bit memory, timers, and
counters are also retained.
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Glossary-1
Glossary
BIOS
Basic Input Output System
BIOS is understood to mean the part of the software which creates the link
between hardware and the operating system, for example, MS-DOS. This software
is stored in an EPROM.Basic Input Output System
Examples of important sections are the loader for the operating system, the
(hardware) setup for defining the hardware configuration and for setting the time.
Bit Memory (M)
A memory area in the system memory of a SIMATIC CPU. This area can be
accessed using write or read access (bit, byte, word, and double word). The bit
memory area can be used by the user to store intermediate results. It can be
accessed bit by bit, byte by byte, word by word, or double word by double word.
Building Ground
The connection between data processing equipment and ground, whereby no
unacceptable functional interference to data processing equipment is caused by
external effects, such as interference caused by power systems. The connection
must be in the form of a low-noise ground.
Bus
A bus is a transfer medium which interconnects several nodes. Data transmissions
can be serial or parallel over electical conductors or fiber-optic cables.
C
Chassis Ground
The chassis ground comprises all interconnected inactive parts of an apparatus,
which even in case of a fault cannot take dangerous touch voltages.
Communications Processor
Communications processors are modules for point-to-point and bus connections.
Compress
The PG online function “Compress” is used to shift all valid blocks in the RAM of
the CPU evenly and without any gaps to the beginning of the user memory. All
gaps caused by deleting or correcting blocks are thus removed.
Glossary-2
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Glossary
Configuration
The configuration is the selection and putting together of the individual components
of a programmable logic controller (PLC).
Configuring
Configuring is the assigning of modules to racks or slots and (with signal modules)
addresses.
Connecting Clip
These are the clips with which the modules are mechanically interconnected within
an M7 module assembly.
Counters
Counters are an area in the system memory of the CPU. The contents of these
counters can be changed using STEP 7 instructions (for example, up counter,
down counter).
CP
Communications Processor
CPU
Central processing unit of the S7 or M7 programmable controller with processor,
arithmetic unit, memory, operating system, and programming device interface.
Cyclic Interrupt
A cyclic interrupt is generated by the S7-400 CPU periodically according to a
programmable time interval. A corresponding organization block is then executed.
D
Data Block (DB)
Data blocks are areas in the user program which contain user data. There are
shared data blocks which can be accessed by all logic blocks, and there are
instance data blocks which are associated with a particular function block (FB) call.
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Glossary-3
Glossary
Data, Static
Static data are data which are used only within a function block. These data are
stored in an instance data block belonging to the function block. The data stored in
the instance data block are retained until the next function block call.
Data, Temporary
Temporary data are local data of a block that are stored in the L stack during
processing of the block and that are not retained after processing.
Default Setting
A default setting is an expedient basic setting which is always used when no other
value is preset by a parameter.
Diagnostics
System Diagnostics
Diagnostic Buffer
The diagnostic buffer is a retentive area of memory within the S7-400 CPU which
stores the diagnostic events in the order they occurred.
Diagnostic Interrupt
Modules with diagnostics capability signal system errors to the S7-400 CPU by
means of diagnostic interrupts.
E
Electromagnetic Compatibility (EMC)
Electromagnetic compatibility is understood to mean the capability of electrical
apparatus to operate without faults in a given environment, without affecting that
environment in an unacceptable manner.
Equipotential Bonding
An electrical connection (equipotential bonding conductor) that ties the exposed
conductive parts of an item of electrical equipment and extraneous conductive
parts to the same, or approximately the same, potential in order to prevent
disturbing or dangerous voltages between these parts.
Glossary-4
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Glossary
Error Display
Error display is one of the possible responses of the operating system to a run-time
error. The other possible responses include: error response in the user program,
STOP mode of the CPU.
Error Handling via OB
When the operating system detects an error (for example, STEP 7 access error), it
calls the specific organization block (error OB) for this error, where the further
response of the CPU can be specified.
Error Response
Response to a run-time error. The operating system can respond to the following
types: transferring of the programmable controller to STOP mode, calling of an
organization block where the user can program a response, or displaying of the
error.
Expansion Module
The expansion module of M7-400 is connected with the CPU via an ISA bus
interface and accommodates up to three interface submodules.
F
FB
Function Block
FC
Function
Flash EPROM
With regard to their characteristic to retain data in the case of a power failure,
FEPROMs correspond to the electrically erasable EEPROMs, but can be erased
much faster (FEPROM = Flash Erasable Programmable Read Only Memory). They
are used on the memory cards.
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Glossary-5
Glossary
Function
According to IEC 61131-3, a function is a code block that contains no static
data. A function allows parameters to be passed in the user program. Functions
are therefore suitable for programming complex functions, e.g. calculations, which
are repeated frequently.
Functional Grounding
Grounding whose only purpose is to ensure the intended function of the electrical
equipment concerned. Functional grounding short-circuits any noise that might
otherwise have a detrimental effect on the equipment.
Function Block (FB)
According to IEC 61131-3, a function block is a code block that contains static
data. An FB allows parameters to be passed in the user program. Function blocks
are therefore suitable for programming complex functions, e.g.
closed-loop controls, mode selections, which are repeated frequently.
Function Module (FM)
A programmable module which, in contrast to the CPU, has no multipoint interface
and can only be operated as a slave.
G
GD Circle
A GD circle comprises a number of CPUs which exchange data via global data
communication and are used as follows:
• A CPU sends a GD packet to the other CPUs.
• A CPU sends and receives a GD packet from another CPU.
A GD circle is identified by a GD circle number.
GD Element
A GD element is created through assigning the global data to be exchanged and is
clearly identified in the global data table by the GD identifier.
GD Packet
A GD packet can consist of one or more GD elements which are transmitted
together in a message frame.
Glossary-6
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Glossary
Global Data
Global data are data which can be accessed from each logic block (FC, FB, OB).
These include bit memory M, inputs I, outputs Q, timers T, counters C, and data
blocks DB. Global data can be accessed either absolutely or symbolically.
Global Data Communication
Global data communication is a procedure with which global data are transferred
between CPUs (without communication function blocks (CFBs)).
Ground
The conductive mass of the ground whose potential can be assumed to be zero at
any point.
In the vicinity of ground electrodes, the ground may have a potential other than
zero. The term “reference ground” is often used in this situation.
Ground (verb)
To ground means connecting an electrically conductive part via a grounding system
to ground (one or more electrically conductive parts that have good contact with the
soil).
H
Hardware
The hardware is understood to be the entire physical and technical equipment of a
programmable controller.
Hardware Interrupt
Interrupt-triggering modules trigger a hardware interrupt in the case of a certain
event in the process. The hardware interrupt is signalled to the CPU. In accordance
with the priority of this interrupt, the corresponding organization block is then
executed.
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Glossary-7
Glossary
I
Instance Data Block
With the S7-400, each call of a function block in the STEP 7 user program is
assigned a data block which is generated automatically. In the instance data block,
the values of the input, output and in/out parameters as well as the local block data
are stored.
Interface, Multipoint
Multipoint Interface.
Interface Submodules
Submodules which provide the automation computer with additional interfaces,
such as VGA, COM, PROFIBUS DP, etc.
Interrupt
The operating system of the S7-400 CPU has 10 different priority classes which
control the processing of the user program. These priority classes include
interrupts, such as hardware interrupts. When an interrupt occurs, the relevant
organization block is called automatically by the operating system in which the user
can program the required reaction to the interrupt (for example, in a function block
(FB)).
Interrupt, Cyclic
Cyclic Interrupt
Interrupt, Diagnostic
Diagnostic Interrupt
Interrupt, Hardware
Hardware Interrupt
Interrupt, Time-Delay
Time-Delay Interrupt
Interrupt, Time-Of-Day
Time-Of-Day Interrupt
Glossary-8
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Glossary
ISA Bus
The ISA bus is the standard bus in the AT-compatible PC. It is looped through the
M7-400 module assembly via the 120-pin expansion sockets and plugs of the
individual M7-400 modules.
Isolated
In the case of isolated I/O modules, the reference potentials of the control and load
circuits are galvanically isolated from each other, for example, by optocouplers,
relay contacts, or transformers. The I/O circuits can be connected to a common
potential.
K
Keyswitch
The keyswitch is the mode selector switch of the CPU. The keyswitch is operated
with a key which can be withdrawn.
L
Load Memory
The load memory is part of the S7-400 CPU. It contains objects created by the
programming device. It can be either a plug-in memory card or an integrated
memory.
Load Power Supply
Power supply for the signal and function modules and the process I/O connected to
them.
Local Data
Data, Temporary
Logic Block
In SIMATIC S7, a logic block is a block that contains part of the STEP 7 user
program. The other type of block is a data block which contains only data.
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Glossary-9
Glossary
M
Mass Storage Module
An expansion of the M7-400 programmable controller. It is connected to the CPU
via an ISA bus interface and contains a floppy disk drive and a hard disk drive.
Measuring Range Submodule
Measuring range submodules are plugged onto the analog input module for
adapting to various measuring ranges.
Memory Card
Memory cards are storage media in credit-card format for CPUs and CPs. They are
available as RAM or FEPROM.
Mode Selector Switch
Keyswitch
Module Parameters
Module parameters are used to set the module reactions. A difference is made
between static and dynamic module parameters.
Multipoint Interface (MPI)
The multipoint interface is the programming device interface in SIMATIC S7/M7. It
enables the simultaneous operation of a number of nodes (programming devices,
text display operator interfaces, and operator panels) from one or more CPUs.
Each node is identified by an address (MPI address).
MPI Address
Multipoint Interface (MPI)
N
Nesting Depth
A block can be called from another block by means of block calls. The nesting
depth is the number of simultaneously called logic blocks.
Glossary-10
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Glossary
Network
In communications, a network is the connection between two or more
S7-400s/M7-400s and other terminals such as a programming device, via a
connecting cable. Data are exchanged over the network between the connected
stations.
Node Number
The node number represents the accessing address of a CPU or programming
device or of another intelligent I/O module when they communicate with each other
via a network. The node number is assigned by the CPU or programming device
using the STEP 7 software.
Non-Isolated
In the case of non-isolated I/O modules, the reference potentials of the control and
load circuits are electrically connected to each other.
O
OB
Organization Block
OB Priority
The operating system of the S7-400 CPU differentiates between various priority
classes, for example, cyclic program processing, process interrupt-controlled
program processing. Each priority class is assigned organization blocks (OBs),
where the S7 user can program a reaction. As a standard, the OBs have different
priorities to which they are processed when they occur simultaneously or when
they interrupt each other.
On-Board Silicon Disk
The on-board silicon disk is a memory unit in which all or part of the software of a
CPU 488-4 is stored retentively, including static data.
Operating State
The SIMATIC S7 programmable controllers recognize the following operating
states: STOP, STARTUP, RUN.
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Glossary-11
Glossary
Operating System of the CPU
The operating system of the CPU organizes all functions and sequences of the
CPU which are not connected to a specific control task.
Organization Block (OB)
Organization blocks form the interface between the operating system of the S7-400
CPU and the user program. The sequence in which the user program should be
processed is laid down in the organization blocks.
P
Parameter
1. Variable of a STEP 7 logic block
2. Variable for setting the reaction of a module (one or more per module).
Parameters can be static or dynamic.
Parameters, Dynamic
In contrast to static parameters, dynamic parameters of modules can be changed
during operation by calling an SFC in the user program, for example, limit values of
an analog signal input module.
Parameters, Static
In contrast to dynamic parameters, static parameters of modules cannot be
changed by means of the user program, but only via STEP 7 (not in the RUN
state); for example, input delay of a digital signal input module.
PG
Programming Device
PLC
Programmable Logic Controller
Glossary-12
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Glossary
Process Image
The process image is a component part of the system memory of the S7-400 CPU.
At the beginning of the cyclic program, the signal states of the input modules are
transferred to the process-image input table (PII). At the end of the cyclic program,
the process-image output table (PIQ) is transferred to the output modules as the
signal state.
Programmable Logic Controller (PLC)
Programmable controllers are electronic control devices whose functions are
stored in the controller in the form of a program. The structure and wiring of a PLC
therefore do not depend on the actual functions of the controller. Programmable
controllers and computers have similar structure: they consist of a CPU (central
processing unit) with memory, input/output modules, and an internal bus system.
The I/O and programming language are tailored to the requirements of open-loop
control technnology.
Programming Device (PG)
A personal computer with a special compact design, suitable for industrial
conditions. A Siemens programming device is completely equipped for
programming the SIMATIC programmable logic controllers.
Protective Ground
Connection via protective conductor to a common ground conductor for the
exposed, conductive parts of electrical apparatus which are not normally live, but at
which a voltage may be present in the event of a fault, and which are jointly
protected via a protective device.
R
RAM
The RAM (Random Access Memory) is a semiconductor memory with random
access (read/write memory).
Reference Ground
Ground
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Glossary-13
Glossary
Reference Potential
The potential on which the voltages of the various circuits are based and according
to which they are measured.
Retentive Data
Retentive data are not lost after a power failure, if a backup battery is provided.
Revision Level
Products with the same order number are differentiated by their revision level. The
revision level is increased for upwardly-compatible function expansions, for
changes due to production reasons (use of new components) and for fault
correction.
Run-Time Error
Errors that occur in the programmable controller (that is, not in the process) during
execution of the user program.
S
Scan Cycle Time
The scan cycle time is the time the CPU takes to run the user program once
through.
Scan Rate
The scan rate defines how often GD packets are sent and received on the basis of
the CPU cycle.
SFB
System Function Block
SFC
System Function
Glossary-14
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Glossary
Signal Module
Signal modules (SMs) are the interface between the process and the
programmable controller. Signal modules comprise digital input and output
modules (I/O module, digital) and analog input and output modules (I/O module,
analog).
SRAM Backup
A static RAM: with the programmable modules of the M7-400 programmable
controller, part of the main memory is backed up as an SRAM.
STARTUP
The CPU goes through the STARTUP state during the transition from STOP to
RUN mode. It can be set using the mode selector on the CPU, following power-on,
or by an operation on the programming device.
STEP 7
Programming language for writing user programs for SIMATIC S7 programmable
controllers.
Substitute Value
Substitute values are values which are output to the process in the case of faulty
signal output modules or which are used in the user program instead of a process
variable in the case of faulty signal input modules. The substitute values can be
specified in advance by the user (for example, maintain old value).
System Diagnostics
System diagnostics is the detection, evaluation, and reporting of errors occurring
within the programmable controller. Examples of such errors are: program errors or
failures on modules. System errors can be indicated with LED indicators or by
STEP 7.
System Function (SFC)
A system function (SFC) is a function integrated in the CPU operating system
which can be called in the user program when required.
System Function Block (SFB)
A system function block (SFB) is a function block integrated in the CPU operating
system which can be called in the STEP 7 user program when required, just like a
function block (FB).
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Glossary-15
Glossary
System Memory
The system memory is integrated in the CPU and executed in the form of RAM.
The address areas (timers, counters, bit memory, etc.) and data areas required
internally by the operating system (for example, backup for communication) are
stored in the system memory.
T
Time-Delay Interrupt
The time-delay interrupt belongs to one of the priority classes in SIMATIC S7-400
program processing. It is generated after expiry of a time started in the user
program. A corresponding organization block is then executed.
Time-Of-Day Interrupt
The time-of-day interrupt belongs to a priotity class in SIMATIC S7-400 program
processing. It is generated depending on a certain date (or daily) and time of day
(for example, 9:50 or hourly, per minute). A corresponding organization block is
then executed.
Timer (T)
Timers are an area in the system memory of the CPU. The contents of these timers
are updated by the operating system asynchronously to the user program. You can
use STEP 7 instructions to define the exact function of the timer (for example,
on-delay timer) and start processing it (Start).
Total Current
Sum of currents of all output channels of a digital output module.
Transmission Rate
Speed of data transmission in bits per second
U
Ungrounded
Without galvanic connection to ground.
Glossary-16
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Glossary
User Memory
The user memory contains logic blocks and data blocks of the user program. The
user memory can either be intergrated in the CPU or can be plugged in on memory
card or memory submodules. In general, however, the user program is executed
from the work memory (RAM) of the CPU.
User Program
With SIMATIC a difference is made between the operating system of the CPU and
user programs. The latter are generated by means of the STEP 7 programming
software in the possible programming languages (Ladder Logic, Statement List,
Function Block Diagram) and are stored in logic blocks. Data are stored in data
blocks.
V
Varistor
Voltage-dependent resistor
W
Warm Restart
When a CPU starts up (for example, when the mode selector is moved from STOP
to RUN or when power is turned on), before cyclic program processing starts
(OB1), OB100 (complete restart) is processed first. In a warm restart, the
process-image input table is read in and the STEP 7 user program processed
starting with the first statement in OB1.
Work Memory
The work memory is the RAM (Random Access Memory) in the CPU to which the
STEP 7 user program is automatically reloaded from the load memory. The
processor executes the program in the work memory in RUN mode.
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Glossary-17
Glossary
Glossary-18
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Index
A
C
Accessories, 2-39
Addresses
geographical, 3-2
logical, 3-2
Addressing modules, M7-400, 8-5
Analog modules, replacing, 7-7
Assembling the bus cable, on a bus connector
with order number 6ES7 ..., 5-20
Assembling, M7-400
MPI subnet, 8-30
PROFIBUS-DP subnet, 8-30
Assembly
central, 2-2
distributed, 2-2
Assembly, M7-400
interface submodules, 6-18, 8-13
module accessories, 8-10
AT card, M7-400, fitting, 8-56
ATM 478, M7-400
fitting the short AT card, 8-15
replacing a short AT card, 8-56
C bus, 2-7
Cable lengths, maximum, 5-15
Cabling, inside buildings, A-17
Changing fuse, digital modules, 7-9
Channel
on a digital module, 3-6
on an analog module, 3-7
Checklist, M7-400
installation, 8-9
preparing for operation, 8-32
Choosing the Power Supply Module, M7-400,
8-6
COM interface, M7-400, connecting a
PC/programming device, 8-36
Commissioning, M7-400
checklist, 8-9
sections, 8-32
Communication, programming device – CPU,
6-6
Communication bus (C-bus), 2-7
Components
for MPI network, 5-8
of the S7-400, 1-1
PROFIBUS-DP network, 5-8
Configuration
electrical, A-2
interference-free, 4-15
Connecting a mouse, M7-400, 8-35
Connecting a programming device, 6-5
Connecting terminal, M7-400, 8-22
Connecting, M7-400
module assembly, 8-29
operator panels and I/O devices, 8-33
PC, 8-36
programming device, 8-36
Connection, rules, 2-5
Connection, M7-400
keyboard, 8-33
VGA monitor, 8-33
Connector, M7-400, removing the cover, 8-18
B
Backup battery
disposing, 7-3
inserting, 6-13
removing, 7-2
replacing, 7-2
using, 7-3
Baud Rate, 5-3
Bus cable, length of spur lines, 5-16
Bus connector
connecting to the module, 5-22
purpose, 5-19
removing, 5-22
setting the terminating resistor, 5-22
terminating resistor, 5-9
Bus connectors, assembling bus cables, 5-20
Bus segment. See Segment
S7-400 and M7-400 Programmable Controllers Hardware and Installation
A5E00069481-04
Index-1
Index
Coupling
capacitive, A-6
direct, A-6
inductive, A-6
CPU, 1-3
resetting the, 6-7, 6-10
restarting the, 6-10
CPU, M7-400, replacing a module assembly,
8-49
CPUs, replacing, 7-5
CPUs, M7-400, covering unused submodule
slots, 6-19, 8-14
D
Digital modules
fuses, 7-9
replacing, 7-7
Distributed I/Os, 2-38
Fitting, M7-400
AT adapter module, 8-15
ATM 478, 8-15
extension modules, 8-17
memory cards, 2-31, 7-19, 8-11
Front connector
coding key, 4-35
labeling, 4-31
plugging in, 4-35
wiring, 4-26
with crimp snap-on terminals, 4-24
with screw-type terminals, 4-24
with spring-type terminals., 4-24
Front connector coding, 4-35
Fuse of the fan subassembly, replacing, 7-13
G
Grounded configuration, M7-400, connecting a
programming device, 8-43
E
Electrical configuration, M7-400, 8-6
EMC-compatible mounting – examples, A-10
EMERGENCY OFF devices, A-2
Equipotential bonding, A-15, A-22
Error, how to proceed if an error occurs, 6-2
Expansion connector, M7-400, removing the
cover, 8-18
Expansion module, M7-400, covering unused
submodule slots, 6-19, 8-14
Expansion modules, M7-400, replacing a
module assembly, 8-49
Expansion socket, M7-400, removing the
cover, 8-18
Extension modules, M7-400, fitting to a CPU,
8-17
F
Fan subassembly
replacing fans, 7-14
replacing the filter frame, 7-16
replacing the fuse, 7-13
replacing the monitoring PCB, 7-18
replacing the power supply PCB, 7-18
Index-2
H
Highest MPI address, 5-4
I
I/O bus, 2-7
I/O devices, M7-400, connecting, 8-33
Installation
for EMC, A-5
of cabinets, 2-26
Installing, M7-400, 8-8
checklist, 8-9
module assembly, 8-24
Insulation monitoring, 4-9
Interface module, M7-400, replacing, 8-47
Interface modules
inserting, 8-13
replacing, 7-11
Interface submodules, M7-400, installing, 6-18,
7-22, 8-13
Interference, radiated, A-6
S7-400 and M7-400 Programmable Controllers Hardware and Installation
A5E00069481-04
Index
K
Keyboard, M7-400, connecting the, 8-33
Keyboard, M7-400, maximum line length, 8-35
L
Lightning protection, A-19, A-20
for 24 VDC supply, A-25
for signal modules, A-25
high-voltage protector, A-23
low-voltage protection, A-26
Lightning protection zones, A-21
Lightning strike, A-21
Load current circuit, 4-5
Load current power supplies, 4-4
Location, M7-400
module designation, 1-6
order number, 1-6
product release, 1-6
M
M7-400
electrical configuration, 8-6
mechanical configuration, 8-2
Main power supply, A-3
Mechanical configuration, M7-400, 8-2
Memory card, inserting, 6-11, 6-12
Memory card, M7-400, inserting/removing,
8-28
Memory cards, M7-400, replacing, 8-54
Methods of ventilation, 2-19
Mode selector switch, M7-400, inserting the
key, 8-27
Module accessories, M7-400, 8-10
Module assembly, M7-400
connecting, 8-29
installing in the rack, 8-24
Modules
installing, 2-33
isolated, 4-10
signal, 2-7
slot numbers, 2-37
Modules, M7-400
interconnecting, 8-21
latching, 8-22
removing the cover, 8-20
replacing, 8-46
screwing on, 8-26
Monitor, M7-400
connecting the, 8-33
maximum line length, 8-35
setting up, 8-34
MPI, definition, 5-2
MPI address, 5-4
highest, 5-4
rules, 5-4
MPI addresses, recommendation, 5-8
MPI network
components, 5-8
configuration example, 5-11, 5-13
configuration rules, 5-7
data packets in, 5-8
segment, 5-15
MPI parameters, 6-9
MPI subnet, M7-400, assembling, 8-30
MPI, M7-400
connecting a programming device to a
node, 8-39
connecting a programming device to
ungrounded nodes, 8-43
connecting the programming device to
several nodes, 8-40
Multipoint interface, 8-43
N
Networking, possibilities, 2-38
Node, 5-3
Nodes, number of, 5-4
O
Operator panels, M7-400, connecting, 8-33
Overall installation, in the TN-S system, 4-6
Overvoltage, A-20
S7-400 and M7-400 Programmable Controllers Hardware and Installation
A5E00069481-04
Index-3
Index
Overvoltage protection, A-30
R
Rack, 1-3
clearances, 2-10
P
mounting dimensions, 2-10
Power supply connector
segmented, 2-8, 2-9
disconnect, 4-20
subdivided, 2-9
plugging in, 4-23
with I/O bus and C bus, 2-7
wiring, 4-21
Racks
Power supply module, 1-3
grounding, 2-10
choosing, 4-3
mounting, 2-10
replacing, 7-4
of the S7-400 system, 2-6
Preparing for operation, M7-400, 8-32
Rating plate, M7-400, 1-6
checking status and error indicators, 8-45
Reference potential
checklist, 8-32
grounded, 4-7
connecting a PC/programming device to the
ungrounded, 4-8
COM interface, 8-36
Regulations, for operating the S7-400, A-2
connecting the operator panels and I/O
Replacing interface submodules, 7-22
devices, 8-33
Replacing memory cards, 7-19
starting up a PROFIBUS-DP, 8-44
RS 485 repeater, 5-7, 5-23
Printer, M7-400
assembly, 5-23
connecting, 8-34
connecting the PROFIBUS-DP bus cable,
maximum line length, 8-35
5-24
PROFIBUS-DP, starting up, 6-17
terminating resistor, 5-9
PROFIBUS-DP address, 5-4
wiring the power supply unit, 5-23
PROFIBUS-DP addresses, recommendation,
Rules
5-8
for configuring a network, 5-7
PROFIBUS-DP bus cable, 5-18
for ensuring electromagnetic compatibility,
characteristics, 5-18
A-7
rules for laying the, 5-18
general, A-2
PROFIBUS-DP network
wiring, 4-17
components, 5-8
Running cables, outside buildings, A-19
configuration example, 5-12, 5-13
configuration rules, 5-7
segment, 5-15
S
PROFIBUS-DP subnet, M7-400
Segment, 5-3
assembling, 8-30
MPI network, 5-15
starting up, 8-44
PROFIBUS-DP network, 5-15
Programming device, connecting, 6-5
Setting up, M7-400, monitor, 8-34
Programming device, M7-400
Short AT card, M7-400, fitting, 8-15
connecting to a grounded configuration,
Signal module, 1-3
8-43
Socket, M7-400, removing the cover, 8-18
connecting to an ungrounded configuration,
Space requirements
8-43
of cabinets, 2-29
in the MPI subnet, 8-41
of the racks, 2-30
via spur line to MPI subnet, 8-42
with fan subassembly, 2-11
Protection against overvoltage, A-20
Protective measures, 4-5
Index-4
S7-400 and M7-400 Programmable Controllers Hardware and Installation
A5E00069481-04
Index
Spur lines, 5-7
lengths, 5-16
Start address
of analog modules, 3-5
of digital modules, 3-4
Startup, procedure, 6-2
Station. See Teilnehmer
Status and error indicators, checking, 8-45
Submodules, M7-400, replacing, 8-46
Supply, grounded, 4-5
Surge protection, components, A-26
Surge voltages, inductive, A-30
Surges, A-21
Switching on, checks prior to switching on for
the first time, 6-3
Switching on an S7-400, for the first time, 6-6
T
Terminating resistor, 5-7
example, 5-10
on the bus connector, 5-9
on the RS 485 repeater, 5-9
setting at the bus connector, 5-22
Transmission rate, 5-3
Types of cabinets, 2-28
U
Ungrounded configuration, M7-400, connecting
a programming device, 8-43
S7-400 and M7-400 Programmable Controllers Hardware and Installation
A5E00069481-04
Index-5
Index
Index-6
S7-400 and M7-400 Programmable Controllers Hardware and Installation
A5E00069481-04