Siemens S7-400 manuale d’uso

Preface, Contents Product Overview 1 Installing the S7-400 2 Addressing the S7-400 3 Wiring the S7-400 4 Networking 5 Commissioning 6 Maintenance 7 Appendices Assembling and Installing Systems A Guidelines for Handling Electro- statically-Sensitive Devices (ESD) B Glossary , Index 1 1/2006 A5E00850741-01 Automation System S7-400 Hardware and Instal[...]

! Danger indicates that death or severe personal injury will result if proper precautions are not taken. ! W arning indicates that death or severe personal injury may result if proper precautions are not taken. ! Caution with a safety alert symbol indicates that minor personal injury can result if proper precautions are not taken. Caution without a[...]

iii Automation System S7-400 Hardware and Installation A5E00850741-01 Preface Purpose of the Manual The manual contains reference information on operator actions, descriptions of functions and technical specifications of the central processing units, power supply modules and interface modules of the S7-400. How to configure, assemble and wire these[...]

Preface iv Automation System S7-400 Hardware and Installation A5E00850741-01 Navigating The manual offers the following access help to m ake it easy for you to find specific information: • At the start of the manual you will find a complete table of contents and a list of the diagrams and tables that appear in the manual. • An overview of the c[...]

Preface v Automation System S7-400 Hardware and Installation A5E00850741-01 T echnical Support Y ou can reach the T echnical Suport for all A&D products • Via t he Web formula for the Support Request http://www.siemens.com/automation/support-request • Phone: + 49 180 5050 222 • Fax:+ 49 180 5050 223 Additional information about our T echn[...]

Preface vi Automation System S7-400 Hardware and Installation A5E00850741-01[...]

vii Automation System S7-400 Hardware and Installation A5E00850741-01 Contents 1 Product Overview 1-1 ...................................................... 2 Installing the S7-400 2-1 .................................................... 2.1 S7-400 Installation 2-2 .............................................. 2.2 Installing the Central Rack (CR) [...]

Contents viii Automation System S7-400 Hardware and Installation A5E00850741-01 4.9 Grounding 4-13 ...................................................... 4.10 Interference-Free Configurat ion for Local and Remote Connections 4-15 .... 4.1 1 Wiring Rules 4-17 .................................................... 4.12 Wiring the Power Supply Module 4-[...]

Contents ix Automation System S7-400 Hardware and Installation A5E00850741-01 7 Maintenance 7- 1 ........................................................... 7.1 Replacing the Backup Battery 7-2 ..................................... 7.2 Replacing a Power Supply Module 7-4 ................................. 7.3 Replacing CPUs 7-5 .....................[...]

Contents x Automation System S7-400 Hardware and Installation A5E00850741-01 Figures 2-1 Rack Fitted with Modules in the S7-400 System 2-2 ..................... 2-2 Max. Cabinet Ambient T emperature as a Function of Power Dissipation of Equipment in the Cabinet 2-27 ...................................... 2-3 Removing the Cover 2-31 ................[...]

Contents xi Automation System S7-400 Hardware and Installation A5E00850741-01 A-1 The Possible Routes for Electromagnetic Interference A-5 ................ A-2 Example of Cabinet Installation for EMC A-10 ............................ A-3 Wall Mounting an S7-400 for EMC A-12 ................................. A-4 Mounting Cable Shields A-14 .........[...]

Contents xii Automation System S7-400 Hardware and Installation A5E00850741-01 Ta b l e s 2-1 Cabinet types 2-26 ................................................... 2-2 Modules in the different racks 2-29 ..................................... 2-3 Accessories for Modules and Racks 2-35 ............................... 4-1 VDE Specifications for Assem[...]

1-1 Automation System S7-400 Hardware and Installation A5E00850741-01 Product Overview Overview of the S7 -400 The S7-400 is a programmable logic 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 ex[...]

Product Overview 1-2 Automation System S7-400 Hardware and Installation A5E00850741-01 S7-400 components The most important components of the S7-400 and their functions are given in the following tables: Components Function Illustration Racks (UR: Universal Rack) (CR: Central Rack) (ER: Expansion Rack) ... provide the mechanical and electrical conn[...]

Product Overview 1-3 Automation System S7-400 Hardware and Installation A5E00850741-01 Components Illustration 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 line[...]

Product Overview 1-4 Automation System S7-400 Hardware and Installation A5E00850741-01 Example of a rating plate Order no. Module designation Approvals and marks Product version[...]

2-1 Automation System S7-400 Hardware and Installation A5E00850741-01 Installing the S7 -400 Chapter Overview Section Description Page 2.1 S7-400 Installation 2-2 2.2 Installing the Central Rack (CR) and Expansion Rack (ER) 2-6 2.3 Segmented CR 2-8 2.4 Subdivided CR 2-9 2.5 Mounting and Grounding the Racks 2-10 2.6 Chassis T erminal Connection in t[...]

Installing the S7 -400 2-2 Automation System S7-400 Hardware and Installation A5E00850741-01 2.1 S7 -400 Installation Introduction An S7-400 programmable controller consists of a central rack (CR) and one or more expansion racks (ERs), as required. Y ou can add ERs to compensate for lack of slots for your application or operate signal modules at re[...]

Installing the S7 -400 2-3 Automation System S7-400 Hardware and Installation A5E00850741-01 Connecting the CR and ER(s) T o 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. Y ou can connect one chain of up to four ERs to each of the two interfaces of a send IM in the CR. Different IMs [...]

Installing the S7 -400 2-4 Automation System S7-400 Hardware and Installation A5E00850741-01 W ays of Connecting Central and Expansion Racks Central rack CR Expansion rack ER 1 Expansion rack ER 4 Expansion rack ER 1 Expansion rack ER 1 Expansion rack ER 4 Expansion without 5 V local transfer Expansion with 5 V local transfer Remote expansion IM 46[...]

Installing the S7 -400 2-5 Automation System S7-400 Hardware and Installation A5E00850741-01 Rules for Connection When you connect a central rack to expansion racks, you must observe the following rules: • Y ou 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 c[...]

Installing the S7 -400 2-6 Automation System S7-400 Hardware and Installation A5E00850741-01 2.2 Installing the Central Rack (CR) and Expansion Rack (ER) Function of the Racks The racks of the S7-400 system form t he basic framework which accepts the individual modules. The modules exchange data and signals and are powered via the backplane bus. Th[...]

Installing the S7 -400 2-7 Automation System S7-400 Hardware and Installation A5E00850741-01 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 rac[...]

Installing the S7 -400 2-8 Automation System S7-400 Hardware and Installation A5E00850741-01 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 , t he I/O bus consists of two I/O b[...]

Installing the S7 -400 2-9 Automation System S7-400 Hardware and Installation A5E00850741-01 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 bu[...]

Installing the S7 -400 2-10 Automation System S7-400 Hardware and Installation A5E00850741-01 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 are compliant with DIN 41 494. According to the [...]

Installing the S7 -400 2-1 1 Automation System S7-400 Hardware and Installation A5E00850741-01 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[...]

Installing the S7 -400 2-12 Automation System S7-400 Hardware and Installation A5E00850741-01 465 mm 240 mm 290 mm 190 mm 40 mm 123 456 78 9 1 0 1 1 1 2 1 3 1 4 1 5 1 6 1 7 1 8 123 456 78 9 60 mm 290 mm 190 mm 40 mm 123 4 123 4 11 5 m m 258 mm 133 mm 483 mm Depth = 28 mm without modules Depth = 237 mm with modules Step 2: Mounting the Rack Screw th[...]

Installing the S7 -400 2-13 Automation System S7-400 Hardware and Installation A5E00850741-01 Mounting Screws Y ou have a choice of the following types of screw for securing a rack: Screw T ype Explanation M6 cylinder-head screw to ISO 1207/ISO 1580 (DIN 84/DIN 85) Choose the screw length according to your assembly . Y o u a l s o n e e d “ 6 4 ?[...]

Installing the S7 -400 2-14 Automation System S7-400 Hardware and Installation A5E00850741-01 Step 4: Mounting Additional Racks For S7-400 assemblies containing two or more racks, make allowances for additional clearance between the racks for installing a fan subassembly or cable duct. The figure below shows the clearance you must allow between two[...]

Installing the S7 -400 2-15 Automation System S7-400 Hardware and Installation A5E00850741-01 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 . Mou[...]

Installing the S7 -400 2-16 Automation System S7-400 Hardware and Installation A5E00850741-01 2.6 Chassis T erminal 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[...]

Installing the S7 -400 2-17 Automation System S7-400 Hardware and Installation A5E00850741-01 Connection to the Reference Point 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 assembly: Undo the fixing screws [...]

Installing the S7 -400 2-18 Automation System S7-400 Hardware and Installation A5E00850741-01 2.7 Methods of V entilation Methods of V entilation Under extreme ambient conditions, particularly when operating 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 t[...]

Installing the S7 -400 2-19 Automation System S7-400 Hardware and Installation A5E00850741-01 The following figure shows the ventilation when air is drawn in from the bottom. Exhaust air Wa l l Supply air Cable duct or fan subassembly Modules Modules[...]

Installing the S7 -400 2-20 Automation System S7-400 Hardware and Installation A5E00850741-01 2.8 Changing the V entilation with the Cable Duct and Fan Subassembly Changing the V entilation At the base of the cable duct and the fan subassembly , there is a cover that you can move in order to modify the air duct. T o do this, proceed as follows: 1. [...]

Installing the S7 -400 2-21 Automation System S7-400 Hardware and Installation A5E00850741-01 Cover Quick-release locks Cover Snap catches Snap hinges Cover fitted at bottom Cover fitted at back (supply air from the rear) (supply air from below) Base Base Delivered state: Shipping state The cover is fitted in the base of the cable duct or fan subas[...]

Installing the S7 -400 2-22 Automation System S7-400 Hardware and Installation A5E00850741-01 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 . T o do this, move the left cov[...]

Installing the S7 -400 2-23 Automation System S7-400 Hardware and Installation A5E00850741-01 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 [...]

Installing the S7 -400 2-24 Automation System S7-400 Hardware and Installation A5E00850741-01 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. 19-inch referen[...]

Installing the S7 -400 2-25 Automation System S7-400 Hardware and Installation A5E00850741-01 2.1 1 Choosing and Setting up Cabinets with the S7 -400 Why Cabinets are Required With larger installations and in an environm ent subject to interference or pollution, you can install the S7-400 in cabinets. The requirements of UL/CSA are met, for example[...]

Installing the S7 -400 2-26 Automation System S7-400 Hardware and Installation A5E00850741-01 T able 2-1 provides an overview of the most common types of cabinet. Y ou will also find the principle of heat removal, as well as the estimated, maximum achievable power loss removal and the degree of protection. T able 2-1 Cabinet types Open Cabinets Clo[...]

Installing the S7 -400 2-27 Automation System S7-400 Hardware and Installation A5E00850741-01 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 fo[...]

Installing the S7 -400 2-28 Automation System S7-400 Hardware and Installation A5E00850741-01 Example of selecting the cabinet type The example below clarifies the maximum permissible ambient temperature at a particular power loss for various cabinet types. Equipment suitable for installation in a cabinet: 1 central rack 150 W 2 expansion racks, 15[...]

Installing the S7 -400 2-29 Automation System S7-400 Hardware and Installation A5E00850741-01 2.12 Rules for the Arrangement of Modules Arrangement of the Modules Y ou only need to observe two r ules for rack mounting of the modules: • In all racks, the power supply module must always be inserted on the extreme left (beginning with slot 1). In th[...]

Installing the S7 -400 2-30 Automation System S7-400 Hardware and Installation A5E00850741-01 2.13 Installing Modules in a Rack Introduction All modules are installed using the same procedure. ! Caution Modules and racks can be damaged. Do not apply any undue force when installing the modules in a rack, because you will more than likely damage the [...]

Installing the S7 -400 2-31 Automation System S7-400 Hardware and Installation A5E00850741-01 Removing the Cover With modules which have a cover (for example, power supply modules and CPUs), you remove this before installing the module in the rack. Proceed as follows: 1. Push the interlock lever down (1). 2. Swing the cover forward and of f (2). (2[...]

Installing the S7 -400 2-32 Automation System S7-400 Hardware and Installation A5E00850741-01 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 2-4 Attaching the Modules Screwing the Modules in Pl[...]

Installing the S7 -400 2-33 Automation System S7-400 Hardware and Installation A5E00850741-01 2.14 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 assembl[...]

Installing the S7 -400 2-34 Automation System S7-400 Hardware and Installation A5E00850741-01 2.15 Methods of Expansion and Networking Introduction Apart from the structures mentioned in th is chapter , other expansions are possible, for example, by connecting distributed I/Os or by networking. Distributed I/Os When an S7-400 is configured with a d[...]

Installing the S7 -400 2-35 Automation System S7-400 Hardware and Installation A5E00850741-01 2.16 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 a[...]

Installing the S7 -400 2-36 Automation System S7-400 Hardware and Installation A5E00850741-01[...]

3-1 Automation System S7-400 Hardware and Installation A5E00850741-01 Addressing the S7 -400 Chapter Overview Section Description Page 3.1 Geographical and Logical Addresses 3-2 3.2 How to Determine the Default Address of a Module 3-4 3.3 How to Determine the Default Address of a Channel 3-6 3[...]

Addressing the S7 - 400 3-2 Automation System S7-400 Hardware and Installation A5E00850741-01 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. Y ou must establish a unique assignment between the (geographical) location of a[...]

Addressing the S7 - 400 3-3 Automation System S7-400 Hardware and Installation A5E00850741-01 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/[...]

Addressing the S7 - 400 3-4 Automation System S7-400 Hardware and Installation A5E00850741-01 3.2 How to Determine the Default Address of a Module Default Addressing Y ou 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 di[...]

Addressing the S7 - 400 3-5 Automation System S7-400 Hardware and Installation A5E00850741-01 Default Addresses of Analog Modules On the S7-400, the default addresses for analog modules start from 512 (first slot in the central rack which is usually occupied by the power supply module) up to 1600. The algorithm used to calculate the default address[...]

Addressing the S7 - 400 3-6 Automation System S7-400 Hardware and Installation A5E00850741-01 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 addre[...]

Addressing the S7 - 400 3-7 Automation System S7-400 Hardware and Installation A5E00850741-01 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[...]

Addressing the S7 - 400 3-8 Automation System S7-400 Hardware and Installation A5E00850741-01[...]

4-1 Automation System S7-400 Hardware and Installation A5E00850741-01 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 P[...]

Wiring the S7-400 4-2 Automation System S7-400 Hardware and Installation A5E00850741-01 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 [...]

Wiring the S7-400 4-3 Automation System S7-400 Hardware and Installation A5E00850741-01 4.2 Choosing the Power Supply Module Estimating the Power Requirement Y ou 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. Current consumption and power dis[...]

Wiring the S7-400 4-4 Automation System S7-400 Hardware and Installation A5E00850741-01 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 characteristic[...]

Wiring the S7-400 4-5 Automation System S7-400 Hardware and Installation A5E00850741-01 4.4 Assembling an S7 -400 with Process I/Os Definition of a Grounded Supply (TN-S Network) In grounded supplies, the neutral conductor of the system is grounded. A single fault between a live conductor and ground or a grounded part of the installation results in[...]

Wiring the S7-400 4-6 Automation System S7-400 Hardware and Installation A5E00850741-01 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 a[...]

Wiring the S7-400 4-7 Automation System S7-400 Hardware and Installation A5E00850741-01 4.5 Assembling an S7 -400 with Grounded Reference Potential (M) Application Y ou 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 potentia[...]

Wiring the S7-400 4-8 Automation System S7-400 Hardware and Installation A5E00850741-01 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[...]

Wiring the S7-400 4-9 Automation System S7-400 Hardware and Installation A5E00850741-01 Filtering the 24 VDC Supply When you power the S7-400 from a battery with the ungrounded configuration, you must provide interference suppression for the 24 VDC supply . Use a Siemens power cable filter , such as the B84102-K40. Insulation Monitoring If a double[...]

Wiring the S7-400 4-10 Automation System S7-400 Hardware and Installation A5E00850741-01 4.7 Assembling an S7 -400 with Isolated Modules Definition In a configuration with isolated modules, the reference potentials of the control circuit (M internal ) and the load circuit (M external ) are isolated (see also Figure 4-4). Application Isolated module[...]

Wiring the S7-400 4-1 1 Automation System S7-400 Hardware and Installation A5E00850741-01 Configuration with Isolated Modules Shown in Figure 4-4 are the potentials of an S7-400 configured with isolated input and output modules. PS CPU L1 N L+ L1 N DI DO PE Rack U internal Data M external 230 V AC load current PS Ground bus in cabinet 24 VDC load c[...]

Wiring the S7-400 4-12 Automation System S7-400 Hardware and Installation A5E00850741-01 4 . 8 Parallel Wiring of Digital S7-400 Outputs Parallel Wiring of a Digital Output with Different Rated Load V oltages The parallel wiring of a digital output (rated load voltage 1L+) with another digital output (rated load voltage 2L+) or a rated load voltage[...]

Wiring the S7-400 4-13 Automation System S7-400 Hardware and Installation A5E00850741-01 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 g[...]

Wiring the S7-400 4-14 Automation System S7-400 Hardware and Installation A5E00850741-01 Connecting the Load V oltage Ground Many output modules require an additional l oad voltage to switch the actuators. T w o different modes are possible for this load voltage: • Non-isolated operation • Floating operation The following table shows how the lo[...]

Wiring the S7-400 4-15 Automation System S7-400 Hardware and Installation A5E00850741-01 4.10 Interference -F ree 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 Configu[...]

Wiring the S7-400 4-16 Automation System S7-400 Hardware and Installation A5E00850741-01 Figure 4-8 shows the methods described here. If the permissible potential difference between grounding points is exceeded, you must install an equipotential bonding conductor (copper conductor with a cross-section of ≥ 16 mm 2 ). CR ER Send IM Receive IM Shie[...]

Wiring the S7-400 4-17 Automation System S7-400 Hardware and Installation A5E00850741-01 4.1 1 Wiring Rules Lines and T ools For wiring the S7-400 modules, there are some rules for the cables and tools to use. Rules for ... Powe r Supply ... Front Connectors Crimp terminal Screw-type terminal Spring-type terminal Conductor cross-sections: Outer dia[...]

Wiring the S7-400 4-18 Automation System S7-400 Hardware and Installation A5E00850741-01 4.12 Wiring the Power Supply Module Power Supply Connector Y ou 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 D[...]

Wiring the S7-400 4-19 Automation System S7-400 Hardware and Installation A5E00850741-01 Wiring the Power Supply Connector T o wire the power supply connector , follow the steps outlined below: ! W arning There is a risk of personal injury . If you wire the connector with voltage applied, you may suff er a shock and personal injury . Only wire the [...]

Wiring the S7-400 4-20 Automation System S7-400 Hardware and Installation A5E00850741-01 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 . 6t o0 . 8N / m . DC AC L+ L1 N[...]

Wiring the S7-400 4-21 Automation System S7-400 Hardware and Installation A5E00850741-01 Plugging In the Power Supply Connector Y ou can only plug in the connector when the power supply module is installed (lower mounting screw tightened). T o plug the wired power supply connector into the power supply module, follow the steps outlined below: 1. Op[...]

Wiring the S7-400 4-22 Automation System S7-400 Hardware and Installation A5E00850741-01 4.13 Wiring the Signal Modules Procedure How to connect your sensors and actuators to the S7-400 signal modules: 1. Wire the front connector . This includes all incoming and outgoing connections of the sensorsan actuators. 2. Install the front connector on the [...]

Wiring the S7-400 4-23 Automation System S7-400 Hardware and Installation A5E00850741-01 Preparing to Wire the Front Connector 1. Insert a screwdriver at the point marked on the bottom left of the front connector , then lever of f the lower corner of the cover . 2. Open the cover completely . 3. Pull the opened cover forward at the bottom and swing[...]

Wiring the S7-400 4-24 Automation System S7-400 Hardware and Installation A5E00850741-01 4.14 Wiring the Front Connector , Crimping Procedure T o wire the prepared front connector: 1. Strip the conductors at a length of approx. 5 mm. 2. Crimp the contacts onto the conductors. A crimptool is aailable on order as an accessory for your signal modules.[...]

Wiring the S7-400 4-25 Automation System S7-400 Hardware and Installation A5E00850741-01 4.15 Wiring the Front Connector , Screw T erminals Procedure T o wire the prepared front connector: 1. Are you using wire ferrules? If yes: Strip the conductors at a length of 10 mm. Press-fit the wire end ferrules onto the conductors. If not: Strip the conduct[...]

Wiring the S7-400 4-26 Automation System S7-400 Hardware and Installation A5E00850741-01 4.16 Wiring the Front Connector , Spring -T ype T erminals Procedure T o 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 co[...]

Wiring the S7-400 4-27 Automation System S7-400 Hardware and Installation A5E00850741-01 Principle of the spring loaded terminal The following figure shows the principle of spring contacts. Releasing and engaging from the front is illustrated. 1. Insert the screwdriver 2. Insert the wire into the spring contact as far as it will go 3. Withdraw the [...]

Wiring the S7-400 4-28 Automation System S7-400 Hardware and Installation A5E00850741-01 4.17 Fitting the Strain Relief Cable Ties as Strain R elief 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 st[...]

Wiring the S7-400 4-29 Automation System S7-400 Hardware and Installation A5E00850741-01 4.18 Labeling a Front Connector Labels and T erminal 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 4-18 shows the locations for fitting the individual[...]

Wiring the S7-400 4-30 Automation System S7-400 Hardware and Installation A5E00850741-01 Figure 4-19 shows details for fitting a label in the front connector . Label with blank Cutout in front connector Figure 4-19 F itting a Label in the Front Connector Labels • Print labels are prerequisite for professional, convenient labeling of your SIMA TIC[...]

Wiring the S7-400 4-31 Automation System S7-400 Hardware and Installation A5E00850741-01 Notes on Ordering Labeling Sheets for S7-400 Order Number Description SIMA TIC S7-400, 10 A4 label sheets, 4 labeling strips / sheets for signal modules. Materia l: film, perforated, for laser printers. 10 sheets per package. 6ES7492-2AX00-0AA0 Petrol 6ES7492-2[...]

Wiring the S7-400 4-32 Automation System S7-400 Hardware and Installation A5E00850741-01 4.19 Fitting the Front Connector Principle of a Coding Key T o 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 c[...]

Wiring the S7-400 4-33 Automation System S7-400 Hardware and Installation A5E00850741-01 T o 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. [...]

Wiring the S7-400 4-34 Automation System S7-400 Hardware and Installation A5E00850741-01 Figure 4-21 shows how to screw on the front connector . Figure 4-21 S crewing On the Front Connector[...]

Wiring the S7-400 4-35 Automation System S7-400 Hardware and Installation A5E00850741-01 4.20 Interconnecting the CR and ER(s) Interconnecting the Interface Modules When you assemble an automation system comprising a CR and one or more ERs, you connect the racks via the connecting cables of the interface modules. T o interconnect the interface modu[...]

Wiring the S7-400 4-36 Automation System S7-400 Hardware and Installation A5E00850741-01 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 connecti[...]

Wiring the S7-400 4-37 Automation System S7-400 Hardware and Installation A5E00850741-01 4.21 Setting the Fan Subassembly to the Line V oltage and Wir ing I t Setting the Fan Subassembly to the Line V oltage Check whether the voltage selector switch in the fan subassembly is set to your line voltage (see Figure 4-24). Fuse The fan subassembly has t[...]

Wiring the S7-400 4-38 Automation System S7-400 Hardware and Installation A5E00850741-01 4.22 Cable routing in 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 suf ficient to accept all cables. Y ou sho[...]

5-1 Automation System S7-400 Hardware and Installation A5E00850741-01 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 / Diagnostics Repeater 5-21 5.8 PROFI[...]

Networking 5-2 Automation System S7-400 Hardware and Installation A5E00850741-01 5.1 Configuring a Network Subnets Y ou can connect an S7-400 device to various subnets: • Via Simatic Net CP Ethernet to an Industrial Ethernet subnet • Via Simatic Net CP PROFIBUS to a PROFIBUS-DP subnet • Via the integrated MPI interface to an MPI subnet • Vi[...]

Networking 5-3 Automation System S7-400 Hardware and Installation A5E00850741-01 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[...]

Networking 5-4 Automation System S7-400 Hardware and Installation A5E00850741-01 Number of Nodes MPI PROFIBUS DP 127 127 * (default: 32) of which: 1 master (reserved) 1 PG port (reserved) 1 PG port (reserved) 125 slaves or other masters * Observe the CPU-specific maximum numbers in the Reference Manual CPU Data MPI/PROFIBUS-DP Addresses In order fo[...]

Networking 5-5 Automation System S7-400 Hardware and Installation A5E00850741-01 Rules for MPI Addresses Observe the following rules before assigning MPI addresses: • All MPI addresses in an MPI network must be different. • The highest possible MPI address must be equal to or higher than the highest actual MPI address and must be set to the sam[...]

Networking 5-6 Automation System S7-400 Hardware and Installation A5E00850741-01 PG Access A CPU exchanges data with other systems using communication mechanisms, for example with other programmable controlle rs, with operator interface stations (OP , OS) or with programming devices (see Figure 5-2). CPU SIMA TIC NET MPI PG OS PLC PG OS Slave PG OS[...]

Networking 5-7 Automation System S7-400 Hardware and Installation A5E00850741-01 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[...]

Networking 5-8 Automation System S7-400 Hardware and Installation A5E00850741-01 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 ne[...]

Networking 5-9 Automation System S7-400 Hardware and Installation A5E00850741-01 T erminating Resistor on the Bus Connector on off on off T erminating resistor switched on T erminating resistor switched off Figure 5-3 T erminating resistor on bus connector T erminating Resistor on the RS 485 Repeater DC 24 V L+ M PE M 5.2 A1 B1 A1 B1 A2 B2 A2 B2 SI[...]

Networking 5-10 Automation System S7-400 Hardware and Installation A5E00850741-01 Example: T erminating Resistor in the MPI Network The figure below shows where you have to connect the terminating resistor in a possible configuration for an MPI network. RS 485 repeater { { { { T erminating resistor switch on S7-400 S7-400 S7-400 Spur line S7-300 ?[...]

Networking 5-1 1 Automation System S7-400 Hardware and Installation A5E00850741-01 Example of an MPI Network * Only connected via spur line for start up/maintenance (with default MPI address) ** Connected to the MPI later on (with default MPI address) 0 ... x MPI address of nodes { T erminating resistor switch on S7-400** S7-400 S7-400 S7-400 S7-40[...]

Networking 5-12 Automation System S7-400 Hardware and Installation A5E00850741-01 Example of a PROFIBUS-DP Network 0 ... x PROFIBUS DP addresses of nodes S7-400 with CPU 414-2-DP as DP master ET 200M 0 6 7 8 12 3 4 5 PG* OP PG ET 200M S5-95U ET 200B ET 200B { { { T erminating resistor switched on * Only connected via spur line for startup/maintenan[...]

Networking 5-13 Automation System S7-400 Hardware and Installation A5E00850741-01 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 [...]

Networking 5-14 Automation System S7-400 Hardware and Installation A5E00850741-01 Programming Device Access Beyond Network Limits (Routing) Y ou can access all modules beyond network limits using a programming device. ET 200 PROFIBUS-DP network 2 Programming device / PC 2 Programming device / PC 3 Programming device / PC 1 MPI network 1 S7-400 with[...]

Networking 5-15 Automation System S7-400 Hardware and Installation A5E00850741-01 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. T able 5-1 Permitted Cable Length of a Segment in an MPI Network T ransmission [...]

Networking 5-16 Automation System S7-400 Hardware and Installation A5E00850741-01 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 allo[...]

Networking 5-17 Automation System S7-400 Hardware and Installation A5E00850741-01 Example The figure below shows a possible configuration of an MPI network. This example clarifies the maximum possible distances in an MPI network. max. 50m max. 50m max. 1000m RS 485- repeater RS 485- repeater { { { { { { S7-400 S7-400 S7-400 S7-400 S7-400 Spur line [...]

Networking 5-18 Automation System S7-400 Hardware and Installation A5E00850741-01 5.5 PROFIBUS -DP Bus Cables PROFIBUS-DP Bus Cables Siemens supply the following PROFIBUS-DP bus cables (see catalog ST 70): PROFIBUS-DP bus cable 6XV1830-0AH10 PROFIBUS-DP cable for burying in ground 6XV1830-3AH10 PROFIBUS-DP trailing cable 6XV1830-3BH10 PROFIBUS-DP b[...]

Networking 5-19 Automation System S7-400 Hardware and Installation A5E00850741-01 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 wit[...]

Networking 5-20 Automation System S7-400 Hardware and Installation A5E00850741-01 Connecting Bus Cables to Bus Connectors ( 6ES7972-0B.20 ...) For detailed information on how to connect a bus cable to a bus connector , refer to the SIMA TIC NET Profibus Networks manual. Connecting the Bus Connector T o connect the bus connector , proceed as follows[...]

Networking 5-21 Automation System S7-400 Hardware and Installation A5E00850741-01 5.7 RS 485 Repeater / Diagnostics Repeater Purpose of the Repeater The RS 485 Repeater / Diagnostics Repeater amplifies data signals on bus cables and couples bus segments. Y ou need an repeater when: • More than 32 nodes are connected in the network, • A grounded[...]

Networking 5-22 Automation System S7-400 Hardware and Installation A5E00850741-01 5.8 PROFIBUS -D P 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 traf fic on the bus is not to be impaired by external interference fields, use [...]

Networking 5-23 Automation System S7-400 Hardware and Installation A5E00850741-01 Optical PROFIBUS-DP Network in Partyline T opology 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 [...]

Networking 5-24 Automation System S7-400 Hardware and Installation A5E00850741-01 PROFIBUS Optical Bus T erminal (OBT) A PROFIBUS node can be connected to the optical PROFIBUS-DP network via a PROFIBUS Optical Bus T erminal (OBT) (6GK1 500-3AA00) without an integrated fiber-optic cable interface (e.g. programming devices (PGs) or operator panels (O[...]

Networking 5-25 Automation System S7-400 Hardware and Installation A5E00850741-01 T able 5-4 Features of the F iber-Optic Cables, continued Description SIMA TIC NET PROFIBUS Plastic Fiber-Optic Duplex Conductor Plastic Fiber-Optic Standard Cable PCF Fiber-Optic Standard Cable Cable grip - Kevlar fibers Kevlar fibers Maximum permissible tensile forc[...]

Networking 5-26 Automation System S7-400 Hardware and Installation A5E00850741-01 Order Numbers Y ou can order the fiber-optic cables under the order numbers specified in T able 5-4. T able 5-5 Order Numbers - Fiber-Optic Cables Fiber-Optic Cables Form Order Number SIMA TIC NET PROFIBUS plastic fiber-optic, duplex conductor I-VY2P 980/1000 150A Pla[...]

Networking 5-27 Automation System S7-400 Hardware and Installation A5E00850741-01 Structure T wo Simplex connectors (a sender and a receiver) and a connector adapter with the following attributes are required for a fiber-optic cable connection: • Degree of protection IP20 protection • T ransmission rate 9.6 kbps to 12 Mbps Sender Receiver Fiber[...]

Networking 5-28 Automation System S7-400 Hardware and Installation A5E00850741-01 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 spe[...]

Networking 5-29 Automation System S7-400 Hardware and Installation A5E00850741-01 Installation Instructions for Plastic Fiber-Optic Cable (with Photos) Here 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 SIMA TIC NET PROFIBUS Netw[...]

Networking 5-30 Automation System S7-400 Hardware and Installation A5E00850741-01[...]

6-1 Automation System S7-400 Hardware and Installation A5E00850741-01 Commissioning Chapter Overview Section Description Page 6.1 Recommended Procedure for First Startup 6-2 6.2 Checks Prior to Switching On for the First T ime 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 Resetti[...]

Commissioning 6-2 Automation System S7-400 Hardware and Installation A5E00850741-01 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 a[...]

Commissioning 6-3 Automation System S7-400 Hardware and Installation A5E00850741-01 6.2 Checks Prior to Switching On for the First T ime 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. T able 6-1 contains a guide [...]

Commissioning 6-4 Automation System S7-400 Hardware and Installation A5E00850741-01 T able 6-1 Checklist to be Used Before Switching O n for the First Time, continued Module Settings Is the CPU mode switch set to STOP? 6 1 Are the numbers of the racks cor- rectly set on the coding switches of the receive IMs and not duplicated? 7 If measuring range[...]

Commissioning 6-5 Automation System S7-400 Hardware and Installation A5E00850741-01 According to the backup concept, T able 6-2 shows how you must set the battery monitoring switch on the different power supply modules. T able 6-2 Setting the Battery Monitoring Switch If Y ou ... ...Then do not use battery monitoring, set the BA TT INDIC switch to [...]

Commissioning 6-6 Automation System S7-400 Hardware and Installation A5E00850741-01 Communication between Programming Device and CPU The following conditions apply when communicating between a programming device and a CPU: • Y ou need a programming device with STEP 7. • The CPU can communicate with the programming device in the following modes:[...]

Commissioning 6-7 Automation System S7-400 Hardware and Installation A5E00850741-01 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[...]

Commissioning 6-8 Automation System S7-400 Hardware and Installation A5E00850741-01 Resetting the CPU with the Mode Selector Switch The mode selector switch is designed as a toggle switch. The following figure shows all positions of the mode selector switch. RUN STOP MRES Figure 6-2 Positions of the mode selector switch Proceed as follows to reset [...]

Commissioning 6-9 Automation System S7-400 Hardware and Installation A5E00850741-01 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 clea[...]

Commissioning 6-10 Automation System S7-400 Hardware and Installation A5E00850741-01 6.6 Cold, W arm, and Hot Restarts with the Mode Selector Switch Restart (warm start) • A restart resets the process image and the non - -retentive flags, timers, times and counters. Retentive flags, times and counters retain their last valid value. All DBs assign[...]

Commissioning 6-1 1 Automation System S7-400 Hardware and Installation A5E00850741-01 6.7 Inserting a Memory Card The Memory Card as Load Memory Y ou can insert a Memory Card into any S7-400 CPU. This card represents the load memory expansion of the CPU. Depending on the type of memory card, the user program is retained on the memory card even when[...]

Commissioning 6-12 Automation System S7-400 Hardware and Installation A5E00850741-01 Inserting a Memory Card T o insert a memory card, follow the steps outlined below: 1. Set the mode selector switch on the CPU to ST OP . 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 o[...]

Commissioning 6-13 Automation System S7-400 Hardware and Installation A5E00850741-01 6.8 Inserting a Backup Battery (Option) Backup Depending on the power supply module, you can use one or two backup batteries: • T o back up a user program and save it without loss in the event of a power failure. • For retentive storage of bit memory , timers, [...]

Commissioning 6-14 Automation System S7-400 Hardware and Installation A5E00850741-01 The following figure shows how to insert a backup battery in the single-width power supply module.[...]

Commissioning 6-15 Automation System S7-400 Hardware and Installation A5E00850741-01 The following figure shows how to insert two backup batteries in a double-width power supply module. ! W arning Hazardous to persons and property , risk of pollutant emission. A lithium battery can explode if treated incorrectly; improper disposal of old lithium ba[...]

Commissioning 6-16 Automation System S7-400 Hardware and Installation A5E00850741-01 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 capab[...]

Commissioning 6-17 Automation System S7-400 Hardware and Installation A5E00850741-01 6.9 Starting Up a PROFIBUS -DP S ubnet 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: [...]

Commissioning 6-18 Automation System S7-400 Hardware and Installation A5E00850741-01 6.10 Installing Interface Modules (CPU 414 -2, 414-3, 416 - 3, 417 -4 and 417-4H) A vailable Interface Modules Note Only use interface submodules that are explicitly released for use in S7-400 devices. Installing Interface Modules ! W arning The modules can be dama[...]

Commissioning 6-19 Automation System S7-400 Hardware and Installation A5E00850741-01 3. Slowly push the interface submodule into the slot until the front plate rests on t h ef r a m eo ft h ec a r ds l o t . 4. Important! Secure the front plate with t he two fitted, captive M 2.5 x 10 slot-head screws on the left frame of the card slot. Guide rails[...]

Commissioning 6-20 Automation System S7-400 Hardware and Installation A5E00850741-01[...]

7-1 Automation System S7-400 Hardware and Installation A5E00850741-01 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 [...]

Maintenance 7-2 Automation System S7-400 Hardware and Installation A5E00850741-01 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 compa[...]

Maintenance 7-3 Automation System S7-400 Hardware and Installation A5E00850741-01 Using Backup Batteries Y ou should c hange 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 yea[...]

Maintenance 7-4 Automation System S7-400 Hardware and Installation A5E00850741-01 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 W[...]

Maintenance 7-5 Automation System S7-400 Hardware and Installation A5E00850741-01 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 configuratio[...]

Maintenance 7-6 Automation System S7-400 Hardware and Installation A5E00850741-01 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 ST OP . 5. Insert the memory card. 6. [...]

Maintenance 7-7 Automation System S7-400 Hardware and Installation A5E00850741-01 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. Y ou can replace[...]

Maintenance 7-8 Automation System S7-400 Hardware and Installation A5E00850741-01 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 ins[...]

Maintenance 7-9 Automation System S7-400 Hardware and Installation A5E00850741-01 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 DC 20 - -125 V/1,5A (6ES7422-5EH10-0AB0) • Digital output module SM 422; [...]

Maintenance 7-10 Automation System S7-400 Hardware and Installation A5E00850741-01 ! W arning 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 V AC or >60 VDC may be present at the pins of the module. When such voltages are pre[...]

Maintenance 7-1 1 Automation System S7-400 Hardware and Installation A5E00850741-01 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. Hot - - swapping Modules Observe the followin[...]

Maintenance 7-12 Automation System S7-400 Hardware and Installation A5E00850741-01 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 swi[...]

Maintenance 7-13 Automation System S7-400 Hardware and Installation A5E00850741-01 7.7 Replacing the Fuse of the Fan Subassembly Fuse T ype 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 bl[...]

Maintenance 7-14 Automation System S7-400 Hardware and Installation A5E00850741-01 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 . Fan 1 Fan 2 Fan 3 L E D s :F1=F a n1 F2=F a n2 F3=F a[...]

Maintenance 7-15 Automation System S7-400 Hardware and Installation A5E00850741-01 5. Slide the new fan in until it engages. 6. Slide the base in again and press it up. 7. Use a screwdriver to make a quarter turn clockwise and close the two quick-release locks. 8. Use a pointed object to press the RESET button. The fault LED will go of f and the fa[...]

Maintenance 7-16 Automation System S7-400 Hardware and Installation A5E00850741-01 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 hand[...]

Maintenance 7-17 Automation System S7-400 Hardware and Installation A5E00850741-01 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 t[...]

Maintenance 7-18 Automation System S7-400 Hardware and Installation A5E00850741-01 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-relea[...]

Maintenance 7-19 Automation System S7-400 Hardware and Installation A5E00850741-01 7.1 1 Replacing Interface Submodules A vailable Interface Submodules Note Only use interface submodules that are explicitly released for use in S7-400 devices. Installing Interface Submodules ! W arning The modules can be damaged. When inserting or removing interface[...]

Maintenance 7-20 Automation System S7-400 Hardware and Installation A5E00850741-01 Y ou 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 (not the synchronization module of a redundant system). 2. Switch of f the power supply (not[...]

A-1 Automation System S7-400 Hardware and Installation A5E00850741-01 Assembling and Installing Systems 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 Ass[...]

Assembling and Installing Systems A-2 Automation System S7-400 Hardware and Installation A5E00850741-01 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. Y ou must at least comply w[...]

Assembling and Installing Systems A-3 Automation System S7-400 Hardware and Installation A5E00850741-01 120/230 V AC Supply The following table shows which points you must observe when connecting the S7-400 to a 120/230 V AC supply . With ... ... Y ou Must Ensure ... buildings that suitable external lightning protection measures are provided. suppl[...]

Assembling and Installing Systems A-4 Automation System S7-400 Hardware and Installation A5E00850741-01 Protection Against Other Electrical Effects The following table shows the other external effects against which you must provide protection. Protection against ... ... by Means o f ... inadvertent actuation of operator controls a suitable arrangem[...]

Assembling and Installing Systems A-5 Automation System S7-400 Hardware and Installation A5E00850741-01 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 env[...]

Assembling and Installing Systems A-6 Automation System S7-400 Hardware and Installation A5E00850741-01 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 [...]

Assembling and Installing Systems A-7 Automation System S7-400 Hardware and Installation A5E00850741-01 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, provid[...]

Assembling and Installing Systems A-8 Automation System S7-400 Hardware and Installation A5E00850741-01 Rule 4: Special EMC Measures Employ special EMC measures for particu lar applications (see Section 4.1 1). • Fit suppressors to all inductors which are not controlled by S7-400 modules. • Use incandescent bulbs or suppressed fluorescent lamps[...]

Assembling and Installing Systems A-9 Automation System S7-400 Hardware and Installation A5E00850741-01 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. Th[...]

Assembling and Installing Systems A-10 Automation System S7-400 Hardware and Installation A5E00850741-01 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[...]

Assembling and Installing Systems A-1 1 Automation System S7-400 Hardware and Installation A5E00850741-01 Key for example 1 The numbers in the following list refer to the numbers in Figure A-2. T able A-1 Key for Example 1 No. Key Meaning 1 Grounding strips If there are no large-area metal-to-metal connections, you must interconnectinactive metal p[...]

Assembling and Installing Systems A-12 Automation System S7-400 Hardware and Installation A5E00850741-01 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 t[...]

Assembling and Installing Systems A-13 Automation System S7-400 Hardware and Installation A5E00850741-01 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 g[...]

Assembling and Installing Systems A-14 Automation System S7-400 Hardware and Installation A5E00850741-01 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 shiel[...]

Assembling and Installing Systems A-15 Automation System S7-400 Hardware and Installation A5E00850741-01 A.6 Equipotential Bonding Potential Differences Potential differences can occur betw een separate system components, leading to high transient currents; for example, if cable shields are fitted on both sides and grounded at different system comp[...]

Assembling and Installing Systems A-16 Automation System S7-400 Hardware and Installation A5E00850741-01 Figure A-5 Routing Equipotential Bonding Conductor and Signal Line[...]

Assembling and Installing Systems A-17 Automation System S7-400 Hardware and Installation A5E00850741-01 A.7 Cabling Inside Buildings Introduction Inside buildings, clearances must be observed between groups of different cables to achieve the necessary electromagnetic compatibility (EMC). T able A-2 provides you with information on the general rule[...]

Assembling and Installing Systems A-18 Automation System S7-400 Hardware and Installation A5E00850741-01 T able A-2 Cabling I nside Buildings, continued Run ... and Cables for ... Connect Cables for ... DC voltage ( > 60 V and ≤ 400 V), unshielded AC voltage ( > 25 V and ≤ 400 V), unshielded LAN signals, shielded (SINEC L1, PROFIBUS DP) D[...]

Assembling and Installing Systems A-19 Automation System S7-400 Hardware and Installation A5E00850741-01 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 me[...]

Assembling and Installing Systems A-20 Automation System S7-400 Hardware and Installation A5E00850741-01 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 protecti[...]

Assembling and Installing Systems A-21 Automation System S7-400 Hardware and Installation A5E00850741-01 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 m[...]

Assembling and Installing Systems A-22 Automation System S7-400 Hardware and Installation A5E00850741-01 Diagram of the Lightning Protection Zones The following diagram illustrates a lightning protection zone concept for a detached building. Lightning Protection Zone 0, Field Side Lightning Protection Lightning Protection Zone 3 Device Energy- T ec[...]

Assembling and Installing Systems A-23 Automation System S7-400 Hardware and Installation A5E00850741-01 A.9.2 Rules for the T ransition between Lightning Protection Zones 0a n d1 Rule for the T ransition 0 < -> 1 (Lightning Protection Equipotential Bonding) The following measures are suitable for lightning protection equipotential bonding at[...]

Assembling and Installing Systems A-24 Automation System S7-400 Hardware and Installation A5E00850741-01 T able A-3 High-V oltage Protection of Cables with t he Help of Surge Protection Equipment, continued Ser . No. Order No. ... equip transition point 0 < - - > 1 with: Cables for ... AC TT system 1p i e c eo f DEHNbloc/1 lightning conductor[...]

Assembling and Installing Systems A-25 Automation System S7-400 Hardware and Installation A5E00850741-01 A.9.3 Rules for the T ransitions between Lightning Protection Zones 1 < -> 2 and Greater Rules for T ransitions 1 <- > 2 and Above (Local Equipotential Bonding) for all lightning protection zone transitions 1 <-> 2 and greater:[...]

Assembling and Installing Systems A-26 Automation System S7-400 Hardware and Installation A5E00850741-01 Low-V oltage 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 T able A-4 Low-V oltage Protection Component s[...]

Assembling and Installing Systems A-27 Automation System S7-400 Hardware and Installation A5E00850741-01 Low-V oltage 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 use[...]

Assembling and Installing Systems A-28 Automation System S7-400 Hardware and Installation A5E00850741-01 A.9.4 Sample of a Surge Protection Circuit for Networked S7-400 PLCs Sample Circuit The sample in the figure A-7 shows you how install an effective surge protection for 2 networked S7-400 PLCs: CPU SV 10 mm 2 PE  Switchgear cubicle1 L1 L2 L3 [...]

Assembling and Installing Systems A-29 Automation System S7-400 Hardware and Installation A5E00850741-01 Components in figure A-7 The table A-6 explains consecutive numbers in the figure A-7: T able A-6 Example of a Circuit Conforming to Lightning Protection Requirements (Legend to Figure A-7) Ser . No. from fi- gure A-7 Components Description 1 Li[...]

Assembling and Installing Systems A-30 Automation System S7-400 Hardware and Installation A5E00850741-01 A . 1 0 How to Protect Digital Output Modules against Inductive Surge Inductive Surge V oltage Overvoltage occurs when inductive devices are switched off. Examples are relay coils and contactors Integrated Surge Arrester S7-400 digital output mo[...]

Assembling and Installing Systems A-31 Automation System S7-400 Hardware and Installation A5E00850741-01 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 [...]

Assembling and Installing Systems A-32 Automation System S7-400 Hardware and Installation A5E00850741-01 A.1 1 Safety of Electronic Control Equipment Intoduction The notes below apply independent of the type or manufacturer of the electronic control. Reliability Maximum reliability of SIMA TIC devices and components is achieved by implementing exte[...]

Assembling and Installing Systems A-33 Automation System S7-400 Hardware and Installation A5E00850741-01 Splitting the group into safety-relevant areas and areas which are not savety-relevant Most plants contain components for handling s afety-relevant functions (e.g. EMERGENCY -OFF switch, protective gates, two-hand controls). T o avoid the need t[...]

Assembling and Installing Systems A-34 Automation System S7-400 Hardware and Installation A5E00850741-01 A.12 Interference -Free C onnection of Monitors Introduction Y ou c an use control and monitoring interfaces with monitor ports from the WinCC product family . The layout of apparatus and degree of interference are decisive factors for the inter[...]

Assembling and Installing Systems A-35 Automation System S7-400 Hardware and Installation A5E00850741-01 Shielding and Grounding under Industrial Conditions If the monitor and programmable controller are operated under harsh industrial conditions, you must observe the following: On the side of the programmable controller: • Connect the cable shie[...]

Assembling and Installing Systems A-36 Automation System S7-400 Hardware and Installation A5E00850741-01 Figure A-1 1 shows a schematic view of the shielding and grounding for your monitor and S7-400. CR CP Shielding busbar Outer shield connected to ground clamp Monitor with isolated electronic ground and chassis ground Figure A-1 1 Shielding and G[...]

B-1 Automation System S7-400 Hardware and Installation A5E00850741-01 Guidelines for Handling Electrostatically - Sensitive Devices (ESD) Chapter Overview Section Y ou will find Page B.1 What is ESD? B-2 B.2 Electrostatic Charging of Persons B-3 B.3 General Protective Measures Against Electrostatic Discharge Damage B-4 B[...]

Guidelines for Handling Electrostatically -Sensitive Devices (ESD) B-2 Automation System S7-400 Hardware and Installation A5E00850741-01 B.1 What is ESD? Definition: All electronic modules are equipped with large-scale integrated ICs or components. Due to their design, these electronic ele ments are very sensitive to overvoltages and thus to any el[...]

Guidelines for Handling Electrostatically -Sensitive Devices (ESD) B-3 Automation System S7-400 Hardware and Installation A5E00850741-01 B.2 Electrostatic Charging of Persons Charging Every person with a non-conductive connecti on to the electrical potential of its surroundings is subject to electrostatic charge. Figure B-1 shows you the maximum va[...]

Guidelines for Handling Electrostatically -Sensitive Devices (ESD) B-4 Automation System S7-400 Hardware and Installation A5E00850741-01 B.3 General Protective Measures Against Electrostatic Discharge Damage Ensure Sufficient Grounding Make sure that the personnel, working surfaces, and packaging are suf ficiently grounded when handling electrostat[...]

Glossary-1 Automation System S7-400 Hardware and Installation A5E00850741-01 Glossary A Address An address is the identifier for a specific area of memory on which an instruction acts. Examples: Input I 12.1; Memory Word MW24; Data Block DB3. Analog Module Analog modules convert analog process var iables (for example, temperature) into digital valu[...]

Glossary Glossary-2 Automation System S7-400 Hardware and Installation A5E00850741-01 C Central module Programmable S7-400 module with MPI interface, controls the automation tasks. Chassis Ground The chassis ground comprises all interconnected inactive parts of an apparatus, which even in case of a fault cannot take dangerous touch voltages. Cold r[...]

Glossary Glossary-3 Automation System S7-400 Hardware and Installation A5E00850741-01 Counters Counters are an area in the system memory of the CPU. The contents of these counters can be changed using STEP 7 inst ructions (for example, up counter , down counter). CP → Communications Processor CPU Central processing unit of the S7 programmable con[...]

Glossary Glossary-4 Automation System S7-400 Hardware and Installation A5E00850741-01 Diagnostic Buffer The diagnostic buffer is a retentive area of memory within the S7-400 CPU which stores the diagnostic events in the order they occurred. Diagnostic Interrupt Modules with diagnostics capability signal system errors to the S7-400 CPU by means of d[...]

Glossary Glossary-5 Automation System S7-400 Hardware and Installation A5E00850741-01 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 er[...]

Glossary Glossary-6 Automation System S7-400 Hardware and Installation A5E00850741-01 Functional Grounding Grounding whose only purpose is to ensure the intended function of the electrical equipment concerned. Functional grounding short-circuits any noise that might otherwise have a detrimental effect on the equipment. Function Block (FB) According[...]

Glossary Glossary-7 Automation System S7-400 Hardware and Installation A5E00850741-01 H Hardware Interrupt Interrupt-triggering modules trigger a hardware interrupt in the case of a certain event in the process. The hardware interrupt is signalled to the CPU. In accordance with the priority of this interrupt, the corresponding organization block is[...]

Glossary Glossary-8 Automation System S7-400 Hardware and Installation A5E00850741-01 L Load Memory The load memory is part of the S7-400 CPU. It contains objects created by the programming device. It can be either a plug-in memory card or an integrated memory . Contains the complete user program during runtime, the comments and the symbolic system[...]

Glossary Glossary-9 Automation System S7-400 Hardware and Installation A5E00850741-01 Multipoint Interface (MPI) The multipoint interface is the programming device interface in SIMA TIC S7. It enables the simultaneous operation of a number of nodes (programming devices, text display operator interfaces, and operator panels) from one or more CPUs. E[...]

Glossary Glossary-10 Automation System S7-400 Hardware and Installation A5E00850741-01 O OB → Organization Block OB Priority The operating system of the S7-400 CPU dif ferentiates between various priority classes, for example, cyclic program processing, process interrupt-controlled program processing. Each priority class is assigned organization [...]

Glossary Glossary-1 1 Automation System S7-400 Hardware and Installation A5E00850741-01 Parameters, Static In contrast to dynamic parameters, static parameters of modules cannot be changed by means of the user program, but only via STEP 7 (not in the RUN state); for example, input delay of a digital signal input module. PG → Programming Device PR[...]

Glossary Glossary-12 Automation System S7-400 Hardware and Installation A5E00850741-01 R RAM The RAM (Random Access Memory) is a semiconductor memory with random access (read/write memory). May be used as for storing interim data for later use. This memory is not retentive, that is, its data are lost after power failure. Reference Ground → Ground[...]

Glossary Glossary-13 Automation System S7-400 Hardware and Installation A5E00850741-01 Segment → Bus segment SFB → System Function Block SFC → System Function 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)[...]

Glossary Glossary-14 Automation System S7-400 Hardware and Installation A5E00850741-01 System Diagnostics System diagnostics is the detection, eval uation, and reporting of errors occurring within the programmable controller . Examples of such errors are: program errors or failures on modules. System errors can be indicated with LED indicators or b[...]

Glossary Glossary-15 Automation System S7-400 Hardware and Installation A5E00850741-01 Tim e r (T ) T imers are an area in the system memory of the CPU. The contents of these t imers are updated by the operating system asynchronously to the user program. Y ou can use STEP 7 instructions to define t he exact function of the timer (for example, on-de[...]

Glossary Glossary-16 Automation System S7-400 Hardware and Installation A5E00850741-01 V V aristor V oltage-dependent resistor W W arm Restart During a CPU startup and before cyclic program processing starts (OB1), either OB101 (hot restart), or OB100 (restart / warm start), or OB102 is processed first. Prerequisite for the execution of the “hot [...]

Index-1 Automation System S7-400 Hardware and Installation A5E00850741-01 Index A Accessories, 2-35 Addresses geographical, 3-2 logical, 3-2 Analog modules, replacing, 7-7 Assembling the bus cable, on a bus connector with order number 6ES7 ..., 5-20 Assembly central, 2-2 distributed, 2-2 Assembly , M7-400, interface submodules, 6-18 B Backup batter[...]

Index Index-2 Automation System S7-400 Hardware and Installation A5E00850741-01 Front connector coding key , 4-32 labeling, 4-29 plugging in, 4-32 wiring, 4-24 with crimp snap-on terminals, 4-22 with screw-type terminals, 4-22 with spring-type terminals., 4-22 Front connector coding, 4-32 Fuse of the fan subassembly , replacing, 7-13 H Highest MPI [...]

Index Index-3 Automation System S7-400 Hardware and Installation A5E00850741-01 PROFIBUS-DP network components, 5-8 configuration example, 5-12, 5-13 configuration rules, 5-7 segment, 5-15 Programming device, connecting, 6-5 Protection against overvoltage, A-20 Protective measures, 4-5 R Rack, 1-2 clearances, 2-10 mounting dimensions, 2-10 segmente[...]

Index Index-4 Automation System S7-400 Hardware and Installation A5E00850741-01[...]