S7-400 and M7-400, Notas de estudo de Cultura

Baixe S7-400 and M7-400 e outras Notas de estudo em PDF para Cultura, somente na Docsity! Preface, Contents Product Overview 1 Installing the S7-400 2 Addressing the S7-400 3 Wiring the S7-400 4 Networking 5 Starting Up 6 Maintenance 7 Assembling the M7-400 8 Appendices Assembling and Installing Systems A Guidelines for Handling Electrostatically-Sensitive Devices (ESD) B Glossary, Index S7-400 and M7-400 Programmable Controllers Hardware and Installation Installation Manual SIMATIC This manual is part of the documentation package with the order number 6ES7498-8AA03-8BA0 Edition 12/2002 A5E00069481-04 Index-2 S7-400 and M7-400 Programmable Controllers Hardware and Installation A5E00069480-02 ! Danger indicates that death, severe personal injury or substantial property damage will result if proper precau- tions are not taken. ! Warning indicates that death, severe personal injury or substantial property damage can result if proper precautions are not taken. ! Caution indicates that minor personal injury can result if proper precautions are not taken. Caution indicates that property damage can result if proper precautions are not taken. Notice draws your attention to particularly important information on the product, handling the product, or to a particular part of the documentation. Qualified Personnel Only qualified personnel should be allowed to install and work on this equipment. Qualified persons are defined as persons who are authorized to commission, to ground and to tag circuits, equipment, and systems in accordance with established safety practices and standards. Correct Usage Note the following: ! Warning This device and its components may only be used for the applications described in the catalog or the technical description, and only in connection with devices or components from other manufacturers which have been approved or recommended by Siemens. This product can only function correctly and safely if it is transported, stored, set up, and installed correctly, and operated and maintained as recommended. Trademarks SIMATIC, SIMATIC HMI and SIMATIC NET are registered trademarks of SIEMENS AG. Third parties using for their own purposes any other names in this document which refer to trademarks might infringe upon the rights of the trademark owners. Safety Guidelines This manual contains notices intended to ensure personal safety, as well as to protect the products and connected equipment against damage. These notices are highlighted by the symbols shown below and graded according to severity by the following texts: We have checked the contents of this manual for agreement with the hardware and software described. Since deviations cannot be precluded entirely, we cannot guarantee full agreement. However, the data in this manual are reviewed regularly and any necessary corrections included in subsequent editions. Suggestions for improvement are welcomed. Disclaim of LiabilityCopyright
Siemens AG 1999-2002 All rights reserved The reproduction, transmission or use of this document or its contents is not permitted without express written authority. Offenders will be liable for damages. All rights, including rights created by patent grant or registration of a utility model or design, are reserved. Siemens AG Bereich Automation and Drives Geschaeftsgebiet Industrial Automation Systems Postfach 4848, D- 90327 Nuernberg  Siemens AG 1999– 2002 Technical data subject to change. Siemens Aktiengesellschaft A5E00069481-04 Preface v S7-400 and M7-400 Programmable Controllers Hardware and Installation A5E00069481-04 Finding Your Way The manual offers the following access aids to make it easy for you to find specific information quickly: • At the beginning of the manual you will find a complete table of contents and lists of the figures and tables contained in the manual. • In each chapter you will find information in the left-hand margin on each page that gives you an overview of the contents of the relevant section. • After the appendices you will find a glossary containing definitions of important terms and concepts that are used in the manual. • At the end of the manual you will find a detailed index, allowing you to quickly find the information you are looking for. Specific Information for S7-400 You require the following manuals and manual packages in order to program and commission an S7-400: Manual/ Manual Package Contents Standard Software for S7 and M7 STEP 7 Basic Information • Installing and starting up STEP 7 on a programming device / PC • Working with STEP 7 with the following contents: Managing projects and files Configuring and assigning parameters to the S7-400 configuration Assigning symbolic names for user programs Creating and testing a user program in STL/LAD Creating data blocks Configuring the communication between two or more CPUs Loading, storing and deleting user programs in the CPU / programming device Monitoring and controlling user programs Monitoring and controlling the CPU • Guide for efficiently implementing the programming task with the programming device / PC and STEP 7 • How the CPUs work (for example, memory concept, access to inputs and outputs, addressing, blocks, data management) • Description of STEP 7 data management • Using data types of STEP 7 • Using linear and structured programming • Using block call instructions • Using the debug and diagnostic functions of the CPUs in the user program (for example, error OBs, status word) Preface vi S7-400 and M7-400 Programmable Controllers Hardware and Installation A5E00069481-04 Manual/ Manual Package Contents STEP 7 Reference Information Statement List (STL) for S7-300 and S7-400 Ladder Logic (LAD) • Basic procedure for working with STL, LAD, or FBD (for example, structure of STL, LAD, or FBD, number formats, syntax) • Description of all instructions in STEP 7 (with program examples) • Description of the various addressing methods in STEP 7 (with examples) • Description of all functions integrated in the CPUs • Description of the internal registers in the CPUfor S7-300 and S7-400 Function Block Diagram (FBD) for S7-300 and S7-400 System and Standard Functions • Description of all system functions integrated in the CPUs • Description of all organization blocks integrated in the CPUs Manual PG 7xx • Description of the programming device hardware • Connecting a programming device to various devices • Starting up a programming device Preface vii S7-400 and M7-400 Programmable Controllers Hardware and Installation A5E00069481-04 Specific Information for M7-400 This documentation package describes the hardware of the M7-400. You will need the following additional documentation for programming and starting up an M7-400: Documentation Contents Order No. System Software for M7-300/400 Program Design Programming Manual Designing, writing and testing a C program for M7 CPU/FM modules with the M7 SYS programming package, using the M7 SYS functions 6ES7802-0FA14-0BA0 System Software for M7-300/400 System and Standard Functions Reference Manual Detailed description of the M7 SYS functions and data structures, listing of messages types System Software for M7-300/400 Installation and Operation User Manual Installing and configuring the operating system and system software Recycling and Disposal The S7-400 is environmentally friendly and can thus recyclable. Consult a certified disposal agency for electronics junk to recycle and dispose of your old equipment in an environmentally friendly manner. Further Support If you have any technical questions, please get in touch with your Siemens representative or agent responsible. http://www.siemens.de/partner Training Centers Siemens offers a number of training courses to familiarize you with the SIMATIC S7 automation system. Please contact your regional training center or our central training center in D-90327 Nuremberg, Germany for details: Telephone: +49 (911) 895-3200. Internet: http://www.sitrain.com Preface x S7-400 and M7-400 Programmable Controllers Hardware and Installation A5E00069481-04 xi S7-400 and M7-400 Programmable Controllers Hardware and Installation A5E00069481-04 Contents 1 Product Overview 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Installing the S7-400 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1 Assembling an S7-400 2-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2 Assembling the Central Rack (CR) and Expansion Rack (ER) 2-6. . . . . . . . . 2.3 Segmented CR 2-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4 Subdivided CR 2-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5 Mounting and Grounding the Racks 2-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6 Chassis Terminal Connection in the Non-Isolated Configuration 2-16. . . . . . . . 2.7 Methods of Ventilation 2-19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8 Changing the Ventilation with the Cable Duct and Fan Subassembly 2-21. . . . 2.9 Installing the Fan Subassembly 2-23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.10 Installing the Cable Duct 2-25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11 Choosing and Setting up Cabinets with the S7-400 2-26. . . . . . . . . . . . . . . . . . . 2.12 Rules for the Arrangement of Modules 2-30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.13 Fitting Memory Cards in the CPU 2-31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.14 Installing Modules in a Rack 2-33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.15 Marking the Modules with Slot Labels 2-37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.16 Methods of Expansion and Networking 2-38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.17 Accessories 2-39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Addressing the S7-400 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1 Geographical and Logical Addresses 3-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2 How to Determine the Default Address of a Module 3-4. . . . . . . . . . . . . . . . . . 3.3 How to Determine the Default Address of a Channel 3-6. . . . . . . . . . . . . . . . . . Contents xii S7-400 and M7-400 Programmable Controllers Hardware and Installation A5E00069481-04 4 Wiring the S7-400 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1 Supplying Power to Modules 4-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2 Choosing the Power Supply Module 4-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3 Choosing the Load Current Power Supply 4-4. . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4 Assembling an S7-400 with Process I/Os 4-5. . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5 Assembling an S7-400 with Grounded Reference Potential (M) 4-7. . . . . . . . 4.6 Assembling an S7-400 with Ungrounded Reference Potential (Ungrounded Configuration) 4-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.7 Assembling an S7-400 with Isolated Modules 4-10. . . . . . . . . . . . . . . . . . . . . . . . 4.8 Parallel Wiring of Digital S7-400 Outputs 4-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.9 Grounding 4-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.10 Interference-Free Configuration for Local and Remote Connections 4-15. . . . 4.11 Wiring Rules 4-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.12 Setting the VAC Power Supply Module to the Line Voltage 4-18. . . . . . . . . . . . . 4.13 Wiring the Power Supply Module 4-20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.14 Wiring the Signal Modules 4-24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.15 Wiring the Front Connector, Crimp Snap-On Terminals 4-26. . . . . . . . . . . . . . . . 4.16 Wiring the Front Connector, Screw-Type Terminals 4-27. . . . . . . . . . . . . . . . . . . 4.17 Wiring the Front Connector, Spring-Type Terminals 4-28. . . . . . . . . . . . . . . . . . . 4.18 Fitting the Strain Relief 4-30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.19 Labeling a Front Connector 4-31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.20 Fitting the Front Connector 4-35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.21 Interconnecting the CR and ER(s) 4-38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.22 Setting the Fan Subassembly to the Line Voltage and Wiring It 4-40. . . . . . . . . 4.23 Routing Cables Using Cable Ducts or Fan Subassemblies 4-42. . . . . . . . . . . . 4.24 Routing Cables Using Fiber-Optic Cables 4-42. . . . . . . . . . . . . . . . . . . . . . . . . . . Contents xv S7-400 and M7-400 Programmable Controllers Hardware and Installation A5E00069481-04 A Assembling and Installing Systems A-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.1 General Rules and Regulations for Operating the S7-400 A-2. . . . . . . . . . . . . A.2 Principles of System Installation for EMC A-5. . . . . . . . . . . . . . . . . . . . . . . . . . . A.3 Installation of Programmable Controllers for EMC A-9. . . . . . . . . . . . . . . . . . . . A.4 Examples of EMC-Compatible Assembly A-10. . . . . . . . . . . . . . . . . . . . . . . . . . . A.5 Shielding Cables A-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.6 Equipotential Bonding A-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.7 Cabling Inside Buildings A-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.8 Cabling Outside Buildings A-19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.9 Lightning Protection and Overvoltage Protection A-20. . . . . . . . . . . . . . . . . . . . . A.9.1 Lightning Protection Zone Concept A-21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.9.2 Rules for the Transition between Lightning Protection Zones 0 and 1 A-23. . . A.9.3 Rules for the Transitions between Lightning Protection Zones 1 <-> 2 and Greater A-25. . . . . . . . . . . . . . . . . . . . . . A.9.4 Sample of a Surge Protection Circuit for Networked S7-400 PLCs A-28. . . . . . A.10 How to Protect Digital Output Modules against Inductive Surge A-30. . . . . . . . A.11 Safety of Electronic Control Equipment A-32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.12 Interference-Free Connection of Monitors A-34. . . . . . . . . . . . . . . . . . . . . . . . . . . B Guidelines for Handling Electrostatically-Sensitive Devices (ESD) B-1. . . . . . . . . . B.1 What is ESD? B-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.2 Electrostatic Charging of Persons B-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.3 General Protective Measures Against Electrostatic Discharge Damage B-4. Glossary Index Contents xvi S7-400 and M7-400 Programmable Controllers Hardware and Installation A5E00069481-04 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 2-28. . . . . . . . . . . . . . . . . . . . 2-3 Fitting Memory Cards in the CPUs 2-32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 Memory Card 2-32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 Removing the Cover 2-34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 Attaching the Modules 2-35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 Screwing the Modules in Place 2-35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 Inserting the Key in the CPU 2-36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 Fitting a Slot Label 2-37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Operating the S7-400 from a Grounded Supply 4-6. . . . . . . . . . . . . . . . . . . . . . 4-2 An S7-400 Configured with Grounded Reference Potential 4-7. . . . . . . . . . . . 4-3 An S7-400 Configured with Ungrounded Reference Potential 4-8. . . . . . . . . . 4-4 Simplified Representation of Configuration with Isolated Modules 4-11. . . . . . . 4-5 Parallel Wiring of a Digital Output with Different Rated Load Voltages 4-12. . . 4-6 Parallel Wiring of a Digital Output with Identical Rated Load Voltages 4-12. . . 4-7 Grounded connection load voltage 4-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 Shielding and Grounding the Connecting Cable for a Remote Connection 4-16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9 Setting the voltage selector 4-19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 Disconnecting power supply connector 4-20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11 Wiring the power supply connector 4-22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12 Plugging the power supply connector 4-23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13 Preparing to wire the front connector 4-25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14 Wiring a Front Connector with Crimp Snap-On Terminals 4-26. . . . . . . . . . . . . . 4-15 Wiring a Front Connector with Screw-Type Terminals 4-27. . . . . . . . . . . . . . . . . 4-16 Wiring a Front Connector with Spring-Type Terminals 4-28. . . . . . . . . . . . . . . . . 4-17 Principle of the spring contact 4-29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18 Fitting a Strain Relief (Viewed from Below) 4-30. . . . . . . . . . . . . . . . . . . . . . . . . . 4-19 Fitting the Labels on the Front Connector 4-31. . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20 Fitting a Label in the Front Connector 4-32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21 Attaching the Front Connector 4-36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22 Screwing On the Front Connector 4-37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23 Plugging a Connecting Cable into a Send IM 4-38. . . . . . . . . . . . . . . . . . . . . . . . 4-24 Connection Between a Send IM and Two Receive IMs 4-39. . . . . . . . . . . . . . . . 4-25 Wiring the Fan Subassembly 4-41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 Communication between Programming Device/Operator Panel and a Module without MPI 5-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 Data Exchange 5-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 Terminating resistor on bus connector 5-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 Terminating resistor on RS 485 repeater 5-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5 Terminating resistor on MPI network 5-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 Example of an MPI network 5-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 Example of a PROFIBUS DP network 5-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8 Example with CPU 414-2 5-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9 Programming device access beyond network limits 5-14. . . . . . . . . . . . . . . . . . . 5-10 Configuration of an MPI network 5-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11 Bu s connector 5-19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12 Strip bus cable 5-20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13 Inserting cores into the screw termninal blocks 5-21. . . . . . . . . . . . . . . . . . . . . . 5-14 Switch on terminating resistant 5-22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Contents xvii S7-400 and M7-400 Programmable Controllers Hardware and Installation A5E00069481-04 5-15 Turning back braided shield over cable 5-24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16 Optical PROFIBUS-DP Network with Nodes that have an Integrated Fiber-Optic Cable Interface 5-26. . . . . . . . . . . . . . . . . . 5-17 Simplex Connectors and a Special Connector Adapter for the IM 153-2 FO and IM 467 FO (installed) 5-30. . . . . . . . . . . . . . . . . . . . . . . 6-1 Connecting PG to an S7-400 6-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 Inserting a Memory Card in a CPU 6-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3 Inserting Interface Submodules in the CPU 6-19. . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 Fitting Memory Cards in the CPUs 7-20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 Memory Card 7-21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3 Inserting an Interface Submodule in a CPU 7-23. . . . . . . . . . . . . . . . . . . . . . . . . 8-1 Fitting Memory Cards in the CPUs 8-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2 3.3 V Memory Card 8-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3 Inserting an Interface Submodule in an Expansion Module 8-14. . . . . . . . . . . . 8-4 Fitting an AT Card in the ATM 478 AT Adapter Module 8-16. . . . . . . . . . . . . . . . 8-5 Locations of the Expansion Socket and Plug 8-18. . . . . . . . . . . . . . . . . . . . . . . . 8-6 EXM 478 Expansion Module Fitted with Connecting Clips 8-19. . . . . . . . . . . . . 8-7 Removing the Cover 8-20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8 Interconnecting a CPU and Expansion Modules 8-21. . . . . . . . . . . . . . . . . . . . . 8-9 Module Assembly Comprising CPU and Expansion Modules 8-22. . . . . . . . . . . 8-10 Connecting Clip 8-23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11 Securing the Modules with Connecting Clips (Schematic Diagram) 8-23. . . . . 8-12 Attaching a Module Assembly Comprising CPU and Expansion Modules and Swinging it into Position 8-25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13 Screwing the Modules On 8-26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14 Inserting the Key in the CPU 8-27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-15 Inserting a Memory Card in a CPU 8-28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16 Example of a Configuration with the CPU in an MPI Subnet and PROFIBUS-DP Subnet 8-31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-17 Connecting a Programming Device to the M7-400 8-39. . . . . . . . . . . . . . . . . . . . 8-18 Connecting a Programming Device to Two or More M7-400s 8-41. . . . . . . . . . 8-19 Connecting a Programming Device to an M7-400 Subnet 8-42. . . . . . . . . . . . . 8-20 Ungrounded Operation of the M7-400 Network 8-43. . . . . . . . . . . . . . . . . . . . . . 8-21 Removing an Interface Submodule from the Card Slot of an Expansion Module 8-48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-22 Removing the Cover 8-49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-23 Unscrewing Modules 8-50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-24 Swinging a Module Assembly Out and Lifting it Up and Out 8-51. . . . . . . . . . . . 8-25 Module Assembly Comprising CPU and Expansion Modules 8-51. . . . . . . . . . . 8-26 Removing the Connecting Clips from the Module to be Replaced 8-52. . . . . . . 8-27 Separating the Modules, for Example When the Mass Storage Module is to be Replaced 8-53. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-28 Removing Memory Cards from the CPUs 8-55. . . . . . . . . . . . . . . . . . . . . . . . . . . 8-29 3.3 V Memory Card 8-55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-30 Removing an AT Card from the ATM 478 AT Adapter Module 8-57. . . . . . . . . . Contents xx S7-400 and M7-400 Programmable Controllers Hardware and Installation A5E00069481-04 1-1 S7-400 and M7-400 Programmable Controllers Hardware and Installation A5E00069481-04 Product Overview Overview of the S7-400 The S7-400 is a programmable controller. Almost any automation task can be implemented with a suitable choice of S7-400 components. S7-400 modules have a block design for swing-mounting in a rack. Expansion racks are available to extend the system. In this chapter, we show you the most important components with which you can assemble an S7-400. Features of the S7-400 The S7-400 programmable controller combines all the advantages of the previous system with those of a new system and new software. These are: • A graded CPU platform • Upwardly-compatible CPUs • Enclosed modules of rugged design • Convenient terminal system for the signal modules • Compact modules with a high component density • Optimum communication and networking facilities • Convenient incorporation of operator interface systems • Software parameter assignment for all modules • Extensive choice of slots • Operation without fans • Multicomputing in the non-segmented rack 1 Product Overview 1-2 S7-400 and M7-400 Programmable Controllers Hardware and Installation A5E00069481-04 Overview of the M7-400 The SIMATIC S7 programmable controller is extended by the SIMATIC M7 automation computer with its AT-compatible computer functionality. This enables the SIMATIC user to make use of the open software world, either as an extension to an S7 programmable controller or as a stand-alone M7 computer system. The entire SIMATIC S7 range of I/O devices is available to the M7 user. Features of the M7-400 The M7-400 automation computer is suitable for the following typical tasks: • Process data acquisition • Storage of large volumes of data • Control of local process I/Os • Communication • Closed-loop control, positioning, counting • Operator interface systems. It offers the following features: • Running of DOS/Windows software available on the market • Free programming (high-level language) • RMOS real-time multitasking operating system – running of real time-capable software – event-driven program processing – multitasking • A standard, short AT card can be plugged in • Multicomputing in the non-segmented rack • Full incorporation in S7-400 systems. Product Overview 1-5 S7-400 and M7-400 Programmable Controllers Hardware and Installation A5E00069481-04 Components IllustrationFunction Expansion Modules (EXMs) ... serve to accommodate three interface submodules (IFs). AT Adapter Modules (ATMs) ... provide a slot for a 16-bit AT module (up to 164 mm long). Mass Storage Modules (MSMs) ... serve to store programs and data on a hard disk (2.5”) or floppy disk (3.5”). Interface Submodules (IFs) ... for connecting I/O devices such as VGA monitor, mouse, keyboard, printer. Applicable Modules in the S7-400 Range The following modules from the S7-400 range can be used with the M7-400: • Power supply modules (PSs) • Function modules (FMs) • Signal modules (SMs) • Interface modules (IMs) • Fan subassemblies Suitable I/O Devices The following I/O devices can be connected via the appropriate interface submodules: • VGA monitor • Keyboard • Mouse • Printer • Sensors and actuators • Distributed I/Os Product Overview 1-6 S7-400 and M7-400 Programmable Controllers Hardware and Installation A5E00069481-04 Connecting the M7-400 to a Programming Device / PC For the remote setup of the M7-400, you can connect a programming device or PC to the CPU of the M7-400 via a V.24 cable. A PC/PG cable is used to connect a programming device or PC and CPU of the M7-400 via the multipoint interface (MPI). Location of Order Number and Product Version The order number and product version are printed on every module of the SIMATIC S7-400/M7-400. The firmware version is also printed on the CPUs. The following figure shows their locations on a module. For the product version, an X is entered instead of the valid number. The following figure shows a module with Product Version 1. Product version Abbreviated order number (6ES7 ...) Type label Module designation
   
 
 Firmware version (in CPUs)  Example of a Rating Plate 
   
 SIMATIC M7  Order no. Module designation X 2 3 4 5 6 7 Product version 
 
  
  8   
! Approvals and marks 2-1 S7-400 and M7-400 Programmable Controllers Hardware and Installation A5E00069481-04 Installing the S7-400 Chapter Overview Section Description Page 2.1 Assembling an S7-400 2-2 2.2 Assembling the Central Rack (CR) and Expansion Rack (ER) 2-6 2.3 Segmented CR 2-8 2.5 Mounting and Grounding the Racks 2-10 2.6 Chassis Terminal Connection in the Non-Isolated Configuration 2-16 2.7 Methods of Ventilation 2-19 2.8 Changing the Ventilation with the Cable Duct and Fan Subassembly 2-21 2.9 Installing the Fan Subassembly 2-23 2.10 Installing the Cable Duct 2-25 2.11 Choosing and Setting up Cabinets with the S7-400 2-26 2.12 Rules for the Arrangement of Modules 2-30 2.13 Fitting Memory Cards in the CPU 2-31 2.14 Installing Modules in a Rack 2-33 2.15 Marking the Modules with Slot Labels 2-37 2.16 Methods of Expansion and Networking 2-38 2.17 Accessories 2-39 2 Installing the S7-400 2-4 S7-400 and M7-400 Programmable Controllers Hardware and Installation A5E00069481-04 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 Expansion with 5 V local transfer Remote expansion IM 460-0 IM 460-1 IM 460-3 Chain length max. 3 m Chain length max. 102.25 m Chain length max. 1.5 m IM 461-0 IM 461-0 IM 461-1 IM 461-3 IM 461-3 IM 460-4 Expansion rack ER 1 Expansion rack ER 4 Chain length max. 605 m IM 461-4 IM 461-4 Installing the S7-400 2-5 S7-400 and M7-400 Programmable Controllers Hardware and Installation A5E00069481-04 Rules for Connection When you connect a central rack to expansion racks, you must observe the following rules: • You can connect up to 21 ERs of the S7-400 to one CR. • The ERs are assigned numbers to identify them. The rack number must be set on the coding switch of the receive IM. Any rack number between 1 and 21 may be assigned. Numbers must not be duplicated. • You may insert up to six send IMs in one CR. However, only two send IMs with 5 V transfer are allowed in one CR. • Each chain connected to the interface of a send IM can comprise up to four ERs (without 5 V transfer) or one ER (with 5 V transfer). • The exchange of data via the communication bus is limited to 7 racks, meaning the CR and ER numbers 1 to 6. • The maximum (total) cable lengths specified for the type of connection must not be exceeded. Type of Connection Maximum (Total) Cable Length Local connection with 5 V transfer via IM 460-1 and IM 461-1 1.5 m Local connection without 5 V transfer via IM 460-0 and IM 461-0 5 m Remote connection via IM 460-3 and IM 461-3 102.25 m Remote connection via IM 460-4 and IM 461-4 605 m Installing the S7-400 2-6 S7-400 and M7-400 Programmable Controllers Hardware and Installation A5E00069481-04 2.2 Assembling the Central Rack (CR) and Expansion Rack (ER) Function of the Racks The racks of the S7-400 system form the basic framework which accepts the individual modules. The modules exchange data and signals and are powered via the backplane bus. The racks are designed for wall mounting, for mounting on rails, and for installation in frames and cabinets. Racks in the S7-400 System Rack No. of Slots Available Buses Application Characteristics UR1 18 I/O bus CR Rack for all module types in the S7-400 and as central rack for CPUs and their UR2 9 Communication bus or ER expansion modules from the M7-400 range (see Section 8.1). ER1 18 Restricted I/O Racks for signal modules (SMs), receive IMs, and all power supply modules. The I/O bus has the following restric- tions: • Interrupts from modules have no effect because no interrupt lines exist. • Modules are not supplied with 24 V, ER2 9 bus ERs i.e. modules requiring 24 V cannot be used (see technical data of the modules). • Modules are neither backed up by the battery in the power supply module nor by the voltage applied externally to the CPU or receive IM (EXT.BATT. socket). I/O bus, segmented Segmented Rack for all module types in the S7-400 except receive IMs and for the CPUs and their expansion modules from the CR2 18 Communication bus, continuous CR M7-400 range (see Section 8.1). The I/O bus is subdivided into 2 I/O bus segments of 10 and 8 slots respectively. CR3 4 I/O bus Communication bus CR in standard systems Racks for all S7-400 module types ex- cept receive IMs. CPUs 41x-H only in stand-alone operation. UR2-H 2*9 I/O bus, segmented Communication bus, segmented Subdivided CR or ER for compact in- stallation of a fault– tolerant system Rack for all module types in the S7-400. The I/O bus and communication bus are divided into 2 bus segments, each with 9 slots. Installing the S7-400 2-9 S7-400 and M7-400 Programmable Controllers Hardware and Installation A5E00069481-04 2.4 Subdivided CR Characteristics The ”subdivided” characteristic relates to the configuration of the CR. In the (non-divided) CR the I/O bus and communication bus are continuous and interconnect all the slots; in the subdivided CR, however, the I/O bus and communication bus consist of two segments each. The UR2-H rack used here functions as two electrically isolated UR2 racks on the same rack profile. A subdivided CR has the following important characteristics: • The communication bus and I/O bus are subdivided into two segments with 9 slots each. • Each segment represents a self-contained CR. The following figure shows a divided CR with a divided I/O bus and communication bus.
      
      
      
       Division I Division II I/O bus Segment 1 I/O bus Segment 2 Communication bus Segment 1 Communication bus Segment 2 Installing the S7-400 2-10 S7-400 and M7-400 Programmable Controllers Hardware and Installation A5E00069481-04 2.5 Mounting and Grounding the Racks Important Notes on Installation The S7-400 racks are designed for wall mounting, mounting on rails, and for installation in frames and cabinets. Their mounting dimensions comply with DIN 41 494. According to the UL/CSA and the EU Directive 73/23/EEC (low-voltage directive), installation in a cabinet, a casing, or a closed operations room is necessary in order to fulfil the requirements for electrical safety (see Reference Manual, Chapter 1). In principle, the M7-400 is mounted like an S7-400 except that preassembly is required (see Section 8.4 “Installing the M7-400”). Step 1: Retaining Distances Between Devices You must observe the minimum distances between the rack and neighboring devices. You need these minimum clearances during installation and operation. • For fitting and removing modules • For fitting and disconnecting the module front connectors • To ensure the air flow required for cooling the modules during operation The following figure shows the minimum space you must provide for a rack. 20 mm 20 mm 40 mm 22 mm 522.5 mm (18 slots) 352 mm Mounting depth, fitted: max. 237 mm 40 mm facilitates the mounting of a fan subassembly * * 297.5 mm ( 9 slots)
      









 172.5 mm (4 slots) Installing the S7-400 2-11 S7-400 and M7-400 Programmable Controllers Hardware and Installation A5E00069481-04 Space Required When Using Cable Channels and Fan Subassemblies A cable duct or fan subassembly must be installed in the 19-inch pitch immediately below the rack. Additional space for cable routing must be provided on both sides. The following figure shows how much space you need to allow for when using a cable duct or fan subassembly. Cable duct/fan subassembly 440 mm Mounting depth, fitted: max. 237 mm 522.5 mm (with cable duct) 19-inch reference level 542.5 mm (with fan subassembly)
      









 Dimensions of the Racks The following figure shows the dimensions for racks with 18, 9 and 4 slots and the positions of cutouts for screw mounting. The cutouts are arranged according to the 19-inch standard. Installing the S7-400 2-14 S7-400 and M7-400 Programmable Controllers Hardware and Installation A5E00069481-04 Step 4: Mounting Additional Racks If you assemble an S7-400 with two or more racks, you must allow additional clearance between the individual racks or install a fan subassembly or cable duct. The figure below shows the clearance you must allow between two racks of the S7-400 during installation. 110 mm
      










      









 Installing the S7-400 2-15 S7-400 and M7-400 Programmable Controllers Hardware and Installation A5E00069481-04 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. Mounting depth, fitted: max. 237 mm 840 mm 19-inch reference level Cable duct/fan subassembly Cable duct/fan subassembly
      










      









 Note A minimum clearance as shown in the above figure between rack and cable duct or fan subassembly must not be provided, but is essential between two adjacent racks and between racks and other equipment. Installing the S7-400 2-16 S7-400 and M7-400 Programmable Controllers Hardware and Installation A5E00069481-04 2.6 Chassis Terminal Connection in the Non-Isolated Configuration Reference Point The racks offer the option of connecting the 24-V load voltage ground in the non-isolated configuration to the 5-V ground (reference potential M, logic ground). Connect the chassis ground to the reference point for non-isolated modules. The reference point is metallically connected to the reference potential M. Note The position of the reference point on the racks was changed in 10/99. The following figure shows the position of the reference point on a rack up until 10/99. Chassis ground terminal Reference point
      Connecting to the Reference Point until 10/99 For the connection to the reference point, use a cable lug for M4, a suitable spring washer (for example, strain washer to DIN 6796) and an M4 x 6 cylinder-head screw. Installing the S7-400 2-19 S7-400 and M7-400 Programmable Controllers Hardware and Installation A5E00069481-04 2.7 Methods of Ventilation Methods of Ventilation Under extreme ambient conditions, particularly when operating the S7-400 modules in cabinets, you can use the cable duct or fan subassembly to optimize ventilation. There are two methods of supplying air to the modules. You draw in air either from the back or from below. The cable duct and fan subassembly can be converted for this purpose. The following figure shows the ventilation when air is drawn in from the back. Exhaust air Cable duct or fan subassembly ÇÇ ÇÇ ÇÇ ÇÇ ÇÇ ÇÇ ÇÇ ÇÇ ÇÇ ÇÇ ÇÇ ÇÇ ÇÇ ÇÇ ÇÇ ÇÇ ÇÇ ÇÇ ÇÇ ÇÇ ÇÇ ÇÇ ÇÇ Exhaust air Modules Wall Modules Supply air Installing the S7-400 2-20 S7-400 and M7-400 Programmable Controllers Hardware and Installation A5E00069481-04 The following figure shows the ventilation when air is drawn in from the bottom. Ç Ç Ç Ç Ç Ç Ç Ç Ç Ç Ç Ç Ç Ç Ç Ç Ç Ç Ç Ç Ç Ç Exhaust air Wall Supply air Cable duct or fan subassembly Modules Modules Installing the S7-400 2-21 S7-400 and M7-400 Programmable Controllers Hardware and Installation A5E00069481-04 2.8 Changing the Ventilation with the Cable Duct and Fan Subassembly Changing the Ventilation At the base of the cable duct and the fan subassembly, there is a cover that you can move in order to change the air duct. To do this, proceed as follows: 1. Using a screwdriver, make a quarter turn counter-clockwise to open the two quick-release locks at the front of the cable duct or fan subassembly. 2. Grasp the base with both hands; press it gently downward and pull it fully out of the cable duct or fan subassembly. 3. The cover is secured to the base with snap catches. Press the cover from below, close to the snap catches, and remove the cover. 4. At approximately right angles to the base, insert the cover in the snap hinges at the rear edge of the base. 5. Slide the base in again and push it up. 6. Use a screwdriver to make a quarter turn clockwise and close the two quick-release locks. The following figure shows both methods of selecting the ventilation by appropriately fitting the cover in the base of the cable duct or fan subassembly. Installing the S7-400 2-24 S7-400 and M7-400 Programmable Controllers Hardware and Installation A5E00069481-04 4. Attach the dummy plates to the free slots: – Place the dummy plates on the rear wall of the cable routing, – Push the dummy plates back so that the noses of the dummy plates will fit into the cutouts provided, – Push the dummy plates in until the snap-in mechanism engages in the openings on the back of the cable routing. 5. Then install the fan assembly in the 19-inch pitch directly under the rack or between two racks. Use M6 size screws for mounting. The following figure shows how to mount the fan subassembly between two racks.



















 Blanking cover 19-inch reference level 6. Refit the left cover. 7. Secure the left cover with the quick-release lock. Monitoring the Fan Subassembly To monitor the functioning of the fan subassembly via your program, connect the outputs to a digital module. Further details on the monitoring concept can be found in the Reference Manual, Chapter 9. Installing the S7-400 2-25 S7-400 and M7-400 Programmable Controllers Hardware and Installation A5E00069481-04 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 reference level Installing the S7-400 2-26 S7-400 and M7-400 Programmable Controllers Hardware and Installation A5E00069481-04 2.11 Choosing and Setting up Cabinets with the S7-400 Why Cabinets are Required With larger installations and in an environment subject to interference or pollution, you can install the S7-400 in cabinets. The requirements of UL/CSA are met, for example, by an installation in cabinets. Types and Dimensions of Cabinets Observe the following criteria when selecting cabinet types and their dimensions: • Ambient conditions at the point of installation of the cabinet • Required clearances for the racks • Total power dissipation of components contained by the cabinet The ambient conditions at the point of installation of the cabinet (temperature, humidity, dust, effects of chemicals, explosion hazard) govern the required degree of protection of the cabinet (IP xx). Further information on degrees of protection can be found in IEC 529 and DIN 40050. Installing the S7-400 2-29 S7-400 and M7-400 Programmable Controllers Hardware and Installation A5E00069481-04 Example for Determining the Type of Cabinet The following example clarifies the maximum ambient temperature which is permissible for a particular power dissipation with various types of cabinet. The following equipment configuration is to be installed in a cabinet: 1 central rack 150 W 2 expansion racks of 150 W power dissipation each 300 W 1 load current power supply under full load 200 W Total power dissipation 650 W From Figure 2-2, with a total power dissipation of 650 W, the ambient temperatures obtained are as follows: Type of Cabinet Max. Permissible Ambient Temperature Closed, with natural convection and forced circulation (Curve 3) (no operation possible) Open, with through-ventilation (Curve 2) approx. 38° C Closed, with heat exchanger (Curve 1) approx. 45° C Dimensions of Cabinet To determine the dimensions of a cabinet suitable for assembling an S7-400, you must take the following into account: • Space requirement of the racks • Minimum clearances between racks and cabinet walls • Minimum clearances between racks • Space requirement of cable ducts or fan subassemblies • Locations of rails Installing the S7-400 2-30 S7-400 and M7-400 Programmable Controllers Hardware and Installation A5E00069481-04 2.12 Rules for the Arrangement of Modules Rules for S7-400 and M7-400 Given in this section are the rules you must observe when arranging modules in the S7-400. The rules for M7-400 modules can be found in Section 8.1 “Mechanical Configuration”. Arrangement of Modules You need observe only two rules for the arrangement of modules in a rack: • In all racks, the power supply module must always be inserted on the extreme left (beginning with slot 1). In the UR2-H from slot 1 in both segments. • The receive IM in the ER must always be inserted on the extreme right. In the UR2-H at slot 9 once per segment. Note Establish whether there are additional regulations applying to all modules not described in this manual. The following table shows which modules can be used in the different racks: Table 2-2 Modules in the different racks Modules Racks Racks UR1, UR2 UR2-H as CR UR1, UR2 as ER UR2-H as ER* CR2, CR3 ER1, ER2 Power Supply Modules      CPUs   Send IMs   Receive IMs    Signal Modules      * No IM 463–2, no adapter module, no power supply module along with the IM 461-1. Space Requirement of the Racks In the S7-400 system, there are modules occupying one, two, or three slots (width 25, 50, or 75 mm). Refer to the technical specifications of the module under the keyword “dimensions” to see how many slots a module occupies. The mounting depth of a rack fitted with modules is 237 mm maximum. Installing the S7-400 2-31 S7-400 and M7-400 Programmable Controllers Hardware and Installation A5E00069481-04 2.13 Fitting Memory Cards in the CPU Memory Expansion With the CPU 417-4 and CPU 417-4 H you can expand the work memory with memory submodules. The following points are important: 1. If only one submodule is inserted, l must be in slot 1. 2. You may only insert a second submodule if a 4 Mbyte-submodule is inserted in slot 1. The following combinations are then possible: Slot 1 Slot 2 2 Mbytes - 4 Mbytes - 4 Mbytes 2 Mbytes 4 Mbytes 4 Mbytes Note Only use the memory cards intended for the particular CPU. ! Warning The modules can be damaged. Failure to observe ESD guidelines can result in damage to both the CPU and memory cards. Observe the ESD guidelines when fitting memory cards. Fitting Memory Cards in the CPU Proceed as follows: 1. Remove the cover from the left side of the CPU by loosening the three screws. 2. Push the first memory card down through an angle of approximately 45o into slot 1 (see Figure 2-3). Note the cutout at the front of the card (polarity reversal protection). 3. Push the memory card down until the tabs in the slot slide into the corresponding cutouts on the side of the card. Make sure that the metal flag at the end of the card lies on the metal edge of the module. 4. If necessary, insert the second memory card in slot 2 in the same way (see Figure 2-3). Installing the S7-400 2-34 S7-400 and M7-400 Programmable Controllers Hardware and Installation A5E00069481-04 5. Tighten the module screws top and bottom with a torque of 0.8 to 1.1 Nm (see Figure 2-7). Triple-width modules are secured with two screws at the top and at the bottom. 6. Refit the module cover, if applicable. 7. Fit the remaining modules in the same way. 8. Insert the key into the keyswitch in the CPU when you have installed all the modules (see Figure 2-8). The individual steps for installation are explained in the following. The method of removing modules is described in Chapter 7. Removing the Cover With modules which have a cover (for example, power supply modules and CPUs), you remove this before installing the module in the rack. Proceed as follows: 1. Press the locking lever down (1). 2. Swing the cover forward and off (2). (2) (1) Figure 2-5 Removing the Cover Installing the S7-400 2-35 S7-400 and M7-400 Programmable Controllers Hardware and Installation A5E00069481-04 Attaching the Modules Attach the modules one by one (1) and swing them carefully downwards (2). If you feel a resistance when swinging the module down, raise it slightly and then continue. (1) (2) Figure 2-6 Attaching the Modules Screwing the Modules in Place Tightening torque 0.8 to 1.1 Nm Figure 2-7 Screwing the Modules in Place Installing the S7-400 2-36 S7-400 and M7-400 Programmable Controllers Hardware and Installation A5E00069481-04 Inserting the Keyswitch You can insert the key in the CPU in the STOP position of the switch. You can remove the key in the STOP or RUN settings. Figure 2-8 Inserting the Key in the CPU Installing the S7-400 2-39 S7-400 and M7-400 Programmable Controllers Hardware and Installation A5E00069481-04 2.17 Accessories Accessories Some of the accessories needed for fitting the modules in the rack are provided in the packaging of the modules and racks. The front connectors of the signal modules must always be ordered separately. There are also optional accessories for some modules. The accessories for modules and racks are listed and briefly explained in Table 2-3. A list of spare parts for SIMATIC S7 can be found in the Reference Manual, Appendix C as well as in the current ST 70 catalog. The accessories for installing the M7-400 can be found in Section 8.4. Table 2-3 Accessories for Modules and Racks Module Accessories Supplied Accessories Not Supplied Purpose of the Accessory Rack (UR, CR, ER) Number wheel with slot labels - For identifying the modules with slot labels Power Supply Module (PS) - 1 or 2 backup batte- ries For central backup of RAM areas in the CPU CPU 2 keys - To operate the mode selector of the CPU - Memory cards Load memories required for the CPU Signal Module (SM) 2 labels Plate with pinout - - For labeling the inputs and outputs on the front connector To identify the pinout of the front connectors - Front connector with strain relief for screw, crimp or spring-type terminal For wiring the SMs - - - Extraction tool (for crimp terminals) Crimp contacts Crimping tool For rewiring SMs with a front connector with crimp terminals Installing the S7-400 2-40 S7-400 and M7-400 Programmable Controllers Hardware and Installation A5E00069481-04 3-1 S7-400 and M7-400 Programmable Controllers Hardware and Installation A5E00069481-04 Addressing the S7-400 Chapter Overview Section Description Page 3.1 Geographical and Logical Addresses 3-2 3.2 How to Determine the Default Address of a Module 3-4 3.3 How to Determine the Default Address of a Channel 3-6 3 Addressing the S7-400 3-4 S7-400 and M7-400 Programmable Controllers Hardware and Installation A5E00069481-04 3.2 How to Determine the Default Address of a Module Default Addressing You determine the default address of a module from the number of the slot of the module in the CR. The algorithms used to calculate the default address are different for analog and digital modules. The following figure shows the numbering of slots in a rack with 18 slots. You can also read off the slot numbers directly from the rack.
      










      









 Default Addresses of Digital Modules On the S7-400, the default addresses for digital modules start from 0 (First slot in the central rack which is usually occupied by the power supply module) up to 68 (18th slot). The algorithm used to calculate the default address of a digital module is: Default address = (slot number - 1) x 4 Example The default address of a digital module in the 12th slot is as follows: Default address = (12 - 1) x 4 = 44 Addressing the S7-400 3-5 S7-400 and M7-400 Programmable Controllers Hardware and Installation A5E00069481-04 Default Addresses of Analog Modules On the S7-400, the default addresses for analog modules start from 512 (first slot in the central rack which is usually occupied by the power supply module) up to 1600. The algorithm used to calculate the default address of an analog module is: Default address = (slot number - 1) x 64 + 512 Example The default address of an analog module in the 6th slot is as follows: Default address = (6 - 1) x 64 + 512 = 832 Addressing the S7-400 3-6 S7-400 and M7-400 Programmable Controllers Hardware and Installation A5E00069481-04 3.3 How to Determine the Default Address of a Channel Channel on a Digital Module A channel on a digital module is addressed bit-wise. For a digital input module with 32 inputs, four bytes (starting with the default address of the module) are used to address the inputs, and for a digital input module with 16 inputs, two bytes are used. Bits 0 to 7 in these bytes are then reserved by the individual inputs (from top to bottom). This is clarified by the following figure with the example of a digital input module with 32 channels at slot 12 (default address 44). With a digital output module, the first character is a Q instead of an I. I 44.0 I 44.1 I 44.2 I 44.3 I 44.4 I 44.5 I 44.6 I 44.7 I 45.0 I 45.1 I 45.2 I 45.3 I 45.4 I 45.5 I 45.6 I 45.7 I 46.0 I 46.1 I 46.2 I 46.3 I 46.4 I 46.5 I 46.6 I 46.7 I 47.0 I 47.1 I 47.2 I 47.3 I 47.4 I 47.5 I 47.6 I 47.7 Channel addresses 4-1 S7-400 and M7-400 Programmable Controllers Hardware and Installation A5E00069481-04 Wiring the S7-400 Chapter Overview Section Description Page 4.1 Supplying Power to Modules 4-2 4.2 Choosing the Power Supply Module 4-3 4.3 Choosing the Load Current Power Supply 4-4 4.4 Assembling an S7-400 with Process I/Os 4-5 4.5 Assembling an S7-400 with Grounded Reference Potential (M) 4-8 4.6 Assembling an S7-400 with Ungrounded Reference Potential (Ungrounded Configuration) 4-9 4.7 Assembling an S7-400 with Isolated Modules 4-11 4.8 Parallel Wiring of Digital S7-400 Outputs 4-13 4.9 Grounding 4-14 4.10 Interference-Free Configuration for Local and Remote Connections 4-16 4.11 Wiring Rules 4-18 4.12 Setting the VAC Power Supply Module to the Line Voltage 4-19 4.13 Wiring the Power Supply Module 4-21 4.14 Wiring the Signal Modules 4-25 4.15 Wiring the Front Connector, Crimp Snap-On Terminals 4-27 4.16 Wiring the Front Connector, Screw-Type Terminals 4-28 4.17 Wiring the Front Connector, Spring-Type Terminals 4-29 4.18 Fitting the Strain Relief 4-31 4.19 Labeling a Front Connector 4-32 4.20 Fitting the Front Connector 4-36 4.21 Interconnecting the CR and ER(s) 4-39 4.22 Setting the Fan Subassembly to the Line Voltage and Wiring It 4-41 4.23 Routing Cables Using Cable Ducts or Fan Subassemblies 4-43 4.24 Routing Cables Using Fiber-Optic Cables 4-43 4 Wiring the S7-400 4-2 S7-400 and M7-400 Programmable Controllers Hardware and Installation A5E00069481-04 4.1 Supplying Power to Modules Power Supply Modules and Load Current Power Supplies The modules of the S7-400 system are supplied with all the required operating voltages by a power supply module, via the backplane bus of the rack. Which power supply module you use in a rack depends on your system requirements (line voltage, current consumption of the modules used). You must provide load voltages and currents via external load current power supplies. The following figure shows how the individual modules of the S7-400 are supplied with current and voltage. S7-400 power supply module S7-400 modules (DC or AC) Operating voltages 5 VDC and 24 VDC via backplane bus Load current via front connector Load current power supply Line voltage: 120/230 VAC with supply isolator or 24 VDC Note The power supply modules must not be connected in parallel on their secondary sides. Wiring the S7-400 4-3 S7-400 and M7-400 Programmable Controllers Hardware and Installation A5E00069481-04 4.2 Choosing the Power Supply Module Estimating the Power Requirement You should make an estimate of the power requirement for each rack of your S7-400 system in order to select the appropriate power supply module for the rack. Selection of the power supply for an M7-400 configuration is described separately in Section 8.3 “Electrical Configuration.” Current consumption and power dissipation of the individual modules can be found in the relevant data sheets. Calculation Example The following modules are to be fitted in a CR with 18 slots: • 1 CPU 414-1 • 3 analog input modules SM 431, AI 16 x 16 bits • 5 digital input modules SM 421;DI 32 x 24 VDC • 6 digital input modules SM 422;DO 32 x 24 VDC/0.5A • 1 send IM, IM 460-0 You can calculate Current Consumption I in this rack as follows, with the data from the individual data sheets: Module Quantity +5 VDC (Max. Current Consumption Values) I / Module I Total CPU 414-1 1 1800 mA 1800 mA SM 431; AI 16 x 16 bits 3 700 mA 2100 mA SM 421;DI 32 x 24 VDC 5 30 mA 150 mA SM 422;DO 32 x 24 VDC/0.5A 6 200 mA 1200 mA IM 460-0 1 140 mA 140 mA Total 5390 mA From the data in the table, you can see that you must install a power supply module PS 407 10A (for connection to 120/230 VAC) or PS 405 10A (for connection to 24 VDC) in the rack, to cover the current consumption calculated here. Note If you wish to connect an ER to the CR via a send IM with current transfer, you must also take the current consumption of this ER into account when choosing the power supply module. Wiring the S7-400 4-6 S7-400 and M7-400 Programmable Controllers Hardware and Installation A5E00069481-04 Table 4-1 VDE Specifications for Assembling a Programmable Controller Compare ... Ref. to Figure 4-1 VDE 0100 VDE 0113 Disconnection element for control system, sensors, and actuators  ... Part 460: Main switches ... Part 1: Isolating switches Short-circuit and overload protection: in groups for sensors and actuators  ... Part 725: Single-pole protection of circuits ... Part 1: • With grounded secondary circuit: single-pole protection • Otherwise: all-pole protection Load current PS for AC power circuits with more than five items of electromagnetic apparatus  Isolation by transformer is recommended Isolation by transformer is required Rule: Grounding the Load Current Circuits Load current circuits should be grounded. Reliable functional safety is provided by the common reference potential (ground). Provide a detachable connection to the protective ground conductor at the load current power supply (Terminal L- or M) or on the isolating transformer (Figure 4-1, ). In the event of faults in the power distribution, this will facilitate the locating of ground faults. Wiring the S7-400 4-7 S7-400 and M7-400 Programmable Controllers Hardware and Installation A5E00069481-04 S7-400 in the Overall Installation Shown in Figure 4-1 is the position of the S7-400 in the overall installation (load current power supply and grounding concept) with supply from a TN-S system. Note: The arrangement of supply terminals shown is not the actual arrangement; it has been chosen for reasons of clarity. Ground bus in cabinet N L1 L + M PS CPU L1 L2 L3 N  Load circuit 24 to 230 VAC for AC modules Load circuit 5 to 60 VDC for isolated DC modules Cabinet AC AC  AC DC  Signal modules Low-voltage distribution e.g. TN-S system (3 x 400 V) PE  SM Racks P E Data   Figure 4-1 Operating the S7-400 from a Grounded Supply Wiring the S7-400 4-8 S7-400 and M7-400 Programmable Controllers Hardware and Installation A5E00069481-04 4.5 Assembling an S7-400 with Grounded Reference Potential (M) Application You use an S7-400 with grounded reference potential in machines or industrial plants. Discharge of Interference Currents When the S7-400 is configured with a grounded reference potential, any interference currents are discharged to the chassis ground. Terminal Connection Model When delivered, the racks have a detachable metallic connection between the internal reference potential M of the modules and the frame element of the racks. Situated behind this connection is an RC network which is placed in the circuit for the ungrounded configuration. This connection is located at the left edge of the rack. The terminal for the chassis ground also has an electrical connection to the frame element. Shown in Figure 4-2 is an S7-400 configured with grounded reference potential. To ground the reference potential M, you must connect the chassis ground terminal to the chassis ground and you must not remove the jumper between reference potential M and the frame element terminal on the rack. Metallic connection Frame element terminal Chassis ground terminal RC network M 6.8 nF 10 MΩ Detachable jumper Reference potential M Figure 4-2 An S7-400 Configured with Grounded Reference Potential Wiring the S7-400 4-11 S7-400 and M7-400 Programmable Controllers Hardware and Installation A5E00069481-04 4.7 Assembling an S7-400 with Isolated Modules Definition In a configuration with isolated modules, the reference potentials of the control circuit (Minternal) and the load circuit (Mexternal) are isolated (see also Figure 4-4). Application Isolated modules are used for: • All AC load circuits • DC load circuits with a separate reference potential Examples of load circuits with a separate reference potential: – DC load circuits whose sensors have different reference potentials (for example, when grounded sensors are used far from the programmable controller and equipotential bonding is not possible). – DC load circuits whose positive terminal (L+) is grounded (battery circuits). Isolated Modules and Grounding Concept You can use isolated modules, regardless of whether or not the reference potential of the programmable controller is grounded. Wiring the S7-400 4-12 S7-400 and M7-400 Programmable Controllers Hardware and Installation A5E00069481-04 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 24 VDC load current PS Mexternal L + Uinternal Reference potential M Data L1 N DI DO PE 230 VAC load current PS Ground bus in cabinet Racks Figure 4-4 Simplified Representation of Configuration with Isolated Modules Wiring the S7-400 4-13 S7-400 and M7-400 Programmable Controllers Hardware and Installation A5E00069481-04 4.8 Parallel Wiring of Digital S7-400 Outputs Parallel Wiring of a Digital Output with Different Rated Load Voltages The parallel wiring of a digital output (rated load voltage 1L+) with another digital output (rated load voltage 2L+) or a rated load voltage 3L+ is only possible using series diodes. 1 L+ 2 L+ 3 L+ Figure 4-5 Parallel Wiring of a Digital Output with Different Rated Load Voltages Parallel Wiring of a Digital Output with Identical Rated Load Voltages If the L+ supplies of the digital output modules and the L+ voltage connected in parallel to the output are always the same (difference < 0.5 V), there is no need to use diodes, see figure 4-6. L+ Figure 4-6 Parallel Wiring of a Digital Output with Identical Rated Load Voltages Wiring the S7-400 4-16 S7-400 and M7-400 Programmable Controllers Hardware and Installation A5E00069481-04 4.10 Interference-Free Configuration for Local and Remote Connections Use only Approved Components Note If you use components which are not approved for setting up local and remote connections, interference rejection may be impaired. Interference-Free Configuration for Local Connections If you connect the CR and ER via suitable interface modules (send IM and receive IM), no particular shielding and grounding need be implemented. Ensure, however, that • All racks have a low-impedance connection to each other • The racks in a grounded arrangement have a star grounding configuration • The contact springs of the racks are clean and not bent and will therefore ensure the discharge of interference currents. Wiring the S7-400 4-17 S7-400 and M7-400 Programmable Controllers Hardware and Installation A5E00069481-04 Interference-Free Configuration for Remote Connections If you connect the CR and ER via suitable interface modules (send IM and receive IM), normally no particular shielding and grounding need be implemented. Special shielding and grounding may become necessary if you operate your system in an environment with an extremely high level of interference. In that case, observe the following points: • In the cabinet, connect the cable shields to the shield bus immediately after entry. – Strip the outer cable insulation in the region of the shield bus without damaging the braided shield. – Ensure that the braided shield has the greatest possible contact area on the shield bus, for example, with metal hose clamps surrounding the shield over a large area. • Connect the shield bus(es) over a large area to the frame or cabinet wall. • Connect the shield bus(es) to the chassis ground. In a remote connection, ensure that the VDE regulations for laying the protective ground are not infringed. Figure 4-8 shows the methods described here. If the permissible potential difference between grounding points is exceeded, you must install an equipotential bonding conductor (copper conductor with a cross-section of  16 mm2). CR ER Send IM Receive IM Î Î Î ÎÎ ÎÎ ÎÎ Shield/ protective ground bar < 7 V Figure 4-8 Shielding and Grounding the Connecting Cable for a Remote Connection Special Cases For remote connections, you must use precut/preassembled connecting cables of fixed length. When the connecting cables are laid, therefore, there may be excess lengths. These must be coiled with a bifilar winding and deposited. Wiring the S7-400 4-18 S7-400 and M7-400 Programmable Controllers Hardware and Installation A5E00069481-04 4.11 Wiring Rules Lines and Tools For wiring the S7-400 modules, there are some rules for the cables and for the tool you use. Information on connecting an M7-400 module assembly can be found in Section 8.5. Rules for ... Power Supply ... Front Connectors Crimp terminal Screw-type terminal Spring-type terminal Conductor cross-sections: Outer diameter: 3 to 9 mm Flexible cond. without wire end ferrule no 0.5 to 1.5 mm2 0.25 to 2.5 mm2 0.08 to 2.5 mm2 Flexible cond. with wire end ferrule 230 VAC: flexible sheathed cable 3  1.5 mm2 24 VDC: flexible sheathed cable 3  1.5 mm2 or individual wires 1.5 mm2 no 0.25 to 1.5 mm2 0.25 to 1.5 mm2 No. of conductors per terminal 1 1 1 * 1 * Stripping length of single conductors 7 mm 5 mm 8 to 10 mm without ferrule 10 mm with ferrule 8 to 10 mm without ferrule 10 mm with ferrule Wire end ferrules 230 VAC: with insulating collar to DIN 46228 E1,5-8 24 VDC: without insulating collar to DIN 46228, shape A, short version - with or without insulating collar to DIN 46228 Part 1 or 4, Shape A, normal version with or without insulating collar to DIN 46228 Part 1 or 4, Shape A, normal version Blade width and shape of the screw driver 3.5 mm (cylindrical shape) - 3.5 mm (cylindrical shape) 0.5 mm x 3.5 mm DIN 5264 Tightening torque: for connecting conductors 0.6 to 0.8 Nm - 0.6 to 0.8 Nm - * You can also connect a combination of two conductors of up to 1.0 mm each to a screw-type or spring-type terminal. You must use special wire end ferrules for this purpose. Two types and manufacturers of such ferrules are given below: • Phoenix TWIN Type no. 32 00 81 0, for 2 x 1 mm2 • AMP Order no. 966 144-4, for 2 x 1 mm2 Wiring the S7-400 4-21 S7-400 and M7-400 Programmable Controllers Hardware and Installation A5E00069481-04 4.13 Wiring the Power Supply Module Power Supply Connector You use the power supply connector to connect a power supply module to your supply. When delivered, the power supply connector is plugged into the power supply module. There are two versions (AC and DC) of power supply connector. The two versions are coded, meaning an AC connector can only be plugged into an AC power supply module, and a DC connector can only be plugged into a DC power supply module. Disconnecting the Power Supply Connector Before wiring, you must unplug the power supply connector from the power supply module. 1. Open the cover of the power supply module. 2. Detach the connector by levering it off with a suitable tool, for example, a screwdriver, at the opening provided (1). 3. Pull the connector forward and out of the power supply module (2). (1) (2) Figure 4-10 Disconnecting power supply connector Wiring the S7-400 4-22 S7-400 and M7-400 Programmable Controllers Hardware and Installation A5E00069481-04 Wiring the Power Supply Connector To wire the power supply connector, follow the steps outlined below: ! Warning There is a risk of personal injury. If you wire the connector with voltage applied, you may suffer a shock and personal injury. Only wire the connector with power disconnected. 1. Switch off the line voltage at your VAC supply disconnector. Note The standby switch of the power supply module does not disconnect the power supply module from the supply. 2. Are you using a flexible sheathed cable with outer insulation (with 230 VAC)? If so: Strip the outer insulation over a length of 70 mm. Note that an overall cable diameter of between 3 mm and 9 mm must be present under the strain relief after connection. If not: Wrap the cores with insulating tape so that an overall cable diameter of between 3 mm and 9 mm will be present under the strain relief after connection. As an alternative to insulating tape, you can use a shrink-on sleeve. 3. Shorten the two cores which are not needed for connection to protective ground (PE) by 10 mm. 4. Strip the cores over a length of 7 mm. 5. Slacken the screw in the cover of the power supply connector and open the connector. Wiring the S7-400 4-23 S7-400 and M7-400 Programmable Controllers Hardware and Installation A5E00069481-04 6. Slacken the screw of the strain relief and insert the cable. 7. Connect the cores according to the illustration on the cover of the power supply connector. Connect the longer core to PE. Screw on the cores with a torque of 0.6 to 0.8 Nm. DCAC L+L1 N PE PE L– Terminals Cable Strain-relief assembly Screw for the strain- relief assembly Figure 4-11 Wiring the power supply connector 8. Tighten the screw of the strain relief, so that the cable is secured properly. 9. Close the power supply connector and screw on the cover. ! Caution The power supply module or power supply connector can be damaged. If you plug in or disconnect the connector with voltage applied, the power supply module or the connector may be damaged. Only plug in or disconnect the power supply connector with power removed.