Siemens Automation System S7-400 - Manuals

Page 2 - Safety Guidelines

! Danger indicates that death or severe personal injury will result if proper precautions are not taken. ! Warning 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 pr...

Page 3 - iii; Preface; Purpose of the Manual; The manual applies to the S7-400 automation system.; Approvals; This manual is part of the documentation package for S7-400.; System; Documentation Package

iii Automation System S7-400 Hardware and Installation A5E00850741-01 Preface Purpose of the Manual The manual contains reference information on operator actions, descriptions offunctions and technical specifications of the central processing units, power supplymodules and interface modules of the S...

Page 4 - Navigating

Preface iv Automation System S7-400 Hardware and Installation A5E00850741-01 Navigating The manual offers the following access help to make it easy for you to find specificinformation: • At the start of the manual you will find a complete table of contents and a list of the diagrams and tables that ...

Page 5 - Technical Support; You can reach the Technical Suport for all A&D products; Service & Support on the Internet; where you will find the following:

Preface v Automation System S7-400 Hardware and Installation A5E00850741-01 Technical Support You can reach the Technical Suport for all A&D products • Via the Web formula for the Support Request http://www.siemens.com/automation/support-request • Phone: + 49 180 5050 222 • Fax:+ 49 180 5050 223...

Page 7 - Contents; Product Overview

vii Automation System S7-400 Hardware and Installation A5E00850741-01 Contents 1 Product Overview 1-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Installing the S7-400 2-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...

Page 8 - Networking

Contents viii Automation System S7-400 Hardware and Installation A5E00850741-01 4.9 Grounding 4-13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.10 Interference-Free Configuration for Local and Remote Connections 4-15 . . . . 4.11 Wirin...

Page 9 - Maintenance

Contents ix Automation System S7-400 Hardware and Installation A5E00850741-01 7 Maintenance 7-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1 Replacing the Backup Battery 7-2 . . . . . . . . . . . . . . . . . . . . . . . . ....

Page 10 - Figures

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 Temperature as a Function of Power Dissipation of Equipment in the Cabinet 2-27 . . . . . . . ...

Page 12 - Tables

Contents xii Automation System S7-400 Hardware and Installation A5E00850741-01 Tables 2-1 Cabinet types 2-26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Modules in the different racks 2-29 . . . . . . . . . . . . . . . . . . . . . . . . ....

Page 14 - Components

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 thefollowing tables: Components Function Illustration Racks (UR: Universal Rack) (CR: Central Rack) (ER: Expansion Rac...

Page 15 - Location of the order number and product version; figure shows a module with Product Version 1.

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...

Page 16 - Example of a rating plate

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

Page 17 - Chapter Overview; Section

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...

Page 18 - Introduction; Reference Manual

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 ormore expansion racks (ERs), as required. You can add ERs to compensate for lackof slots for you...

Page 19 - Connecting with a 5 V Supply; Observe the connection rules at the end of this section.; Local Connection

Installing the S7-400 2-3 Automation System S7-400 Hardware and Installation A5E00850741-01 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 toeach of the two int...

Page 20 - Ways of Connecting Central and Expansion Racks

Installing the S7-400 2-4 Automation System S7-400 Hardware and Installation A5E00850741-01 Ways 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 Expansio...

Page 21 - Rules for Connection; You can connect up to 21 ERs of the S7-400 to one CR.; Type of Connection

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 thefollowing rules: • You can connect up to 21 ERs of the S7-400 to one CR. • The ERs are assigned numbers to identify...

Page 22 - Function of the Racks

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 the basic framework which accepts theindividual modules. The modules exchange data and sig...

Page 23 - Electrical Supply

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 thepower supply module fit...

Page 24 - Segmented CR; Properties; A segmented CR has the following important characteristics:

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, h...

Page 25 - Subdivided CR; Characteristics; A subdivided CR has the following important characteristics:

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 andinterconnect all the slots;...

Page 26 - Mounting and Grounding the Racks; Important Notes on Installation; Step 1: Retaining Distances Between Devices; For fitting and removing modules

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 forinstallation in frames and cabinets. Their mounting dimensions ...

Page 27 - Space Required When Using Cable Channels and Fan Subassemblies; Dimensions of the Racks; The cutouts are arranged according to the 19-inch standard.

Installing the S7-400 2-11 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 immediatelybelow the rack. Additional space for cable routing must be pro...

Page 28 - Step 2: Mounting the Rack; Screw the rack onto the mounting panel.

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 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 1 2 3 4 5 6 7 8 9 60 mm 290 mm 190 mm 40 mm 1 2 3 4 1 2 3 4 115 mm 258 mm 133 mm 483 mm Depth = 28 mm without modulesDepth = 237...

Page 29 - Mounting Screws; Screw Type; Step 3: Connecting the Rack to the Chassis Ground; Minimum cross-section of the conductor to the chassis ground: 10 mm; Note; conductor with a large surface to establish large-area contact.

Installing the S7-400 2-13 Automation System S7-400 Hardware and Installation A5E00850741-01 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) Choose the screw length according to ...

Page 30 - Step 4: Mounting Additional Racks

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 foradditional clearance between the racks for installing a fan subassembly or cableduct. The figure below...

Page 31 - racks and between racks and other equipment.

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 anS7-400 from two racks with a cable duct or fan subassembly. This requirement isincreased by a height of 400 mm for each additional r...

Page 32 - Reference Point; disconnect upper screw for

Installing the S7-400 2-16 Automation System S7-400 Hardware and Installation A5E00850741-01 2.6 Chassis Terminal Connection in the Non-IsolatedConfiguration Reference Point The racks offer the option of connecting the 24-V load voltage ground in thenon-isolated configuration to the 5-V ground (refe...

Page 33 - Connection to the Reference Point; Ungrounded configuration

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 springlock washer (for example, clamping washer to DIN 6796) and the cylinder-headscrew supplie...

Page 34 - Methods of Ventilation

Installing the S7-400 2-18 Automation System S7-400 Hardware and Installation A5E00850741-01 2.7 Methods of Ventilation Methods of Ventilation Under extreme ambient conditions, particularly when operating S7-400 modules incabinets, you can use the cable duct or fan subassembly to optimize ventilatio...

Page 36 - Changing the Ventilation; the cable duct or fan subassembly.

Installing the S7-400 2-20 Automation System S7-400 Hardware and Installation A5E00850741-01 2.8 Changing the Ventilation with the Cable Duct and FanSubassembly Changing the Ventilation At the base of the cable duct and the fan subassembly, there is a cover that youcan move in order to modify the ai...

Page 37 - Shipping state

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 ...

Page 38 - Installing the Fan Subassembly; Procedure; Remove the left cover from the fan subassembly.; split up the individual plates as required.

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 f...

Page 39 - Attach the dummy plates to the free slots:; Monitoring the Fan Subassembly; Further details on the monitoring concept can be found in the

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 pro...

Page 40 - Installing the Cable Duct

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 ...

Page 41 - Choosing and Setting up Cabinets with the S7-400; Why Cabinets are Required; Ambient conditions at the point of installation of the cabinet

Installing the S7-400 2-25 Automation System S7-400 Hardware and Installation A5E00850741-01 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. Th...

Page 42 - Open Cabinets

Installing the S7-400 2-26 Automation System S7-400 Hardware and Installation A5E00850741-01 Table 2-1 provides an overview of the most common types of cabinet. You will alsofind the principle of heat removal, as well as the estimated, maximum achievablepower loss removal and the degree of protectio...

Page 43 - Removable Power Dissipation from Cabinets (Example); Warning

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....

Page 44 - Example of selecting the cabinet type; Type of Cabinet; Cabinet dimensions

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 aparticular power loss for various cabinet types. Equipment suitable for installation in a cab...

Page 45 - Rules for the Arrangement of Modules; Arrangement of the Modules; You only need to observe two rules for rack mounting of the modules:; described in this manual.; Modules; Space Requirement of the Racks; The mounting depth of a rack fitted with modules is 237 mm maximum.

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 You only need to observe two rules for rack mounting of the modules: • In all racks, the power supply module must always be inserted on th...

Page 46 - Installing Modules in a Rack; All modules are installed using the same procedure.; Caution; Tool; To install modules in a rack:

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 rac...

Page 48 - Screwing the Modules in Place

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 youfeel a resistance when swinging the module down, raise it slightly and thencontinue. (1) (2) Figure 2-4 A...

Page 49 - Marking the Modules with Slot Labels; Slot Number; The slot number is printed on the rack.; Fitting Slot Labels; To attach the slot labels:

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 toavoid the risk of mixing up modules during operation. If modules do get m...

Page 50 - Methods of Expansion and Networking

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 this chapter, other expansions are possible,for example, by connecting distributed I/Os or by networking. Distribu...

Page 51 - Accessories; Reference

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 inthe packaging of the modules and racks. The front connectors of the signalmodules must always be...

Page 54 - Addresses; You assign the channel address in two stages:

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. You must establish a uniqueassign...

Page 55 - Default Addressing; No multicomputing

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 logicaladdress and geographical address for you (default addressing). The logicaladdresses are then permanently assigned ...

Page 56 - How to Determine the Default Address of a Module

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 You determine the default address of a module from the number of the slot of themodule in the CR. The algorithms used to calculate the d...

Page 57 - Default Addresses of Analog Modules

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 slotin the central rack which is usually occupied by the power supply module) up to1600. The a...

Page 58 - How to Determine the Default Address of a Channel; Channel on a Digital Module

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 with32 inputs, four bytes (starting with the d...

Page 59 - Channel on an Analog Module; Channels on analog modules are addressed word-wise.

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 addressof the uppermost channel of the module, the ad...

Page 62 - Supplying Power to Modules; Power Supply Modules and Load Current Power Supplies

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 operatingvoltages by a power supply module, via the backplan...

Page 63 - Choosing the Power Supply Module; Estimating the Power Requirement; The following modules are to be fitted in a CR with 18 slots:; Module

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 You should make an estimate of the power requirement for each rack of yourS7-400 system in order to select the appropriate power supply module...

Page 64 - Choosing the Load Current Power Supply; Characteristics of; Load Current Power Supplies; Only a safe, isolated extra-low voltage of; Determining the Load Current

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 andactuators are powered by the load current power supply...

Page 65 - Components and Protective Measures; Figure; Rule: Grounding the Load Current Circuits; Load current circuits must be grounded.

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 singlefault between a live conductor and ground o...

Page 66 - S7-400 in the Overall Installation

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 (loadcurrent power supply and grounding concept) with supply from a TN-S system. Note: The arrangem...

Page 67 - Application; Metallic connection; Reference potential M

Wiring the S7-400 4-7 Automation System S7-400 Hardware and Installation A5E00850741-01 4.5 Assembling an S7-400 with Grounded ReferencePotential (M) Application You use an S7-400 with grounded reference potential in machines or industrialplants. Discharge of Interference Currents When the S7-400 is...

Page 68 - Frame element terminal; Power Supply Units

Wiring the S7-400 4-8 Automation System S7-400 Hardware and Installation A5E00850741-01 4.6 Assembling an S7-400 with Ungrounded ReferencePotential (Ungrounded Configuration) Application In large installations, it may be necessary to configure the S7-400 with anungrounded reference potential, for ex...

Page 69 - Filtering the 24 VDC Supply; operation is mandatory for the ER.

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, youmust provide interference suppression for the 24 VDC supply. Use a Siemenspower cable filter, such as the...

Page 70 - Assembling an S7-400 with Isolated Modules; Definition; Isolated modules are used for:; Isolated Modules and Grounding Concept

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 controlcircuit (M internal ) and the load circuit (M external ) are isolated (s...

Page 71 - Configuration with Isolated Modules

Wiring the S7-400 4-11 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 inputand output modules. PS CPU L1 N L + L1 N DI DO PE Rack U internal Data M external 230 VAC loa...

Page 72 - Parallel Wiring of Digital S7-400 Outputs; parallel to the output are always the same

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 Voltages The parallel wiring of a digital output (rated load voltage 1L+) with another digital output (...

Page 73 - Grounding; Always ensure that operating currents do not flow via ground.; Protective Ground; Device

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 theprerequisite for proper functioning of a programmable controller. Each individual component of the S7-400...

Page 74 - Connecting the Load Voltage Ground; Non-isolated operation; Mode

Wiring the S7-400 4-14 Automation System S7-400 Hardware and Installation A5E00850741-01 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 opera...

Page 75 - Use only Approved Components; connections, interference rejection may be impaired.; Interference-Free Configuration for Local Connections; All racks must have a low-impedance connection to each other; Interference-Free Configuration for Remote Connections; damaging the braided shield.

Wiring the S7-400 4-15 Automation System S7-400 Hardware and Installation A5E00850741-01 4.10 Interference-Free Configuration for Local and RemoteConnections Use only Approved Components Note If you use components which are not approved for setting up local and remote connections, interference rejec...

Page 76 - Special Cases

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 potentialdifference between grounding points is exceeded, you must install an equipotentialbonding conductor (copper conductor with a cross-section...

Page 77 - Wiring Rules; Lines and Tools; Rules for; and manufacturers of such ferrules are given below:

Wiring the S7-400 4-17 Automation System S7-400 Hardware and Installation A5E00850741-01 4.11 Wiring Rules Lines and Tools For wiring the S7-400 modules, there are some rules for the cables and tools to use. Rules for ... Power Supply ... Front Connectors Crimp terminal Screw-type terminal Spring-ty...

Page 78 - Wiring the Power Supply Module; Power Supply Connector

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 You use the power supply connector to connect a power supply module to yoursupply. When delivered, the power supply connector is plugged into the powers...

Page 79 - Wiring the Power Supply Connector; Switch off the line voltage at your VAC supply disconnector.; supply module from the supply.

Wiring the S7-400 4-19 Automation System S7-400 Hardware and Installation A5E00850741-01 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 ...

Page 81 - Plugging In the Power Supply Connector

Wiring the S7-400 4-21 Automation System S7-400 Hardware and Installation A5E00850741-01 Plugging In the Power Supply Connector You can only plug in the connector when the power supply module is installed(lower mounting screw tightened). To plug the wired power supply connector into the power supply...

Page 82 - Wiring the Signal Modules; Install the front connector on the module.; The Three Types of Front Connector; Front connector with crimp terminals

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 ...

Page 83 - Preparing to Wire the Front Connector; connector, then lever off the lower corner of the cover.; functions on certain signal modules. Do not remove this jumper.

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 off the lower corner of the cover. 2. Open the cover completely.3. Pull the...

Page 84 - Wiring the Front Connector, Crimping; To wire the prepared front connector:

Wiring the S7-400 4-24 Automation System S7-400 Hardware and Installation A5E00850741-01 4.14 Wiring the Front Connector, Crimping Procedure To 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...

Page 85 - Wiring the Front Connector, Screw Terminals

Wiring the S7-400 4-25 Automation System S7-400 Hardware and Installation A5E00850741-01 4.15 Wiring the Front Connector, Screw Terminals Procedure To 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...

Page 86 - Wiring the Front Connector, Spring-Type Terminals; Repeat steps 3 and 4 for all other wires.

Wiring the S7-400 4-26 Automation System S7-400 Hardware and Installation A5E00850741-01 4.16 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....

Page 87 - Principle of the spring loaded terminal

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 andengaging from the front is illustrated. 1. Insert the screwdriver 2. Insert the wire into the spr...

Page 88 - Fitting the Strain Relief; Cable Ties as Strain Relief

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 Relief When you have wired the front connector, the cable tie provided should be fitted atthe bottom of the front connector as a strain relief for the connecte...

Page 89 - Labeling a Front Connector; Labels and Terminal Diagram; of the cover of the front connector.

Wiring the S7-400 4-29 Automation System S7-400 Hardware and Installation A5E00850741-01 4.18 Labeling a Front Connector Labels and Terminal Diagram Each signal module is provided with three labels: two blank labels and one printedlabel showing the terminal diagram for inputs and outputs. Figure 4-1...

Page 90 - Labels

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 Fitting a Label in the Front Connector Labels • Print labels are prerequisite for prof...

Page 91 - Notes on Ordering Labeling Sheets for S7-400; Order Number; How to Label S7-400 Modules; Method 1: Using Templates; Find the templates on the Internet; Method 2: Using the “S7-SmartLabel” Add-On Tool for SIMATIC STEP 7

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 SIMATIC S7-400, 10 A4 label sheets, 4 labeling strips / sheets for signal modules. Material: film, perforated, for laser printers. 10 sheets ...

Page 92 - Fitting the Front Connector; Principle of a Coding Key; Signal Modules; Plugging In the Front Connector

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 To reduce the risk of a wired front connector being plugged into the wrong type ofmodule after rewiring or module replacement, the signal modules have a...

Page 93 - To plug in the front connector, follow the steps outlined below:

Wiring the S7-400 4-33 Automation System S7-400 Hardware and Installation A5E00850741-01 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 enga...

Page 94 - Figure 4-21 shows how to screw on the front connector.

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 Screwing On the Front Connector

Page 95 - Interconnecting the Interface Modules; To interconnect the interface modules:

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 inter...

Page 96 - (receive interface) of the receive IM and screw the connector on.; Reference Manual Module Specifications

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....

Page 97 - Setting the Fan Subassembly to the Line Voltage; Wiring the Fan Subassembly

Wiring the S7-400 4-37 Automation System S7-400 Hardware and Installation A5E00850741-01 4.21 Setting the Fan Subassembly to the Line Voltage andWiring It Setting the Fan Subassembly to the Line Voltage Check whether the voltage selector switch in the fan subassembly is set to yourline voltage (see ...

Page 98 - Cable routing in cable ducts or fan subassemblies; secure the cables to these eyes with cable ties, for example.; Shield Contact; Routing Fiber-Optic Cables; Cable Routing; Minimum bending radius of the cables:

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 particularrack, the cross-section of the cable duct or fan subassembly may ...

Page 100 - Configuring a Network; Subnets; You can connect an S7-400 device to various subnets:; Same Configuration; Configuring Hardware and Communication Connections

Networking 5-2 Automation System S7-400 Hardware and Installation A5E00850741-01 5.1 Configuring a Network Subnets You 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 integ...

Page 101 - Fundamentals; Segment; expressed in terms of bits per second.; Connectable Nodes; MPI

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 inthe following. Segment A segment is a bus cable between two terminating resistors. A segment cancontain u...

Page 102 - Number of Nodes; Observe the CPU-specific maximum numbers in the; Default MPI Addresses; Default MPI Address

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 Manu...

Page 103 - Rules for MPI Addresses; Observe the following rules before assigning MPI addresses:; Maximum Number of Connections via MPI

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...

Page 104 - PG Access; to the CPU from the programming device.

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 controllers, with operator interface stations (OP, OS) or with programming devices (see Figure 5-2). ...

Page 105 - Rules for Configuring a Network; Rules; Before; Reference Manual CPU Data

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 an...

Page 106 - Data Packets in the MPI Network; Observe the following feature in the MPI network:; Recommendation for MPI Addresses

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 ...

Page 107 - Terminating Resistor on the Bus Connector

Networking 5-9 Automation System S7-400 Hardware and Installation A5E00850741-01 Terminating Resistor on the Bus Connector on off on off Terminating resistor switched on Terminating resistor switched off Figure 5-3 Terminating resistor on bus connector Terminating Resistor on the RS 485 Repeater DC ...

Page 108 - Example: Terminating Resistor in the MPI Network

Networking 5-10 Automation System S7-400 Hardware and Installation A5E00850741-01 Example: Terminating Resistor in the MPI Network The figure below shows where you have to connect the terminating resistor in apossible configuration for an MPI network. RS 485 repeater { { { { Terminating resistor swi...

Page 109 - Example of an MPI Network

Networking 5-11 Automation System S7-400 Hardware and Installation A5E00850741-01 Example of an MPI Network * Only connected via spur line for startup/maintenance (with default MPI address)** Connected to the MPI later on (with default MPI address) 0 ... x MPI address of nodes { Terminating resistor...

Page 110 - Example of a PROFIBUS-DP Network

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 1 2 3 4 5 PG* OP PG ET 200M S5-95U ET 200B ET 200B { { { Terminating resistor switched on * ...

Page 112 - Programming Device Access Beyond Network Limits (Routing); Use STEP 7 from version 5.0 onwards

Networking 5-14 Automation System S7-400 Hardware and Installation A5E00850741-01 Programming Device Access Beyond Network Limits (Routing) You 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 Pr...

Page 113 - Cable Lengths; Segment in the MPI Network; Segment in the PROFIBUS-DP Network; Transmission Rate; Longer Cable Lengths; connect up to ten RS 485 repeaters in series.

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. This50 m applies from the first node to the last node in the segment. Table 5-1 Permitted Cable Leng...

Page 114 - Lengths of Spur Lines

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, whenusing a PROFIBUS-DP bus terminal), you must take into account the maximumpossible spur line length. The following ta...

Page 115 - Example

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 exampleclarifies the maximum possible distances in an MPI network. max. 50m max. 50m max. 1000m RS 485- repeater RS 485- repeater { { { { ...

Page 116 - PROFIBUS-DP Bus Cables; Rules for Laying Cables

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 PROFI...

Page 117 - Bus Connectors; Purpose of the Bus Connector; There are two different bus connectors:

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 orPROFIBUS-DP interface. In this way, you establish the connection to other nodes. There are two...

Page 118 - Connecting Bus Cables to Bus Connectors (; SIMATIC NET Profibus Networks; Connecting the Bus Connector; To connect the bus connector, proceed as follows:; not; Removing the Bus Connector; With a; looped-through bus cable; you can remove the bus connector from the

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 tothe SIMATIC NET Profibus Networks manual. Connecting the Bus Connector To ...

Page 119 - RS 485 Repeater / Diagnostics Repeater; Purpose of the Repeater; Assembly

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 cablesand couples bus segments. You need an repeater when: • More than 32 node...

Page 120 - PROFIBUS-DP Network with Fiber-Optic Cables; Electrical/Optical Conversion; SIMATIC NET PROFIBUS Networks; Benefits and Areas of Application

Networking 5-22 Automation System S7-400 Hardware and Installation A5E00850741-01 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 ...

Page 121 - Optical PROFIBUS-DP Network in Partyline Topology; cable interface has a; partyline topology; . The PROFIBUS nodes are; network is operated with a partyline topology:

Networking 5-23 Automation System S7-400 Hardware and Installation A5E00850741-01 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...

Page 122 - means of the PROFIBUS cable. The OBT is integrated in the optical; Features of the Fiber-Optic Cables; Description

Networking 5-24 Automation System S7-400 Hardware and Installation A5E00850741-01 PROFIBUS Optical Bus Terminal (OBT) A PROFIBUS node can be connected to the optical PROFIBUS-DP network via a PROFIBUS Optical Bus Terminal (OBT) (6GK1 500-3AA00) without an integrated fiber-optic cable interface (e.g....

Page 124 - Order Numbers; Simplex Connectors and Connector Adapter

Networking 5-26 Automation System S7-400 Hardware and Installation A5E00850741-01 Order Numbers You can order the fiber-optic cables under the order numbers specified in Table 5-4. Table 5-5 Order Numbers - Fiber-Optic Cables Fiber-Optic Cables Form Order Number SIMATIC NET PROFIBUS plastic fiber-op...

Page 125 - Structure; Degree of protection IP20

Networking 5-27 Automation System S7-400 Hardware and Installation A5E00850741-01 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: • Degree of protection IP20 protection • Transmission ra...

Page 126 - Connecting a Fiber-Optic Cable to the PROFIBUS Device; With fiber-optic cables, the length of the cable segment; does not depend; on the; SIMATIC NET; Mixed Use of Plastic Fiber-Optic and PCF Fiber-Optic Cable; slaves locally (distances; Laying PCF Fiber-Optic Cable

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 netwo...

Page 127 - Rules for Laying Cable; Installing the Connector Adapter

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: • I...

Page 129 - Commissioning

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 Time 6-3 6.3 Connecting a Programming Device (PG) to an S7-400 6-5 6.4 Switchin...

Page 130 - Recommended Procedure for First Startup; Recommended Procedure; indicators can be found in the; How to Proceed in the Case of an Error; If an error occurs, you can proceed as follows:

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 bevery extensive and complex. A first startup of an S7-400 with two or more ...

Page 131 - Checks Prior to Switching On for the First Time

Commissioning 6-3 Automation System S7-400 Hardware and Installation A5E00850741-01 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 outso far, before switching on f...

Page 132 - Module Settings

Commissioning 6-4 Automation System S7-400 Hardware and Installation A5E00850741-01 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 1 Are the numbers of the racks cor- rectly set on the coding switches of the rece...

Page 134 - Communication between Programming Device and CPU; You need a programming device with STEP 7.; Operator Control; Switching On an S7-400 for the First Time; First switch on the power cutout.; Switching On an H System for the First Time

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 programmingdevice and a CPU: • You need a programming device with STEP 7. • The CPU can communicate with th...

Page 135 - Resetting the CPU with the Mode Selector Switch; How to Carry Out a Memory Reset; You must reset the CPU:; How to Perform a Memory Reset; There are two ways of resetting the CPU:

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 initialstate. The CPU also initializes its hardware parameters ...

Page 136 - Case A: You want to transfer a new, complete user program to the CPU.

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 figureshows all positions of the mode selector switch. RUN STOP MRES Figure 6-2 Positions of the ...

Page 137 - What Happens in the CPU During a Memory 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...

Page 138 - remaining DBs retain their last valid value.; Hot restart; Program execution is resumed at the breakpoint.

Commissioning 6-10 Automation System S7-400 Hardware and Installation A5E00850741-01 6.6 Cold, Warm, and Hot Restarts with the Mode SelectorSwitch Restart (warm start) • A restart resets the process image and the non--retentive flags, timers, times and counters.Retentive flags, times and counters re...

Page 139 - Inserting a Memory Card; The Memory Card as Load Memory; There are two types of memory card: RAM cards and Flash cards.

Commissioning 6-11 Automation System S7-400 Hardware and Installation A5E00850741-01 6.7 Inserting a Memory Card The Memory Card as Load Memory You can insert a Memory Card into any S7-400 CPU. This card represents the loadmemory expansion of the CPU. Depending on the type of memory card, the userpr...

Page 141 - Backup; as data in variable data blocks.; Inserting a Backup Battery; Ensure correct polarity of the battery.

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: • To back up a user program and save it without loss in the event of a power failure. • F...

Page 143 - therefore be observed without fail:

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-widthpower supply module. ! Warning Hazardous to persons and property, risk of pollutant emission.A lithium battery can explode if treated in...

Page 144 - Reducing the Passivation Layer; Insert the backup battery/batteries in the battery compartment.; Removing a Backup Battery; Chapter 7 describes how to remove the backup battery (batteries).

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 theS7-400. In lithium batteries of this technology, a passivation layer can develop afterstorage for a ver...

Page 145 - Starting Up a PROFIBUS-DP Subnet; Startup if Preset Config. Actual

Commissioning 6-17 Automation System S7-400 Hardware and Installation A5E00850741-01 6.9 Starting Up a PROFIBUS-DP Subnet Introduction This section describes the procedure for starting up a PROFIBUS-DP subnet withan S7-400 CPU as the DP master. Requirements Before you can start up the PROFIBUS-DP su...

Page 146 - Available Interface Modules; Installing Interface Modules

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) Available Interface Modules Note Only use interface submodules that are explicitly released for use in S7-400 devices. Installing Interfac...

Page 147 - the frame of the card slot.; Covering Unused Submodule Slots; Leave unused submodule slots secured.

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 the frame of the card slot. 4. Important! Secure the front plate with the two fitted, captive M2.5 x 10 slot-head screws on the lef...

Page 150 - Replacing the Backup Battery; Switch on battery monitoring with the BATT INDIC slide switch.

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 b...

Page 151 - Using Backup Batteries; You should change the backup battery once a year.; Rules for the Care of Backup Batteries; dering work on the cell casing (max. temperature 100

Maintenance 7-3 Automation System S7-400 Hardware and Installation A5E00850741-01 Using Backup Batteries You should change the backup battery once a year. Observe the usual regulations/guidelines for disposing of lithium batteries in yourcountry. Backup batteries should be stored in a cool, dry plac...

Page 152 - Replacing a Power Supply Module; Slot Numbering; Installing a New Module; Set the CPU mode switch to RUN if applicable.; How the S7-400 Behaves after Exchanging Modules

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 mustremove the number from the old module when replacing it and apply the number tothe new mod...

Page 153 - Replacing CPUs; Save the user program including configuration data.; Removing the Module; Set the standby switch of the power supply module to

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 mustremove the number from the old module when replacing it and apply the number tothe new module. Saving the D...

Page 154 - whether or not you have configured your system for networking.

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 s...

Page 155 - Replacing Digital or Analog Modules; a way that the pins of the module are not touched.; removal and insertion.

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 mustremove the number from the old module when replacing it and apply the number tothe new...

Page 156 - Removing the Front Connector Coding Key

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 thecoding key, because this part is already fitted in the wired front connector. ! Caution The m...

Page 157 - Changing the Fuses in the Digital Modules; Modules with Fuses; Correct the faults which led to the fuses blowing.; Changing the Fuses

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 aredefective: • Digital output module SM 422; DO 16 x DC 20--125 V/1,5A (6ES7422-5...

Page 158 - casing and close the covers until they click into place.; How the S7-400 Behaves after Replacing the Fuse

Maintenance 7-10 Automation System S7-400 Hardware and Installation A5E00850741-01 ! 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...

Page 159 - Replacing Interface Modules; before carrying out any actions.; Removing Modules / Exchanging Cables; battery or via an external battery supply at the CPU (see

Maintenance 7-11 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 mustremove the number from the old module when replacing it and apply the number tothe new module...

Page 161 - Replacing the Fuse of the Fan Subassembly; Fuse Type; Use the following fuse:; Replacing the Fuse; To replace the fuse of the module, follow the steps outlined below:

Maintenance 7-13 Automation System S7-400 Hardware and Installation A5E00850741-01 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 andnot a spare part. Use the following fuse: • 160 mA slow blow if the voltage sele...

Page 162 - Removing the Fans; quick-release locks on the front of the fan subassembly.; Fan grip

Maintenance 7-14 Automation System S7-400 Hardware and Installation A5E00850741-01 7.8 Replacing Fans in the Fan Subassembly DuringOperation 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...

Page 163 - the fan will start running.

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 RES...

Page 164 - Replacing the Filter Frame

Maintenance 7-16 Automation System S7-400 Hardware and Installation A5E00850741-01 7.9 Replacing the Filter Frame of the Fan SubassemblyDuring 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 f...

Page 165 - with the snap catches.

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...

Page 166 - Exchanging the Mother Board

Maintenance 7-18 Automation System S7-400 Hardware and Installation A5E00850741-01 7.10 Replacing the Power Supply PCB and Monitoring PCBof 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...

Page 167 - Replacing Interface Submodules; Available Interface Submodules; Installing Interface Submodules

Maintenance 7-19 Automation System S7-400 Hardware and Installation A5E00850741-01 7.11 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 b...

Page 169 - Assembling and Installing Systems

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 Controll...

Page 170 - General Basic Rules; Event

Assembling and Installing Systems A-2 Automation System S7-400 Hardware and Installation A5E00850741-01 A.1 General Rules and Regulations for Operatingthe S7-400 General Basic Rules On account of the many possible applications of the S7-400, this chapter can onlycover the basic rules for the electri...

Page 171 - Protection Against External Electrical Effects

Assembling and Installing Systems A-3 Automation System S7-400 Hardware and Installation A5E00850741-01 120/230 VAC Supply The following table shows which points you must observe when connecting theS7-400 to a 120/230 VAC supply. With ... ... You Must Ensure ... buildings that suitable external ligh...

Page 172 - Protection Against Other Electrical Effects

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 mustprovide protection. Protection against ... ... by Means of ... inadvertent ac...

Page 173 - Principles of System Installation for EMC; Electromagnetic fields which directly affect the system

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 apparatusto operate without faults in a given electromagnet...

Page 174 - Coupling Mechanisms

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 couplingmechanisms, depending on the transmission medium (conducted ornon-conducted) and distance between ...

Page 175 - Five Basic Rules for Ensuring Electromagnetic Compatibility; and is therefore less suitable for grounding.; Rule 2: Correct Cable Routing; such as cabinet elements, metal bars and cabinet panels.; Rule 3: Secure Cable Shields; do not ground it there again.

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 thefollowing five basic rules: Rule 1: Large Area Grounding Whe...

Page 176 - Rule 4: Special EMC Measures; and functional measure.; See also

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 particular applications (see Section 4.11). • Fit suppressors to all inductors which are not controlled by S7-400 modules. • Use incand...

Page 177 - Installation of Programmable Controllers for EMC; scratch the layer off fully at the contact point.

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 controlsystem is already operational, and the proper recepti...

Page 178 - Examples of EMC-Compatible Assembly

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 s...

Page 179 - Key for example 1; Key; Module Data reference

Assembling and Installing Systems A-11 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. Table A-1 Key for Example 1 No. Key Meaning 1 Grounding strips If there are no large-area metal-to-metal co...

Page 180 - Ensure the following for frame and wall mounting:; the insulating protective layers.

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-impeda...

Page 181 - Shielding Cables; Purpose of the Shielding; An equipotential bonding conductor cannot be laid

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, andelectromagnetic interference on this cable. Principle of Operation Interfere...

Page 182 - Handling the Shields; Observe the following points with regard to the shield:

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...

Page 183 - Equipotential Bonding; Potential Differences; Equipotential Bonding Conductor; efficiency of the equipotential bonding.

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 between separate system components, leading tohigh transient currents; for example, if cable shields are fitted on ...

Page 185 - Cabling Inside Buildings

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 cablesto achieve the necessary electromagnetic compatibility (EMC). Table A-2 p...

Page 187 - Cabling Outside Buildings; Rules for EMC

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 insidebuildings. The following also applies: • Run cables on metallic cable s...

Page 188 - Lightning Protection and Overvoltage Protection; Overview

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 w...

Page 189 - Lightning Protection Zone Concept; Effects of a Lightning Strike

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...

Page 190 - Diagram of the Lightning Protection Zones; measures to prevent surges being conducted further.

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 detachedbuilding. Lightning Protection Zone 0, Field Side Lightning Protectio...

Page 191 - Lay the cables in one of the following ways:; Additional Measures

Assembling and Installing Systems A-23 Automation System S7-400 Hardware and Installation A5E00850741-01 A.9.2 Rules for the Transition between Lightning Protection Zones0 and 1 Rule for the Transition 0 <-> 1 (Lightning Protection Equipotential Bonding) The following measures are suitable for...

Page 193 - Rules for Transitions 1; for all lightning protection zone transitions 1; Lightning Protection Element for the 24 VDC Supply

Assembling and Installing Systems A-25 Automation System S7-400 Hardware and Installation A5E00850741-01 A.9.3 Rules for the Transitions between Lightning ProtectionZones 1 <-> 2 and Greater Rules for Transitions 1 <-> 2 and Above (Local Equipotential Bonding) for all lightning protectio...

Page 196 - Sample Circuit; Lightning-protection zone 1

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 S7-400PLCs Sample Circuit The sample in the figure A-7 shows you how install an effective surge protection for2 networked S7-400 PLCs: CPU...

Page 197 - Components in figure A-7; The table A-6 explains consecutive numbers in the figure A-7:

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: Table A-6 Example of a Circuit Conforming to Lightning Protection Requirements (Legend to Figure A-7) Ser. N...

Page 198 - Inductive Surge Voltage; If the inductive loads are not controlled by SIMATIC modules.

Assembling and Installing Systems A-30 Automation System S7-400 Hardware and Installation A5E00850741-01 A.10 How to Protect Digital Output Modules againstInductive Surge Inductive Surge Voltage Overvoltage occurs when inductive devices are switched off. Examples are relaycoils and contactors Integr...

Page 199 - Suppression for DC-Operated Coils; DC-operated coils are interconnected to diodes or Zener diodes.; Suppression with Diodes / Zener Diodes; The Zener diode switches off more quickly than a diode circuit.; Suppression with AC-Operated Coils; AC-operated coils are suppressed with varistors or RC elements.

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...

Page 200 - Safety of Electronic Control Equipment; Intoduction; Systematic and computer-aided testing of all components; Risks

Assembling and Installing Systems A-32 Automation System S7-400 Hardware and Installation A5E00850741-01 A.11 Safety of Electronic Control Equipment Intoduction The notes below apply independent of the type or manufacturer of the electroniccontrol. Reliability Maximum reliability of SIMATIC devices ...

Page 201 - and an area that is; . In the non-safety area, no special demands are placed on the; Important Information

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 safety-relevant functions (e.g.EMERGENCY-OFF switch, protective ...

Page 202 - Interference-Free Connection of Monitors

Assembling and Installing Systems A-34 Automation System S7-400 Hardware and Installation A5E00850741-01 A.12 Interference-Free Connection of Monitors Introduction You can use control and monitoring interfaces with monitor ports from the WinCCproduct family. The layout of apparatus and degree of int...

Page 203 - Shielding and Grounding under Industrial Conditions

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 industrialconditions, you must observe the following: On the side of the pr...

Page 205 - Guidelines for Handling

B-1 Automation System S7-400 Hardware and Installation A5E00850741-01 Guidelines for Handling Electrostatically-Sensitive Devices (ESD) Chapter Overview Section You 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 Dis...

Page 206 - These; ESD; after a prolonged period of operation.

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 elements are ve...

Page 207 - Charging

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 connection to the electrical potential of itssurroundings is subject to electrosta...

Page 208 - Ensure Sufficient Grounding

Guidelines for Handling Electrostatically-Sensitive Devices (ESD) B-4 Automation System S7-400 Hardware and Installation A5E00850741-01 B.3 General Protective Measures Against ElectrostaticDischarge Damage Ensure Sufficient Grounding Make sure that the personnel, working surfaces, and packaging are ...

Page 209 - Glossary; Address; Entity of a serial bus system, coupled via repeaters.

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 instructionacts.Examples: Input I 12.1; Memory Word MW24; Data Block DB3. Analog Module Analog modules convert analog process variabl...

Page 211 - Communications Processor

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 thesecounters can be changed using STEP 7 instructions (for example, up counter,down counter). CP → Communications Processor CPU Centra...

Page 212 - Diagnostic Buffer; A master which is compliant with EN 50170, Part 3.; DP Slave

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 whichstores the diagnostic events in the order they occurred. Diagnostic Interrupt Modules with diagnostics capability sig...

Page 213 - Error Handling via OB; Function Block

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-timeerror. The other possible responses include: error response in the user program,STOP mode of the CPU. Error Handling...

Page 214 - Functional Grounding

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 electricalequipment concerned. Functional grounding short-circuits any noise that mightotherwise have a detrimental effect...

Page 215 - Hardware Interrupt; Multipoint Interface.; Isolated

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 certainevent in the process. The hardware interrupt is signalled to the CPU. In accordancewith the priority of this in...

Page 216 - For detailed information on OB57, refer to the

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 theprogramming device. It can be either a plug-in memory card or an integratedmemory. Contains the complete user program durin...

Page 217 - MPI Address

Glossary Glossary-9 Automation System S7-400 Hardware and Installation A5E00850741-01 Multipoint Interface (MPI) The multipoint interface is the programming device interface in SIMATIC S7. Itenables the simultaneous operation of a number of nodes (programming devices,text display operator interfaces...

Page 218 - OB; Organization Block; OB Priority

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 differentiates between various priorityclasses, for example, cyclic program processing, process interrupt-controlledprogram processing. ...

Page 219 - PG; Programming Device; PROFIBUS DP

Glossary Glossary-11 Automation System S7-400 Hardware and Installation A5E00850741-01 Parameters, Static In contrast to dynamic parameters, static parameters of modules cannot bechanged by means of the user program, but only via STEP 7 (not in the RUNstate); for example, input delay of a digital si...

Page 220 - Ground

Glossary Glossary-12 Automation System S7-400 Hardware and Installation A5E00850741-01 R RAM The RAM (Random Access Memory) is a semiconductor memory with randomaccess (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 ...

Page 221 - Bus segment

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 theprogrammable controller. Signal modules comprise digital inpu...

Page 222 - System Diagnostics

Glossary Glossary-14 Automation System S7-400 Hardware and Installation A5E00850741-01 System Diagnostics System diagnostics is the detection, evaluation, and reporting of errors occurringwithin the programmable controller. Examples of such errors are: program errors orfailures on modules. System er...

Page 223 - Sum of currents of all output channels of a digital output module.

Glossary Glossary-15 Automation System S7-400 Hardware and Installation A5E00850741-01 Timer (T) Timers are an area in the system memory of the CPU. The contents of these timersare updated by the operating system asynchronously to the user program. You canuse STEP 7 instructions to define the exact ...

Page 224 - Varistor; Voltage-dependent resistor; Warm Restart

Glossary Glossary-16 Automation System S7-400 Hardware and Installation A5E00850741-01 V Varistor Voltage-dependent resistor W Warm Restart During a CPU startup and before cyclic program processing starts (OB1), eitherOB101 (hot restart), or OB100 (restart / warm start), or OB102 is processed first....

Page 225 - Index; See

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, M...

Page 226 - Front connector

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...