Preface, Contents SIMATIC Product Overview Installing the S7-400 S7-400 and M7-400 Programmable Controllers Hardware and Installation Installation Manual Addressing the S7-400 Wiring the S7-400 Networking Starting Up Maintenance Assembling the M7-400 1 2 3 4 5 6 7 8 Appendices Assembling and Installing Systems A Guidelines for Handling Electrostatically-Sensitive Devices (ESD) B Glossary, Index This manual is part of the documentation package with the order number 6ES7498-8AA03-8BA0 Edition 12/20
Safety Guidelines This manual contains notices intended to ensure personal safety, as well as to protect the products and connected equipment against damage. These notices are highlighted by the symbols shown below and graded according to severity by the following texts: ! ! ! Danger indicates that death, severe personal injury or substantial property damage will result if proper precautions are not taken.
Preface Purpose of the Manual The information given in this manual makes it possible for you to: • install and wire an S7-400 memory programmable controller • configure an M7-400 automation computer for mechanical and electrical installation A description of the functions and technical specifications of the signal modules, power supply modules and interface modules can be found in the reference manual Module Specifications.
Preface Certification The SIMATIC S7-400 product range has the following certificates and approvals: • Underwriters Laboratories, Inc.: UL 508 (Industrial Control Equipment) • Canadian Standards Association: CSA C22.2 Nummer 142, tested (Process Control Equipment) • Factory Mutual Research: Approval Standard Class Number 3611. You can find details on the certificates and approvals in the “Module Specifications” manual.
Preface Finding Your Way The manual offers the following access aids to make it easy for you to find specific information quickly: • At the beginning of the manual you will find a complete table of contents and lists of the figures and tables contained in the manual. • In each chapter you will find information in the left-hand margin on each page that gives you an overview of the contents of the relevant section.
Preface Manual/ Manual Package Contents STEP 7 Reference Information • Basic procedure for working with STL, LAD, or FBD (for example, structure of Statement List (STL) for S7-300 and S7-400 • • • • • • Ladder Logic (LAD) for S7-300 and S7-400 Function Block Diagram (FBD) for S7-300 and S7-400 STL, LAD, or FBD, number formats, syntax) Description of all instructions in STEP 7 (with program examples) Description of the various addressing methods in STEP 7 (with examples) Description of all functions
Preface Specific Information for M7-400 This documentation package describes the hardware of the M7-400.
Preface A&D Technical Support Worldwide, available 24 hours a day: Nuernberg Johnson City Beijing Technical Support Worldwide (Nuernberg) Technical Support 24 hours a day, 365 days a year Phone: +49 (0) 180 5050-222 Fax: +49 (0) 180 5050-223 E-Mail: adsupport@ siemens.com GMT: +1:00 Europe / Africa (Nuernberg) United States (Johnson City) Asia / Australia (Beijing) Authorization Technical Support and Authorization Technical Support and Authorization Local time: Mon.-Fri.
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Preface x S7-400 and M7-400 Programmable Controllers Hardware and Installation A5E00069481-04
Contents 1 Product Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 2 Installing the S7-400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 2.1 Assembling an S7-400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 2.2 Assembling the Central Rack (CR) and Expansion Rack (ER) . . . . . . . . . 2-6 2.3 Segmented CR . . . . .
Contents 4 xii Wiring the S7-400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 4.1 Supplying Power to Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 4.2 Choosing the Power Supply Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 4.3 Choosing the Load Current Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 4.
Contents 5 6 7 Networking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 5.1 Configuring a Network . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 5.2 Fundamentals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 5.3 Rules for Configuring a Network . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Contents 8 xiv Assembling the M7-400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 8.1 Mechanical Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2 8.2 Addressing the M7-400 Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5 8.3 Electrical Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6 8.4 8.4.1 8.4.
Contents A B Assembling and Installing Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1 A.1 General Rules and Regulations for Operating the S7-400 . . . . . . . . . . . . . A-2 A.2 Principles of System Installation for EMC . . . . . . . . . . . . . . . . . . . . . . . . . . . A-5 A.3 Installation of Programmable Controllers for EMC . . . . . . . . . . . . . . . . . . . . A-9 A.4 Examples of EMC-Compatible Assembly . . . . . . . . . . . . . . . . . . . .
Contents Figures 2-1 2-2 2-3 2-4 2-5 2-6 2-7 2-8 2-9 4-1 4-2 4-3 4-4 4-5 4-6 4-7 4-8 4-9 4-10 4-11 4-12 4-13 4-14 4-15 4-16 4-17 4-18 4-19 4-20 4-21 4-22 4-23 4-24 4-25 5-1 5-2 5-3 5-4 5-5 5-6 5-7 5-8 5-9 5-10 5-11 5-12 5-13 5-14 xvi Rack Fitted with Modules in the S7-400 System . . . . . . . . . . . . . . . . . . . . . Max. Cabinet Ambient Temperature as a Function of Power Dissipation of Equipment in the Cabinet . . . . . . . . . . . . . . . . . . . . Fitting Memory Cards in the CPUs . . . . . . . . .
Contents 5-15 5-16 5-17 6-1 6-2 6-3 7-1 7-2 7-3 8-1 8-2 8-3 8-4 8-5 8-6 8-7 8-8 8-9 8-10 8-11 8-12 8-13 8-14 8-15 8-16 8-17 8-18 8-19 8-20 8-21 8-22 8-23 8-24 8-25 8-26 8-27 8-28 8-29 8-30 Turning back braided shield over cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Optical PROFIBUS-DP Network with Nodes that have an Integrated Fiber-Optic Cable Interface . . . . . . . . . . . . . . . . . .
Contents A-1 A-2 A-3 A-4 A-5 A-6 A-7 A-8 A-9 A-10 A-11 B-1 xviii The Possible Routes for Electromagnetic Interference . . . . . . . . . . . . . . . . Example of Cabinet Installation for EMC . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wall Mounting an S7-400 for EMC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mounting Cable Shields . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Routing Equipotential Bonding Conductor and Signal Line .
Contents Tables 2-1 2-2 2-3 4-1 4-2 4-3 4-4 5-1 5-2 5-3 5-4 5-5 5-6 5-7 6-1 6-2 8-1 8-2 8-3 8-5 8-6 8-7 8-8 8-9 8-10 A-1 A-2 A-3 A-4 A-5 A-6 Types of Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Modules in the different racks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Accessories for Modules and Racks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Contents xx S7-400 and M7-400 Programmable Controllers Hardware and Installation A5E00069481-04
Product Overview 1 Overview of the S7-400 The S7-400 is a programmable controller. Almost any automation task can be implemented with a suitable choice of S7-400 components. S7-400 modules have a block design for swing-mounting in a rack. Expansion racks are available to extend the system. In this chapter, we show you the most important components with which you can assemble an S7-400.
Product Overview Overview of the M7-400 The SIMATIC S7 programmable controller is extended by the SIMATIC M7 automation computer with its AT-compatible computer functionality. This enables the SIMATIC user to make use of the open software world, either as an extension to an S7 programmable controller or as a stand-alone M7 computer system. The entire SIMATIC S7 range of I/O devices is available to the M7 user.
Product Overview Components of an S7-400 The most important components of the S7-400 and their functions are given in the following tables: Components Function Racks (UR: Universal Rack) (CR: Central Rack) (ER: Expansion Rack) ... provide the mechanical and electrical connections between the S7-400 modules. Power Supply Modules (PS = Power Supply) ... convert the line voltage (120/230 VAC or 24 VDC) to the 5 VDC and 24 VDC operating voltages required to power the S7-400.
Product Overview Components Function PG cables ...connect a CPU to a programming device. PROFIBUS components for example, PROFIBUS bus terminal ... connect the S7-400 to other S7-400 devices or programming devices. RS 485 repeaters ...amplify data signals on bus lines and links bus segments. Programming device (PG) or PC with the STEP 7 software package ...configures, programs, debugs, and assigns parameters to the S7-400. Fan subassemblies (for special areas of application) ...
Product Overview Components Function Expansion Modules (EXMs) ... serve to accommodate three interface submodules (IFs). AT Adapter Modules (ATMs) ... provide a slot for a 16-bit AT module (up to 164 mm long). Mass Storage Modules (MSMs) ... serve to store programs and data on a hard disk (2.5”) or floppy disk (3.5”). Interface Submodules (IFs) ... for connecting I/O devices such as VGA monitor, mouse, keyboard, printer.
Product Overview Connecting the M7-400 to a Programming Device / PC For the remote setup of the M7-400, you can connect a programming device or PC to the CPU of the M7-400 via a V.24 cable. A PC/PG cable is used to connect a programming device or PC and CPU of the M7-400 via the multipoint interface (MPI). Location of Order Number and Product Version The order number and product version are printed on every module of the SIMATIC S7-400/M7-400. The firmware version is also printed on the CPUs.
2 Installing the S7-400 Chapter Overview Section Description Page 2.1 Assembling an S7-400 2-2 2.2 Assembling the Central Rack (CR) and Expansion Rack (ER) 2-6 2.3 Segmented CR 2-8 2.5 Mounting and Grounding the Racks 2-10 2.6 Chassis Terminal Connection in the Non-Isolated Configuration 2-16 2.7 Methods of Ventilation 2-19 2.8 Changing the Ventilation with the Cable Duct and Fan Subassembly 2-21 2.9 Installing the Fan Subassembly 2-23 2.10 Installing the Cable Duct 2-25 2.
Installing the S7-400 2.1 Assembling an S7-400 Introduction An S7-400 programmable controller consists of a central rack (CR) and one or more expansion racks (ERs), as required. You use ERs when there are insufficient slots in the CR for your application, or when you wish to operate signal modules separated from the CR (e.g. in the immediate vicinity of your process). When using ERs, you need interface modules (IMs) as well as the additional racks, and additional power supply modules if necessary.
Installing the S7-400 Connecting the CR and ER(s) To connect one or more ERs to a CR, you must fit one or more send IMs in the CR. The send IMs have two interfaces. You can connect one chain of up to four ERs to each of the two interfaces of a send IM in the CR. Different IMs are available for local connection and remote connection. Connecting with a 5 V Supply For a local connection with the IM 460-1 and IM 461-1, the 5 V supply voltage is also transferred via the interface modules.
Installing the S7-400 Ways of Connecting Central and Expansion Racks Central rack CR IM 460-4 IM 460-3 IM 460-1 IM 460-0 Expansion without 5 V local transfer Expansion rack ER 1 Expansion rack ER 4 IM 461-0 IM 461-0 Chain length max. 3 m Expansion with 5 V local transfer Expansion rack ER 1 IM 461-1 Chain length max. 1.5 m Remote expansion Expansion rack ER 4 Expansion rack ER 1 IM 461-3 IM 461-3 Chain length max. 102.
Installing the S7-400 Rules for Connection When you connect a central rack to expansion racks, you must observe the following rules: • You can connect up to 21 ERs of the S7-400 to one CR. • The ERs are assigned numbers to identify them. The rack number must be set on the coding switch of the receive IM. Any rack number between 1 and 21 may be assigned. Numbers must not be duplicated. • You may insert up to six send IMs in one CR. However, only two send IMs with 5 V transfer are allowed in one CR.
Installing the S7-400 2.2 Assembling the Central Rack (CR) and Expansion Rack (ER) Function of the Racks The racks of the S7-400 system form the basic framework which accepts the individual modules. The modules exchange data and signals and are powered via the backplane bus. The racks are designed for wall mounting, for mounting on rails, and for installation in frames and cabinets. Racks in the S7-400 System Rack No.
Installing the S7-400 Electrical Supply The modules inserted in the rack are supplied with the required operating voltages (5 V for logic, 24 V for interfaces) via the backplane bus and base connector, by the power supply module fitted in the slot on the extreme left in the rack. For local connections, ERs can also be supplied with power via the IM 460-1 / IM 461-1 interface modules.
Installing the S7-400 2.3 Segmented CR Properties The “segmented” characteristic relates to the configuration of the CR. In the (non-segmented) CR the I/O bus is continuous and interconnects all 18 or 9 slots; in the segmented CR, however, the I/O bus consists of two I/O bus segments. A segmented CR has the following important characteristics: • The communication bus is continuous (global), whilst the I/O bus is divided into two I/O bus segments of 10 and 8 slots respectively.
Installing the S7-400 2.4 Subdivided CR Characteristics The ”subdivided” characteristic relates to the configuration of the CR. In the (non-divided) CR the I/O bus and communication bus are continuous and interconnect all the slots; in the subdivided CR, however, the I/O bus and communication bus consist of two segments each. The UR2-H rack used here functions as two electrically isolated UR2 racks on the same rack profile.
Installing the S7-400 2.5 Mounting and Grounding the Racks Important Notes on Installation The S7-400 racks are designed for wall mounting, mounting on rails, and for installation in frames and cabinets. Their mounting dimensions comply with DIN 41 494. According to the UL/CSA and the EU Directive 73/23/EEC (low-voltage directive), installation in a cabinet, a casing, or a closed operations room is necessary in order to fulfil the requirements for electrical safety (see Reference Manual, Chapter 1).
Installing the S7-400 Space Required When Using Cable Channels and Fan Subassemblies A cable duct or fan subassembly must be installed in the 19-inch pitch immediately below the rack. Additional space for cable routing must be provided on both sides. The following figure shows how much space you need to allow for when using a cable duct or fan subassembly. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 440 mm Cable duct/fan subassembly 522.5 mm (with cable duct) 542.
Installing the S7-400 60 mm 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 6 7 9 17 18 290 mm 190 mm 40 mm 465 mm 482.5 mm 1 2 3 4 1 2 3 4 1 2 3 4 5 8 290 mm 190 mm Depth = 27.5 mm without modules Depth = 237.0 mm with modules 40 mm 115 mm 240 mm 132.5 mm 257.5 mm Step 2: Mounting the Rack Screw the rack to the base. Is the base material a grounded metal plate or a grounded equipment plate? If so: Establish a low-impedance connection between rack and base material.
Installing the S7-400 Mounting Screws You have a choice of the following types of screw for securing a rack: Screw Type Explanation M6 cylinder-head screw to ISO 1207/ISO 1580 (DIN 84/DIN 85) M6 hex. screw to ISO 4017 (DIN 4017) Choose the screw length according to your assembly. You also need “6.4” washers to ISO 7092 (DIN 433). Step 3: Connecting the Rack to the Chassis Ground Connect the rack to the chassis ground. A threaded bolt is provided for this purpose on the bottom left of the rack.
Installing the S7-400 Step 4: Mounting Additional Racks If you assemble an S7-400 with two or more racks, you must allow additional clearance between the individual racks or install a fan subassembly or cable duct. The figure below shows the clearance you must allow between two racks of the S7-400 during installation.
Installing the S7-400 The figure below shows how much space you must allow for when assembling an S7-400 from two racks with a cable duct or fan subassembly. This requirement is increased by a height of 400 mm for each additional rack with a cable duct or fan subassembly. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 Cable duct/fan subassembly 840 mm 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 Cable duct/fan subassembly Mounting depth, fitted: max.
Installing the S7-400 2.6 Chassis Terminal Connection in the Non-Isolated Configuration Reference Point The racks offer the option of connecting the 24-V load voltage ground in the non-isolated configuration to the 5-V ground (reference potential M, logic ground). Connect the chassis ground to the reference point for non-isolated modules. The reference point is metallically connected to the reference potential M. Note The position of the reference point on the racks was changed in 10/99.
Installing the S7-400 Note Do not use any cyclinder-head screws longer than 6 mm for the connection to the reference point. Otherwise, you may create an undesired connection between the reference point and the rack profile behind it and therefore the connection for the chassis ground. The following figure shows the position of the reference point on a rack up after 10/99.
Installing the S7-400 Connection to the Reference Point After 10/99 For the connection to the reference point, use a cable lug for M4, a suitable spring lock washer (for example, clamping washer to DIN 6796) and the cylinder-head screw supplied. Ungrounded configuration: Undo the fixing screws of the metallic connection on the rack. Tilt the connection downwards. For the connection to the reference point, use the original M4 x 8 supplied. Use the tilted metallic connection as a washer.
Installing the S7-400 2.7 Methods of Ventilation Methods of Ventilation Under extreme ambient conditions, particularly when operating the S7-400 modules in cabinets, you can use the cable duct or fan subassembly to optimize ventilation. There are two methods of supplying air to the modules. You draw in air either from the back or from below. The cable duct and fan subassembly can be converted for this purpose. The following figure shows the ventilation when air is drawn in from the back.
Installing the S7-400 The following figure shows the ventilation when air is drawn in from the bottom.
Installing the S7-400 2.8 Changing the Ventilation with the Cable Duct and Fan Subassembly Changing the Ventilation At the base of the cable duct and the fan subassembly, there is a cover that you can move in order to change the air duct. To do this, proceed as follows: 1. Using a screwdriver, make a quarter turn counter-clockwise to open the two quick-release locks at the front of the cable duct or fan subassembly. 2.
Installing the S7-400 Cover Delivered state: Cover fitted at bottom (supply air from the rear) Base Quick-release locks Snap catches Cover Cover fitted at back (supply air from below) Base Snap hinges State When Shipped The cover is fitted in the base of the cable duct or fan subassembly. Air is supplied from the back. Filter Mat (Optional) To filter the air supply, you can fit a filter mat for the cable duct and fan subassembly.
Installing the S7-400 2.9 Installing the Fan Subassembly Procedure 1. Remove the left cover from the fan subassembly. Using a 17 mm open-ended wrench, slacken the quick-release lock a quarter turn. Pull out the left cover of the fan subassembly. To do this, move the left cover parallel to the fan subassembly in order to avoid damaging the plug-in contact on the other side. The following figure shows you how to remove the left cover.
Installing the S7-400 4. Attach the dummy plates to the free slots: – Place the dummy plates on the rear wall of the cable routing, – Push the dummy plates back so that the noses of the dummy plates will fit into the cutouts provided, – Push the dummy plates in until the snap-in mechanism engages in the openings on the back of the cable routing. 5. Then install the fan assembly in the 19-inch pitch directly under the rack or between two racks. Use M6 size screws for mounting.
Installing the S7-400 2.10 Installing the Cable Duct Procedure 1. Install the cable duct in the 19-inch pitch directly under the rack or between two racks. Use M6 size screws for mounting. The following figure shows how to mount the cable duct between two racks.
Installing the S7-400 2.11 Choosing and Setting up Cabinets with the S7-400 Why Cabinets are Required With larger installations and in an environment subject to interference or pollution, you can install the S7-400 in cabinets. The requirements of UL/CSA are met, for example, by an installation in cabinets.
Installing the S7-400 Table 2-1 provides an overview of the most common types of cabinet. You will also find the principle of heat removal, as well as the estimated, maximum achievable power loss removal and the degree of protection.
Installing the S7-400 Removable Power Dissipation from Cabinets (Example) The removable power dissipation from a cabinet is governed by the type of cabinet, its ambient temperature, and the arrangement of equipment in the cabinet. Figure 2-2 shows a diagram with guide values for the permissible ambient temperature of a cabinet measuring 600 x 600 x 2000 mm as a function of power dissipation. These values only apply if you observe the specified installation dimensions and clearances for racks.
Installing the S7-400 Example for Determining the Type of Cabinet The following example clarifies the maximum ambient temperature which is permissible for a particular power dissipation with various types of cabinet.
Installing the S7-400 2.12 Rules for the Arrangement of Modules Rules for S7-400 and M7-400 Given in this section are the rules you must observe when arranging modules in the S7-400. The rules for M7-400 modules can be found in Section 8.1 “Mechanical Configuration”. Arrangement of Modules You need observe only two rules for the arrangement of modules in a rack: • In all racks, the power supply module must always be inserted on the extreme left (beginning with slot 1).
Installing the S7-400 2.13 Fitting Memory Cards in the CPU Memory Expansion With the CPU 417-4 and CPU 417-4 H you can expand the work memory with memory submodules. The following points are important: 1. If only one submodule is inserted, l must be in slot 1. 2. You may only insert a second submodule if a 4 Mbyte-submodule is inserted in slot 1.
Installing the S7-400 5. Fit the cover on the upper left side of the CPU by securing it with three screws. Note The connectors to accept the memory cards are coded (see Figure 2-4). Do not apply force when fitting the memory cards. Lightly press the guide supports out to remove the memory cards (see Figure 2-4).
Installing the S7-400 Figure 2-4 Memory Card 2.14 Installing Modules in a Rack Introduction All modules are installed in a rack using the same procedure. ! Caution Modules and racks can be damaged. If you use force when installing modules in a rack, these components may be damaged. Carefully follow the steps described below for the installation sequence. Tool The tool needed to install the modules is a cylindrical screwdriver with 3.5 mm blade width.
Installing the S7-400 5. Tighten the module screws top and bottom with a torque of 0.8 to 1.1 Nm (see Figure 2-7). Triple-width modules are secured with two screws at the top and at the bottom. 6. Refit the module cover, if applicable. 7. Fit the remaining modules in the same way. 8. Insert the key into the keyswitch in the CPU when you have installed all the modules (see Figure 2-8). The individual steps for installation are explained in the following.
Installing the S7-400 Attaching the Modules Attach the modules one by one (1) and swing them carefully downwards (2). If you feel a resistance when swinging the module down, raise it slightly and then continue. (1) (2) Figure 2-6 Attaching the Modules Screwing the Modules in Place Tightening torque 0.8 to 1.
Installing the S7-400 Inserting the Keyswitch You can insert the key in the CPU in the STOP position of the switch. You can remove the key in the STOP or RUN settings.
Installing the S7-400 2.15 Marking the Modules with Slot Labels Slot Number Once the modules are installed, you should mark each one with its slot number to avoid the risk of mixing up modules during operation. If modules do get mixed up, you may have to reconfigure the assembly. The slot number is printed on the rack. Double-width modules occupy two slots and are assigned the consecutive slot numbers of both slots.
Installing the S7-400 2.16 Methods of Expansion and Networking Introduction Apart from the structures mentioned in this chapter, other expansions are possible, for example, by connecting distributed I/Os or by networking. The modules with which you can connect an M7-400 to PROFIBUS DP can be found in Section 6.9 “Starting Up a PROFIBUS-DP Subnet.
Installing the S7-400 2.17 Accessories Accessories Some of the accessories needed for fitting the modules in the rack are provided in the packaging of the modules and racks. The front connectors of the signal modules must always be ordered separately. There are also optional accessories for some modules. The accessories for modules and racks are listed and briefly explained in Table 2-3.
Installing the S7-400 2-40 S7-400 and M7-400 Programmable Controllers Hardware and Installation A5E00069481-04
3 Addressing the S7-400 Chapter Overview Section Description Page 3.1 Geographical and Logical Addresses 3-2 3.2 How to Determine the Default Address of a Module 3-4 3.
Addressing the S7-400 3.1 Geographical and Logical Addresses Addresses In order to control a process, you must address the channels (inputs and outputs) of the signal modules from the user program. You must establish a unique assignment between the (geographical) location of a channel and an address in the user program. Information on addressing M7-400 modules can be found in Section 8.2. Geographical Addresses The geographical address of a particular channel is permanently assigned.
Addressing the S7-400 Default Addressing Under certain conditions, the CPU can handle the assignment between logical address and geographical address for you (default addressing). The logical addresses are then permanently assigned to the slots (default address). Distributed I/Os are not taken into account.
Addressing the S7-400 3.2 How to Determine the Default Address of a Module Default Addressing You determine the default address of a module from the number of the slot of the module in the CR. The algorithms used to calculate the default address are different for analog and digital modules. The following figure shows the numbering of slots in a rack with 18 slots. You can also read off the slot numbers directly from the rack.
Addressing the S7-400 Default Addresses of Analog Modules On the S7-400, the default addresses for analog modules start from 512 (first slot in the central rack which is usually occupied by the power supply module) up to 1600.
Addressing the S7-400 3.3 How to Determine the Default Address of a Channel Channel on a Digital Module A channel on a digital module is addressed bit-wise. For a digital input module with 32 inputs, four bytes (starting with the default address of the module) are used to address the inputs, and for a digital input module with 16 inputs, two bytes are used. Bits 0 to 7 in these bytes are then reserved by the individual inputs (from top to bottom).
Addressing the S7-400 Channel on an Analog Module Channels on analog modules are addressed word-wise. Starting with the default address of the module, which also represents the address of the uppermost channel of the module, the addresses of the individual channels (from top to bottom) increase by two bytes (= one word). This is clarified by the following figure with the example of a digital input module with 8 channels at slot 6 (default address 832).
Addressing the S7-400 3-8 S7-400 and M7-400 Programmable Controllers Hardware and Installation A5E00069481-04
4 Wiring the S7-400 Chapter Overview Section Description Page 4.1 Supplying Power to Modules 4-2 4.2 Choosing the Power Supply Module 4-3 4.3 Choosing the Load Current Power Supply 4-4 4.4 Assembling an S7-400 with Process I/Os 4-5 4.5 Assembling an S7-400 with Grounded Reference Potential (M) 4-8 4.6 Assembling an S7-400 with Ungrounded Reference Potential (Ungrounded Configuration) 4-9 4.7 Assembling an S7-400 with Isolated Modules 4-11 4.
Wiring the S7-400 4.1 Supplying Power to Modules Power Supply Modules and Load Current Power Supplies The modules of the S7-400 system are supplied with all the required operating voltages by a power supply module, via the backplane bus of the rack. Which power supply module you use in a rack depends on your system requirements (line voltage, current consumption of the modules used). You must provide load voltages and currents via external load current power supplies.
Wiring the S7-400 4.2 Choosing the Power Supply Module Estimating the Power Requirement You should make an estimate of the power requirement for each rack of your S7-400 system in order to select the appropriate power supply module for the rack. Selection of the power supply for an M7-400 configuration is described separately in Section 8.3 “Electrical Configuration.” Current consumption and power dissipation of the individual modules can be found in the relevant data sheets.
Wiring the S7-400 4.3 Choosing the Load Current Power Supply Choosing the Load Current Power Supply The input and output circuits (load current circuits) as well as sensors and actuators are powered by the load current power supply. Listed in the following are the characteristics of the load current power supplies required in special applications for choosing the load current power supplies. Characteristics of the Load Current Power Supply Safe isolation Required for ...
Wiring the S7-400 Determining the Load Current The required load current is governed by the total current of all sensors and actuators connected to the outputs. During a short-circuit, a current of two to three times the rated output current flows briefly at DC outputs before the switched electronic short-circuit protection becomes effective. When selecting the load current power supply, therefore, you must ensure that the increased short-circuit current is available.
Wiring the S7-400 Table 4-1 VDE Specifications for Assembling a Programmable Controller Compare ... Ref. to Figure 4-1 VDE 0100 VDE 0113 Disconnection element for control system, sensors, and actuators ... Part 460: Main switches ... Part 1: Isolating switches Short-circuit and overload protection: in groups for sensors and actuators ... Part 725: Single-pole protection of circuits ...
Wiring the S7-400 S7-400 in the Overall Installation Shown in Figure 4-1 is the position of the S7-400 in the overall installation (load current power supply and grounding concept) with supply from a TN-S system. Note: The arrangement of supply terminals shown is not the actual arrangement; it has been chosen for reasons of clarity. L1 L2 L3 N PE Low-voltage distribution e.g.
Wiring the S7-400 4.5 Assembling an S7-400 with Grounded Reference Potential (M) Application You use an S7-400 with grounded reference potential in machines or industrial plants. Discharge of Interference Currents When the S7-400 is configured with a grounded reference potential, any interference currents are discharged to the chassis ground.
Wiring the S7-400 4.6 Assembling an S7-400 with Ungrounded Reference Potential (Ungrounded Configuration) Application In large installations, it may be necessary to configure the S7-400 with an ungrounded reference potential, for example, for ground fault monitoring. This is the case in the chemical industry or in power plants, for example.
Wiring the S7-400 Power Supply Units When using power supply units, ensure that the secondary winding is not connected to the protective ground conductor. Filtering the 24 VDC Supply When you power the S7-400 from a battery with the ungrounded configuration, you must provide interference suppression for the 24 VDC supply. Use a Siemens power cable filter, such as the B84102-K40.
Wiring the S7-400 4.7 Assembling an S7-400 with Isolated Modules Definition In a configuration with isolated modules, the reference potentials of the control circuit (Minternal) and the load circuit (Mexternal) are isolated (see also Figure 4-4).
Wiring the S7-400 Configuration with Isolated Modules Shown in Figure 4-4 are the potentials of an S7-400 configured with isolated input and output modules.
Wiring the S7-400 4.8 Parallel Wiring of Digital S7-400 Outputs Parallel Wiring of a Digital Output with Different Rated Load Voltages The parallel wiring of a digital output (rated load voltage 1L+) with another digital output (rated load voltage 2L+) or a rated load voltage 3L+ is only possible using series diodes.
Wiring the S7-400 4.9 Grounding Introduction Grounding in accordance with regulations and conscientiously implemented is the prerequisite for proper functioning of a programmable controller. Each individual component of the S7-400 and of the controlled system must be properly grounded. Ground Connections Low-resistance ground connections reduce the risk of electric shock in the event of a short-circuit or faults in the system.
Wiring the S7-400 Connecting the Load Voltage Ground Many output modules require an additional load voltage to switch the actuators. Two different modes are possible for this load voltage: • Non-isolated operation • Floating operation The following table shows how the load voltage ground is connected in the individual modes.
Wiring the S7-400 4.10 Interference-Free Configuration for Local and Remote Connections Use only Approved Components Note If you use components which are not approved for setting up local and remote connections, interference rejection may be impaired. Interference-Free Configuration for Local Connections If you connect the CR and ER via suitable interface modules (send IM and receive IM), no particular shielding and grounding need be implemented.
Wiring the S7-400 Interference-Free Configuration for Remote Connections If you connect the CR and ER via suitable interface modules (send IM and receive IM), normally no particular shielding and grounding need be implemented. Special shielding and grounding may become necessary if you operate your system in an environment with an extremely high level of interference. In that case, observe the following points: • In the cabinet, connect the cable shields to the shield bus immediately after entry.
Wiring the S7-400 4.11 Wiring Rules Lines and Tools For wiring the S7-400 modules, there are some rules for the cables and for the tool you use. Information on connecting an M7-400 module assembly can be found in Section 8.5. Rules for ... Power Supply ... Front Connectors Crimp terminal Screw-type terminal Spring-type terminal Conductor cross-sections: Outer diameter: 3 to 9 mm Flexible cond. without wire end ferrule no 0.5 to 1.5 mm2 0.25 to 2.5 mm2 0.08 to 2.5 mm2 Flexible cond.
Wiring the S7-400 Note You must use shielded cables for the analog modules (see Section 4.5). 4.12 Setting the VAC Power Supply Module to the Line Voltage Set the voltage selector with 6ES7 407-0DA00-0AA0 and 6ES7 407-0RA00-0AA0 An S7-400 with VAC power supply can be operated from either a 120 V or 230 V line voltage. Check whether the voltage selector switch is set to your line voltage. To set the VAC power supply module to the correct line voltage, follow the steps outlined below: 1.
Wiring the S7-400 Figure 4-9 Setting the voltage selector 4-20 S7-400 and M7-400 Programmable Controllers Hardware and Installation A5E00069481-04
Wiring the S7-400 4.13 Wiring the Power Supply Module Power Supply Connector You use the power supply connector to connect a power supply module to your supply. When delivered, the power supply connector is plugged into the power supply module. There are two versions (AC and DC) of power supply connector. The two versions are coded, meaning an AC connector can only be plugged into an AC power supply module, and a DC connector can only be plugged into a DC power supply module.
Wiring the S7-400 Wiring the Power Supply Connector To wire the power supply connector, follow the steps outlined below: ! Warning There is a risk of personal injury. If you wire the connector with voltage applied, you may suffer a shock and personal injury. Only wire the connector with power disconnected. 1. Switch off the line voltage at your VAC supply disconnector. Note The standby switch of the power supply module does not disconnect the power supply module from the supply. 2.
Wiring the S7-400 6. Slacken the screw of the strain relief and insert the cable. 7. Connect the cores according to the illustration on the cover of the power supply connector. Connect the longer core to PE. Screw on the cores with a torque of 0.6 to 0.8 Nm. Terminals Cable AC L1 DC L+ N L– PE PE Strain-relief assembly Screw for the strainrelief assembly Figure 4-11 Wiring the power supply connector 8. Tighten the screw of the strain relief, so that the cable is secured properly. 9.
Wiring the S7-400 Plugging In the Power Supply Connector You can only plug in the connector when the power supply module is installed (lower mounting screw tightened). ! Caution An AC power supply module with the order number 6ES7 407-0DA00-0AA0 or 6ES7 407-0RA00-0AA0 can be damaged. If you set the voltage selector switch of an AC power supply module to 120 V and connect the power supply module to a 230 V supply, a fault may develop on the power supply module. In this case the warranty will be void.
Wiring the S7-400 4.14 Wiring the Signal Modules Procedure There are two steps for providing the connection between the signal modules of your S7-400 and the sensors and actuators of your plant: 1. Wiring the front connector. This serves to connect the cables to and from the sensors/actuators to the front connector. 2. Plugging the front connector into the module.
Wiring the S7-400 Preparing to Wire the Front Connector 1. Insert a screwdriver at the point marked on the bottom left of the front connector and lever the lower corner of the cover off the front connector. 2. Open the cover completely. 3. Pull the opened cover forward at the bottom and swing it upwards and off. Levering the cover off Opening the cover Pulling the cover off Figure 4-13 Preparing to wire the front connector 4.
Wiring the S7-400 4.15 Wiring the Front Connector, Crimp Snap-On Terminals Procedure To wire the prepared front connector, follow the steps outlined below: 1. Strip the conductors over approx. 5 mm. 2. Crimp the contacts onto the conductors. You can use a crimping tool which can be ordered as an accessory for your signal modules. 3. Insert the crimp contacts into the cutouts in the front connector. Start at the bottom of the front connector.
Wiring the S7-400 4.16 Wiring the Front Connector, Screw-Type Terminals Procedure To wire the prepared front connector, follow the steps outlined below: 1. Are you using wire end ferrules? If so: Strip the conductors over 10 mm. Press-fit the wire end ferrules onto the conductors. If not: Strip the conductors over 8 to 10 mm. 2. Position the cores. Start at the bottom of the front connector. 3. Screw the ends of the conductors onto the front connector with a tightening torque of 0.6 to 0.8 Nm.
Wiring the S7-400 4.17 Wiring the Front Connector, Spring-Type Terminals Procedure To wire the prepared front connector, follow the steps outlined below: 1. Are you using wire end ferrules? If so: Strip the conductors over 10 mm. Press-fit the wire end ferrules onto the conductors. If not: Strip the conductors over 8 to 10 mm. 2. Use a screwdriver (0.5 x 3.5 mm DIN 5264) to release the spring contact of the first terminal. Start at the bottom of the front connector.
Wiring the S7-400 Principle of the Spring Contact The following figure shows the principle of spring contacts. Releasing and engaging from the front is illustrated. 1. nsert the screwdriver 2. Insert the wire into the spring contact as far as it will go 3.
Wiring the S7-400 4.18 Fitting the Strain Relief Cable Ties as Strain Relief When you have wired the front connector, the cable tie provided should be fitted at the bottom of the front connector as a strain relief for the connected cable. There are three ways of fitting the strain relief, according to the thickness of the cable. Three openings are provided at the bottom of the front connector.
Wiring the S7-400 4.19 Labeling a Front Connector Labels and Terminal Diagram Each signal module is provided with three labels: two blank labels and one printed label showing the terminal diagram for inputs and outputs. Figure 4-19 shows the locations for fitting the individual labels on the front connector. Label in front connector Terminal diagram interior Label exterior Figure 4-19 Fitting the Labels on the Front Connector To label a front connector, follow the steps outlined below: 1.
Wiring the S7-400 Figure 4-20 shows details for fitting a label in the front connector. Label with blank Cutout in front connector Figure 4-20 Fitting a Label in the Front Connector Labeling Sheets • Labeling sheets that can be printed by machine for the I/O modules of SIMATIC S7-400, including FMs, are the prerequisite for professional, convenient labeling of SIMATIC modules. • The labeling strips are already perforated on DIN A4 sheets and can be easily separated without the use of a tool.
Wiring the S7-400 Notes on Ordering Labeling Sheets for S7-400 Order Number 4-34 Description 6ES7492-2AX00-0AA0 SIMATIC S7-400, 10 A4 LABELING SHEETS, COLOR PETROL, 4 LABELING STRIPS/SHEETS FOR SIGNAL MODULES, MATERIAL: FOIL, PERFORATED FOR PRINTING WITH A LASER PRINTER, 10 SHEETS PER PACKAGE 6ES7492-2BX00-0AA0 SIMATIC S7-400, 10 A4 LABELING SHEETS, COLOR LIGHT BEIGE, 4 LABELING STRIPS/SHEETS FOR SIGNAL MODULES, MATERIAL: FOIL, PERFORATED FOR PRINTING WITH A LASER PRINTER, 10 SHEETS PER PACKAGE 6ES7
Wiring the S7-400 How to Label S7-400 Modules Method 1: Using Templates 1. Find the templates on the Internet You can download the templates from the Internet free of charge. You can search for the templates on the initial Customer Supports page (try entering the keyword ”label”, for example). 2. Download The download contains templates for the labeling of S7-400 modules.
Wiring the S7-400 4.20 Fitting the Front Connector Principle of a Coding Key To reduce the risk of a wired front connector being plugged into the wrong type of module after rewiring or module replacement, the signal modules have a coding key for front connectors. A coding key comprises two parts: one part is permanently connected to the module; the second part is still connected to the first part when delivered (see Figure 4-21).
Wiring the S7-400 To plug in the front connector, follow the steps outlined below: 1. Hold the front connector horizontally and engage the front connector with the coding key. After an audible click, the front connector will engage with the mount and can be swung upwards. 2. Swing the front connector upwards. The two parts of the coding key will then be separated. 3. Screw the front connector on.
Wiring the S7-400 Figure 4-22 shows how to screw on the front connector.
Wiring the S7-400 4.21 Interconnecting the CR and ER(s) Interconnecting the Interface Modules When you assemble a programmable controller comprising a CR and one or more ERs, you connect the racks via the connecting cables of the interface modules. To interconnect the interface modules, follow the steps outlined below: 1. Ensure that all the connecting cables needed for the programmable controller are ready.
Wiring the S7-400 7. Open the cover of the first receive IM (interface module in the ER). 8. Plug the free end of the connecting cable into the upper male connector (receive interface) of the receive IM and screw the connector on. 9. Connect the remaining receive IMs by connecting one send interface (lower female connector X2) to one receive interface (upper male connector X1) in each case. Send IM Receive IM Receive IM Terminator Figure 4-24 Connection Between a Send IM and Two Receive IMs 10.
Wiring the S7-400 4.22 Setting the Fan Subassembly to the Line Voltage and Wiring It Setting the Fan Subassembly to the Line Voltage Check whether the voltage selector switch in the fan subassembly is set to your line voltage (see Figure 4-25). Fuse The fan subassembly has two standard fuses: • A 250 mA slow blow fuse for the 120 V range • A 160 mA slow blow fuse for the 230 V range. The fuse for the 230 V range is fitted before delivery.
Wiring the S7-400 Fit the small cover as a strain relief Power terminals (spring contacts) Voltage selector switch Fuse cap Figure 4-25 4-42 Wiring the Fan Subassembly S7-400 and M7-400 Programmable Controllers Hardware and Installation A5E00069481-04
Wiring the S7-400 4.23 Routing Cables Using Cable Ducts or Fan Subassemblies Cable Routing Depending on the number of cables and plug-in lines merging at the particular rack, the cross-section of the cable duct or fan subassembly may not be sufficient to accept all cables. You should therefore route half the cables toward each side via the cable duct or fan subassembly.
5 Networking Chapter Overview Section Description Page 5.1 Configuring a Network 5-2 5.2 Fundamentals 5-3 5.3 Rules for Configuring a Network 5-7 5.4 Cable Lengths 5-15 5.5 PROFIBUS-DP Bus Cables 5-18 5.6 Bus Connectors 5-19 5.7 RS 485 Repeater 5-23 5.
Networking 5.1 Configuring a Network Subnets You can connect an S7-400 device to various subnets: • Via a Simatic Net CP Ethernet to an Industrial Ethernet subnet • Via a Simatic Net CP PROFIBUS to a PROFIBUS-DP subnet • Via the integrated multipoint interface to an MPI subnet • Via the integrated PROFIBUS-DP interface to a PROFIBUS-DP subnet With the M7-400, an MPI or PROFIBUS-DP network can be configured in the same way.
Networking 5.2 Fundamentals Station = Node Declaration: All the stations you connect in a network are referred to as nodes in the following. Segment A segment is a bus cable between two terminating resistors. A segment can contain up to 32 nodes. Furthermore, a segment is limited by the permissible cable length according to the transmission rate. Baud Rate The baud rate (transmission rate) is the speed at which data is transmitted, expressed in terms of bits per second. • Baud rates of 19.
Networking Number of Nodes MPI PROFIBUS DP 127 127 * (default: 32) of which: 1 PG port (reserved) 1 master (reserved) 1 PG port (reserved) 125 slaves or other masters * Observe the CPU-related maximum numbers in the Reference Manual CPU Data, Chapter 4 MPI/PROFIBUS-DP Addresses In order for all nodes to be able to communicate with one another, you must assign them an address: • In the MPI network, an MPI address • A PROFIBUS-DP address in the PROFIBUS-DP network Default MPI Addresses The followi
Networking Communication from PG/OP to Module without MPI If one of the programming devices or operator panels connected to a multipoint interface (MPI) communicates with an S7-400 module which does not have an MPI connection (for example, SIMATIC NET CPs, FM 456 etc.), this module can be reached via the CPU to whose MPI the programming device or operator panel is connected. In this case, the CPU simply acts as an intermediary for the transfer.
Networking PG Access A CPU exchanges data with other systems using communication mechanisms, for example with other programmable controllers, with operator interface stations (OP, OS) or with programming devices (see Figure 5-2).
Networking 5.3 Rules for Configuring a Network Rules Observe the following rules for connecting the nodes of a network: • Before you interconnect the individual nodes of the network, you must assign to each node the MPI address and the highest MPI address or PROFIBUS-DP address. Tip: Mark the address of each node in a network on the housing. To do this, use the adhesive labels enclosed with the CPU. You can then always see which address is assigned to which node in your plant.
Networking Data Packets in the MPI Network Observe the following feature in the MPI network: Note If you connect an additional CPU to the MPI network during operation, data may be lost. Remedy: 1. Disconnect power from the nodes to be connected. 2. Connect the nodes to the MPI network. 3. Switch on the nodes. Recommendation for MPI Addresses Reserve MPI address “0” for a service programming device and “1” for a service OP, which will later be briefly connected to the MPI network as required.
Networking Terminating Resistor on the Bus Connector Terminating resistor switched on Terminating resistor switched off on off on off Figure 5-3 Terminating resistor on bus connector Terminating Resistor on the RS 485 Repeater DC 24 V L+ M PE M 5.
Networking Example: Terminating Resistor in the MPI Network The figure below shows where you have to connect the terminating resistor in a possible configuration for an MPI network.
Networking Example of an MPI Network S7-400** S7-400 S7-400 S7-400 PG OP** 2 1 3 4 5 S7-400 S7-400 OP 11 6 10 S7-300 OP 9 8 7 0 Programming device * Only connected via spur line for startup/maintenance (with default MPI address) ** Connected to the MPI later on (with default MPI address) 0 ...
Networking Example of a PROFIBUS-DP Network S7-400 with CPU 414-2-DP as DP master ET 200M ET 200M S5-95U PG 1 2 ET 200B OP PG* 0 8 3 7 4 5 ET 200B 6 * Only connected via spur line for startup/maintenance (with default PROFIBUS-DP address = 0) 0 ...
Networking Example Using a CPU 414-2 The figure below shows an example of a configuration with CPU 414-2 DP which is integrated in an MPI network and simultaneously used as DP master in a PROFIBUS-DP network. In both networks, the node numbers can be assigned separately without conflicts resulting.
Networking Programming Device Access Beyond Network Limits (Routing) You can access all modules beyond network limits using a programming device. S7-400 with CPU 416 Programming device / PC 3 S7-400 with CPU 417 MPI network 3 MPI network 1 S7-300 with CPU 318 S7-300 with CPU 318 Programming device / PC 1 PROFIBUS-DP network 2 ET 200 Programming device / PC 2 Figure 5-9 Programming device access beyond network limits Requirements : • Use STEP 7 from version 5.
Networking 5.4 Cable Lengths Segment in the MPI Network In a segment of an MPI network, you can use cable lengths of up to 50 m. This 50 m applies from the first node to the last node in the segment. Table 5-1 Permitted Cable Length of a Segment in an MPI Network Transmission Rate Maximum Cable Length of a Segment (in m) 187.5 Kbps 50 19.
Networking Lengths of Spur Lines If you do not fit the bus cable directly at the bus connector (for example, when using a PROFIBUS-DP bus terminal), you must take into account the maximum possible spur line length. The following table gives the maximum lengths of spur lines allowed per bus segment: Table 5-3 Lengths of Spur Lines per Segment Transmission Rate Maximum Length of a Spur Line Number of Nodes per Spur Line Length of ... 1.5 m and 1.6 m 3m Maximum Length of Spur Lines per Segment 9.
Networking Example The figure below shows a possible configuration of an MPI network. This example clarifies the maximum possible distances in an MPI network. S7-400 S7-400 S7-400 OP 3 4 5 PG* Programming device* 7 6 RS 485repeater max. 1000m Spur line 0 max. 50m S7-400 OP 11 S7-400 OP 10 RS 485repeater 9 8 max. 50m Terminating resistor switched on Programming device connected via spur line for maintenance 0 ...
Networking 5.
Networking 5.6 Bus Connectors Purpose of the Bus Connector The bus connector is used to connect the PROFIBUS-DP bus cable to the MPI or PROFIBUS-DP interface. In this way, you establish the connection to other nodes. There are two different bus connectors: • Bus connector without PG connector (6ES7 972-0BA20-0XA0) • Bus connector with PG connector (6ES7 972-0BB20-0XA0) Appearance (6ES7 972-0B.20 ...) Screws for mounting on station 9-pin sub.
Networking Connecting Bus Cables to Bus Connectors (6ES7 972-0B.20 ...) 1. Strip the bus cable according to the following figure. 11 5.5 Without PG connector 2 13 6 2 13 2 8 2 5.5 5.5 A B 7 A B A B 7.5 5.5 11 Angled outgoing cable unit AB With PG connector Figure 5-12 Strip bus cable 2. Open the housing of the bus connector by slackening the housing screw and swinging the cover upwards. 3. Slacken the clamp hinge cover. 4. The bus connector with order number 6ES7 972-0B.
Networking 5. Insert the green and red cores in the screw terminal block as shown in the following figure. Ensure that the same cores are always connected to the same terminals A or B (for example, green conductor always wired to terminal A, and red conductor to terminal B). Bus cable connection for first and last station on the bus Bus cable connection for all other stations on the bus A B A B ÇÇ A B A B The bus cable can be connected either right or left.
Networking Connecting the Bus Connector To connect the bus connector, proceed as follows: 1. Plug the bus connector into the module. 2. Screw the bus connector into the module. 3. If the bus connector, order no. 6ES7 972-0B.20-0XA0, is situated at the beginning or end of a segment, you must switch on the terminating resistor.
Networking 5.7 RS 485 Repeater Purpose of the RS 485 Repeater The RS 485 repeater enhances data signals on bus cables and links bus segments. You need an RS 485 repeater when: • More than 32 nodes are connected in the network, • A grounded segment is to be connected to an ungrounded segment, or • The maximum cable length of a segment is exceeded.
Networking Connecting the PROFIBUS-DP Bus Cable Connect the PROFIBUS-DP bus cable to the RS 485 repeater as follows: 1. Cut the PROFIBUS-DP bus cable to the required length. 2. Strip the PROFIBUS-DP bus cable according to the following figure. The braided shield must be turned back over the cable. This is essential so that the shielding point can serve later for strain relief and as a securing element. 6XV1 830-3AH10 6XV1 830-0AH10 6XV1 830-3BH10 8.5 16 10 ÇÇ ÇÇ 16 16 10 ÇÇ ÇÇ 8.
Networking 5.8 PROFIBUS-DP Network with Fiber-Optic Cables Electrical/Optical Conversion If you want to use the field bus for larger distances irrespective of the transmission rate, or if the data traffic on the bus is not to be impaired by external interference fields, use fiber-optic cables rather than copper cables.
Networking Optical PROFIBUS-DP Network in Partyline Topology The optical PROFIBUS-DP network with nodes that have an integrated fiber-optic cable interface has a partyline topology. The PROFIBUS nodes are interconnected in pairs by means of Duplex fiber-optic cables. Up to 32 PROFIBUS nodes with a fiber-optic cable interface can be series-connected in an optical PROFIBUS-DP network.
Networking 5.8.
Networking Table 5-4 Features of the Fiber-Optic Cables, continued Description SIMATIC NET PROFIBUS Plastic Fiber-Optic Duplex Conductor Plastic Fiber-Optic Standard Cable PCF Fiber-Optic Standard Cable 35 N/ 10 cm 100 N/ 10 cm 750 N/ 10 cm 30 mm 100 mm 75 mm 50 mm (flat side only) 150 mm 75 mm -30 _C to +70 C -30 C to +70 C -30 C to +70 C 0 C to +50 C 0 C to +50 C -5 C to +50 C -30 C to +70 C -30 C to +70 C -20 C to +70 C Conditional 1) Conditiona
Networking Order Numbers You can order the fiber-optic cables specified in Table 5-4 as follows.
Networking Structure Two Simplex connectors (a sender and a receiver) and a connector adapter with the following attributes are required for a fiber-optic cable connection: • IP 20 protection • Transmission rates of 9.
Networking 5.8.3 Connecting a Fiber-Optic Cable to the PROFIBUS Device Cable Lengths With fiber-optic cables, the length of the cable segment does not depend on the transmission rate. Each bus node in the optical PROFIBUS-DP network has repeater functionality. The distances specified below are the distances between two neighboring PROFIBUS nodes in the partyline topology. The maximum cable length between two PROFIBUS nodes depends on the type of the fiber-optic cable used.
Networking Installation Instructions for Plastic Fiber-Optic Cable (with Photos) You will find detailed installation instructions and a series of photographs on fitting plastic fiber-optic cables with Simplex connectors: • In the appendix of the SIMATIC NET PROFIBUS Networks manual • On the Internet – German: http://www.ad.siemens.de/csi/net – English: http://www.ad.siemens.de/csi_e/net Click SEARCH on this page, enter the number “574203” under “Entry-ID” and start the search function.
6 Starting Up Chapter Overview Section Description Page 6.1 Recommended Procedure for First Startup 6-2 6.2 Checks Prior to Switching On for the First Time 6-3 6.3 Connecting a Programming Device (PG) to an S7-400 6-5 6.4 Switching On an S7-400 for the First Time 6-6 6.5 Resetting the CPU with the Mode Selector Switch 6-7 6.6 Cold, Warm, and Hot Restarts with the Mode Selector Switch 6-10 6.7 Inserting a Memory Card 6-11 6.8 Inserting a Backup Battery (Option) 6-13 6.
Starting Up 6.1 Recommended Procedure for First Startup Recommended Procedure Due to the modular assembly and the many expansion options, an S7-400 can be very extensive and complex. A first startup of an S7-400 with two or more racks and all modules inserted is therefore not advisable. Instead, a startup in stages is recommended.
Starting Up 6.2 Checks Prior to Switching On for the First Time Checks Prior to Switching On for the First Time After installing and wiring your S7-400, it is advisable to check the steps carried out so far, before switching on for the first time. Table 6-1 contains a guide in the form of a checklist for your S7-400, and refers to the chapters containing additional information on the subject.
Starting Up Table 6-1 Checklist to be Used Before Switching On for the First Time, continued Module Settings Is the CPU mode switch set to STOP? 6 Are the numbers of the racks correctly set on the coding switches of the receive IMs and not duplicated? 1 7 If measuring range modules are fitted on the analog input modules, are they correctly set? 5, 6 Have the rules for connection been observed? 2 Have the correct cables been used for connections to existing ERs? 2, 4 Is the last receive IM of ea
Starting Up Table 6-2 Setting the Battery Monitoring Switch ...Then If You ... 6.3 do not use battery monitoring, set the BATT INDIC switch to OFF. use battery monitoring with a single-width power supply module, set the BATT INDIC switch to BATT. want to monitor a backup battery with a double or triple-width power supply module, set the BATT INDIC switch to 1BATT. want to monitor two backup batteries with a double or triple-width power supply module, set the BATT INDIC switch to 2BATT.
Starting Up Communication between Programming Device and CPU The following conditions apply when communicating between a programming device and a CPU: • You need a programming device with STEP 7. • The CPU can communicate with the programming device in the following modes: RUN-P, RUN, STOP, STARTUP, and HOLD. Operator Control A description of operator control of communication between CPUs and programming devices can be found in the STEP 7 manuals. 6.
Starting Up 6.5 Resetting the CPU with the Mode Selector Switch How to Carry Out a Memory Reset When you reset a CPU, you place the memories of the CPU in a defined initial state. The CPU also initializes its hardware parameters and some of the system program parameters. If you have inserted a Flash card with a user program in the CPU, the CPU transfers the user program and the system parameters stored on the Flash card into the main memory after the memory reset.
Starting Up Resetting the CPU with the Mode Selector Switch The mode selector switch is designed as a keyswitch. The following figure shows the possible positions of the mode selector switch. RUN-P RUN STOP MRES Proceed as follows to reset the CPU using the mode switch: Case A: You want to transfer a new, complete user program to the CPU. 1. Turn the switch to the STOP setting. Result: The STOP LED lights up. 2. Turn the switch to the MRES setting and keep it at this setting.
Starting Up What Happens in the CPU During a Memory Reset When you carry out a memory reset, the following process occurs in the CPU: • The CPU deletes the entire user program from the main memory and load memory (integrated RAM and, if applicable, RAM card). • The CPU clears all counters, bit memory, and timers (except for the time of day). • The CPU tests its hardware. • The CPU initializes its hardware and system program parameters, (internal default settings in the CPU).
Starting Up 6.6 Cold, Warm, and Hot Restarts with the Mode Selector Switch Sequence of Events During a Cold Restart (CPU 417 and 417 H) 1. Turn the switch to the STOP setting. Result: The STOP LED lights up. 2. Turn the switch to the RUN/RUNP setting. Sequence of Events During a Warm Restart (CPU 417 and 417 H) 1. Turn the switch to the STOP setting. Result: The STOP LED lights up. 2. Turn the switch to the MRES setting and keep it at this setting.
Starting Up 6.7 Inserting a Memory Card The Memory Card as Load Memory You can insert a memory card in all CPUs of the S7-400. It is the load memory of the CPU. Depending on the type of memory card, the user program is retained on the memory card even when power is removed. What Type of Memory Card Should You Use? There are two types of memory card: RAM cards and Flash cards. Whether you use a RAM card or a Flash card depends on how you intend to use the memory card. If You ...
Starting Up Inserting a Memory Card To insert a memory card, follow the steps outlined below: 1. Set the mode selector switch on the CPU to STOP. 2. Insert the memory card in the submodule slot of the CPU and push the memory card in as far as it will go. Note the position of the marker dot. You can only insert the memory card in the card slot in the direction shown in Figure 6-2. Result: The CPU requests a memory reset by slow flashing of the STOP LED at 0.5 Hz. 3.
Starting Up 6.8 Inserting a Backup Battery (Option) Backup Depending on the power supply module, you can use one or two backup batteries: • To back up a user program and save it without loss in the event of a power failure. • For retentive storage of bit memory, timers, counters, and system data as well as data in variable data blocks. You can also provide this backup with an external battery (5 to 15 VDC). You achieve this by connecting the external battery to the EXT. BATT.
Starting Up The following figure shows how to insert a backup battery in the single-width power supply module.
Starting Up The following figure shows how to insert two backup batteries in a double-width power supply module. ! Warning Hazardous to persons and property, risk of pollutant emission. A lithium battery can explode if treated incorrectly; improper disposal of old lithium batteries can result in pollutant emission. The following instructions should therefore be observed without fail: • Do not throw new or discharged batteries into a fire and do not solder onto the cell body (max. temperature 100° C).
Starting Up Reducing the Passivation Layer Lithium batteries (lithium/thionyl chloride) are used as backup batteries for the S7-400. In lithium batteries of this technology, a passivation layer can develop after storage for a very long time, and the immediate functional capability of the battery may not be certain. This may result in an error message when the power supply module is switched on.
Starting Up 6.9 Starting Up a PROFIBUS-DP Subnet Introduction This section describes the procedure for starting up a PROFIBUS-DP subnet with an S7-400 CPU as the DP master. Requirements Before you can start up the PROFIBUS-DP subnet, the following requirements must be met: • The PROFIBUS-DP subnet has been set up (see Chapter 5).
Starting Up 6.10 Installing Interface Submodules (CPU 414-2, 414-3, 416-3, 417-4 and 417-4H) Available Interface Submodules Note Only use interface submodules that are explicitly released for use in S7-400 devices. Installing Interface Submodules ! Warning The modules can be damaged. When inserting or removing interface submodules with power applied, the CPU and interface submodules can be damaged (exception: using synchronization submodules in an H system).
Starting Up 5. Slowly push the interface submodule into the slot until the front plate rests on the frame of the card slot. 6. Important! Secure the front plate with the two fitted, captive M2.5 x 10 slot-head screws on the left frame of the card slot. 7. Attach the additional front plate for an IF 964-DP and for an IF 960 HF (synchronization module).
Starting Up 6-20 S7-400 and M7-400 Programmable Controllers Hardware and Installation A5E00069481-04
7 Maintenance Chapter Overview Section Description Page 7.1 Replacing the Backup Battery 7-2 7.2 Replacing a Power Supply Module 7-4 7.3 Replacing CPUs 7-5 7.4 Replacing Digital or Analog Modules 7-7 7.5 Changing the Fuses in the Digital Modules 7-9 7.6 Replacing Interface Modules 7-11 7.7 Replacing the Fuse of the Fan Subassembly 7-13 7.8 Replacing Fans in the Fan Subassembly During Operation 7-14 7.9 Replacing the Filter Frame of the Fan Subassembly During Operation 7-16 7.
Maintenance 7.1 Replacing the Backup Battery Replacing the Backup Battery 1. Discharge any static charge by touching a grounded metal part of the S7-400. 2. Open the cover of the power supply module. 3. Using the loop(s), pull the backup battery/batteries out of the battery compartment. 4. Insert the new backup battery/batteries in the battery compartment of the power supply module. Ensure correct polarity of the battery/batteries. 5. Switch on battery monitoring with the BATT INDIC slide switch.
Maintenance Note If you store the batteries for a long period, a passivation layer may form. Please read Section 6.8, Inserting a Backup Battery. Using Backup Batteries You should change the backup battery once a year. Observe the usual regulations/guidelines for disposing of lithium batteries in your country. Backup batteries should be stored in a cool, dry place. Backup batteries can be stored for ten years. If they are stored for a longer period, however, a passivation layer may form.
Maintenance 7.2 Replacing a Power Supply Module Slot Numbering If you have provided the modules in your system with slot numbering, you must remove the number from the old module when replacing it and apply the number to the new module. Removing the Module (Ignore Steps 1 and 2 When Using Redundant Power Supply Modules) 1. Set the CPU mode switch to STOP. When you replace the power supply module in an ER, the CR may remain in the RUN state, depending on CPU programming.
Maintenance 7.3 Replacing CPUs Slot Numbering If you have provided the modules in your system with slot numbering, you must remove the number from the old module when replacing it and apply the number to the new module. Saving the Data Save the user program including configuration data. Removing the Module 1. Set the CPU mode switch to STOP. 2. Set the standby switch of the power supply module to (0 V output voltages). 3. Remove the cover of the CPU. 4. Disconnect the MPI connector, if applicable. 5.
Maintenance Installing a New Module 1. Attach the new module of the same type and swing it downwards. 2. Screw the module on. 3. If applicable, plug the connector for the external battery supply into the socket. 4. Set the CPU mode switch to STOP. 5. Insert the memory card. 6. Set the standby switch of the power supply module to I (output voltages at rated value). The remaining procedure depends on whether you use a Flash card and whether or not you have configured your system for networking. 7.
Maintenance 7.4 Replacing Digital or Analog Modules Slot Numbering If you have provided the modules in your system with slot numbering, you must remove the number from the old module when replacing it and apply the number to the new module. Installing a Module 1. You can replace analog and digital modules in RUN mode. You must have taken the appropriate action in your STEP 7 program to ensure correct responses from your system.
Maintenance Removing the Front Connector Coding Key Before fitting the front connector, you must remove (break off) the front part of the coding key, because this part is already fitted in the wired front connector. ! Caution The module can be damaged. If, for example, you insert a front connector of a digital module in an analog module, the module may be damaged. Only operate modules with their complete front connector coding key. Installing a New Module 1.
Maintenance 7.5 Changing the Fuses in the Digital Modules Modules with Fuses The following modules have fuses which you can change yourself if they are defective: • Digital output module SM 422; DO 16 x AC 20-120 V/2A (6ES7422-5EH00-0AB0) • Digital output module SM 422;DO 8 x AC 120/230 V/5A (6ES7422-1FF00-0AA0) • Digital output module SM 422;DO 16 x AC 120/230 V/2A (6ES7422-1FH00-0AA0) Check the Plant Correct the faults which led to the fuses blowing.
Maintenance ! Warning Improper handling of the front connectors can result in injury and damage. If the front connector is removed and inserted during operation, hazardous voltages of >25 VAC or >60 VDC may be present at the pins of the module. When such voltages are present at the front connector, modules with power applied may only be replaced by electrical specialists or trained personnel in such a way that the pins of the module are not touched.
Maintenance 7.6 Replacing Interface Modules Slot Numbering If you have provided the modules in your system with slot numbering, you must remove the number from the old module when replacing it and apply the number to the new module. Fitting and Removing Modules During Operation Observe the following warning when fitting and removing the interface modules and the corresponding connecting cables. ! Caution Data can be lost or corrupted.
Maintenance Installing a New Module 1. Set the number of the rack at receive IMs. 2. Attach the new module of the same type and swing it downwards. 3. Screw the module on. 4. Fit the connecting cables. 5. Plug in the terminator, if applicable. 6. Secure the cover. 7. First switch on the power supply module in the ER. 8. Then switch on the power supply module in the CR. 9. Set the CPU mode switch to RUN mode.
Maintenance 7.7 Replacing the Fuse of the Fan Subassembly Fuse Type The fuse of the fan subassembly is a standard 5 x 20 mm cartridge fuse to DIN and not a spare part. Use the following fuse: • 160 mA slow blow if the voltage selector switch is set to 230 V • 250 mA slow blow if the voltage selector switch is set to 120 V Replacing the Fuse To replace the fuse of the module, follow the steps outlined below: 1. Disconnect the power cable of the fan subassembly from the supply. 2.
Maintenance 7.8 Replacing Fans in the Fan Subassembly During Operation Removing the Fans 1. Use a screwdriver to make a quarter turn counter-clockwise and open the two quick-release locks on the front of the fan subassembly.
Maintenance 2. Grasp the base with both hands, press it down slightly and pull it fully out of the fan subassembly. 3. Release the fan to be replaced by pressing the fan grip away from the housing with your thumb. Fan Fan grip Base 4. Pull out the fan to be replaced. 5. Slide the new fan in until it engages. 6. Slide the base in again and press it up. 7. Use a screwdriver to make a quarter turn clockwise and close the two quick-release locks. 8. Use a pointed object to press the RESET button.
Maintenance 7.9 Replacing the Filter Frame of the Fan Subassembly During Operation Replacing the Filter Frame 1. Use a screwdriver to make a quarter turn counter-clockwise and open the two quick-release locks on the front of the fan subassembly. 2. Grasp the base with both hands, press it down slightly, pull it first fully forward and then up at an angle out of the fan subassembly. 3. The filter frame is secured either in the bottom of the base or at its rear edge with snap hinges and snap catches.
Maintenance Filter mat Filter frame Cover Snap catches Base with cover and filter frame (optionally fitted at bottom or rear) Snap hinges Quick-release locks 4. Fit the new filter frame: – Fitting the filter frame at the bottom of the base: Insert the filter frame in the snap hinges at the base cutout and engage it with the snap catches. – Fitting the filter frame at the rear edge of the base: At about a right angle to the base, insert the filter frame in the snap hinges at the rear edge of the base.
Maintenance 7.10 Replacing the Power Supply PCB and Monitoring PCB of the Fan Subassembly Exchanging the Mother Board 1. Disconnect the power cable of the fan subassembly from the supply. 2. Use a screwdriver to make a quarter turn counter-clockwise and open the two quick-release locks on the front of the fan subassembly. 3. Remove the base of the fan subassembly (see Section 7.9). Shown in the following figure is a front view of the fan subassembly.
Maintenance 7.11 Replacing Memory Cards Memory Expansion The CPU 417-4 and CPU 417-4 H memory modules are expandable. Take note of the following rules for the expansion procedure: 1. If you are inserting only one module, it has to be inserted on slot 1. 2. A second module may only be inserted if a module of 4 Mbytes is inserted on slot 1.
Maintenance 6. If necessary, insert the second memory card in slot 2 in the same way. 7. Fit the cover on the upper left side of the CPU by securing it with three screws.
Maintenance Note The connectors to accept the memory cards are coded (see Figure 7-2). Do not apply force when fitting the memory cards. Lightly press the guide supports out to remove the memory cards (see Figure 7-2).
Maintenance 7.12 Replacing Interface Submodules Available Interface Submodules Note Only use interface submodules that are explicitly released for use in S7-400 devices. Installing Interface Submodules ! Warning The modules can be damaged. When inserting or removing interface submodules with power applied, the CPU and interface submodules can be damaged (exception: using synchronization submodules in an H system).
Maintenance You can replace an interface submodule with another one without having to remove the associated CPU from the rack. Follow the steps outlined below: 1. Switch the CPU to STOP. 2. Disconnect the CPU module from the network (unless it is a synchronization submodule). 3. Loosen the screws of the sub-D-connector and remove all connectors. 4.
Maintenance 7-24 S7-400 and M7-400 Programmable Controllers Hardware and Installation A5E00069481-04
8 Assembling the M7-400 This Chapter The assembling of an M7-400 automation computer is largely identical to that of an S7-400 programmable controller. Most of the instructions in the S7-400 chapters can therefore be applied to the M7-400. Wherever details relate specifically to the M7-400, these are pointed out to you at the beginning of each S7-400 chapter with a cross-reference to the corresponding M7-400 section.
Assembling the M7-400 8.1 Mechanical Configuration Introduction Explained in this section are the rules you must observe for arranging modules in the M7-400 automation computer. All other information which is important for the mechanical configuration applies both to the S7-400 and the M7-400, and is described in Chapter 2. Rules for the Arrangement of Modules You must observe the following rules for the arrangement of modules in a rack: • The power supply module must be inserted in slot 1 in all racks.
Assembling the M7-400 Table 8-1 Sequence in the Module Subassembly CPU Slot Slot Slot Slot n and n + 1 for Double-Width CPUs n+2 n+3 n+4 EXM 478 - - EXM 478 EXM 478 - EXM 478 EXM 478 EXM 478 EXM 478 EXM 478 ATM 478 EXM 478 ATM 478 ATM 478 EXM 478 ATM 478 - ATM 478 - - ATM 478 ATM 478 - CPU 486-3, CPU 488-3 ATM 478 ATM 478 ATM 478 MSM 478 - - EXM 478 MSM 478 - EXM 478 EXM 478 MSM 478 EXM 478 MSM 478 ATM 478 MSM 478 ATM 478 ATM 478 MSM 478 ATM 478 - Note
Assembling the M7-400 Dimensions of Modules in the M7-400 There are modules of 25 mm and 50 mm in width in the M7-400 system. Table 8-3 contains a summary of dimensions of the modules used in the M7-400. Table 8-3 Dimensions of Modules in the M7-400 System Slots Occupied Module Height CPU 486-3 (incl. mode switch) CPU 488-3 (incl. mode switch) Mass Storage Module MSM 478 AT Adapter Module ATM 478 219 mm (236.5 mm) 2 Expansion Module EXM 478 Depth (Depth when Fitted) 290 mm 210 mm (227.
Assembling the M7-400 8.2 Addressing the M7-400 Modules Which Modules Can Be Reached Via a Start Address? Out of the M7-400 modules, only the application modules can be addressed directly via an address. The EXM 478 expansion module, ATM 478 AT adapter module and MSM 478 mass storage module cannot be accessed via the S7-400 backplane bus. Communication between these modules and the CPU is exclusively via the ISA bus.
Assembling the M7-400 8.3 Electrical Configuration Introduction This section contains the important information you need for the electrical configuration of an M7-400. You will learn: • How to calculate the current consumption of an M7-400, based on a configuration example, and how to select the required power supply module. • The additional facilities for expansion with PROFIBUS DP.
Assembling the M7-400 With the details from the individual data sheets, you can calculate Current Consumption I in this rack as follows: Table 8-4 Calculation Example for Power Supply Module Module Slots Occupied +5 VDC (Max.
Assembling the M7-400 8.4 Installing the M7-400 Introduction This section contains the important information you need for installing the M7-400.
Assembling the M7-400 8.4.1 Checklist for Installation Checklist for Installation This section explains the procedure in stages for installing the M7-400. You should proceed as follows: 1. Install the rack and remove the dummy plates from the required slots (Chapter 5). 2. Remove, if applicable, the cover of the module and refit it after wiring. 3. Check that the power supply on the rack is correctly rated (page 8-7). 4. Insert the power supply module in the first slot of the rack (Chapter 5). 5.
Assembling the M7-400 8.4.2 Module Accessories Introduction The module packaging contains the basic accessories you need to install the M7-400 modules in the rack. There are optional accessories for some modules. Accessories The accessories for the modules are listed and briefly explained in Table 8-5. A list of spare parts for the SIMATIC M7-400 can be found in the Reference Manual, Chapter 11.
Assembling the M7-400 8.4.3 Fitting Memory Cards in the CPU Introduction For the CPUs of the M7-400 automation computer, the MEM 478 memory cards are supplied separately. Before the module with its expansion modules is inserted in the rack, the memory cards must be fitted. Note With a CPU, a DRAM memory card of the same size must be inserted at Slot 1 and Slot 2. Only use the memory cards intended for the particular CPU. ! Warning The modules can be damaged.
Assembling the M7-400 3 4 4 2 Slot 1 Slot 2 Figure 8-1 Fitting Memory Cards in the CPUs 3.3 V DRAM memory card (for main memory) Recess Slots 1 and 2 Figure 8-2 8-12 3.
Assembling the M7-400 8.4.4 Installing Interface Submodules Installing Interface Submodules The following modules have card slots to accept interface submodules: • CPU 486-3, two card slots • CPU 488-3, two card slots • EXM 478 expansion module, three card slots. ! ! Warning The modules can be damaged. When inserting or removing interface submodules with power applied, the CPU and expansion modules as well as the interface submodules can be damaged.
Assembling the M7-400 Guides Frame of card slot with mounting hole EXM 478 Figure 8-3 Inserting an Interface Submodule in an Expansion Module Covering Unused Submodule Slots On delivery, only the upper submodule slot is open in the central and expansion racks. All other card slots are covered. The cover is secured to the frame of the card slot with screws. Loosen the screws and remove the cover to insert more than one interface submodule in an expansion module.
Assembling the M7-400 8.4.5 Fitting the Short AT Card Installing the AT Card A short AT card can be used with the AT adapter module ATM 478. Only short AT cards with a slot in the mounting bracket can be fitted (see also the chapter on M7-400 expansion in the Reference Manual). To assemble an AT card in an AT adapter module ATM 478, proceed as follows: ! Warning The modules can be damaged.
Assembling the M7-400 5 6 5 2 7 3 5 4 Figure 8-4 8-16 Fitting an AT Card in the ATM 478 AT Adapter Module S7-400 and M7-400 Programmable Controllers Hardware and Installation A5E00069481-04
Assembling the M7-400 8.4.6 Assembling Expansion Modules on a Central Rack Introduction Before installing the M7-400 in the rack, you must preassemble the programmable modules with all the required expansion modules. This section contains the information you need to create a module assembly using a central rack with expansion modules such as the EXM 478 expansion module, ATM 478 AT adapter module, and MSM 478 mass storage module. Order of Assembly Proceed in the following order when assembling: 1.
Assembling the M7-400 Removing the Connector and Socket Covers On the right-hand side of a central rack, there is a 120-pin socket for connecting expansion racks to the ISA bus (see Figure 8-5). This socket is protected by a screw-mounted metal cover. The EXM 478, ATM 478, and MSM 478 expansion modules contain • The matching plug on the left side, • An expansion socket on the right side so that other expansion modules can be plugged in.
Assembling the M7-400 Removing the Connecting Clips Connecting clips are fitted at the top and bottom of expansion modules. Pull these off upward and downward respectively.
Assembling the M7-400 Removing the Cover For modules with a cover (for example, CPUs), remove these before fitting the modules together. Proceed as follows: 1. Press the locking lever down (1). 2. Swing the cover forward and off (2). Figure 8-7 shows how to remove the cover.
Assembling the M7-400 Interconnecting Modules Take the CPU and first expansion module, position them on a level surface and press them carefully together so that all pins of the expansion module plug are precisely inserted into the CPU socket. Then plug the other modules successively into the assembled group (see Figure 8-8). e. g. CPU 488-3 e. g. EXM 478 e. g. MSM 478 e. g. ATM 478 1. 2. 3.
Assembling the M7-400 This completes all the expansion on the ISA bus of the CPU (see Figure 8-9). Level surface Figure 8-9 ! Module Assembly Comprising CPU and Expansion Modules Warning The connector pins can be damaged. If the modules are not exactly lined up for interconnecting, the pins can be damaged. Line up the modules precisely when interconnecting.
Assembling the M7-400 3. Press the connecting clip on its two 90° ends downward until it engages. Figure 8-11 shows a connecting clip in its final position. 4. Carry out steps 1 to 3 similarly on the bottom of the modules to be secured.
Assembling the M7-400 8.4.7 Installing a Module Assembly in the Rack Introduction The installation of an M7-400 CPU together with modules from the S7-400 series in a rack is carried out as described in Chapter 5. If the M7-400 central rack has expansion racks, this must be preassembled with its expansion racks into a module group (see also Section 8.4.6 ”Assembling Expansion Modules on a Central Rack”). The installation of such a module group in the rack is the subject of this section.
Assembling the M7-400 Attaching the Module Assembly Attach the module assembly (1) and swing it downwards (2). Figure 8-12 shows how to attach a module assembly onto a rack and swing it into position. Note Do not push the module assembly down whilst swinging it into position.
Assembling the M7-400 Screwing On the Modules Figure 8-13 shows how to screw on the modules. Tightening torque 0.8 to 1.
Assembling the M7-400 Inserting the Mode Selector Switch Figure 8-14 shows how to insert the key in the CPU at the STOP position of the switch. You can remove the key at the STOP or RUN settings.
Assembling the M7-400 8.4.8 Inserting/Removing a Memory Card Purpose of the Memory Card You can do the following with a memory card: • Store the operating system, user programs, and data (similarly to using a floppy disk), • Transport the programs and data stored on the memory card, • Retain the programs and data, even during Power Off.
Assembling the M7-400 8.5 Connecting a Module Assembly Introduction The individual modules and interface submodules of a module assembly can be connected via commercially-available cables and connectors. Requirements The connector housings and cables must meet the following requirements: • Connector housing The height of the connector housing should not be more than 43 mm, the width up to 19 mm. It must have a 45° side outlet for the cable.
Assembling the M7-400 Connecting Mass Storage Modules (MSM) Pin assignments of the parallel interface of the MSM 478 mass storage module can be found in the chapter on M7-400 expansion of the Reference Manual. Connecting the Short AT Card The interface pin assignments of short AT cards which you intend to use can be found in the corresponding documentation. 8.
Assembling the M7-400 Programming device* S5-95U M7-400 S5-95U M7-400 S5-95U M7-400 with CPU as DP master M7-400 ET 200M ET 200M OP 25 M7-400 RS 485 repeater ET 200B ET 200B ET 200B ET 200B OP 25 MPI subnet PROFIBUS-DP subnet * Only connected via spur line for startup/maintenance Terminating resistance switched on Figure 8-16 Example of a Configuration with the CPU in an MPI Subnet and PROFIBUS-DP Subnet S7-400 and M7-400 Programmable Controllers Hardware and Installati
Assembling the M7-400 8.
Assembling the M7-400 8.7.1 Connecting the Operator Panels and I/O Devices Introduction The operator panels and I/O devices which can be connected to your M7-400 depend on its configuration. Extensive information on all connection options of the M7-400 can be found in the appropriate sections of the technical data. To prepare for operation, you need either a PC/programming device or the M7-400 configuration with monitor, keyboard, expansion module, and mass storage module as well as interface submodules.
Assembling the M7-400 Notes for Setting Up Monitors Please observe the following notes when setting up monitors: • Ensure that the clearance between two monitors in asynchronous operation is at least 15 cm, otherwise video interference may occur. Exception: Monitors with a mu-metal shield. • Provide sufficient space between the monitor and extraneous magnetic sources. • Do not set up the monitors in steel shelving or on steel benches.
Assembling the M7-400 Connecting a Mouse Connect the mouse to the IF 962-COM interface submodule. Maximum Cable Length The following table shows you where the maximum cable lengths of the connecting cables of the individual devices are. A requirement is a hardware configuration with interference immunity. Table 8-6 Maximum Cable Lengths for Operator Panels and I/O Devices Device Maximum Length Keyboard • via IF 962-VGA 2.5 m Monitor • via IF 962-VGA 2.
Assembling the M7-400 8.7.2 Connecting a Programming Device (PG) to the COM Interface Introduction To operate your M7-400 without monitor and keyboard, you need a programming device or PC for initial settings in the BIOS Setup. This section explains how to connect a programming device via the COM1 interface of an IF 962-COM interface submodule to your M7-400. However, it is also possible to connect a programming device via the MPI of the M7-400 CPU. In this case, please refer to Sections 8.7.3 to 8.7.5.
Assembling the M7-400 Table 8-7 Null Modem Cable for Connecting a CPU via IF to the COM Interface of a Programming Device with 9-pin Sub. D Male Connector, continued Signal Pin S1 / DTR 4 E2 / GND Pin Signal connected to 6 M1 / DSR 5 connected to 5 E2 / GND M1 / DSR 6 connected to 4 S1 / DTR S2 / RTS 7 connected to 8 M2 / CTS M2 / CTS 8 connected to 7 S2 / RTS M3 / RI 9 - 9 M3 / RI 9-pin sub. D female conn.
Assembling the M7-400 Connecting without Control Cables If the data traffic via the COM interface is to be controlled exclusively via the data lines, a connecting cable as described below is sufficient for connecting your CPU to a programming device. If the free COM interface of your programming device has a 9-pin subminiature D male connector, you can use Table 8-9 below for the pin assignments of the connecting cable.
Assembling the M7-400 8.7.3 Connecting a Programming Device (PG) to the M7-400 Connecting a Programming Device (PG) to the M7-400 You can connect the programming device via a preassembled programming device cable to the MPI of the CPU. Alternatively, you can fabricate the connecting cable with the PROFIBUS-DP bus cable and bus connectors (see Chapter 5). Shown in Figure 8-17 are the components for connecting a programming device to the M7-400.
Assembling the M7-400 8.7.4 Connecting a Programming Device (PG) to Two or More Nodes Two Arrangements To connect a programming device to two or more nodes, you must distinguish between two arrangements: • A programming device permanently installed in the MPI subnet • A programming device connected for startup and maintenance Depending on this, you connect the programming device to the other nodes as follows (see also Chapter 5).
Assembling the M7-400 Permanently-Installed Programming Device in the MPI Subnet The programming device permanently installed in the MPI subnet should be connected directly via bus connectors to the other nodes of the MPI subnet, according to the rules in Chapter 5. Figure 8-18 shows an M7-400 subnet with two M7-400s. They are interconnected via bus connectors.
Assembling the M7-400 Programming Device for Commissioning or Servicing For commissioning or servicing purposes, connect the programming device via a spur line to a node on the MPI subnet. The bus connector of this node must have a programming device socket for this (see also Chapter 5). Figure 8-19 shows a network with two M7-400s, to which a programming device is connected.
Assembling the M7-400 8.7.5 Connecting a Programming Device (PG) to Ungrounded Nodes of an MPI Subnet Connecting a Programming Device to Ungrounded Nodes If you configure the nodes of an MPI subnet or an M7-400 as ungrounded devices (see Chapter 4), you should only connect an ungrounded programming device to the MPI subnet or M7-400 device. Connecting a Grounded Programming Device to the MPI You want to operate the nodes as ungrounded devices (see Chapter 4).
Assembling the M7-400 8.7.6 Starting Up a PROFIBUS-DP Subnet This Chapter This section contains the procedures for starting up a PROFIBUS-DP subnet with a CPU 486-3 or CPU 488-3 as the DP master. Requirements Before you can start up the PROFIBUS-DP subnet, the following requirements must be met: • The PROFIBUS-DP subnet has been set up (see Chapter 7). • The M7 system software is installed (see M7-SYS User Manual). • The central rack is fitted with an interface submodule IF 964-DP.
Assembling the M7-400 Behavior of the CPU During Startup During startup, the CPU compares the preset and actual configurations. You set the duration of the test with STEP 7 in the “Startup” parameter block with the “module time limits” parameter. If the preset configuration = actual configuration, the CPU goes to RUN.
Assembling the M7-400 8.8 Replacing Modules and Submodules/Cards Contents This section explains • How to replace interface submodules, • How to replace CPUs or expansion modules of a module assembly, • How to replace memory cards, • How to replace a short AT card. All other important information for replacing modules applies both to the S7-400 and the M7-400 modules and is described in Chapter 7. Tool To replace modules and submodules/cards, you need a cylindrical screwdriver with 3.5 mm blade width.
Assembling the M7-400 8.8.1 Replacing an Interface Module Removing an Interface Submodule You can replace an interface submodule without needing to remove the corresponding CPU or expansion module from the rack. Proceed according to the following sequence: ! Warning The modules can be damaged. When inserting or removing interface submodules with power applied, the CPU and expansion modules as well as the interface submodules can be damaged.
Assembling the M7-400 ! Warning The interface submodules can be damaged. If you replace two or more interface submodules simultaneously and interchange their front connectors, the interface submodules can be damaged. Mark the front connectors so that they are assigned to the corresponding interface submodules.
Assembling the M7-400 8.8.2 Replacing the CPU or Expansion Modules of a Module Assembly Removing a Module To remove a module from a module assembly, follow the steps outlined below: 1. Switch the CPU and all function modules in your M7-400 to STOP with the mode switch. 2. Switch off the load voltage for the modules. 3. Disconnect the automation computer from the supply. 4. Remove the covers from the modules, if applicable. Figure 8-22 shows how to remove the cover. – Press the locking lever down (1).
Assembling the M7-400 6. Loosen the mounting screws of all modules in the module assembly. Figure 8-23 shows the locations of mounting screws on a module. Figure 8-23 Unscrewing Modules 7. Ensure that all the mounting screws of the module assembly are undone. 8. Swing the module assembly forward out of the bus connectors and lift it upward and out of the guides of the rack (Figure 8-24).
Assembling the M7-400 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).
Assembling the M7-400 10.Remove the connecting clips, top and bottom, from the module to be replaced (as shown in Figure 8-26). Figure 8-26 Removing the Connecting Clips from the Module to be Replaced 11. Carefully withdraw the adjacent modules from the module to be replaced. The modules to be separated should be held above the bus connector and pulled apart at the side walls of the modules, so that the ISA bus connection is disconnected (Figure 8-27). ! Warning The connector pins can be damaged.
Assembling the M7-400 1. 2. Level surface Figure 8-27 Separating the Modules, for Example When the Mass Storage Module is to be Replaced Fitting a Module Fit the new module in the reverse order. Further details can be found in Section 8.4.6, “Fitting Expansion Modules to a CPU” and Section 8.4.7, “Installing a Module Assembly in the Rack” on pages 8-17 and 8-24. Reactions of the M7-400 After Replacing a Module After replacing a module, the CPU goes to the RUN state if there are no errors.
Assembling the M7-400 8.8.3 Replacing Memory Cards in a CPU Introduction To be able to replace MEM 478 memory cards in a CPU, you must remove the module assembly from the rack (see Section 8.8.2, page 8-49). It is not necessary to disassemble the module assembly because the CPU is always situated on the left end of the assembly, and the slot for the memory cards is therefore accessible. Note With both CPUs, a DRAM card of the same size must be inserted in each of Slots 1 and 2.
Assembling the M7-400 4 3 Slot 1 2 5 Figure 8-28 Slot 2 Removing Memory Cards from the CPUs Note The connectors to accept the memory cards are coded (see Figure 8-29). Do not apply force when fitting the memory cards. 3.3 V DRAM memory card (for main memory) Recess Slots 1 and 2 Figure 8-29 3.
Assembling the M7-400 8.8.4 Replacing a Short AT Card Removing an AT Card Before you can replace a short AT card, you must remove the module assembly and remove the ATM 478 AT adapter module from the assembly (see Section 8.8.2, from page 8-49). ! Warning The modules can be damaged. If the AT card is inserted or removed with power applied and without observing the ESD guidelines, the CPU, AT adapter module, and the AT card can be damaged. Never insert or remove the AT card with power applied.
Assembling the M7-400 3 2 3 1 3 4 Figure 8-30 Removing an AT Card from the ATM 478 AT Adapter Module S7-400 and M7-400 Programmable Controllers Hardware and Installation A5E00069481-04 8-57
Assembling the M7-400 8-58 S7-400 and M7-400 Programmable Controllers Hardware and Installation A5E00069481-04
Assembling and Installing Systems A Chapter Overview Section Description Page A.1 General Rules and Regulations for Operating the S7-400 A-2 A.2 Principles of System Installation for EMC A-5 A.3 Installation of Programmable Controllers for EMC A-9 A.4 Examples of EMC-Compatible Assembly A-10 A.5 Shielding Cables A-13 A.6 Equipotential Bonding A-15 A.7 Cabling Inside Buildings A-17 A.8 Cabling Outside Buildings A-19 A.9 Lightning Protection und Overvoltage Protection A-20 A.9.
Assembling and Installing Systems A.1 General Rules and Regulations for Operating the S7-400 General Basic Rules On account of the many possible applications of the S7-400, this chapter can only cover the basic rules for the electrical configuration. You must at least comply with these basic rules to ensure fault-free operation of the S7-400. The M7-400 modules operate similarly to the S7-400 modules. Differences in operation or data can be found at the appropriate point or in Section 8.
Assembling and Installing Systems 120/230 VAC Supply The following table shows which points you must observe when connecting the S7-400 to a 120/230 VAC supply. With ... ... You Must Ensure ... buildings that suitable external lightning protection measures are provided. supply cables and signal lines that suitable internal and external lightning protection measures are provided.
Assembling and Installing Systems Protection Against Other Electrical Effects The following table shows the other external effects against which you must provide protection. Protection against ... A-4 ... by Means of ... inadvertent actuation of operator controls a suitable arrangement or covering of keyboard and operator controls or a recessed arrangement of operator controls. splashing and surging water suitable protective devices or installation in waterproof housings.
Assembling and Installing Systems A.2 Principles of System Installation for EMC Definition: EMC EMC (electromagnetic compatibility) describes the capability of electrical apparatus to operate without faults in a given electromagnetic environment, without being affected by the environment and without affecting it in an unacceptable manner.
Assembling and Installing Systems Coupling Mechanisms Interference can reach the programmable controller via four different coupling mechanisms, depending on the transmission medium (conducted or non-conducted) and distance between interference source and the equipment. Coupling Mechanism Direct Coupling Cause Direct or metallic coupling always occurs when two circuits have a common conductor.
Assembling and Installing Systems Five Basic Rules for Ensuring Electromagnetic Compatibility In many cases, you can ensure electromagnetic compatibility by observing the following five basic rules: Rule 1: Large Area Grounding When installing the programmable controllers, provide large-area good quality grounding of the inactive metal parts (see Section A.3). • Make a large-area low-impedance connection of all inactive metal parts to chassis ground.
Assembling and Installing Systems Rule 4: Special EMC Measures Employ special EMC measures for particular applications (see Section 4.11). • Fit suppressors to all inductors which are not controlled by S7-400 modules. • Use incandescent bulbs or suppressed fluorescent lamps in the immediate vicinity of your controller for illuminating cabinets or housings. Rule 5: Standard Reference Potential Create a standard reference potential; ground all electrical apparatus if possible (see Sections 4.10 and 4.12).
Assembling and Installing Systems A.3 Installation of Programmable Controllers for EMC Introduction Measures for suppressing interference are often only applied when the control system is already operational, and the proper reception of a useful signal is found to be impaired. The cause of such interference is often due to insufficient reference potentials which can be attributed to errors during assembly. This section tells you how to avoid such errors.
Assembling and Installing Systems A.4 Examples of EMC-Compatible Assembly Introduction Below you will find two examples of configurations for programmable controllers for EMC. Example 1: Cabinet Configuration for EMC Figure A-2 shows a cabinet installation in which the measures described above (grounding of inactive metal parts and connection of cable shields) have been applied. However, this example only applies to grounded operation. Observe the points marked in the figure when installing your system.
Assembling and Installing Systems Key for example 1 The numbers in the following list refer to the numbers in Figure A-2. Table A-1 No. Key for Example 1 Key Meaning 1 Grounding strips If there are no large-area metal-to-metal connections, you must interconnectinactive metal parts such as cabinet doors or support plates via grounding strips or to ground. Use short grounding strips with a large surface.
Assembling and Installing Systems Ensure the following for frame and wall mounting: • Use special contact washers with painted and anodized metal parts, or remove the insulating protective layers. • Provide large-area, low-impedance metal-to-metal connections when securing the shield/protective ground bar. • Cover the AC supply conductors in a shockproof arrangement.
Assembling and Installing Systems A.5 Shielding Cables Purpose of the Shielding A cable is shielded to attenuate the effects of magnetic, electrical, and electromagnetic interference on this cable. Principle of Operation Interference currents on cable shields are discharged to ground via the shield bus which is electrically connected to the housing.
Assembling and Installing Systems Handling the Shields Observe the following points with regard to the shield: • Only use cable clamps made of metal to secure braided shields. The clamps must surround the shield over a large area and provide good contact. • Connect the shield to a shield bus immediately after entry of the cable into the cabinet. Route the shield to the module but do not connect it there again to the chassis ground or the shield bus.
Assembling and Installing Systems A.6 Equipotential Bonding Potential Differences Potential differences can occur between separate system components, leading to high transient currents; for example, if cable shields are fitted on both sides and grounded at different system components. Potential differences can be caused by different electrical supplies. ! Caution This can result in damage. Cable shields are not suitable for equipotential bonding. Use the prescribed cables exclusively (e.g.
Assembling and Installing Systems Figure A-5 A-16 Routing Equipotential Bonding Conductor and Signal Line S7-400 and M7-400 Programmable Controllers Hardware and Installation A5E00069481-04
Assembling and Installing Systems A.7 Cabling Inside Buildings Introduction Inside buildings, clearances must be observed between groups of different cables to achieve the necessary electromagnetic compatibility (EMC). Table A-2 provides you with information on the general rules governing clearances to enable you to choose the right cables. How to Read the Table If you want to know how two lines of different types should be laid, proceed as follows: 1.
Assembling and Installing Systems Table A-2 Cabling Inside Buildings, continued Connect Cables for ... DC voltage ( 60 V and 400 V), unshielded AC voltage ( 25 V and 400 V), unshielded and Cables for ... LAN signals, shielded (SINEC L1, PROFIBUS DP) Data signals, shielded (programming devices, operator panels, printers, counter inputs, etc.) Analog signals, shielded DC voltage ( 60 V), unshielded Process signals ( 25 V), shielded AC voltage ( 25 V), unshielded Monitors (coaxial cable) Run ...
Assembling and Installing Systems A.8 Cabling Outside Buildings Rules for EMC When installing cables outside buildings, the same EMC rules apply as for inside buildings. The following also applies: • Run cables on metallic cable supports (racks, trays etc.). • Establish a metallic connection between the joints in the cable supports • Ground the cable supports • If necessary, provide adequate equipotential bonding between the various items of equipment connected.
Assembling and Installing Systems A.9 Lightning Protection and Overvoltage Protection Overview Failures are very often the result of overvoltages caused by: • Atmospheric discharge or • Electrostatic discharge. First of all, we want to introduce you to the lightning protection zone concept, on which the protection against overvoltage is based. At the end of this section, you will find rules for the transitions between the individual lightning protection zones.
Assembling and Installing Systems A.9.1 Lightning Protection Zone Concept Principle of the Lightning Protection Zone Concept According to IEC 61312-1/DIN VDE 0185 T103 The principle of the lightning protection zone concept states that the volume to be protected, for example, a manufacturing hall, is subdivided into lightning protection zones in accordance with EMC guidelines (see Figure A-6).
Assembling and Installing Systems Diagram of the Lightning Protection Zones The following diagram illustrates a lightning protection zone concept for a detached building.
Assembling and Installing Systems A.9.
Assembling and Installing Systems Table A-3 Ser. No. High-Voltage Protection of Cables with the Help of Surge Protection Equipment, continued Cables for ... ... equip transition point 0 <–> 1 with: Order No.
Assembling and Installing Systems A.9.3 Rules for the Transitions between Lightning Protection Zones 1 <-> 2 and Greater Rules for Transitions 1 <-> 2 and Above (Local Equipotential Bonding) for all lightning protection zone transitions 1 <-> 2 and greater: • Set up local equipotential bonding at each subsequent lightning protection zone transition. • Include all cables (also metal pipelines, for example) in the local equipotential bonding at all subsequent lightning protection zone transitions.
Assembling and Installing Systems Low-Voltage Protection Elements for 1<–> 2 For the transition points between lightning protection zones 1 <–> 2 we recommend the surge protection components listed in table A-4 Table A-4 Ser. No. 1 Low-Voltage Protection Components for Lightning Protection Zones 1 <–> 2 Cables for ... ... equip transition point 1 <–> 2 with: Order No.
Assembling and Installing Systems Low-Voltage Protection Elements for 2<–> 3 For the transition points between lightning protection zones 2 <–> 3 we recommend the surge protection components listed in the table below. This low-voltage protection must be used in S7-400 for CE compliance. Table A-5 Cables for ... Ser. No. 1 Surge Protection Components for Lightning Protection Zones 2 <–> 3 ... ..
Assembling and Installing Systems A.9.
Assembling and Installing Systems Components in figure A-7 The table A-6 explains consecutive numbers in the figure A-7: Table A-6 Ser. No. from figure A-7 Example of a Circuit Conforming to Lightning Protection Requirements (Legend to Figure A-7) Components Description 1 Lightning arrestor, depending on the mains system, e.g.
Assembling and Installing Systems A.10 How to Protect Digital Output Modules against Inductive Surge Inductive Surge Voltage Overvoltage occurs when inductive devices are switched off.
Assembling and Installing Systems Suppression for DC-Operated Coils DC-operated coils are interconnected to diodes or Zener diodes. With diode With Zener diode + + - - Figure A-9 Suppression for DC-Operated Coils Suppression with Diodes / Zener Diodes Suppression with diodes or Zener diodes exhibits the following characteristics: • Switching overvoltages can be avoided entirely. A Zener diode has a higher turn-off voltage.
Assembling and Installing Systems A.11 Safety of Electronic Control Equipment Intoduction The notes below apply independent of the type or manufacturer of the electronic control.
Assembling and Installing Systems Risks In all cases where the occurrenced of failures can failures can result in material damage or injury to persons, special measures must be taken to enhance the safety of the installation - and therefore also of the situation. System-specific and special regulations exist for such applications. They must be observed on installing the control system (e.g. VDEE 0116 for burner control systems).
Assembling and Installing Systems Important Information Even when electronic control equipment has been configured for maximum design safety – e.g. with a multi-channel structure – it is imperative conform with instructions given in the operating manual. Incorrect handling can render measures intended to prevent dangerous faults ineffective, or generate additional sources of danger. A.
Assembling and Installing Systems Operation under Industrial Conditions Where the monitor and programmable controller are operated under harsh industrial conditions or there is a great distance between monitor and programmable controller, the apparatus may be at different ground potentials; this, in turn, can result in interference and disturbances caused by ground loops. In these cases, double-shielded coaxial cable (triaxial cable) must be used to transmit the video signals.
Assembling and Installing Systems ! Caution There is a risk of personal injury. Dangerous touch voltages may be present at the video sockets of the monitor. Fit suitable touch protection to the sockets. • Connect the ground clamp of the monitor to the chassis ground. • Connect the cable shields to the ground clamp of the monitor as follows: Proceed as follows: – Strip the outer cable insulation of the video cables in the region of the ground clamp of the monitor, without damaging the braided shield.
Guidelines for Handling Electrostatically-Sensitive Devices (ESD) B Chapter Overview Section Description Page B.1 What is ESD? B-2 B.2 Electrostatic Charging of Persons B-3 B.
Guidelines for Handling Electrostatically-Sensitive Devices (ESD) B.1 What is ESD? Definition: All electronic modules are equipped with large-scale integrated ICs or components. Due to their design, these electronic elements are very sensitive to overvoltages and thus to any electrostatic discharge. These Electrostatically-Sensitive Devices are commonly referred to by the abbreviation ESD.
Guidelines for Handling Electrostatically-Sensitive Devices (ESD) B.2 Electrostatic Charging of Persons Charging Every person with a non-conductive connection to the electrical potential of its surroundings can be charged electrostatically. Figure B-1 shows you the maximum values for electrostatic voltages which can build up on a person coming into contact with the materials indicated in the figure. These values are in conformity with the specifications of IEC 61000-4-2.
Guidelines for Handling Electrostatically-Sensitive Devices (ESD) B.3 General Protective Measures Against Electrostatic Discharge Damage Ensure Sufficient Grounding Make sure that the personnel, working surfaces, and packaging are sufficiently grounded when handling electrostatically-sensitive devices. You thus avoid electrostatic charging. Avoid Direct Contact You should touch electrostatically-sensitive devices only if it is unavoidable (for example, during maintenance work).
Glossary A Accumulator (ACCU) The accumulators are registers in the CPU and are a buffer for load, transfer and comparison, math and conversion instructions. Address An address is the identifier for a specific area of memory on which an instruction acts. Examples: Input I 12.1; Memory Word MW24; Data Block DB3.
Glossary BIOS Basic Input Output System BIOS is understood to mean the part of the software which creates the link between hardware and the operating system, for example, MS-DOS. This software is stored in an EPROM.Basic Input Output System Examples of important sections are the loader for the operating system, the (hardware) setup for defining the hardware configuration and for setting the time. Bit Memory (M) A memory area in the system memory of a SIMATIC CPU.
Glossary Configuration The configuration is the selection and putting together of the individual components of a programmable logic controller (PLC). Configuring Configuring is the assigning of modules to racks or slots and (with signal modules) addresses. Connecting Clip These are the clips with which the modules are mechanically interconnected within an M7 module assembly. Counters Counters are an area in the system memory of the CPU.
Glossary Data, Static Static data are data which are used only within a function block. These data are stored in an instance data block belonging to the function block. The data stored in the instance data block are retained until the next function block call. Data, Temporary Temporary data are local data of a block that are stored in the L stack during processing of the block and that are not retained after processing.
Glossary Error Display Error display is one of the possible responses of the operating system to a run-time error. The other possible responses include: error response in the user program, STOP mode of the CPU. Error Handling via OB When the operating system detects an error (for example, STEP 7 access error), it calls the specific organization block (error OB) for this error, where the further response of the CPU can be specified. Error Response Response to a run-time error.
Glossary Function According to IEC 61131-3, a function is a code block that contains no static data. A function allows parameters to be passed in the user program. Functions are therefore suitable for programming complex functions, e.g. calculations, which are repeated frequently. Functional Grounding Grounding whose only purpose is to ensure the intended function of the electrical equipment concerned.
Glossary Global Data Global data are data which can be accessed from each logic block (FC, FB, OB). These include bit memory M, inputs I, outputs Q, timers T, counters C, and data blocks DB. Global data can be accessed either absolutely or symbolically. Global Data Communication Global data communication is a procedure with which global data are transferred between CPUs (without communication function blocks (CFBs)).
Glossary I Instance Data Block With the S7-400, each call of a function block in the STEP 7 user program is assigned a data block which is generated automatically. In the instance data block, the values of the input, output and in/out parameters as well as the local block data are stored. Interface, Multipoint Multipoint Interface. Interface Submodules Submodules which provide the automation computer with additional interfaces, such as VGA, COM, PROFIBUS DP, etc.
Glossary ISA Bus The ISA bus is the standard bus in the AT-compatible PC. It is looped through the M7-400 module assembly via the 120-pin expansion sockets and plugs of the individual M7-400 modules. Isolated In the case of isolated I/O modules, the reference potentials of the control and load circuits are galvanically isolated from each other, for example, by optocouplers, relay contacts, or transformers. The I/O circuits can be connected to a common potential.
Glossary M Mass Storage Module An expansion of the M7-400 programmable controller. It is connected to the CPU via an ISA bus interface and contains a floppy disk drive and a hard disk drive. Measuring Range Submodule Measuring range submodules are plugged onto the analog input module for adapting to various measuring ranges. Memory Card Memory cards are storage media in credit-card format for CPUs and CPs. They are available as RAM or FEPROM.
Glossary Network In communications, a network is the connection between two or more S7-400s/M7-400s and other terminals such as a programming device, via a connecting cable. Data are exchanged over the network between the connected stations. Node Number The node number represents the accessing address of a CPU or programming device or of another intelligent I/O module when they communicate with each other via a network.
Glossary Operating System of the CPU The operating system of the CPU organizes all functions and sequences of the CPU which are not connected to a specific control task. Organization Block (OB) Organization blocks form the interface between the operating system of the S7-400 CPU and the user program. The sequence in which the user program should be processed is laid down in the organization blocks. P Parameter 1. Variable of a STEP 7 logic block 2.
Glossary Process Image The process image is a component part of the system memory of the S7-400 CPU. At the beginning of the cyclic program, the signal states of the input modules are transferred to the process-image input table (PII). At the end of the cyclic program, the process-image output table (PIQ) is transferred to the output modules as the signal state.
Glossary Reference Potential The potential on which the voltages of the various circuits are based and according to which they are measured. Retentive Data Retentive data are not lost after a power failure, if a backup battery is provided. Revision Level Products with the same order number are differentiated by their revision level. The revision level is increased for upwardly-compatible function expansions, for changes due to production reasons (use of new components) and for fault correction.
Glossary Signal Module Signal modules (SMs) are the interface between the process and the programmable controller. Signal modules comprise digital input and output modules (I/O module, digital) and analog input and output modules (I/O module, analog). SRAM Backup A static RAM: with the programmable modules of the M7-400 programmable controller, part of the main memory is backed up as an SRAM. STARTUP The CPU goes through the STARTUP state during the transition from STOP to RUN mode.
Glossary System Memory The system memory is integrated in the CPU and executed in the form of RAM. The address areas (timers, counters, bit memory, etc.) and data areas required internally by the operating system (for example, backup for communication) are stored in the system memory. T Time-Delay Interrupt The time-delay interrupt belongs to one of the priority classes in SIMATIC S7-400 program processing. It is generated after expiry of a time started in the user program.
Glossary User Memory The user memory contains logic blocks and data blocks of the user program. The user memory can either be intergrated in the CPU or can be plugged in on memory card or memory submodules. In general, however, the user program is executed from the work memory (RAM) of the CPU. User Program With SIMATIC a difference is made between the operating system of the CPU and user programs.
Glossary Glossary-18 S7-400 and M7-400 Programmable Controllers Hardware and Installation A5E00069481-04
Index A C Accessories, 2-39 Addresses geographical, 3-2 logical, 3-2 Addressing modules, M7-400, 8-5 Analog modules, replacing, 7-7 Assembling the bus cable, on a bus connector with order number 6ES7 ...
Index Coupling capacitive, A-6 direct, A-6 inductive, A-6 CPU, 1-3 resetting the, 6-7, 6-10 restarting the, 6-10 CPU, M7-400, replacing a module assembly, 8-49 CPUs, replacing, 7-5 CPUs, M7-400, covering unused submodule slots, 6-19, 8-14 D Digital modules fuses, 7-9 replacing, 7-7 Distributed I/Os, 2-38 Fitting, M7-400 AT adapter module, 8-15 ATM 478, 8-15 extension modules, 8-17 memory cards, 2-31, 7-19, 8-11 Front connector coding key, 4-35 labeling, 4-31 plugging in, 4-35 wiring, 4-26 with crimp snap
Index K Keyboard, M7-400, connecting the, 8-33 Keyboard, M7-400, maximum line length, 8-35 L Lightning protection, A-19, A-20 for 24 VDC supply, A-25 for signal modules, A-25 high-voltage protector, A-23 low-voltage protection, A-26 Lightning protection zones, A-21 Lightning strike, A-21 Load current circuit, 4-5 Load current power supplies, 4-4 Location, M7-400 module designation, 1-6 order number, 1-6 product release, 1-6 M M7-400 electrical configuration, 8-6 mechanical configuration, 8-2 Main power s
Index Overvoltage protection, A-30 R Rack, 1-3 clearances, 2-10 P mounting dimensions, 2-10 Power supply connector segmented, 2-8, 2-9 disconnect, 4-20 subdivided, 2-9 plugging in, 4-23 with I/O bus and C bus, 2-7 wiring, 4-21 Racks Power supply module, 1-3 grounding, 2-10 choosing, 4-3 mounting, 2-10 replacing, 7-4 of the S7-400 system, 2-6 Preparing for operation, M7-400, 8-32 Rating plate, M7-400, 1-6 checking status and error indicators, 8-45 Reference potential checklist, 8-32 grounded, 4-7 connecti
Index Spur lines, 5-7 lengths, 5-16 Start address of analog modules, 3-5 of digital modules, 3-4 Startup, procedure, 6-2 Station.
Index Index-6 S7-400 and M7-400 Programmable Controllers Hardware and Installation A5E00069481-04
