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Siemens SIMATIC S7-400 Installation Manual

Automation system, hardware and installation.
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SIMATIC
Automation System S7-400
Hardware and Installation
Installation Manual
This manual is part of the documentation
package with the order number
6ES7498-8AA05-8BA0
11/2006
A5E00850741-01
Preface, Contents
Product Overview
Installing the S7-400
Addressing the S7-400
Wiring the S7-400
Networking
Commissioning
Maintenance
Appendices
Assembling and
Installing Systems
Guidelines for Handling Electro-
statically-Sensitive Devices (ESD)
Glossary, Index
1
2
3
4
5
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7
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   Summary of Contents for Siemens SIMATIC S7-400

  • Page 1 Preface, Contents SIMATIC Product Overview Automation System S7-400 Installing the S7-400 Hardware and Installation Addressing the S7-400 Installation Manual Wiring the S7-400 Networking Commissioning Maintenance Appendices Assembling and Installing Systems Guidelines for Handling Electro- statically-Sensitive Devices (ESD) Glossary, Index This manual is part of the documentation...
  • Page 2 Trademarks All names identified by ® are registered trademarks of the Siemens AG. The remaining trademarks in this publication may be trademarks whose use by third parties for their own purposes could violate the rights of the owner.
  • Page 3: Automation System S7

    S7-400. How to configure, assemble and wire these modules (and other) in an S7-400 system is described in the installation manuals for each system.
  • Page 4: Recycling And Disposal

    Recycling and Disposal The S7-400 is low in contaminants and can therefore be recycled. To recycle and dispose of your old device in an environment-friendly manner, please contact a disposal company certified for disposal of electronic waste.
  • Page 5: Technical Support

    • A forum, where users and experts from all over the world exchange their experiences. • Your local representative for Automation & Drives. • Information on field service, repairs, spare parts and more under “Services”. Automation System S7-400 Hardware and Installation A5E00850741-01...
  • Page 6 Preface Automation System S7-400 Hardware and Installation A5E00850741-01...
  • Page 7: Table Of Contents

    ......... 2-24 2.11 Choosing and Setting up Cabinets with the S7-400 ....2-25 2.12...
  • Page 8 ..... . Connecting a Programming Device (PG) to an S7-400 ....
  • Page 9 ........... . A-25 A.9.4 Sample of a Surge Protection Circuit for Networked S7-400 PLCs ..A-28 A.10...
  • Page 10 Contents Figures Rack Fitted with Modules in the S7-400 System ..... Max. Cabinet Ambient Temperature as a Function of Power Dissipation of Equipment in the Cabinet .
  • Page 11 A-10 Wall Mounting an S7-400 for EMC ....... . .
  • Page 12 ......... . . A-29 Automation System S7-400 Hardware and Installation A5E00850741-01...
  • Page 13: Product Overview

    Product Overview Overview of the S7-400 The S7-400 is a programmable logic controller. Almost any automation task can be implemented with a suitable choice of S7-400 components. S7-400 modules have a block design for swing-mounting in a rack. Expansion racks are available to extend the system.
  • Page 14 Product Overview S7-400 components The most important components of the S7-400 and their functions are given in the following tables: Components Function Illustration Racks ... provide the mechanical and (UR: Universal Rack) electrical connections between (CR: Central Rack) the S7-400 modules.
  • Page 15 Location of the order number and product version The order number and product version are printed on every module of the SIMATIC S7-400. The firmware version is also printed on the CPUs. The following figure shows their locations on a module.
  • Page 16 Product Overview Example of a rating plate Order no. Module designation Product version Approvals and marks Automation System S7-400 Hardware and Installation A5E00850741-01...
  • Page 17: Installing The S7-400

    Changing the Ventilation with the Cable Duct and Fan Subassembly 2-20 Installing the Fan Subassembly 2-22 2.10 Installing the Cable Duct 2-24 2.11 Choosing and Setting up Cabinets with the S7-400 2-25 2.12 Rules for the Arrangement of Modules 2-29 2.13 Installing Modules in a Rack 2-30 2.14...
  • Page 18: S7-400 Installation

    S7-400 Installation Introduction An S7-400 programmable controller consists of a central rack (CR) and one or more expansion racks (ERs), as required. You can add ERs to compensate for lack of slots for your application or operate signal modules at remote locations (e.g. in the immediate vicinity of your process).
  • Page 19 Receive IM 461-0 461-1 461-3 461-4 Max. number of connectable EMs per chain Max. distance 1.5 m 102.25 m 605 m 5 V transfer Max. current transfer per inter- face Communication bus transmission Automation System S7-400 Hardware and Installation A5E00850741-01...
  • Page 20 Expansion rack ER 4 Expansion rack ER 1 IM 461-3 IM 461-3 Chain length max. 102.25 m Expansion rack ER 4 Expansion rack ER 1 IM 461-4 IM 461-4 Chain length max. 605 m Automation System S7-400 Hardware and Installation A5E00850741-01...
  • Page 21 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.
  • Page 22: Installing The Central Rack (cr) And Expansion Rack (er)

    (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.
  • Page 23 The following figure shows a rack with an I/O bus and a communication bus. The I/O bus connector and communication bus connector can be seen at each slot. When the rack is delivered, these connectors are protected by a cover. I/O bus connector Communication bus connector Automation System S7-400 Hardware and Installation A5E00850741-01...
  • Page 24: Segmented Cr

    The following figure shows a segmented CR with divided I/O bus and continuous communication bus. SEG1 SEG2 SEG1 SEG1 SEG1 SEG1 SEG1 SEG1 SEG1 SEG1 SEG1 SEG1 SEG2 SEG2 SEG2 SEG2 SEG2 SEG2 SEG2 SEG2 I/O bus I/O bus Segment 1 Segment 2 Communication bus Automation System S7-400 Hardware and Installation A5E00850741-01...
  • Page 25: Subdivided Cr

    The following figure shows a divided CR with a divided I/O bus and communication bus. Division I Division II I/O bus I/O bus Segment 1 Segment 2 Communication bus Communication bus Segment 2 Segment 1 Automation System S7-400 Hardware and Installation A5E00850741-01...
  • Page 26: Mounting And Grounding The Racks

    Installing the S7-400 Mounting and Grounding the Racks Important Notes on Installation The S7-400 racks are designed for wall mounting, mounting on rails, and for installation in frames and cabinets. Their mounting dimensions are compliant with DIN 41 494. According to the 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).
  • Page 27 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. Automation System S7-400 Hardware and Installation 2-11 A5E00850741-01...
  • Page 28 On varnished or anodized metals, for example, wlayws use a suitable contact agent or special contact washers. Special measures need not be taken if you do not use this type of panel. Automation System S7-400 Hardware and Installation 2-12 A5E00850741-01...
  • Page 29: Mounting Screws

    Connect the rack to the chassis ground. A threaded bolt is provided for this purpose on the bottom left of the rack. Minimum cross-section of the conductor to the chassis ground: 10 mm If the S7-400 is mounted on a mobile rack, you must provide a flexible conductor to the chassis ground. Note Always ensure that there is a low-impedance connection to the chassis ground (see the figure below).
  • Page 30 Installing the S7-400 Step 4: Mounting Additional Racks For S7-400 assemblies containing two or more racks, make allowances for additional clearance between the racks for installing a fan subassembly or cable duct. The figure below shows the clearance you must allow between two racks of the S7-400 during installation.
  • Page 31 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.
  • Page 32: Chassis Terminal Connection In The Non-isolated Configuration

    M. The following figure shows the position of the reference point on a rack. Metallic connection, disconnect upper screw for ungrounded assemblies Load voltage ground connection (reference point) Grounding terminal Automation System S7-400 Hardware and Installation 2-16 A5E00850741-01...
  • Page 33 For this reason as well, leave the metallic connection on the rack and use it as a washer in an ungrounded configuration. Automation System S7-400 Hardware and Installation 2-17 A5E00850741-01...
  • Page 34: Methods Of Ventilation

    Methods of Ventilation Methods of Ventilation Under extreme ambient conditions, particularly when operating S7-400 modules in cabinets, you can use the cable duct or fan subassembly to optimize ventilation. There are two methods of supplying air to the modules. You draw in air either from the back or from below.
  • Page 35 Installing the S7-400 The following figure shows the ventilation when air is drawn in from the bottom. Exhaust air Wall Modules Cable duct or fan subassembly Modules Supply air Automation System S7-400 Hardware and Installation 2-19 A5E00850741-01...
  • Page 36: Changing The Ventilation With The Cable Duct And Fan Subassembly

    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. Automation System S7-400 Hardware and Installation 2-20 A5E00850741-01...
  • Page 37 The filter mat is optional and is not part of the cable duct or fan subassembly. Like the cover, the filter mat can be inserted flat in the base or at its rear edge in the corresponding snap hinges or quick-release locks. Automation System S7-400 Hardware and Installation 2-21 A5E00850741-01...
  • Page 38: Installing The Fan Subassembly

    2. Remove the dummy plates which are not required by slackening the snap-in mechanisms of the covers and pulling them off. 3. Break off as many dummy plates as required. Automation System S7-400 Hardware and Installation 2-22 A5E00850741-01...
  • Page 39 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. Automation System S7-400 Hardware and Installation 2-23 A5E00850741-01...
  • Page 40: Installing The Cable Duct

    Use M6 size screws for mounting. The following figure shows how to mount the cable duct between two racks. 12 13 14 15 17 18 12 13 14 15 17 18 19-inch reference level Automation System S7-400 Hardware and Installation 2-24 A5E00850741-01...
  • Page 41: 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: •...
  • Page 42: Cabinet Types

    700 W up to 2700 W up to 260 W up to 360 W up to 1700 W (1400 W with very fine filter) Automation System S7-400 Hardware and Installation 2-26 A5E00850741-01...
  • Page 43: Max. Cabinet Ambient Temperature As A Function Of Power Dissipation

    600 x 600 x 2000 mm as a function of power dissipation. These values only apply if you observe the specified installation dimensions and clearances for racks. Further information can be found in Siemens catalogs NV21 and ET1.
  • Page 44: Cabinet Dimensions

    38° C Closed, with heat exchanger (Curve 1) approx. 45° C Cabinet dimensions Vital dimensional design factors for an S7-400 cabinet • Space requirement of the racks • Minimum clearance between racks and cabinet walls • Minimum clearance between racks •...
  • Page 45: Rules For The Arrangement Of 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”...
  • Page 46: Installing Modules In A Rack

    6. Refit the module cover, if applicable. 7. Fit the remaining modules in the same way. The individual steps for installation are explained below. The method of removing modules is described in Chapter 7. Automation System S7-400 Hardware and Installation 2-30 A5E00850741-01...
  • Page 47: Removing The Cover

    Proceed as follows: 1. Push the interlock lever down (1). 2. Swing the cover forward and off (2). Figure 2-3 Removing the Cover Automation System S7-400 Hardware and Installation 2-31 A5E00850741-01...
  • Page 48: Attaching The Modules

    Figure 2-4 Attaching the Modules Screwing the Modules in Place Tightening torque 0.8 to 1.1 Nm Figure 2-5 Screwing the Modules in Place Automation System S7-400 Hardware and Installation 2-32 A5E00850741-01...
  • Page 49: Marking The Modules With Slot Labels

    2. Use your finger to press the slot label into the module. The label will break away from the “number wheel”. Figure 2-6 Fitting a Slot Label Automation System S7-400 Hardware and Installation 2-33 A5E00850741-01...
  • Page 50: Methods Of Expansion And Networking

    Apart from the structures mentioned in this chapter, other expansions are possible, for example, by connecting distributed I/Os or by networking. Distributed I/Os When an S7-400 is configured with a distributed I/O system, the inputs/outputs operate in a distributed local arrangement and are directly connected via PROFIBUS DP to a CPU.
  • Page 51: Accessories

    Front connector with For wiring the SMs strain relief for screw, crimp or spring-type terminal Extraction tool (for For rewiring SMs with a front crimp terminals) connector with crimp terminals Crimp contacts Crimping tool Automation System S7-400 Hardware and Installation 2-35 A5E00850741-01...
  • Page 52 Installing the S7-400 Automation System S7-400 Hardware and Installation 2-36 A5E00850741-01...
  • Page 53: Addressing The S7-400

    Addressing the S7-400 Chapter Overview Section Description Page Geographical and Logical Addresses How to Determine the Default Address of a Module How to Determine the Default Address of a Channel Automation System S7-400 Hardware and Installation A5E00850741-01...
  • Page 54: Geographical And Logical Addresses

    • Assign a logical address to the geographical address under STEP 7. This logical address is used for addressing the channel in the user program. Note If your S7-400 comprises only a CR without ER, you can also use default addressing. Automation System S7-400 Hardware and Installation...
  • Page 55: Default Addressing

    • If modules are inserted in STOP mode or during power off (modules inserted while the system is in RUN or during a RUN → STOP → RUN transition will be ignored) Automation System S7-400 Hardware and Installation A5E00850741-01...
  • Page 56: How To Determine The Default Address Of A Module

    9 10 11 12 13 14 15 16 17 18 Default Addresses of Digital Modules On the S7-400, the default addresses for digital modules start from 0 (First slot in the central rack which is usually occupied by the power supply module) up to 68 (18th slot).
  • Page 57 Addressing the S7-400 Default Addresses of Analog Modules On the S7-400, the default addresses for analog modules start from 512 (first slot in the central rack which is usually occupied by the power supply module) up to 1600. The algorithm used to calculate the default address of an analog module is:...
  • Page 58: How To Determine The Default Address Of A Channel

    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 Automation System S7-400 Hardware and Installation A5E00850741-01...
  • Page 59 8 channels at slot 6 (default address 832). With an analog input module, the first characters are IW instead of QW. Channel addresses QW 832 QW 834 QW 836 QW 838 QW 840 QW 842 QW 844 QW 846 Automation System S7-400 Hardware and Installation A5E00850741-01...
  • Page 60 Addressing the S7-400 Automation System S7-400 Hardware and Installation A5E00850741-01...
  • Page 61: Wiring The S7-400

    Choosing the Power Supply Module Choosing the Load Current Power Supply Assembling an S7-400 with Process I/Os Assembling an S7-400 with Grounded Reference Potential (M) Assembling an S7-400 with Ungrounded Reference Potential (Ungrounded Configuration) Assembling an S7-400 with Isolated Modules...
  • Page 62: Supplying Power To Modules

    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).
  • Page 63: Choosing The Power Supply Module

    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. Current consumption and power dissipation of the individual modules can be found in the relevant data sheets.
  • Page 64: Choosing The Load Current Power Supply

    With regulated load current power supplies, particularly at low output levels (up to 20 A), you must ensure a suitable excess current. Automation System S7-400 Hardware and Installation A5E00850741-01...
  • Page 65: Assembling An S7-400 With Process I/os

    Wiring the S7-400 Assembling an S7-400 with Process I/Os Definition of a Grounded Supply (TN-S Network) In grounded supplies, the neutral conductor of the system is grounded. A single fault between a live conductor and ground or a grounded part of the installation results in tripping of the protective devices.
  • Page 66: Operating The S7-400 From A Grounded Supply

    Wiring the S7-400 S7-400 in the Overall Installation Shown in Figure 4-1 is the position of the S7-400 in the overall installation (load current power supply and grounding concept) with supply from a TN-S system. Note: The arrangement of supply terminals shown is not the actual arrangement; it has been chosen for reasons of clarity.
  • Page 67: Assembling An S7-400 With Grounded Reference Potential (m)

    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.
  • Page 68: Assembling An S7-400 With Ungrounded Reference Potential (ungrounded Configuration)

    In this case you must remove the jumper between reference potential M and the frame element terminal on the rack. The reference potential M of the S7-400 is then connected via the RC network to the chassis ground terminal. When you connect this terminal to the chassis ground, RF interference currents will be discharged and static charges will be avoided.
  • Page 69 If a double fault could cause a hazardous state in the installation, you must provide insulation monitoring. Example of Ungrounded Operation If you have configured an S7-400 with a local connection and you only wish to ground the overall installation at the CR, you can operate the ERs in an ungrounded configuration.
  • Page 70: Assembling An S7-400 With Isolated Modules

    Wiring the S7-400 Assembling an S7-400 with Isolated Modules Definition In a configuration with isolated modules, the reference potentials of the control circuit (M ) and the load circuit (M ) are isolated (see also Figure 4-4). internal external Application Isolated modules are used for: •...
  • Page 71: Simplified Representation Of Configuration With Isolated Modules

    Wiring the S7-400 Configuration with Isolated Modules Shown in Figure 4-4 are the potentials of an S7-400 configured with isolated input and output modules. Rack internal Data Ground bus in cabinet external 230 VAC load current PS 24 VDC load current PS...
  • Page 72: Parallel Wiring Of Digital S7-400 Outputs

    Wiring the S7-400 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.
  • Page 73: Grounding

    Introduction Grounding in accordance with regulations and conscientiously implemented is the prerequisite for proper functioning of a programmable controller. Each individual component of the S7-400 and of the controlled system must be properly grounded. Ground Connections Low-resistance ground connections reduce the risk of electric shock in the event of a short-circuit or faults in the system.
  • Page 74: Grounded Connection Load Voltage

    M of operating voltages The following figure shows how the load voltage ground is connected for non-isolated operation. Metallic connection, remove for ungrounded configuration Ground terminal for load voltage Figure 4-7 Grounded connection load voltage Automation System S7-400 Hardware and Installation 4-14 A5E00850741-01...
  • Page 75: Interference-free Configuration For Local And Remote Connections

    • 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. Automation System S7-400 Hardware and Installation 4-15 A5E00850741-01...
  • Page 76: Shielding And Grounding The Connecting Cable For A Remote Connection

    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. Automation System S7-400 Hardware and Installation 4-16 A5E00850741-01...
  • Page 77: Wiring Rules

    Wiring the S7-400 4.11 Wiring Rules Lines and Tools For wiring the S7-400 modules, there are some rules for the cables and tools to use. Rules for ... Power Supply ... Front Connectors Crimp terminal Screw-type Spring-type terminal terminal Conductor...
  • Page 78: Wiring 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). Figure 4-9 Disconnecting power supply connector Automation System S7-400 Hardware and Installation 4-18 A5E00850741-01...
  • Page 79 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. Automation System S7-400 Hardware and Installation 4-19 A5E00850741-01...
  • Page 80: Wiring The Power Supply Connector

    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. Automation System S7-400 Hardware and Installation 4-20 A5E00850741-01...
  • Page 81: Plugging The Power Supply Connector

    4. Close the cover of the power supply module. The following figure shows how to plug the power supply connector into the power supply module. Figure 4-11 Plugging the power supply connector Automation System S7-400 Hardware and Installation 4-21 A5E00850741-01...
  • Page 82: Wiring The Signal Modules

    4.13 Wiring the Signal Modules Procedure How to connect your sensors and actuators to the S7-400 signal modules: 1. Wire the front connector. This includes all incoming and outgoing connections of the sensorsan actuators. 2. Install the front connector on the module.
  • Page 83: Preparing To Wire The Front Connector

    5. Strip the wires according to the table in Section 4.11. Note The front connector contains a jumper which is required to enable specific functions on certain signal modules. Do not remove this jumper. Automation System S7-400 Hardware and Installation 4-23 A5E00850741-01...
  • Page 84: Wiring The Front Connector, Crimping

    3. Insert the crimp contacts into the recesses of the front connector, starting at the bottom. The order number for crimp contacts is found in Appendix C of the Reference Manual . Figure 4-13 Wiring a Front Connector with Crimp Terminals Automation System S7-400 Hardware and Installation 4-24 A5E00850741-01...
  • Page 85: Wiring The Front Connector, Screw Terminals

    3. Screw the ends of the conductors onto the front connector (tightening torque = 0.6 to 0.8 N/m. Also tighten the unwired terminals. 0.6 ... 0.8 Nm Figure 4-14 Wiring a Front Connector with Screw-Type Terminals Automation System S7-400 Hardware and Installation 4-25 A5E00850741-01...
  • Page 86: Wiring The Front Connector, Spring-type Terminals

    4. Repeat steps 3 and 4 for all other wires. Releasing a spring contact from the back Releasing a spring contact from the front Releasing a spring contact from the side Figure 4-15 Wiring a Front Connector with Spring-Type Terminals Automation System S7-400 Hardware and Installation 4-26 A5E00850741-01...
  • Page 87: Principle Of The Spring Contact

    2. Insert the wire into the spring contact as far as it will go 3. Withdraw the screwdriver: the wire is trapped by the contact Figure 4-16 Principle of the spring contact Automation System S7-400 Hardware and Installation 4-27 A5E00850741-01...
  • Page 88: Fitting The Strain Relief

    There are three ways of fitting the strain relief, according to the thickness of the cable. Three openings are provided at the bottom of the front connector. Figure 4-17 Fitting a Strain Relief (Viewed from Below) Automation System S7-400 Hardware and Installation 4-28 A5E00850741-01...
  • Page 89: Labeling A Front Connector

    4. Slide the label with the terminal diagram of the inputs or outputs into the interior of the cover of the front connector. 5. Slide a label externally into the cover of the front connector. Automation System S7-400 Hardware and Installation 4-29 A5E00850741-01...
  • Page 90: Fitting A Label In The Front Connector

    • The single-color labels are tear-proof and dirt-resistant. They are available in petrol, light beige, red, and yellow. • SIMATIC S7-400 I/O modules can be easily labeled application-specifically by machine using a standard laser printer in one of the following two ways: -- Use the print templates you can download free of charge from the Internet -- Use the “S7-SmartLabel”...
  • Page 91 2. Download The download contains templates for the labeling of S7-400 modules. The templates for S7-400 make the labeling strips available for the outside of the front connector cover and the terminal diagrams for the inside of the front connector cover.
  • Page 92: Fitting The Front Connector

    If, for example, you plug the front connector of an analog input module into an analog output module, the module can be damaged. When plugging in the front connector, ensure that the module and front connector are matched. Automation System S7-400 Hardware and Installation 4-32 A5E00850741-01...
  • Page 93: Attaching The Front Connector

    2. Swing the front connector upwards. The two parts of the coding key will then be separated. 3. Screw the front connector on. Coding key Figure 4-20 Attaching the Front Connector Automation System S7-400 Hardware and Installation 4-33 A5E00850741-01...
  • Page 94: Screwing On The Front Connector

    Wiring the S7-400 Figure 4-21 shows how to screw on the front connector. Figure 4-21 Screwing On the Front Connector Automation System S7-400 Hardware and Installation 4-34 A5E00850741-01...
  • Page 95: Interconnecting The Cr And Er(s)

    5. If you wish to interconnect two ERs segments to this send IM, plug the connector of the second connecting cable into the second port of the send IM. 6. Close the cover of the send IM. Automation System S7-400 Hardware and Installation 4-35 A5E00850741-01...
  • Page 96: Connection Between A Send Im And Two Receive Ims

    Connection Between a Send IM and Two Receive IMs 10.Plug the terminator into the lower female connector of the receive IM in the last ER of the chain (see Reference Manual Module Specifications, Chapter 6). Automation System S7-400 Hardware and Installation 4-36 A5E00850741-01...
  • Page 97: Setting The Fan Subassembly To The Line Voltage And Wiring It

    4. Screw the strain relief on. Fit the small cover as a strain relief Power terminals (spring contacts) Voltage selector switch Fuse cap Figure 4-24 Wiring the Fan Subassembly Automation System S7-400 Hardware and Installation 4-37 A5E00850741-01...
  • Page 98: Cable Routing In Cable Ducts Or Fan Subassemblies

    The maximum strain load when assembling is 1000 N and during operation 150 N. Bending Radius Minimum bending radius of the cables: • At the connector: 55 mm • Otherwise: 30 mm Automation System S7-400 Hardware and Installation 4-38 A5E00850741-01...
  • Page 99: Networking

    Page Configuring a Network Fundamentals Rules for Configuring a Network Cable Lengths 5-15 PROFIBUS-DP Bus Cables 5-18 Bus Connectors 5-19 RS 485 Repeater / Diagnostics Repeater 5-21 PROFIBUS-DP Network with Fiber-Optic Cables 5-22 Automation System S7-400 Hardware and Installation A5E00850741-01...
  • Page 100: Configuring A Network

    Networking 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 integrated MPI interface to an MPI subnet •...
  • Page 101: Fundamentals

    CPU. Connectable Nodes PROFIBUS DP Programming devices (PGs) Programming devices (PGs) Operator interfaces (SIMATIC-OP), Operator panels (OPs)* WinCC S7-400 PROFIBUS-DP master, PROFIBUS-DP slaves S7-300 PROFIBUS-DP slaves Not recommended in DP operation Automation System S7-400 Hardware and Installation A5E00850741-01...
  • Page 102 Programming device Note If you change the parameter assignment of the highest MPI address of the MPI/DP interface, the new address remains set even after memory reset, voltage failure or removing/inserting the CPU. Automation System S7-400 Hardware and Installation A5E00850741-01...
  • Page 103: Communication Between Programming Device/operator Panel And A Module Without Mpi

    PG / OP - - Module communication without MPI If one of the programming devices or operator panels connected to a multipoint interface (MPI) communicates with an S7-400 module which does not have an MPI connection (for example, SIMATIC NET CPs, FM 456 etc.), this module can be reached via the CPU to whose MPI the programming device or operator panel is connected.
  • Page 104: Data Exchange

    The CPUs have different characteristics. One of these characteristics is their communication performance. If the communication resources of a CPU are occupied completely by process communication, this can severely hamper access to the CPU from the programming device. Automation System S7-400 Hardware and Installation A5E00850741-01...
  • Page 105: Rules For Configuring A Network

    Up to ten segments can be connected in series. • Switch on the terminating resistor at the first and last node of a segment. To ensure the bus operates without interference, you should not switch off these nodes. Automation System S7-400 Hardware and Installation A5E00850741-01...
  • Page 106 Remember to provide a bus connector with PG female port for nodes into which a programming device may be plugged if required. Use RS 485 repeaters for the connection between segments and for extending the cable. Automation System S7-400 Hardware and Installation A5E00850741-01...
  • Page 107: Terminating Resistor On Bus Connector

    L+ M PE M 5.2 A1 B1 A1 B1 Terminating resistor for bus segment 1 Terminating resistor SIEMENS for bus segment 2 RS 485-REPEATER A2 B2A2 B2 Figure 5-4 Terminating resistor on RS 485 repeater Automation System S7-400 Hardware and Installation A5E00850741-01...
  • Page 108: Terminating Resistor On Mpi Network

    The figure below shows where you have to connect the terminating resistor in a possible configuration for an MPI network. S7-400 S7-400 S7-400 S7-300 RS 485 repeater Spur line Programming device Terminating resistor switch on Figure 5-5 Terminating resistor on MPI network Automation System S7-400 Hardware and Installation 5-10 A5E00850741-01...
  • Page 109: 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 switch on Figure 5-6 Example of an MPI network Automation System S7-400 Hardware and Installation 5-11 A5E00850741-01...
  • Page 110: Example Of A Profibus Dp Network

    * Only connected via spur line for startup/maintenance (with default PROFIBUS-DP address = 0) 0 ... x PROFIBUS DP addresses of nodes Terminating resistor switched on Figure 5-7 Example of a PROFIBUS DP network Automation System S7-400 Hardware and Installation 5-12 A5E00850741-01...
  • Page 111: Example With Cpu

    ET 200M RS 485 repeater S7-400 ET 200B S7-200 ET 200B PROFIBUS-DP MPI network network * Only connected via spur line for startup/maintenance Terminating resistor switched on Figure 5-8 Example with CPU 414-2 Automation System S7-400 Hardware and Installation 5-13 A5E00850741-01...
  • Page 112: Programming Device Access Beyond Network Limits

    • Use STEP 7 from version 5.0 onwards • Assign STEP 7 to a programming device or PC on the network (SIMATIC Manager, Assign programming device/PC) • The network limits are bridged by modules with routing capability. Automation System S7-400 Hardware and Installation 5-14 A5E00850741-01...
  • Page 113: Cable Lengths

    Note that you must count an RS 485 repeater as a node of the MPI network in the total number of all nodes to be connected, even if it is not assigned its own MPI number. The use of RS 485 repeaters reduces the number of nodes. Automation System S7-400 Hardware and Installation 5-15 A5E00850741-01...
  • Page 114: Lengths Of Spur Lines Per Segment

    To connect a programming device or PC, use the connecting cable for the programming with theorder number 6ES7901-4BD00-0XA0. You can use several connecting cable with this order number for programming devices in one bus configuration. Automation System S7-400 Hardware and Installation 5-16 A5E00850741-01...
  • Page 115: Configuration Of An Mpi Network

    S7-400 RS 485- repeater max. 50m Terminating resistor switched on Programming device connected via spur line for maintenance 0 ... x MPI addresses of nodes Figure 5-10 Configuration of an MPI network Automation System S7-400 Hardware and Installation 5-17 A5E00850741-01...
  • Page 116: Profibus-dp Bus Cables

    Networking PROFIBUS-DP Bus Cables PROFIBUS-DP Bus Cables Siemens supply the following PROFIBUS-DP bus cables (see catalog ST 70): PROFIBUS-DP bus cable 6XV1830-0AH10 PROFIBUS-DP cable for burying in ground 6XV1830-3AH10 PROFIBUS-DP trailing cable 6XV1830-3BH10 PROFIBUS-DP bus cable with PE sheath (for foodstuffs and...
  • Page 117: Bus Connectors

    MPI or station PROFIBUS-DP interface Switch for terminating resistor Housing screw PG connector (only with 6ES7 972-0BB20-0XA0) Clamp hinge for vertical or 30° cable routing Figure 5-11 Bus connector Automation System S7-400 Hardware and Installation 5-19 A5E00850741-01...
  • Page 118: Switch On Terminating Resistant

    Since the bus connector is powered by the station, the terminating resistor has no effect. Ensure that the stations at which the terminating resistor is switched on are always under power. Automation System S7-400 Hardware and Installation 5-20 A5E00850741-01...
  • Page 119: Rs 485 Repeater / Diagnostics Repeater

    “A1” and “B1”. Connecting the PROFIBUS-DP Bus Cable For detailed information on hwo to connect the PROFIBUS DP bus cable to the RS 485 repeater, refer to the SIMATIC NET Profibus Networks manual: Automation System S7-400 Hardware and Installation 5-21 A5E00850741-01...
  • Page 120: Profibus-dp Network With Fiber-optic Cables

    Module (OLM). • PROFIBUS nodes with an integrated fiber-optic cable interface (e.g. ET 200M (IM 153-2 FO), S7-400 (IM 467 FO)) can be directly integrated in the optical network. How to set up optical networks with the Optical Link Module (OLM) is described in detail in the SIMATIC NET PROFIBUS Networks manual.
  • Page 121: Optical Profibus-dp Network With Nodes That Have An

    The following transmission rates are possible when the optical PROFIBUS-DP network is operated with a partyline topology: • 9.6 kbps • 19.2 kbps • 45.45 kbps • 93.75 kbps • 187.5 kbps • 500 kbps • 1.5 Mbps • 12 Mbps Automation System S7-400 Hardware and Installation 5-23 A5E00850741-01...
  • Page 122: Fiber-optic Cables

    PROFIBUS cable. The OBT is integrated in the optical PROFIBUS-DP line by means of its fiber-optic cable interface. 5.8.1 Fiber-Optic Cables Features of the Fiber-Optic Cables Use Siemens plastic and PCF fiber-optic cables with the following features: Table 5-4 Features of the Fiber-Optic Cables Description SIMATIC NET PROFIBUS...
  • Page 123 Outer dimensions 2.2 4.4 mm Diameter: Diameter: ± 0.01 mm 7.8 ± 0.3 mm 4.7 ± 0.3 mm Weight 7.8 kg/km 65 kg/km 22 kg/km Please ask your Siemens contact about specific applications. Automation System S7-400 Hardware and Installation 5-25 A5E00850741-01...
  • Page 124: Simplex Connectors And Connector Adapter

    Prerequisite The PROFIBUS device must be equipped with a fiber-optic cable interface, such as the ET 200M (IM153-2 FO) or the IM 467 FO for S7-400. Automation System S7-400 Hardware and Installation 5-26...
  • Page 125: Simplex Connectors And A Special Connector Adapter For The Im 153-2 Fo And Im 467 Fo (installed)

    100 Simplex connectors and 5 polishing sets for fitting SIMATIC NET PROFIBUS plastic fiber-optic cables with connectors Connector adapters 6ES7195-1BE00-0XA0 Pack of 50 for fitting plastic Simplex connectors with the IM 467 FO and the IM 153-2 FO Automation System S7-400 Hardware and Installation 5-27 A5E00850741-01...
  • Page 126: Permissible Cable Lengths On The Optical Profibus-dp Network (partyline Topology)

    Laying Plastic Fiber-Optic Cable You can easily fit connectors to and install plastic fiber-optic cables yourself. Please read the following information on how to do this and on the rules for laying the cable. Automation System S7-400 Hardware and Installation 5-28 A5E00850741-01...
  • Page 127 Rules for Laying Cable When you lay plastic fiber-optic cable, please adhere to the following rules: • Use only the Siemens fiber-optic cables specified in Section 5.8.1 • Never exceed the maximum permissible stresses (tensile load, crushing, etc.) of the cable you are using specified in Table 5-4. Impermissible crushing can occur, for example, when screw clamps are used to fix the cable in place.
  • Page 128 Networking Automation System S7-400 Hardware and Installation 5-30 A5E00850741-01...
  • Page 129: Commissioning

    Page Recommended Procedure for First Startup Checks Prior to Switching On for the First Time Connecting a Programming Device (PG) to an S7-400 Switching On an S7-400 for the First Time Resetting the CPU with the Mode Selector Switch Cold, Warm, and Hot Restarts with the Mode Selector Switch...
  • Page 130: Recommended Procedure For First Startup

    Due to the modular assembly and the many expansion options, an S7-400 can be very extensive and complex. A first startup of an S7-400 with two or more racks and all modules inserted is therefore not advisable. Instead, a startup in stages is recommended.
  • Page 131: Checks Prior To Switching On For The First Time

    After installing and wiring your S7-400, it is advisable to check the steps carried out so far, before switching on for the first time. Table 6-1 contains a guide in the form of a checklist for your S7-400, and refers to the chapters containing additional information on the subject.
  • Page 132 (Standby switch set to Is the BATT INDIC switch for battery monitoring correctly set (see Table 6-2)? Has the connection to the supply been made? Line Voltage Is the available line voltage correct? Automation System S7-400 Hardware and Installation A5E00850741-01...
  • Page 133: Connecting A Programming Device (pg) To An S7-400

    BATT INDIC switch to 2BATT. double or triple-width power supply module, Connecting a Programming Device (PG) to an S7-400 Connecting a Programming Device (PG) to an S7-400 You must connect the programming device via a connecting cable to the MPI of the CPU.
  • Page 134: Switching On An S7-400 For The First Time

    A description of operator control of communication between CPUs and programming devices can be found in the STEP 7 manuals. Switching On an S7-400 for the First Time Switching On an S7-400 for the First Time First switch on the power cutout.
  • Page 135: Resetting The Cpu With The Mode Selector Switch

    There are two ways of resetting the CPU: • Reset with the mode selector switch • Reset from the programming device (see STEP 7) Resetting the CPU with the mode selector is described in the following section. Automation System S7-400 Hardware and Installation A5E00850741-01...
  • Page 136: Positions Of The Mode Selector Switch

    (system reset request, for example, when a memory card has been removed or inserted). Set the switch to MRES and then back to STOP. Result: The STOP LED flashes for at least 3 seconds at 2 Hz (reset is being executed) and then remains lit. Automation System S7-400 Hardware and Installation A5E00850741-01...
  • Page 137 The MPI parameters are handled in a special mway during a CPU memory reset. If you haev inserted a Memory Card containing the MPI parameters, the system automatically loads these into the CPU and validates the data. Automation System S7-400 Hardware and Installation A5E00850741-01...
  • Page 138: Cold, Warm, And Hot Restarts With The Mode Selector Switch

    1. Set the switch to STOP. Result: The STOP LED is lit. 2. Set the switch to RUN. Whether the CPU executes a restart / hot restart depends on the CPU configuration. Automation System S7-400 Hardware and Installation 6-10 A5E00850741-01...
  • Page 139: Inserting A Memory Card

    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 load memory expansion of the CPU. Depending on the type of memory card, the user program is retained on the memory card even when power is removed.
  • Page 140: Inserting A Memory Card In A Cpu

    STOP indicator at 0.5 If you insert or remove the memory card with the controller switched off, the CPU performs an automatic memory reset after power on. Automation System S7-400 Hardware and Installation 6-12 A5E00850741-01...
  • Page 141: Inserting A Backup Battery (option)

    To insert the backup battery (batteries) in the power supply module, proceed as follows: 1. Discharge any static charge by touching a grounded metal part of the S7-400. 2. Open the cover of the power supply module. 3. Insert the backup battery/batteries in the battery compartment.
  • Page 142 Commissioning The following figure shows how to insert a backup battery in the single-width power supply module. Automation System S7-400 Hardware and Installation 6-14 A5E00850741-01...
  • Page 143 (max. temperature 100° C). Do not recharge, there is a risk of explosion. Do not open the battery, and only replace it with one of the same type. Obtain the replacement via Siemens (see the Reference Manual, Module specifications appendix C for the order number). This will ensure that you have a short-circuit protected type.
  • Page 144 Reducing the Passivation Layer Lithium batteries (lithium/thionyl chloride) are used as backup batteries for the S7-400. In lithium batteries of this technology, a passivation layer can develop after storage for a very long time, and the immediate functional capability of the battery may not be certain.
  • Page 145: Starting Up A Profibus-dp Subnet

    Starting Up a PROFIBUS-DP Subnet Introduction This section describes the procedure for starting up a PROFIBUS-DP subnet with an S7-400 CPU as the DP master. Requirements Before you can start up the PROFIBUS-DP subnet, the following requirements must be met: •...
  • Page 146: Installing Interface Modules (cpu 414-2, 414-3, 416-3,

    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 Interface Modules Warning The modules can be damaged. When inserting or removing interface submodules with power applied, the CPU and interface submodules can be damaged (exception: using synchronization submodules in an H system).
  • Page 147: Inserting Interface Submodules In The Cpu

    Covering Unused Submodule Slots On delivery, all the submodule slots are secured with a submodule cover. The cover is attached to the frame of the card slot with screws. Leave unused submodule slots secured. Automation System S7-400 Hardware and Installation 6-19 A5E00850741-01...
  • Page 148 Commissioning Automation System S7-400 Hardware and Installation 6-20 A5E00850741-01...
  • Page 149: Maintenance

    Replacing Fans in the Fan Subassembly During Operation 7-14 Replacing the Filter Frame of the Fan Subassembly During Operation 7-16 7.10 Replacing the Power Supply PCB and Monitoring PCB of the Fan 7-18 Subassembly 7.11 Replacing Interface Submodules 7-19 Automation System S7-400 Hardware and Installation A5E00850741-01...
  • Page 150: Replacing The Backup Battery

    Replacing the Backup Battery Replacing the Backup Battery 1. Discharge any static charge by touching a grounded metal part of the S7-400. 2. Open the cover of the power supply module. 3. Using the loop(s), pull the backup battery/batteries out of the battery compartment.
  • Page 151 (max. temperature 100 °C). Do not recharge the battery -- risk of explosion! Do not open a battery. Replace a faulty battery onoly with the same type. Replacement batteries can be ordered from SIEMENS (for order numbers, refer to the “Module data” reference manual, in appendix C).
  • Page 152: Replacing A Power Supply Module

    9. Set the standby switch of the power supply module to I (output voltages at rated value). 10.Set the CPU mode switch to RUN if applicable. How the S7-400 Behaves after Exchanging Modules If an error occurs after replacing a module, you can read out the cause of the error from the diagnostic buffer.
  • Page 153: Replacing Cpus

    4. Disconnect the MPI connector, if applicable. 5. Disconnect the connector at the EXT. BATT. socket, if applicable. 6. Remove the memory card. 7. Loosen the mounting screws of the module. 8. Swing the module out. Automation System S7-400 Hardware and Installation A5E00850741-01...
  • Page 154 Set up your network by plugging in the MPI connector. Set the CPU mode switch to RUN. Close the cover. How the S7-400 Behaves after Exchanging Modules If an error occurs after replacing a module, you can read out the cause of the error from the diagnostic buffer.
  • Page 155: Replacing Digital Or Analog Modules

    4. Swing the module out. Note In order that the removal and insertion of digital or analog modules can be detected by the CPU, a minimum time of two seconds must elapse between removal and insertion. Automation System S7-400 Hardware and Installation A5E00850741-01...
  • Page 156 5. After fitting, each programmable module will be reinitialized by the CPU with parameters. How the S7-400 Behaves after Exchanging Modules If an error occurs after replacing a module, you can read out the cause of the error from the diagnostic buffer.
  • Page 157: Changing The Fuses In The Digital Modules

    Hazardous voltages of >25 VAC or >60 VDC may be present below the covers on the right-hand side of the module. Before you open these covers, ensure that either the front connector for the module is removed or the module is disconnected from the voltage supply. Automation System S7-400 Hardware and Installation A5E00850741-01...
  • Page 158 12.After fitting, each programmable module will be reinitialized by the CPU with parameters. How the S7-400 Behaves after Replacing the Fuse If an error occurs after replacing a fuse, you can read out the cause of the error from the diagnostic buffer.
  • Page 159: Replacing Interface Modules

    (0 V output voltages). 4. Remove the cover. 5. Disconnect the connecting cables. 6. Disconnect the terminator, if applicable. 7. Loosen the mounting screws of the module. 8. Swing the module out. Automation System S7-400 Hardware and Installation 7-11 A5E00850741-01...
  • Page 160 8. Then switch on the power supply module in the CR. 9. Set the CPU mode switch to RUN mode. How the S7-400 Behaves after Exchanging Modules If an error occurs after replacing a module, you can read out the cause of the error from the diagnostic buffer.
  • Page 161: Replacing The Fuse Of The Fan Subassembly

    3. Remove the blown fuse from the fuse cap. 4. Insert the new fuse in the fuse cap and screw the cap into the fan subassembly. 5. Connect the power cable of the fan subassembly to the supply. Automation System S7-400 Hardware and Installation 7-13 A5E00850741-01...
  • Page 162: Replacing Fans In The Fan Subassembly During Operation

    3. Release the fan to be replaced by pressing the fan grip away from the housing with your thumb. Fan grip Base 4. Pull out the fan to be replaced. Automation System S7-400 Hardware and Installation 7-14 A5E00850741-01...
  • Page 163 7. Use a screwdriver to make a quarter turn clockwise and close the two quick-release locks. 8. Use a pointed object to press the RESET button. The fault LED will go off and the fan will start running. Automation System S7-400 Hardware and Installation 7-15 A5E00850741-01...
  • Page 164: Replacing The Filter Frame Of The Fan Subassembly During Operation

    This will release the filter frame from the snap hinges. Filter mat Filter frame Cover Snap catches Base with cover and filter frame (optionally fitted at bottom or rear) Snap hinges Quick-release locks Automation System S7-400 Hardware and Installation 7-16 A5E00850741-01...
  • Page 165 6. Use a screwdriver to make a quarter turn clockwise and close the two quick-release locks. 7. Replacing the filter frame will not trigger an interrupt. There is therefore no need to press the RESET button. Automation System S7-400 Hardware and Installation 7-17 A5E00850741-01...
  • Page 166: Replacing The Power Supply Pcb And Monitoring Pcb Of The Fan Subassembly

    Electronic components can be damaged. If you do not observe the ESD guidelines when handling printed-circuit boards with electronic components, the components can be damaged by a static discharge. Observe the ESD guidelines (see Appendix). Automation System S7-400 Hardware and Installation 7-18 A5E00850741-01...
  • Page 167: Replacing Interface Submodules

    Maintenance 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 be damaged. When inserting or removing interface submodules with power applied, the CPU and interface submodules can be damaged (exception: using synchronization submodules in an H system).
  • Page 168: Inserting An Interface Submodule In A Cpu

    Figure 7-1 Inserting an Interface Submodule in a CPU Installing Interface Submodules In order to install an interface submodule, proceed in reverse order. For further information, see section 6.10 ”Installing Interface Submodules”. Automation System S7-400 Hardware and Installation 7-20 A5E00850741-01...
  • Page 169: Chapter Overview

    Assembling and Installing Systems Chapter Overview Section Description Page General Rules and Regulations for Operating the S7-400 Principles of System Installation for EMC Installation of Programmable Controllers for EMC Examples of EMC-Compatible Assembly A-10 Shielding Cables A-13 Equipotential Bonding A-15...
  • Page 170: A.1 General Rules And Regulations For Operating The S7-400

    S7-400 General Basic Rules On account of the many possible applications of the S7-400, this chapter can only cover the basic rules for the electrical configuration. You must at least comply with these basic rules to ensure fault-free operation of the S7-400.
  • Page 171 Assembling and Installing Systems 120/230 VAC Supply The following table shows which points you must observe when connecting the S7-400 to a 120/230 VAC supply. With ..You Must Ensure ... buildings that suitable external lightning protection measures are provided.
  • Page 172 Automation System S7-400 Hardware and Installation A5E00850741-01...
  • Page 173: A.2 Principles Of System Installation For Emc

    Introduction Although the S7-400 and its components were developed for operation in an industrial environment and meet high EMC requirements, you should carry out EMC planning before installing your control system, taking possible interference sources into account and incorporating them in your observations.
  • Page 174 Local transmitters (for example, conductor is subjected to an two-way radios) electromagnetic wave. Impinging of • Spark gaps (spark plugs, the wave results in induced currents collectors of electric motors, and voltages. welders) Automation System S7-400 Hardware and Installation A5E00850741-01...
  • Page 175 Route the grounded shield as far as the module without interruption, but do not ground it there again. • There must be a low-impedance connection between shield/protective ground bar and cabinet/housing. • Use metal or metallized connector cases for shielded data lines. Automation System S7-400 Hardware and Installation A5E00850741-01...
  • Page 176 Rule 4: Special EMC Measures Employ special EMC measures for particular applications (see Section 4.11). • Fit suppressors to all inductors which are not controlled by S7-400 modules. • Use incandescent bulbs or suppressed fluorescent lamps in the immediate vicinity of your controller for illuminating cabinets or housings.
  • Page 177: A.3 Installation Of Programmable Controllers For Emc

    Grounding of Inactive Metal Parts During Installation When installing the S7-400, ensure large-area grounding of all inactive metal parts. Properly implemented chassis grounding creates a standard reference potential for the control system, and reduces the effects of picked-up interference.
  • Page 178: A.4 Examples Of Emc-compatible Assembly

    (grounding of inactive metal parts and connection of cable shields) have been applied. However, this example only applies to grounded operation. Observe the points marked in the figure when installing your system. Figure A-2 Example of Cabinet Installation for EMC Automation System S7-400 Hardware and Installation A-10 A5E00850741-01...
  • Page 179: Key For Example 1

    If you operate your S7-400 in a low-interference environment in which the permissible ambient conditions are complied with (see the Module Data reference manual, Chapter 1), you can mount your S7-400 in frames or on the wall. Picked-up interference must be given a path to large metal surfaces. You should therefore secure standard mounting channels, shield, and protective ground bars to metal structural elements.
  • Page 180 • Cover the AC supply conductors in a shockproof arrangement. Figure A-3 shows an example of wall mounting for EMC Figure A-3 Wall Mounting an S7-400 for EMC Automation System S7-400 Hardware and Installation A-12 A5E00850741-01...
  • Page 181: A.5 Shielding Cables

    In the event of potential differences between grounding points, a circulating current may flow via the shield connected at both ends. In this case, install an additional equipotential bonding conductor (see Section A.6). Automation System S7-400 Hardware and Installation A-13 A5E00850741-01...
  • Page 182 • For installation other than in cabinets (for example, wall mounting), you can provide contact between the cable shields and the cable duct. Shown in the figure A-4 are some methods of securing shielded cables with cable clamps. Figure A-4 Mounting Cable Shields Automation System S7-400 Hardware and Installation A-14 A5E00850741-01...
  • Page 183: A.6 Equipotential Bonding

    • Lay the equipotential bonding conductor in such a way that the surface between the conductor and the signal lines is as small as possible. (see Figure A-5). Automation System S7-400 Hardware and Installation A-15 A5E00850741-01...
  • Page 184: A-5 Routing Equipotential Bonding Conductor And Signal Line

    Assembling and Installing Systems Figure A-5 Routing Equipotential Bonding Conductor and Signal Line Automation System S7-400 Hardware and Installation A-16 A5E00850741-01...
  • Page 185: Cabling Inside Buildings

    DC and AC voltages Inside cabinets: (>400 V), unshielded in separate bundles or cable ducts (no minimum clearance necessary) Outside cabinets: on separate cable racks with a clearance of at least 10 cm (3.93 in.) Automation System S7-400 Hardware and Installation A-17 A5E00850741-01...
  • Page 186 (>400 V), unshielded (>400 V), unshielded ducts ETHERNET ETHERNET in common bundles or cable ducts Others in separate bundles or cable ducts with a clearance of at least 50 cm (19.65 in.) Automation System S7-400 Hardware and Installation A-18 A5E00850741-01...
  • Page 187: A.8 Cabling Outside Buildings

    An individual appraisal of the entire plant is necessary before initiating any lightning protection measures (see Section A.9). Further Information on Lightning Protection You will find further information in the following sections. Automation System S7-400 Hardware and Installation A-19 A5E00850741-01...
  • Page 188: A.9 Lightning Protection And Overvoltage Protection

    This refers especially to constructional measures for the building already in the planning phase. If you wish to obtain detailed information on overvoltage protection, we therefore recommend you to address your Siemens contact or a company specialized in lightning protection. Automation System S7-400 Hardware and Installation...
  • Page 189: A.9.1 Lightning Protection Zone Concept

    Surges In lightning protection zones 1 and higher, surges can result from switching operations and interference. Automation System S7-400 Hardware and Installation A-21 A5E00850741-01...
  • Page 190 Lines that can carry lightning stroke current include: • Metal pipelines (for example, water, gas and heat) • Power cables (for example, line voltage, 24 V supply) • Data cables (for example, bus cable). Automation System S7-400 Hardware and Installation A-22 A5E00850741-01...
  • Page 191: A.9.2 Rules For The Transition Between Lightning Protection Zones 0 And 1

    2 pieces of DEHNbloc/1 lightning 900 111* conductor 5SD7 032 phase L1 + N to PE AC TN-C system 1 piece of DEHNbloc/1 lightning 900 111* conductor 5SD7 032 phase L to PEN Automation System S7-400 Hardware and Installation A-23 A5E00850741-01...
  • Page 192 919 506* and to 12 V +/-- conductor, 919 510* type B You can order these components directly at: DEHN + SÖHNE GmbH + Co. KG Elektrotechnische Fabrik Hans-Dehn-Str. 1 D-92318 Neumarkt Automation System S7-400 Hardware and Installation A-24 A5E00850741-01...
  • Page 193: A.9.3 Rules For The Transitions Between Lightning Protection Zones 1 <-> 2 And Greater

    You should only use the lightning conductor KT, type 24 VAD SIMATIC for the 24 VDC power supply of the S7-400. All other surge protection components do not meet the required tolerance range of 20.4 V to 28.8 V of the S7-400’s power supply.
  • Page 194: Low-voltage Protection Components For Lightning Protection Zones 1 <--> 2

    12 V +/-- Blitzductor CT type MD 12 V 919 541* You can order these components directly at: DEHN + SÖHNE GmbH + Co. KG Elektrotechnische Fabrik Hans-Dehn-Str. 1 D-92318 Neumarkt Automation System S7-400 Hardware and Installation A-26 A5E00850741-01...
  • Page 195: A-5 Surge Protection Components For Lightning Protection Zones 2 <--> 3

    For the transition points between lightning protection zones 2 <--> 3 we recommend the surge protection components listed in the table below. This low-voltage protection must be used in S7-400 for CE compliance. Table A-5 Surge Protection Components for Lightning Protection Zones 2 <--> 3 Ser.
  • Page 196: A.9.4 Sample Of A Surge Protection Circuit For Networked S7-400 Plcs

    Assembling and Installing Systems A.9.4 Sample of a Surge Protection Circuit for Networked S7-400 PLCs Sample Circuit The sample in the figure A-7 shows you how install an effective surge protection for 2 networked S7-400 PLCs: L1 L2 L3 N PE...
  • Page 197: Example Of A Circuit Conforming To Lightning Protection Requirements

    0 <--> 1 order number: 919 506* and 919 510* You can order these components directly at: DEHN + SÖHNE GmbH + Co. KG Elektrotechnische Fabrik Hans-Dehn-Str. 1 D-92318 Neumarkt Automation System S7-400 Hardware and Installation A-29 A5E00850741-01...
  • Page 198: A.10 How To Protect Digital Output Modules Against Inductive Surge

    Overvoltage occurs when inductive devices are switched off. Examples are relay coils and contactors Integrated Surge Arrester S7-400 digital output modules are equipped with an integrated surge arrester Additional Overvoltage Protection Inductive devices require additional surge arresters only in following cases: •...
  • Page 199 • The steepness of the surge voltage remains the same. • Low turn-off delay. Suppression with an RC element exhibits the following characteristics: • The amplitude and steepness of the switching overvoltage are reduced. • Low turn-off delay. Automation System S7-400 Hardware and Installation A-31 A5E00850741-01...
  • Page 200: A.11 Safety Of Electronic Control Equipment

    VDE 0801). The prototype of the fail-safe S7-400F and S7-400FH PLCs were tested by TÜV (German Institute for Technological Suirveillance), BIA and G EM III; several certificates have been granted. These are suitable therefore for controlling and monitoring safety-relevant applications. Automation System S7-400 Hardware and Installation A-32 A5E00850741-01...
  • Page 201: Important Information

    -- e.g. with a multi-channel structure -- it is imperative conform with instructions given in the operating manual. Incorrect handling can render measures intended to prevent dangerous faults ineffective, or generate additional sources of danger. Automation System S7-400 Hardware and Installation A-33 A5E00850741-01...
  • Page 202: A.12 Interference-free Connection Of Monitors

    • Electronic and chassis grounds of the monitor are isolated from each other. • Electronic and chassis grounds of the monitor are interconnected via a voltage-dependent resistor (VDR) fitted by the manufacturer of the monitor. Automation System S7-400 Hardware and Installation A-34 A5E00850741-01...
  • Page 203 -- Strip the outer cable insulation of the video cables in the region of the ground clamp of the monitor, without damaging the braided shield. -- Secure the outer braided shield over a large area to the ground clamp of the monitor. Automation System S7-400 Hardware and Installation A-35 A5E00850741-01...
  • Page 204: A-11 Shielding And Grounding With A Great Distance Between Monitor And Programmable Controller

    S7-400. Monitor with isolated electronic ground and chassis ground Outer shield connected to ground Shielding clamp busbar Figure A-11 Shielding and Grounding with a Great Distance between Monitor and Programmable Controller Automation System S7-400 Hardware and Installation A-36 A5E00850741-01...
  • Page 205 Guidelines for Handling Electrostatically-Sensitive Devices (ESD) Chapter Overview Section You will find Page What is ESD? Electrostatic Charging of Persons General Protective Measures Against Electrostatic Discharge Damage Automation System S7-400 Hardware and Installation A5E00850741-01...
  • Page 206: B.1 What Is Esd?

    In most cases, the damage caused by an overvoltage is not immediately noticeable and results in total damage only after a prolonged period of operation. Automation System S7-400 Hardware and Installation A5E00850741-01...
  • Page 207: B.2 Electrostatic Charging Of Persons

    3 Antistatic material, for example, wood or concrete 5 10 20 30 40 50 60 70 80 90 100 Relative air humidity in % Figure B-1 Electrostatic Voltages which can build up on a person Automation System S7-400 Hardware and Installation A5E00850741-01...
  • Page 208: B.3 General Protective Measures Against Electrostatic Discharge Damage

    If you have to carry out measurements on a module, you must discharge your body before you start the measurement by touching grounded metallic parts. Use grounded measuring devices only. Automation System S7-400 Hardware and Installation A5E00850741-01...
  • Page 209 The connection must be in the form of a low-noise ground. Bus segment Entity of a serial bus system, coupled via repeaters. Automation System S7-400 Hardware and Installation Glossary-1 A5E00850741-01...
  • Page 210 Glossary Central module Programmable S7-400 module with MPI interface, controls the automation tasks. Chassis Ground The chassis ground comprises all interconnected inactive parts of an apparatus, which even in case of a fault cannot take dangerous touch voltages. Cold restart Restart of an automation system and its user program after all dynamic data ( tags of the I/O image, internal registers, timers, counters etc.
  • Page 211: Default Setting

    The time a → CPU requires to execute the → user program. Cyclic Interrupt A cyclic interrupt is generated by the S7-400 CPU periodically according to a programmable time interval. A corresponding organization block is then executed. Data Block (DB) Data blocks are areas in the user program which contain user data.
  • Page 212: Equipotential Bonding

    Glossary Diagnostic Buffer The diagnostic buffer is a retentive area of memory within the S7-400 CPU which stores the diagnostic events in the order they occurred. Diagnostic Interrupt Modules with diagnostics capability signal system errors to the S7-400 CPU by means of diagnostic interrupts.
  • Page 213 Functions are therefore suitable for storing data in shared DBs. Because FCs are not assigned a memory, you always need to specify their actual parameters. You can not assign initial values to the local data of an FC. Automation System S7-400 Hardware and Installation Glossary-5 A5E00850741-01...
  • Page 214 (one or more electrically conductive parts that have good contact with the soil). GSD File The device master file (GSD file) contains all slave-specific data. The format of GSD files is specified in EN 50170, Volume 2, PROFIBUS. Automation System S7-400 Hardware and Installation Glossary-6 A5E00850741-01...
  • Page 215 Instance Data Block With the S7-400, each call of a function block in the STEP 7 user program is assigned a data block which is generated automatically. In the instance data block, the values of the input, output and in/out parameters as well as the local block data are stored.
  • Page 216: Memory Card

    Glossary Load Memory The load memory is part of the S7-400 CPU. It contains objects created by the programming device. It can be either a plug-in memory card or an integrated memory. Contains the complete user program during runtime, the comments and the symbolic system, additional special information which allows decompilation of the user program, and all module parameters.
  • Page 217 Network In communications, a network is the connection between two or more S7-400 CPUs and other terminals such as a programming device, via a connecting cable. Data are exchanged over the network between the connected stations.
  • Page 218: Operating State

    CPU which are not connected to a specific control task. Organization Block (OB) Organization blocks form the interface between the operating system of the S7-400 CPU and the user program. The sequence in which the user program should be processed is laid down in the organization blocks.
  • Page 219: Priority Classes

    Process Image The process image is a component part of the system memory of the S7-400 CPU. At the beginning of the cyclic program, the signal states of the input modules are transferred to the process-image input table (PII).
  • Page 220 Shared data can be accessed by any code block (FC, FB, OB). These include bit memory M, inputs I, outputs Q, timers T, counters C, and data blocks DB. Global data can be accessed either absolutely or symbolically. Automation System S7-400 Hardware and Installation Glossary-12 A5E00850741-01...
  • Page 221 Can be generated by a DPV1 slave. The DPV1 master responds with a call of OB55. For detailed information on OB57, refer to the “System Software for S7-300/S7-400 System and Standard Functions” reference manual. STEP 7 Programming language for writing user programs for SIMATIC S7 programmable controllers.
  • Page 222: System Diagnostics

    Used to terminate data transfer lines in order to avoid reflections on the bus. Time-Delay Interrupt The time-delay interrupt belongs to one of the priority classes in SIMATIC S7-400 program processing. It is generated after expiry of a time started in the user program.
  • Page 223 Update interrupt An update inbterrupt can be generated by a DPV1 slave. The DPV1 responds with a call of OB56. For detailed information on OB56, refer to the “System Software for S7-300/S7-400 System and Standard Functions” reference manual. User Memory The user memory contains logic blocks and data blocks of the user program.
  • Page 224 STOP, power failure). Watchdog interrupt Generated cyclically within a configurable time pattern by the S7-400 CPU. Triggers the execution of a corresponding OB. Starting point of the clock cycle is the operational transition from STOP to RUN.
  • Page 225 3-7 replacing the filter frame, 7-16 Communication, programming device -- CPU, replacing the fuse, 7-13 replacing the monitoring PCB, 7-18 Communication bus (C-bus), 2-7 replacing the power supply PCB, 7-18 Automation System S7-400 Hardware and Installation Index-1 A5E00850741-01...
  • Page 226 Power supply module, 1-2 order number, 1-3 choosing, 4-3 product release, 1-3 replacing, 7-4 PROFIBUS-DP, starting up, 6-17 PROFIBUS-DP address, 5-4 PROFIBUS-DP addresses, recommendation, PROFIBUS-DP bus cable, 5-18 characteristics, 5-18 rules for laying the, 5-18 Automation System S7-400 Hardware and Installation Index-2 A5E00850741-01...
  • Page 227 Switching on, checks prior to switching on for grounded, 4-7 the first time, 6-3 ungrounded, 4-8 Switching on an S7-400, for the first time, 6-6 Regulations, for operating the S7-400, A-2 Replacing interface submodules, 7-19 Restart, 6-10 operating sequence, 6-10...
  • Page 228 Index Automation System S7-400 Hardware and Installation Index-4 A5E00850741-01...

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