Siemens Simatic M7-400 Installation Manual Download

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Contents

xiv

S7-400 and M7-400 Programmable Controllers Hardware and Installation

A5E00069481-04

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

Installing the M7-400

8-8

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.4.1

Checklist for Installation

8-9

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.4.2

Module Accessories

8-10

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.4.3

Fitting Memory Cards in the CPU

8-11

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.4.4

Installing Interface Submodules

8-13

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.4.5

Fitting the Short AT Card

8-15

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.4.6

Assembling Expansion Modules on a Central Rack

8-17

. . . . . . . . . . . . . . . . . . .

8.4.7

Installing a Module Assembly in the Rack

8-24

. . . . . . . . . . . . . . . . . . . . . . . . . . .

8.4.8

Inserting/Removing a Memory Card

8-28

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.7.1

Connecting the Operator Panels and I/O Devices

8-33

. . . . . . . . . . . . . . . . . . . .

8.7.2

Connecting a Programming Device (PG) to the COM Interface

8-36

. . . . . . . . .

8.7.3

Connecting a Programming Device (PG) to the M7-400

8-39

. . . . . . . . . . . . . . .

8.7.4

Connecting a Programming Device (PG) to Two or More Nodes

8-40

. . . . . . . .

8.7.5

Connecting a Programming Device (PG)
to Ungrounded Nodes of an MPI Subnet

8-43

. . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.7.6

Starting Up a PROFIBUS-DP Subnet

8-44

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.7.7

Checking the Status and Error Indicators

8-45

. . . . . . . . . . . . . . . . . . . . . . . . . . .

8.8

Replacing Modules and Submodules/Cards

8-46

. . . . . . . . . . . . . . . . . . . . . . . . .

8.8.1

Replacing an Interface Module

8-47

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.8.2

Replacing the CPU or Expansion Modules of a Module Assembly

8-49

. . . . . .

8.8.3

Replacing Memory Cards in a CPU

8-54

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.8.4

Replacing a Short AT Card

8-56

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Summary of Contents for Simatic M7-400

Page 1: ...the M7 400 8 Appendices Assembling and Installing Systems A Guidelines for Handling Electrostatically Sensitive Devices ESD B Glossary Index S7 400 and M7 400 Programmable Controllers Hardware and Installation Installation Manual SIMATIC This manual is part of the documentation package with the order number 6ES7498 8AA03 8BA0 Edition 12 2002 A5E00069481 04 ...

Page 2: ...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 Safety Guidelines This manual contains notices intende...

Page 3: ...s 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 vers...

Page 4: ...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...

Page 5: ...on an S7 400 Manual Manual Package Contents Standard Software for S7 and M7 STEP 7 Basic Information Installing and starting up STEP 7 on a programming device PC Working with STEP 7 with the following contents 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 Creatin...

Page 6: ... 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 for S7 300 and S7 400 Function Block Diagram FBD for S7 300 and S7 400 System and Standard Functions Description of the internal registers in the CPU Description of all system functions integrated in the CPUs Description of all ...

Page 7: ...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 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 friend...

Page 8: ...tion Local time Mon Fri 8 00 to 17 00 Phone 49 0 180 5050 222 Fax 49 0 180 5050 223 E Mail adsupport siemens com GMT 1 00 United States Johnson City Technical Support and Authorization Local time Mon Fri 8 00 to 17 00 Phone 1 0 423 262 2522 Fax 1 0 423 262 2289 E Mail simatic hotline sea siemens com GMT 5 00 Asia Australia Beijing Technical Support and Authorization Local time Mon Fri 8 00 to 17 0...

Page 9: ... 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 rep...

Page 10: ...Preface x S7 400 and M7 400 Programmable Controllers Hardware and Installation A5E00069481 04 ...

Page 11: ...hanging 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 Expan...

Page 12: ... 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 Sp...

Page 13: ...t 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 7 Maintenance 7 1 7 1 Replacing the Backup Battery 7 2 7 2 Replacing...

Page 14: ... 28 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 7 1 Connecting the Operator Panels and I O Devices 8 33 8 7 2 Connecting a Programming Device PG to the COM Interface 8 36 8 7 3 Connecting a Programming Device PG to the M7 400 8 39 8 7 4 Connecting a Programming Device PG to Two or More Nodes 8 40 8 7 5 Connecting ...

Page 15: ...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...

Page 16: ...upply connector 4 22 4 12 Plugging the power supply connector 4 23 4 13 Preparing to wire the front connector 4 25 4 14 Wiring a Front Connector with Crimp Snap On Terminals 4 26 4 15 Wiring a Front Connector with Screw Type Terminals 4 27 4 16 Wiring a Front Connector with Spring Type Terminals 4 28 4 17 Principle of the spring contact 4 29 4 18 Fitting a Strain Relief Viewed from Below 4 30 4 19...

Page 17: ...on Modules 8 22 8 10 Connecting Clip 8 23 8 11 Securing the Modules with Connecting Clips Schematic Diagram 8 23 8 12 Attaching a Module Assembly Comprising CPU and Expansion Modules and Swinging it into Position 8 25 8 13 Screwing the Modules On 8 26 8 14 Inserting the Key in the CPU 8 27 8 15 Inserting a Memory Card in a CPU 8 28 8 16 Example of a Configuration with the CPU in an MPI Subnet and ...

Page 18: ...4 A 5 Routing Equipotential Bonding Conductor and Signal Line A 16 A 6 Lightning Protection Zones of a Building A 22 A 7 Sample Circuitry for Networked S7 400 PLCs A 28 A 8 Relay Contact for EMERGENCY OFF in the Output Circuit A 30 A 9 Suppression for DC Operated Coils A 31 A 10 Suppression with AC Operated Coils A 31 A 11 Shielding and Grounding with a Great Distance between Monitor and Programma...

Page 19: ...the Module Subassembly 8 3 8 2 Possible Applications of the M7 400 Modules 8 3 8 3 Dimensions of Modules in the M7 400 System 8 4 8 5 Accessories for Modules and Racks 8 10 8 6 Maximum Cable Lengths for Operator Panels and I O Devices 8 35 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 8 36 8 8 Null Modem Cable for Conn...

Page 20: ...Contents xx S7 400 and M7 400 Programmable Controllers Hardware and Installation A5E00069481 04 ...

Page 21: ...onents 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 communi...

Page 22: ... 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 programmi...

Page 23: ... 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 ...

Page 24: ...les in special cases can be operated with or without a filter 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 Illustration Central Processing Units CPUs Accessories Memory Card DRAM...

Page 25: ...ams 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 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...

Page 26: ...roduct 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 Product version Abbreviated order number 6ES7 Type label Module designation 412Ć1XF03Ć0AB0 2 3 4 ...

Page 27: ...ection 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 ...

Page 28: ...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 Secti...

Page 29: ...ferred 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 conn...

Page 30: ...pansion rack ER 4 Expansion rack ER 1 Expansion rack ER 1 Expansion rack ER 4 Expansion without 5 V local transfer Expansion with 5 V local transfer Remote expansion IM 460 0 IM 460 1 IM 460 3 Chain length max 3 m Chain length max 102 25 m Chain length max 1 5 m IM 461 0 IM 461 0 IM 461 1 IM 461 3 IM 461 3 IM 460 4 Expansion rack ER 1 Expansion rack ER 4 Chain length max 605 m IM 461 4 IM 461 4 ...

Page 31: ...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 ...

Page 32: ... Interrupts from modules have no effect because no interrupt lines exist Modules are not supplied with 24 V ER2 9 Restricted I O bus ERs 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 the battery in the power supply module nor by the voltage applied externally to the CPU or receive IM EXT BATT socket I...

Page 33: ...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 ra...

Page 34: ...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 followin...

Page 35: ...ist 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 1 ...

Page 36: ...hapter 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 fr...

Page 37: ...ided on both sides The following figure shows how much space you need to allow for when using a cable duct or fan subassembly Cable duct fan subassembly 440 mm Mounting depth fitted max 237 mm 522 5 mm with cable duct 19 inch reference level 542 5 mm with fan subassembly 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 Dimensions of the Racks The following figure shows the dimensions for racks with 18...

Page 38: ...without modules Depth 237 0 mm with modules 60 mm 290 mm 190 mm 40 mm 1 2 3 4 1 2 3 4 132 5 mm 115 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 washe...

Page 39: ...ting 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 grou...

Page 40: ... 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 110 mm 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 ...

Page 41: ...ht of 400 mm for each additional rack with a cable duct or fan subassembly Mounting depth fitted max 237 mm 840 mm 19 inch reference level Cable duct fan subassembly Cable duct fan subassembly 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 Note A minimum clearance as shown in the above figure between rack and cable duct or fan subassembly must not be prov...

Page 42: ... 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 Chassis ground terminal Reference point 1 2 3 4 5 6 7 Connecting to the Reference Point until 10 9...

Page 43: ...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 Chassis ground terminal Load voltage ground con nection reference point 1 2 3 4 5 6 7 Metallic connection undo from above in the case of ungrounded configuration The following figure shows the ground connectio...

Page 44: ...her Grounded configuration Leave the metallic connection on the rack For the connection to the reference point use the original M4 x 8 Reference point Original screw with spring lock washer M4 x 8 Connection Spring lock washer Original screw with spring lock washer M4 x 8 Rack Ungrounded configuration Grounded configuration Metallic connection Connection Spring lock washer Note Do not use any cyli...

Page 45: ... 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 Exhaust air Cable duct or fan subassembly ÇÇ ÇÇ ÇÇ ÇÇ ÇÇ ÇÇ ÇÇ ÇÇ ÇÇ ÇÇ ÇÇ ÇÇ ÇÇ ÇÇ ÇÇ ÇÇ...

Page 46: ...able Controllers Hardware and Installation A5E00069481 04 The following figure shows the ventilation when air is drawn in from the bottom Ç Ç Ç Ç Ç Ç Ç Ç Ç Ç Ç Ç Ç Ç Ç Ç Ç Ç Ç Ç Ç Ç Exhaust air Wall Supply air Cable duct or fan subassembly Modules Modules ...

Page 47: ...he 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 ba...

Page 48: ...Base Delivered state 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...

Page 49: ...he following figure shows you how to remove the left cover Left cover Quick release lock Plug in contact Snap in mechanism of dummy covers Back of cable routing Direction for pulling off 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 plat...

Page 50: ...le 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 9 10 11 12 13 14 15 16 17 18 Blanking cover 19 inch reference level 6 Refit the left cover 7 Secure the left cover with the quick release lock Monitorin...

Page 51: ...0 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 ...

Page 52: ...stallation 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...

Page 53: ... 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 ex...

Page 54: ...es for racks Further information can be found in Siemens catalogs NV21 and ET1 200 400 600 800 1000 1200 1400 W Power dissipation 20 30 40 50 60 Ambient temperature in C 1 2 3 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 ...

Page 55: ...00 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 de...

Page 56: ... 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 Modules Racks Racks UR1 UR2 UR2 H as CR UR1 UR2 as ER UR2 H as ER CR2 CR3 ER1 ER2 Power Supply Module...

Page 57: ...r 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 i...

Page 58: ...h 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 Memory card Cutout Slots 1 and 2 Polarity reversal protection Cutout Copper flag Guide support Guide support ...

Page 59: ...ylindrical 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 m...

Page 60: ...maining 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...

Page 61: ...ching 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 ...

Page 62: ...rogrammable Controllers Hardware and Installation A5E00069481 04 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 Inserting the Key in the CPU ...

Page 63: ...s 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 wh...

Page 64: ...utputs 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 networ...

Page 65: ... installing the M7 400 can be found in Section 8 4 Table 2 3 Accessories for Modules and Racks Module Accessories Supplied Accessories Not Supplied Purpose of the Accessory Rack UR CR ER Number wheel with slot labels For identifying the modules with slot labels Power Supply Module PS 1 or 2 backup batte ries For central backup of RAM areas in the CPU CPU 2 keys To operate the mode selector of the ...

Page 66: ...Installing the S7 400 2 40 S7 400 and M7 400 Programmable Controllers Hardware and Installation A5E00069481 04 ...

Page 67: ... and Installation A5E00069481 04 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 3 ...

Page 68: ...ack 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 mod...

Page 69: ...ed 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 du...

Page 70: ...ering 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 7 8 9 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 ...

Page 71: ...ault 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 ...

Page 72: ...igital 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 I 44 0 I 44 1 I 44 2 I 44 3 I 44 4 I 44 5 I 44 6 I 44...

Page 73: ...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 QW 832 QW 834 QW 836 QW 838 QW 840 ...

Page 74: ...Addressing the S7 400 3 8 S7 400 and M7 400 Programmable Controllers Hardware and Installation A5E00069481 04 ...

Page 75: ...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...

Page 76: ...ends 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 S7 400 power supply module S7 400 modules DC or AC Operating voltages 5 VDC and 24 VDC via backplane bus Load current via f...

Page 77: ... 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 ...

Page 78: ...OP power load current supplies have this characteristic 24 VDC load circuits Tolerances of the output voltages 20 4 V to 28 8 V 40 8 V to 57 6 V 51 V to 72 V 24 VDC load circuits 48 VDC load circuits 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 Suppli...

Page 79: ...is 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 t...

Page 80: ...unded 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 potentia...

Page 81: ... 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 Ground bus in cabinet N L1 L M PS CPU L1 L2 L3 N Load circuit 24 to 230 VAC for AC modules Load circuit 5 to 60 VDC for isolated DC modules Cabinet AC AC AC DC Signal modules Low voltage distribution e g TN S system 3 x 400 V PE SM Racks P E...

Page 82: ... 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 potent...

Page 83: ...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 gr...

Page 84: ... 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 ...

Page 85: ...d 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 circui...

Page 86: ... Modules Shown in Figure 4 4 are the potentials of an S7 400 configured with isolated input and output modules PS CPU L1 N 24 VDC load current PS Mexternal L Uinternal Reference potential M Data L1 N DI DO PE 230 VAC load current PS Ground bus in cabinet Racks Figure 4 4 Simplified Representation of Configuration with Isolated Modules ...

Page 87: ...ted load voltage 2L or a rated load voltage 3L is only possible using series diodes 1 L 2 L 3 L Figure 4 5 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 ...

Page 88: ...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...

Page 89: ...ge Non isolated operation Grounded configuration Ungrounded configuration To the reference point of the rack metallic connection between frame element and chassis ground must be fitted 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...

Page 90: ...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 spring...

Page 91: ...ntact 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 poten...

Page 92: ...inal 1 1 1 1 Stripping length of single conductors 7 mm 5 mm 8 to 10 mm without ferrule 10 mm with ferrule 8 to 10 mm without ferrule 10 mm with ferrule Wire end ferrules 230 VAC with insulating collar to DIN 46228 E1 5 8 24 VDC without insulating collar to DIN 46228 shape A short version with or without insulating collar to DIN 46228 Part 1 or 4 Shape A normal version with or without insulating c...

Page 93: ...n 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 avai...

Page 94: ...Wiring the S7 400 4 20 S7 400 and M7 400 Programmable Controllers Hardware and Installation A5E00069481 04 Figure 4 9 Setting the voltage selector ...

Page 95: ...nnector 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 s...

Page 96: ...wer 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 prese...

Page 97: ...C AC L L1 N PE PE L Terminals Cable Strain relief assembly Screw for the strain relief 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 ...

Page 98: ...0 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 m...

Page 99: ...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 term...

Page 100: ...r 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 connec...

Page 101: ...w 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 Fro...

Page 102: ...ou 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 Wir...

Page 103: ...r 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 wire...

Page 104: ...he 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 ...

Page 105: ...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 ...

Page 106: ...ector 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 ...

Page 107: ...or 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 applica...

Page 108: ...92 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 2DX0...

Page 109: ... 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 correct...

Page 110: ...ng 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 o...

Page 111: ...low 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 1 2 Figure 4 21 Attaching the Front Connector ...

Page 112: ...iring the S7 400 4 38 S7 400 and M7 400 Programmable Controllers Hardware and Installation A5E00069481 04 Figure 4 22 shows how to screw on the front connector Figure 4 22 Screwing On the Front Connector ...

Page 113: ...ammable 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 se...

Page 114: ...rface 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...

Page 115: ...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 subassem...

Page 116: ...7 400 and M7 400 Programmable Controllers Hardware and Installation A5E00069481 04 Power terminals spring contacts Voltage selector switch Fuse cap Fit the small cover as a strain relief Figure 4 25 Wiring the Fan Subassembly ...

Page 117: ...cure 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 s...

Page 118: ......

Page 119: ...king 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 5 ...

Page 120: ...mmend 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 Communicati...

Page 121: ...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 vol...

Page 122: ...lt 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 removin...

Page 123: ...is 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 MPI C bus PG or OP Two connection resources occupied in the CPU S7 400 station One connection resource occupied One connection resource occupied Figu...

Page 124: ...network Figure 5 2 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 perfo...

Page 125: ... 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 s...

Page 126: ...work 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 brief...

Page 127: ...erminating resistor switched on Terminating resistor switched 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 A1B1 A2B2A2B2 SIEMENS RS 485 REPEATER ON ON Terminating resistor for bus segment 1 Terminating resistor for bus segment 2 Figure 5 4 Terminating resistor on RS 485 repeater ...

Page 128: ...nating 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 RS 485 repeater Terminating resistor switch on S7 400 S7 400 S7 400 Spur line S7 300 OP OP PG Programming device Figure 5 5 Terminating resistor on MPI network ...

Page 129: ...ly 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 S7 400 S7 400 S7 400 S7 400 S7 400 S7 400 0 11 7 8 9 10 1 2 3 4 5 6 OP OP PG OP S7 300 Programming device Figure 5 6 Example of an MPI network ...

Page 130: ...IBUS DP Network 0 x PROFIBUS DP addresses of nodes S7 400 with CPU 414 2 DP as DP master ET 200M 0 6 7 8 1 2 3 4 5 PG OP PG ET 200M S5 95U ET 200B ET 200B Terminating resistor switched on Only connected via spur line for startup maintenance with default PROFIBUS DP address 0 Figure 5 7 Example of a PROFIBUS DP network ...

Page 131: ...nd simultaneously used as DP master in a PROFIBUS DP network In both networks the node numbers can be assigned separately without conflicts resulting OP S7 400 S7 400 with CPU 414 2 as DP master ET 200M ET 200B RS 485 repeater PG S7 400 S7 400 OP ET 200M ET 200B S7 200 S7 300 OP S7 300 Only connected via spur line for startup maintenance Terminating resistor switched on MPI network PROFIBUS DP net...

Page 132: ... 2 Programming device PC 2 Programming device PC 3 Programming device PC 1 MPI network 1 S7 400 with CPU 417 S7 400 with CPU 416 S7 300 with CPU 318 S7 300 with CPU 318 MPI network 3 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 n...

Page 133: ...erface 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 cab...

Page 134: ...engths of Spur Lines per Segment Transmission Rate Maximum Length of a Number of Nodes per Spur Line Length of Maximum Length of Spur Line 1 5 m and 1 6 m 3 m Spur Lines per Segment 9 6 to 93 75kbps 3 m 32 32 96 m 187 5 kbps 3 m 32 25 75 m 500 kbps 3 m 20 10 30 m 1 5 Mbps 3 m 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...

Page 135: ...ample clarifies the maximum possible distances in an MPI network max 50m max 50m max 1000m RS 485 repeater RS 485 repeater S7 400 S7 400 S7 400 S7 400 S7 400 Spur line 0 11 7 8 9 10 3 4 5 6 OP PG OP OP Programming device connected via spur line for maintenance Terminating resistor switched on 0 x MPI addresses of nodes Programming device Figure 5 10 Configuration of an MPI network ...

Page 136: ...elded 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...

Page 137: ...ish 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 PG connector only with 6ES7 972 0BB20 0XA0 9 pin sub D male connector for connection to MPI or PROFIBUS DP interface Housing screw Switch for terminating resistor ...

Page 138: ...ithout 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 scre...

Page 139: ...ired 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 ...

Page 140: ...t 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 b...

Page 141: ...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 supp...

Page 142: ...ntial so that the shielding point can serve later for strain relief and as a securing element 6XV1 830 0AH10 6XV1 830 3BH10 ÇÇ ÇÇ 8 5 16 10 6XV1 830 3AH10 ÇÇ ÇÇ 8 5 16 10 16 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...

Page 143: ...ow 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 cab...

Page 144: ...cable up to 300 m OBT OBT S7 400 with IM 467 FO ET 200M with IM 153 2 FO Other field devices without fiber optic cable interface Other nodes Figure 5 16 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 kbp...

Page 145: ...r in cabinets Cable lengths up to 50 m Indoors Cable lengths up to 50 m Indoors Cable lengths up to 300 m Fiber type Step index fiber Core diameter 980 µm 200 µm Core material Polymethyl methacrylate PMMA Quartz glass Cladding outer diameter 1000 µm 230 µm Cladding material Fluorinated special polymer Inner sheath Material Color Diameter PVC Gray 2 2 0 01 mm PA Black and orange 2 2 0 01 mm Without...

Page 146: ...0 mm flat side only 100 mm 150 mm 75 mm 75 mm Permissible environmental conditions Transport storage temperature Laying temperature Operating temperature 30 _C to 70 C 0 C to 50 C 30 C to 70 C 30 C to 70 C 0 C to 50 C 30 C to 70 C 30 C to 70 C 5 C to 50 C 20 C to 70 C Resistance against Mineral oil ASTM no 2 grease or water UV radiation Conditional1 Not UV resistant Conditional1 Conditional1 Condi...

Page 147: ...s per meter 50 m ring 100 m ring 6XV1821 0AH10 6XV1821 0AN50 6XV1821 0AT10 SIMATIC NET PROFIBUS PCF fiber optic standard cable I VY2K 200 230 10A17 8B20 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 Other lengths on request 50 m 75 m 100 m 150 m 200 m 250 m 300 m 6XV1821 1CN50 6XV1821 1CN75 6XV1821 1CT10 6...

Page 148: ...implex 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 Order Number SIMATIC NET PROFIBUS plastic fiber optic Simplex connector polishing set 100 Simplex connectors and 5 polishing sets for fitting SIMAT...

Page 149: ...ted 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 ...

Page 150: ...tallation 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 tha...

Page 151: ... 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...

Page 152: ...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 inse...

Page 153: ...ence Manual CPU Data Chapter Racks 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 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 bet ween r...

Page 154: ...s to existing ERs 2 4 7 Is the last receive IM of each connec tion chain terminated with the right terminator 7 Power Supply Module Is the power supply connector cor rectly 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 swit ched off ...

Page 155: ... backup batteries with a double or triple width power supply module set the BATT INDIC switch to 2BATT 6 3 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 PG cable S7 400 Programming de...

Page 156: ...he 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 ...

Page 157: ... 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 The...

Page 158: ...witch 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 requ...

Page 159: ...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 Par...

Page 160: ...tch 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 Tur...

Page 161: ...hen 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 Then only intend to expand the integrated load memory of the CPU you should use a RAM card want to store your user program permanently on the memory card even with power removed w...

Page 162: ...wn 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 mem...

Page 163: ...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 ...

Page 164: ...Starting Up 6 14 S7 400 and M7 400 Programmable Controllers Hardware and Installation A5E00069481 04 The following figure shows how to insert a backup battery in the single width power supply module ...

Page 165: ...t 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 ...

Page 166: ...hium 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...

Page 167: ...cation 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...

Page 168: ...ing 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 guide...

Page 169: ... 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 sl...

Page 170: ...Starting Up 6 20 S7 400 and M7 400 Programmable Controllers Hardware and Installation A5E00069481 04 ...

Page 171: ...tal 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 Replacin...

Page 172: ...up 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...

Page 173: ... 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 b...

Page 174: ...of the power supply module to 0 V output voltages 4 Set the line disconnector to OFF 5 Remove the cover 6 Remove the backup battery batteries if applicable 7 Disconnect the power supply connector from the power supply module 8 Loosen the mounting screws of the module 9 Swing the module out Installing a New Module 1 Check the voltage selector switch 2 Attach the new module of the same type and swin...

Page 175: ...t 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...

Page 176: ...ate 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 pro...

Page 177: ...tly 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...

Page 178: ...priate 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 fr...

Page 179: ...ule 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 b...

Page 180: ... 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 fuse...

Page 181: ... 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 C...

Page 182: ... 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 ...

Page 183: ... 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 Fuse cap Voltage selector switch 3 Remove the blown fuse from the fuse cap 4 Insert the new fuse in the fu...

Page 184: ...s 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 ÄÄÄÄÄÄÄÄÄÄÄ ÄÄÄÄÄÄÄÄÄÄÄ ÄÄÄÄÄ Fan 1 Fan 2 Fan 3 LEDs F 1 Fan 1 F 2 Fan 2 F 3 Fan 3 Quick release locks Reset button Base ...

Page 185: ...he fan to be replaced by pressing the fan grip away from the housing with your thumb Fan Base Fan grip 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 wil...

Page 186: ...rd 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 fi...

Page 187: ...f 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 loc...

Page 188: ...of the printed circuit boards PCBs ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ Fan 1 Fan 2 Fan 3 Power supply PCB Monitoring PCB Quick release lock 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...

Page 189: ...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 ap...

Page 190: ...lers Hardware and Installation A5E00069481 04 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 Fitting Memory Cards in the CPUs ...

Page 191: ...ctors 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 Memory card Cutout Slots 1 and 2 Polarity reversal protection Cutout Copper flag Guide support Guide support Figure 7 2 Memory Card ...

Page 192: ...ynchronization 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 s...

Page 193: ...r 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 ...

Page 194: ...Maintenance 7 24 S7 400 and M7 400 Programmable Controllers Hardware and Installation A5E00069481 04 ...

Page 195: ...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...

Page 196: ...es 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 ...

Page 197: ...M 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 ...

Page 198: ...mary of dimensions of the modules used in the M7 400 Table 8 3 Dimensions of Modules in the M7 400 System Module Slots Occupied Height Depth Depth when Fitted CPU 486 3 incl mode switch 219 mm CPU 488 3 incl mode switch 2 219 mm 236 5 mm Expansion Module EXM 478 210 mm Mass Storage Module MSM 478 1 290 mm 210 mm 227 5 mm AT Adapter Module ATM 478 230 mm 247 5 mm The mounting depth is governed by t...

Page 199: ...ections 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 add...

Page 200: ...r 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 ...

Page 201: ...1 AIO 85 mA 85 mA MSM 478 1 1000 mA 1000 mA ATM 478 1 120 mA 120 mA Short AT Module LAN 1400 mA 1400 mA 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...

Page 202: ...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...

Page 203: ...rst 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 ...

Page 204: ...anual Chapter 11 Table 8 5 Accessories for Modules and Racks Module Accessories Provided Basic Accessories Accessories not Provided Purpose of the Accessory CPUs 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 ...

Page 205: ... 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 protrudin...

Page 206: ...0 and M7 400 Programmable Controllers Hardware and Installation A5E00069481 04 2 4 3 4 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 3 3 V Memory Card ...

Page 207: ...operty 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 in...

Page 208: ... 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 ...

Page 209: ...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 ...

Page 210: ...Assembling the M7 400 8 16 S7 400 and M7 400 Programmable Controllers Hardware and Installation A5E00069481 04 4 5 6 5 3 2 7 5 Figure 8 4 Fitting an AT Card in the ATM 478 AT Adapter Module ...

Page 211: ...mbly 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...

Page 212: ...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 ...

Page 213: ...trollers Hardware and Installation A5E00069481 04 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 ...

Page 214: ...tion A5E00069481 04 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 Removing the Cover ...

Page 215: ... 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 EXM 478 e g ATM 478 e g MSM 478 1 2 3 Level surface e g CPU 488 3 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 r...

Page 216: ...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 mo...

Page 217: ... 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 Bent clip end Clip end bent 90 Figure 8 10 Connecting Clip Fifth grid hole Figure 8 11 Securing the Modules with Connecting Clips Schematic Diagram ...

Page 218: ...crewdriver 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 Fi...

Page 219: ...sembly 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 ...

Page 220: ... 26 S7 400 and M7 400 Programmable Controllers Hardware and Installation A5E00069481 04 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 Screwing the Modules On ...

Page 221: ...trollers Hardware and Installation A5E00069481 04 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 ...

Page 222: ...er 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 ...

Page 223: ...ing 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 f...

Page 224: ...OFIBUS 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...

Page 225: ...master ET 200M S5 95U ET 200B RS 485 repeater M7 400 M7 400 M7 400 OP 25 ET 200M S5 95U ET 200B Terminating resistance switched on Only connected via spur line for startup maintenance PROFIBUS DP MPI subnet S5 95U ET 200B ET 200B subnet Programming device Figure 8 16 Example of a Configuration with the CPU in an MPI Subnet and PROFIBUS DP Subnet ...

Page 226: ...nd 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 ...

Page 227: ... 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 ca...

Page 228: ...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 poss...

Page 229: ...um 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 3 0 m ...

Page 230: ...terface 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 C...

Page 231: ...or 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 ...

Page 232: ...mming Device with 9 pin Sub D Male Connector Signal Pin 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 COM1 for IF 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 female connector you can use Table 8 10 belo...

Page 233: ...7 400 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 PG cable M7 400 Programming device Figure 8 17 Connecting a Programming Device to ...

Page 234: ...en 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 Connection Programming device permanently installed in the network Directly incorporated in the MPI subnet Programming device connected for startu...

Page 235: ...a bus connectors PROFIBUS DP bus cable M7 400 M7 400 Programming device 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...

Page 236: ...s 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 PROFIBUS DP bus cable PG cable spur line M7 400 M7 400 Programmin g device Figure 8 19 Connecting a Programming Device to an M7 400 Subnet...

Page 237: ... 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 interfa...

Page 238: ... 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 sta...

Page 239: ...c 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 ...

Page 240: ...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 ...

Page 241: ...ty Interface modules contain electrostatically sensitive components that may be irre parably 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 E...

Page 242: ...tors the interface submodules can be damaged Mark the front connectors so that they are assigned to the corresponding interface submodules EXM 478 Frame of card slot with mounting hole Guides 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 Se...

Page 243: ...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 interfa...

Page 244: ...crews 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 ...

Page 245: ...ntrollers Hardware and Installation A5E00069481 04 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 ...

Page 246: ...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 dama...

Page 247: ... 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 No...

Page 248: ...serve 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 ...

Page 249: ... A5E00069481 04 3 2 5 Slot 1 Slot 2 4 Figure 8 28 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 ...

Page 250: ...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...

Page 251: ...Assembling the M7 400 8 57 S7 400 and M7 400 Programmable Controllers Hardware and Installation A5E00069481 04 4 3 2 3 3 1 Figure 8 30 Removing an AT Card from the ATM 478 AT Adapter Module ...

Page 252: ...Assembling the M7 400 8 58 S7 400 and M7 400 Programmable Controllers Hardware and Installation A5E00069481 04 ...

Page 253: ...quipotential 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 C...

Page 254: ... 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 Requirement Failu...

Page 255: ... 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...

Page 256: ...ection against 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...

Page 257: ... 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 PROFIB...

Page 258: ...occurs between conductors which are at different potentials The degree of coupling is proportional to the voltage variation as a function of time Interference pickup via parallel signal cables Static discharge of the operator Contactors Inductive Coupling Inductive or magnetic coupling occurs between two conductor loops through which current is flowing Interference voltages are induced by the magn...

Page 259: ...nsure 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 Sh...

Page 260: ...d 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 rack...

Page 261: ...trical 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 cabi...

Page 262: ...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 1 2 4 5 6 7 8 3 Figure A 2 Example of...

Page 263: ...ld 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 protec tive ground bar and supporting bars metal to metal connection Connect the protective ground bar to the protective conductor system via a separate con ductor minimum cross section 10 mm2 8 Conductor to the protective conduc...

Page 264: ...g 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 Wall Mounting an S7 400 for EMC ...

Page 265: ... 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 lo...

Page 266: ...ld 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 a...

Page 267: ...rs 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...

Page 268: ...Assembling and Installing Systems A 16 S7 400 and M7 400 Programmable Controllers Hardware and Installation A5E00069481 04 Figure A 5 Routing Equipotential Bonding Conductor and Signal Line ...

Page 269: ... 2 Cabling Inside Buildings Connect Cables for and Cables for Run 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...

Page 270: ...ded 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 and AC voltages 400 V unshielded 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...

Page 271: ...ide 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 Ove...

Page 272: ...ction 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...

Page 273: ... 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 ...

Page 274: ...ightning Protection Equipotential Bonding Local Equipotential Bonding Internal Cable Metal Galvanic Connection Protection Zone 2 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 z...

Page 275: ...c 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 High Voltage Protection of Cables with the Help of Surge Protection Equipment Se...

Page 276: ...r Supply 1 piece of Blitzductor VT lightning con ductor type A D 24 V 918 402 3 MPI bus cable RS 485 RS 232 V 24 1 piece of Blitzductor CT lightning con ductor type B 919 506 and 919 510 4 Inputs outputs of digital modules 24 V DEHNrail 24 FML 901 104 5 24 VDC power supply module 1 piece of Blitzductor VT lightning con ductor type AD 24 V 918 402 900 111 5SD7 032 6 Inputs outputs of digital module...

Page 277: ...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 ...

Page 278: ... 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 N to PE 900 131 2 24 VDC Power Supply 1 piece of Blitzductor VT lightning conductor type AD 24 V 918 402 3 Bus cable MPI RS 485 Blitzductor CT surge arrester type MD HF 919 506 and 919 570 RS 232 V 24 1 piece of per ...

Page 279: ...00 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 N to PE 900 131 2 24 VDC Power Supply 1 piece of Blitzductor VT lightning conductor type AD 24 V 918 402 3 Bus cable MPI RS 485 Blitzductor CT surge arrester type MD HF 919 506 and 919 570 RS 232 V 2...

Page 280: ...ple Circuit The sample in the figure A 7 shows you how install an effective surge protection for 2 networked S7 400 PLCs CPU SV 10 mm2 PE Switchgear cubicle1 L1L2L3NPE Lightning protection 0 field side zone Lightning protection zone 1 Lightning protection zone 2 SM MPI CPU SV 10 mm2 PE Switchgear cubicle 2 SM MPI Lightning protection zone 2 Figure A 7 Sample Circuitry for Networked S7 400 PLCs ...

Page 281: ...on 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 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 Low voltage surge protection signal mo dules I O at transiti...

Page 282: ...e 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 ...

Page 283: ...ff 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 amplitu...

Page 284: ...tematic 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 sy...

Page 285: ... 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 spe...

Page 286: ... 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...

Page 287: ... 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 th...

Page 288: ...lamp 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 CP Ó Ó Ó Shield bus Outer sh...

Page 289: ...llation A5E00069481 04 Guidelines for Handling Electrostatically Sensitive Devices ESD 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 B ...

Page 290: ...atically Sensitive Devices are commonly referred to by the abbreviation ESD Electrostatically sensitive devices are labeled with the following symbol 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 withou...

Page 291: ...ectrostatically 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 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 kV 5 10 20 30 40 50 60 70 80 90 100 Relative air humidity in 1 3 1 Synthetic material 2 Wool 3 Ant...

Page 292: ...ndling 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 ...

Page 293: ...24 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...

Page 294: ...d 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...

Page 295: ...he 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 progra...

Page 296: ...stics 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...

Page 297: ...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 interfa...

Page 298: ...tains 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 C...

Page 299: ... 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 underst...

Page 300: ...on 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 ...

Page 301: ... 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 Po...

Page 302: ...s 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 displ...

Page 303: ...lated 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 ...

Page 304: ... 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 ...

Page 305: ...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 progr...

Page 306: ... 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 ...

Page 307: ...mable 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 e...

Page 308: ...zation 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 update...

Page 309: ...are 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 fir...

Page 310: ...Glossary Glossary 18 S7 400 and M7 400 Programmable Controllers Hardware and Installation A5E00069481 04 ...

Page 311: ...sistor 5 22 terminating resistor 5 9 Bus connectors assembling bus cables 5 20 Bus segment See Segment C 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...

Page 312: ...sion 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 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 o...

Page 313: ...0 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 addre...

Page 314: ...ing device M7 400 connecting to a grounded configuration 8 43 connecting to an ungrounded configuration 8 43 in the MPI subnet 8 41 via spur line to MPI subnet 8 42 Protection against overvoltage A 20 Protective measures 4 5 R Rack 1 3 clearances 2 10 mounting dimensions 2 10 segmented 2 8 2 9 subdivided 2 9 with I O bus and C bus 2 7 Racks grounding 2 10 mounting 2 10 of the S7 400 system 2 6 Rat...

Page 315: ...modules 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 cabinet...

Page 316: ...Index Index 6 S7 400 and M7 400 Programmable Controllers Hardware and Installation A5E00069481 04 ...

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