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Preface, Contents

Product Overview 1

Installing the S7-400 2

Addressing the S7-400 3

Wiring the S7-400 4

Networking 5

Commissioning 6

Maintenance 7

Appendices Assembling and

Installing Systems A

Guidelines for Handling Electro-

statically-Sensitive Devices (ESD) B

Glossary, Index

11/2006

A5E00850741-01

Automation System S7-400 Hardware and Installation

Installation Manual

SIMATIC

This manual is part of the documentation package with the order number

6ES7498-8AA05-8BA0

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!

Dangerindicates that death or severe personal injury will result if proper precautions are not taken.

!

Warningindicates that death or severe personal injury may result if proper precautions are not taken.

!

Cautionwith a safety alert symbol indicates that minor personal injury can result if proper precautions are not taken.

Caution

without a safety alert symbol indicates that property damage can result if proper precautions are not taken.

Notice

indicates that an unintended result or situation can occur if the corresponding notice is not taken into account.

If more than one degree of danger is present, the warning notice representing the highest degree of danger will be used. A notice warning of injury to persons with a safety alert symbol may also include a warning relating to property damage.

Qualified Personnel

The device/system may only be set up and used in conjunction with this documentation. Commissioning and operation of a device/system may only be performed by qualified personnel. Within the context of the safety notices in this documentation qualified persons are defined as persons who are authorized to commission, ground and label devices, systems and circuits in accordance with established safety practices and standards.

Prescribed Usage

Note the following:

!

WarningThis 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.

Correct, reliable operation of the product requires proper transport, storage, positioning and assembly as well as careful operation and maintenance.

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.

Disclaim of Liability

We have reviewed the contents of this publication to ensure consistency with the hardware and software described. Since variance cannot be precluded entirely, we cannot guarantee full consistency. However, the information in this publication is reviewed regularly and any necessary corrections are included in sub- sequent editions.

This manual contains notices you have to observe in order to ensure your personal safety, as well as to prevent damage to property. The notices referring to your personal safety are highlighted in the manual by a safety alert symbol, notices referring to property damage only have no safety alert symbol. The notices shown below are graded according to the degree of danger.

Copyright E Siemens AG 2006 Technical data subject to change SIEMENS AG

Automation and Drives Postfach 4848 90437 NÜRNBERG GERMANY

A5E00850741-01 11/2006

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Automation System S7-400 Hardware and Installation iii

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Preface

Purpose of the Manual

The manual contains reference information on operator actions, descriptions of functions and technical specifications of the central processing units, power supply modules and interface modules of the S7-400.

How to configure, assemble and wire these modules (and other) in an S7-400 system is described in the installation manuals for each system.

Required Basic Knowledge

You will need general knowledge of automation to understand this manual.

Prerequisite is also sufficient knowledge in the use of computers or PC-type equipment (programming devices, for example) with Windows 2000 or XP

operating system. The S7-400 system is configured in STEP 7 standard software.

You should therefore have sufficient knowledge of this standard software. This knowledge is provided in the “Programming with STEP 7” manual.

Please note the information on the safety of electronic control systems in the appendix of this manual, in particular when operating an S7-400 in safety-relevant areas.

Scope of this Manual

The manual applies to the S7-400 automation system.

Approvals

You can find details on approvals and standards in the “Module Data” reference manual.

Place of this Documentation in the Information Environment This manual is part of the documentation package for S7-400.

System Documentation Package

S7-400S7-400 Programmable Controller; Hardware and Installation

S7-400 Programmable Controllers; Module Data

Automation System S7-400; CPU Data

S7-400 Instruction List

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Preface

iv Automation System S7-400 Hardware and Installation

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Navigating

The manual offers the following access help to make it easy for you to find specific information:

• At the start of the manual you will find a complete table of contents and a list of the diagrams and tables that appear in the manual.

• An overview of the contents of each section is provided in the left column on each page of each chapter.

• You will find a glossary in the appendix at the end of the manual. The glossary contains definitions of the main technical terms used in the manual.

• At the end of the manual you will find a comprehensive index which gives you rapid access to the information you need.

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.

Further Support

If you have any technical questions, please get in touch with your Siemens representative or responsible agent .

You will find your contact person at:

http://www.siemens.com/automation/partner

You will find a guide to the technical documentation offered for the individual SIMATIC Products and Systems here at:

http://www.siemens.com/simatic-tech-doku-portal The online catalog and order system is found under:

http://mall.automation.siemens.com

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

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Preface

Automation System S7-400 Hardware and Installation v

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Technical Support

You can reach the Technical Suport for all A&D products

• Via the Web formula for the Support Request

http://www.siemens.com/automation/support-request

• Phone: + 49 180 5050 222

• Fax:+ 49 180 5050 223

Additional information about our Technical Support can be found on the Internet pages:

http://www.siemens.com/automation/service.

Service & Support on the Internet

In addition to our documentation, we offer our Know-how online on the internet at:

http://www.siemens.com/automation/service&support where you will find the following:

• The newsletter, which constantly provides you with up-to-date information on your products.

• The right documents via our Search function in Service & 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”.

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Preface

vi Automation System S7-400 Hardware and Installation

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Automation System S7-400 Hardware and Installation vii

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Contents

1 Product Overview . . . . 1-1 2 Installing the S7-400 . . . . 2-1 2.1 S7-400 Installation . . . 2-2 2.2 Installing the Central Rack (CR) 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 . . . 2-18 2.8 Changing the Ventilation with the Cable Duct and Fan Subassembly . . . 2-20 2.9 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 Marking the Modules with Slot Labels . . . 2-33 2.15 Methods of Expansion and Networking . . . 2-34 2.16 Accessories . . . 2-35 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 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

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Contents

viii Automation System S7-400 Hardware and Installation

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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 Wiring the Power Supply Module . . . 4-18 4.13 Wiring the Signal Modules . . . 4-22 4.14 Wiring the Front Connector, Crimping . . . 4-24 4.15 Wiring the Front Connector, Screw Terminals . . . 4-25 4.16 Wiring the Front Connector, Spring-Type Terminals . . . 4-26 4.17 Fitting the Strain Relief . . . 4-28 4.18 Labeling a Front Connector . . . 4-29 4.19 Fitting the Front Connector . . . 4-32 4.20 Interconnecting the CR and ER(s) . . . 4-35 4.21 Setting the Fan Subassembly to the Line Voltage and Wiring It . . . 4-37 4.22 Cable routing in cable ducts or fan subassemblies . . . 4-38 4.23 Routing Fiber-Optic Cables . . . 4-38 5 Networking. . . . 5-1 5.1 Configuring a Network . . . 5-2 5.2 Fundamentals . . . 5-3 5.3 Rules for Configuring a Network . . . 5-7 5.4 Cable Lengths . . . 5-15 5.5 PROFIBUS-DP Bus Cables. . . 5-18 5.6 Bus Connectors . . . 5-19 5.7 RS 485 Repeater / Diagnostics Repeater . . . 5-21 5.8 PROFIBUS-DP Network with Fiber-Optic Cables . . . 5-22 5.8.1 Fiber-Optic Cables . . . 5-24 5.8.2 Simplex Connectors and Connector Adapter . . . 5-26 5.8.3 Connecting a Fiber-Optic Cable to the PROFIBUS Device . . . 5-28 6 Commissioning . . . . 6-1 6.1 Recommended Procedure for First Startup . . . 6-2 6.2 Checks Prior to Switching On for the First Time. . . 6-3 6.3 Connecting a Programming Device (PG) to an S7-400 . . . 6-5 6.4 Switching On an S7-400 for the First Time . . . 6-6 6.5 Resetting the CPU with the Mode Selector Switch . . . 6-7 6.6 Cold, Warm, and Hot Restarts with the Mode Selector Switch . . . 6-10 6.7 Inserting a Memory Card . . . 6-11 6.8 Inserting a Backup Battery (Option) . . . 6-13 6.9 Starting Up a PROFIBUS-DP Subnet . . . 6-17 6.10 Installing Interface Modules (CPU 414-2, 414-3, 416-3, 417-4

and 417-4H) . . . 6-18

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Contents

Automation System S7-400 Hardware and Installation ix

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7 Maintenance . . . . 7-1 7.1 Replacing the Backup Battery. . . 7-2 7.2 Replacing a Power Supply Module. . . 7-4 7.3 Replacing CPUs . . . 7-5 7.4 Replacing Digital or Analog Modules . . . 7-7 7.5 Changing the Fuses in the Digital Modules. . . 7-9 7.6 Replacing Interface Modules. . . 7-11 7.7 Replacing the Fuse of the Fan Subassembly . . . 7-13 7.8 Replacing Fans in the Fan Subassembly During Operation. . . 7-14 7.9 Replacing the Filter Frame of the Fan Subassembly During Operation . . 7-16 7.10 Replacing the Power Supply PCB and Monitoring PCB

of the Fan Subassembly. . . 7-18 7.11 Replacing Interface Submodules . . . 7-19 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

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Contents

x Automation System S7-400 Hardware and Installation

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Figures

2-1 Rack Fitted with Modules in the S7-400 System . . . 2-2 2-2 Max. Cabinet Ambient Temperature as a Function of Power Dissipation

of Equipment in the Cabinet . . . 2-27 2-3 Removing the Cover . . . 2-31 2-4 Attaching the Modules . . . 2-32 2-5 Screwing the Modules in Place. . . 2-32 2-6 Fitting a Slot Label. . . 2-33 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 Disconnecting power supply connector . . . 4-18 4-10 Wiring the power supply connector . . . 4-20 4-11 Plugging the power supply connector . . . 4-21 4-12 Preparing to wire the front connector . . . 4-23 4-13 Wiring a Front Connector with Crimp Terminals. . . 4-24 4-14 Wiring a Front Connector with Screw-Type Terminals. . . 4-25 4-15 Wiring a Front Connector with Spring-Type Terminals . . . 4-26 4-16 Principle of the spring contact . . . 4-27 4-17 Fitting a Strain Relief (Viewed from Below). . . 4-28 4-18 Fitting the Labels on the Front Connector . . . 4-29 4-19 Fitting a Label in the Front Connector . . . 4-30 4-20 Attaching the Front Connector . . . 4-33 4-21 Screwing On the Front Connector . . . 4-34 4-22 Plugging a Connecting Cable into a Send IM . . . 4-35 4-23 Connection Between a Send IM and Two Receive IMs . . . 4-36 4-24 Wiring the Fan Subassembly. . . 4-37 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 Bus connector. . . 5-19 5-12 Switch on terminating resistant . . . 5-20 5-13 Optical PROFIBUS-DP Network with Nodes that have an

Integrated Fiber-Optic Cable Interface. . . 5-23 5-14 Simplex Connectors and a Special Connector Adapter for the IM 153-2 FO

and IM 467 FO (installed). . . 5-27 6-1 Connecting PG to an S7-400. . . 6-5 6-2 Positions of the mode selector switch . . . 6-8 6-3 Inserting a Memory Card in a CPU. . . 6-12 6-4 Inserting Interface Submodules in the CPU . . . 6-19 7-1 Inserting an Interface Submodule in a CPU . . . 7-20

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Contents

Automation System S7-400 Hardware and Installation xi

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A-1 The Possible Routes for Electromagnetic Interference. . . A-5 A-2 Example of Cabinet Installation for EMC . . . A-10 A-3 Wall Mounting an S7-400 for EMC . . . A-12 A-4 Mounting Cable Shields . . . A-14 A-5 Routing Equipotential Bonding Conductor and Signal Line . . . A-16 A-6 Lightning Protection Zones of a Building . . . A-22 A-7 Sample Circuitry for Networked S7-400 PLCs . . . A-28 A-8 Relay Contact for EMERGENCY OFF in the Output Circuit. . . A-30 A-9 Suppression for DC-Operated Coils. . . A-31 A-10 Suppression with AC-Operated Coils. . . A-31 A-11 Shielding and Grounding with a Great Distance between Monitor

and Programmable Controller . . . A-36 B-1 Electrostatic Voltages which can build up on a person . . . B-3

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Contents

xii Automation System S7-400 Hardware and Installation

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Tables

2-1 Cabinet types . . . 2-26 2-2 Modules in the different racks . . . 2-29 2-3 Accessories for Modules and Racks . . . 2-35 4-1 VDE Specifications for Assembling a Programmable Controller . . . 4-5 4-2 Methods of Protective Grounding . . . 4-13 4-3 Grounded connection load voltage. . . 4-14 4-4 Front connector coding elements . . . 4-32 5-1 Permitted Cable Length of a Segment in an MPI Network . . . 5-15 5-2 Permitted Cable Length of a Segment in the PROFIBUS-DP Network

Depending on the Transmisson Rate . . . 5-15 5-3 Lengths of Spur Lines per Segment . . . 5-16 5-4 Features of the Fiber-Optic Cables . . . 5-24 5-5 Order Numbers - Fiber-Optic Cables . . . 5-26 5-6 Order Numbers - Simplex connectors and connector adapters . . . 5-27 5-7 Permissible Cable Lengths on the Optical PROFIBUS-DP Network

(Partyline Topology) . . . 5-28 6-1 Checklist to be Used Before Switching On for the First Time . . . 6-3 6-2 Setting the Battery Monitoring Switch . . . 6-5 A-1 Key for Example 1 . . . A-11 A-2 Cabling Inside Buildings . . . A-17 A-3 High-Voltage Protection of Cables with the Help

of Surge Protection Equipment . . . A-23 A-4 Low-Voltage Protection Components for

Lightning Protection Zones 1 <--> 2 . . . A-26 A-5 Surge Protection Components for Lightning Protection Zones 2 <--> 3 . A-27 A-6 Example of a Circuit Conforming to Lightning Protection Requirements

(Legend to Figure A-7) . . . A-29

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Automation System S7-400 Hardware and Installation 1-1

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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.

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

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Product Overview

1-2 Automation System S7-400 Hardware and Installation

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S7-400 components

The most important components of the S7-400 and their functions are given in the following tables:

Components Function Illustration

Racks

(UR: Universal Rack) (CR: Central Rack) (ER: Expansion Rack)

... provide the mechanical and electrical connections between the S7-400 modules.

Power Supply Modules (PS = Power Supply) Accessories:

Backup battery

... convert the line voltage (120/230 VAC or 24 VDC) to the 5 VDC and 24 VDC operating voltages required to power the S7-400.

CPUs

Central Processing Units (CPUs) ... execute the user program;

communicate via the multipoint interface (MPI) with other CPUs or with a programming device (PG).

Memory cards ... store the user program and parameters.

IF 964-DP interface module ... used to connect distributed I/Os via PROFIBUS-DP

Signal Modules (SM = Signal Module) (digital input modules, digital output modules, analog input modules, analog output modules) Accessories:

Front connector with three different terminal systems

... match the different process signal levels to the S7-400.

... form the interface between PLC and process.

Interface modules (IM = Interface Module) Accessories:

Connecting cable Terminator

... interconnect the individual racks of an S7-400.

Cable ducts ...are used for routing cables and as ventilation.

PROFIBUS bus cables ...connect CPUs to programming devices.

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Product Overview

Automation System S7-400 Hardware and Installation 1-3

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Components Function Illustration

PG cables ...connect a CPU to a

programming device.

PROFIBUS components for example, PROFIBUS bus terminal

... connect the S7-400 to other S7-400 devices or programming devices.

RS 485 repeaters ...amplify data signals on bus lines and links bus segments.

Programming device (PG) or PC with the STEP 7 software package

...configures, programs, debugs, and assigns parameters to the S7-400.

Fan subassemblies

(for special areas of application) ...ventilates modules in special cases; can be operated with or without a filter.

Additional components of the S7-400 such as communications processors, function modules, etc., are described in separate manuals.

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.

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

412-1XF04-0AB0 2 3 4 X CPU 412-1

Firmware version (in CPUs)

V 4.0

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Product Overview

1-4 Automation System S7-400 Hardware and Installation

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Example of a rating plate

Order no. Module designation

Approvals and marks Product version

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Automation System S7-400 Hardware and Installation 2-1

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Installing the S7-400

Chapter Overview

Section Description Page

2.1 S7-400 Installation 2-2

2.2 Installing the Central Rack (CR) and Expansion Rack (ER) 2-6

2.3 Segmented CR 2-8

2.4 Subdivided CR 2-9

2.5 Mounting and Grounding the Racks 2-10

2.6 Chassis Terminal Connection in the Non-Isolated Configuration 2-16

2.7 Methods of Ventilation 2-18

2.8 Changing the Ventilation with the Cable Duct and Fan Subassembly 2-20

2.9 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 Marking the Modules with Slot Labels 2-33

2.15 Methods of Expansion and Networking 2-34

2.16 Accessories 2-35

2

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Installing the S7-400

2-2 Automation System S7-400 Hardware and Installation

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2.1 S7-400 Installation

Introduction

An S7-400 programmable controller consists of a central rack (CR) and one or more expansion racks (ERs), as required. 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).

When using ERs, you need interface modules (IMs) as well as the additional racks, and additional power supply modules if necessary. When using interface modules, you must always use the appropriate partners: you insert a send IM in the CR, and the matching receive IM in each connected ER (see Reference Manual,

Chapter 6).

Central Rack (CR) and Expansion Rack (ER)

The rack containing the CPU is known as the central rack (CR). The racks containing modules in the system and connected to the CR are the expansion racks (ERs).

Shown in Figure 2-1 is a rack with 18 slots configured as a CR.

PS CPU SMs

Figure 2-1 Rack Fitted with Modules in the S7-400 System

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Installing the S7-400

Automation System S7-400 Hardware and Installation 2-3

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Connecting the CR and ER(s)

To connect one or more ERs to a CR, you must fit one or more send IMs in the CR.

The send IMs have two interfaces. You can connect one chain of up to four ERs to each of the two interfaces of a send IM in the CR.

Different IMs are available for local connection and remote connection.

Connecting with a 5 V Supply

For a local connection with the IM 460-1 and IM 461-1, the 5 V supply voltage is also transferred via the interface modules. There must therefore be no power supply module inserted in an ER connected to an IM 460-1/IM 461-1.

Up to 5 A may flow through each of the two interfaces of an IM 460-1. This means that each ER connected via an IM 460-1/461-1 can be powered with a maximum of 5 A at 5 V. For further details, see the Reference Manual, Chapter 6.

Overview of the Connections

Observe the connection rules at the end of this section.

Local Connection Remote Connection

Send IM 460-0 460-1 460-3 460-4

Receive IM 461-0 461-1 461-3 461-4

Max. number of connectable

EMs per chain 4 1 4 4

Max. distance 5 m 1.5 m 102.25 m 605 m

5 V transfer No Yes No No

Max. current transfer per inter-

face -- 5 A -- --

Communication bus transmission Yes No Yes No

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Installing the S7-400

2-4 Automation System S7-400 Hardware and Installation

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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. 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

Chain length max. 5 m

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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

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2.2 Installing the Central Rack (CR) and Expansion Rack (ER)

Function of the Racks

The racks of the S7-400 system form the basic framework which accepts 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

Communication CR

or Rack for all module types in the S7 400

UR2 9 Communication

bus or

ER Rack for all module types in the S7-400.

ER1 18

Restricted I/O ERs

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

Restricted I/O

bus ERs Modules are not supplied with 24 V,

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).

CR2 18

I/O bus,

segmented Segmented

Rack for all module types in the S7-400 except receive IMs.

CR2 18 segmented

Communication bus, continuous

Segmented CR

p

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 S7-400 modules except send IMs.

The I/O bus and communication bus are divided into 2 bus segments, each with 9 slots.

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Electrical Supply

The modules inserted in the rack are supplied with the required operating voltages (5 V for logic, 24 V for interfaces) via the backplane bus and base connector, by the power supply module fitted in the slot on the extreme left in the rack.

For local connections, ERs can also be supplied with power via the IM 460-1 / IM 461-1 interface modules.

5 A may flow through each of the two interfaces of a send IM 460-1, meaning each ER in a local connection can be supplied with up to 5 A.

I/O Bus

The I/O bus is a parallel backplane bus designed for the fast interchange of I/O signals. Each rack has an I/O bus. Time-critical operations to access the process data of the signal modules take place via the I/O bus.

Communication Bus (C Bus)

The communication bus (C bus) is a serial backplane bus designed for the fast exchange of large volumes of data parallel to the I/O signals. Except for racks ER1 and ER2, each rack has a communication bus.

Rack with I/O Bus and Communication Bus

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

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

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2.3 Segmented CR

Properties

The “segmented” characteristic relates to the configuration of the CR. In the (non-segmented) CR the I/O bus is continuous and interconnects all 18 or 9 slots;

in the segmented CR, however, the I/O bus consists of two I/O bus segments.

A segmented CR has the following important characteristics:

• The communication bus is continuous (global), whilst the I/O bus is divided into two I/O bus segments of 10 and 8 slots respectively.

• One CPU can be inserted per local bus segment.

• The two CPUs in a segmented CR may be in different operating states.

• The two CPUs can communicate with each other via the communication bus.

• All the modules inserted in a segmented CR are powered by the power supply module at slot 1.

• Both segments have a common backup battery.

The following figure shows a segmented CR with divided I/O bus and continuous communication bus.

I/O bus

Segment 1 I/O bus

Segment 2

SEG1 SEG1 SEG1 SEG1 SEG1 SEG1 SEG1 SEG1 SEG1 SEG1 SEG2 SEG2 SEG2 SEG2 SEG2 SEG2 SEG2 SEG2

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

SEG11 11

SEG2

Communication bus

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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.

1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7 8 9

1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7 8 9

Division I Division II

I/O bus Segment 1

I/O bus Segment 2

Communication bus

Segment 1 Communication bus

Segment 2

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2.5 Mounting and Grounding the Racks

Important Notes on Installation

The S7-400 racks are designed for wall mounting, mounting on rails, and for installation in frames and cabinets. Their mounting dimensions are compliant with DIN 41 494.

According to the 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 (seeReference Manual, Chapter 1).

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 352 mm

Mounting depth, fitted: max. 237 mm

40 mm facilitates the mounting of a fan subassembly

*

*

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

523 mm (18 slots) 298 mm (9 slots) 173 mm (4 slots)

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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 19-inch reference level

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

523 mm (with cable duct) 543 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.

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2-12 Automation System S7-400 Hardware and Installation

A5E00850741-01 465 mm

240 mm 290 mm 190 mm

40 mm

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

1 2 3 4 5 6 7 8 9

60 mm

290 mm 190 mm

40 mm

1 2 3 4

1 2 3 4

115 mm

258 mm 133 mm

483 mm

Depth = 28 mm without modules Depth = 237 mm with modules

Step 2: Mounting the Rack

Screw the rack onto the mounting panel.

When mounting the equipment on a metal mounting plate, make sure to establish a low-impedance connection. 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.

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Mounting Screws

You have a choice of the following types of screw for securing a rack:

Screw Type Explanation

M6 cylinder-head screw to

ISO 1207/ISO 1580 (DIN 84/DIN 85)

Choose the screw length according to your assembly.

You also need “6 4” washers to ISO 7092 M6 hex. screw to ISO 4017 (DIN 4017) You also need “6.4” washers to ISO 7092

(DIN 433).

Step 3: Connecting the Rack to the Chassis Ground

Connect the rack to the chassis ground. A threaded bolt is provided for this purpose on the bottom left of the rack.

Minimum cross-section of the conductor to the chassis ground: 10 mm2.

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). You achieve this with the shortest possible, low-resistance conductor with a large surface to establish large-area contact.

M6 threaded bolt

Terminal Plain washer

Contact washer

M6 nut

To chassis ground

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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.

110 mm

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

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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

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

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.

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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.

The following figure shows the position of the reference point on a rack.

Grounding terminal Load voltage ground

connection (reference point)

1 2 3 4 5 6 7

Metallic connection, disconnect upper screw for ungrounded assemblies

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Connection to the Reference Point

For the connection to the reference point, use a cable lug for M4, a suitable spring lock washer (for example, clamping washer to DIN 6796) and the cylinder-head screw supplied.

Ungrounded assembly: Undo the fixing screws of the metallic connection on the rack. Tilt the connection downwards. For the connection to the reference point, use the original M4 x 8 supplied. Use the tilted metallic connection as a washer.

Grounded assembly: Leave the metallic connection on the rack. For the connection to the reference point, use the original M4 x 8.

Reference point

Original screw withspring lock washer M4 x 8

Connection Spring lock washer

Original screw withspring lock washer M4 x 8

Rack

Ungrounded configuration Grounded configuration

Metallic connection

Connection Spring lock washer

Note

Do not use any cylinder-head screws that are longer than 6 mm for the connection to the reference point. Otherwise, you may create an undesired connection bet- ween the reference point and the rack profile behind it and therefore the connec- tion for the chassis ground. For this reason as well, leave the metallic connection on the rack and use it as a washer in an ungrounded configuration.

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2.7 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. 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

Exhaust air

Modules Wall

Modules

Supply air

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The following figure shows the ventilation when air is drawn in from the bottom.

Exhaust air Wall

Supply air

Cable duct or fan subassembly

Modules Modules

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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 modify 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 base cover is secured with clips. Firmly press down the cover in the clip areas to remove it.

4. Snap the cover into the snap-in hinges at the rear edge of the base, rougly at a right angles to 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.

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Cover

Quick-release locks

Cover Snap catches

Snap hinges Cover fitted at bottom

Cover fitted at back (supply air from the rear)

(supply air from below)

Base

Base Delivered state:

Shipping state

The cover is fitted in the base of the cable duct or fan subassembly. Air is supplied from the back.

Filter Mat (Optional)

To filter the air supply, you can fit a filter mat for the cable duct and fan subassembly. 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.

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2.9 Installing the Fan Subassembly

Procedure

1. Remove the left cover from the fan subassembly.

Using a 17 mm open-ended wrench, slacken the quick-release lock a quarter turn.

Pull out the left cover of the fan subassembly. To do this, move the left cover parallel to the fan subassembly in order to avoid damaging the plug-in contact on the other side.

The following figure shows you how to remove the left cover.

Left cover

Quick-release lock Plug-in contact

Snap-in mechanism of dummy covers

Back of cable routing

Direction for pulling off

Note

Provide the fan subassembly with dummy plates beneath free slots, this will ensure optimum ventilation.

The fan subassembly is supplied with 18 dummy plates, arranged as 2 units, each with 9 individual dummy plates. By breaking at one of the rupture joints, you can split up the individual plates as required.

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.

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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

9 10 11 12 13 14 15 16 17 18

9 10 11 12 13 14 15 16 17 18

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.

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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

9 10 11 12 13 14 15 16 17 18

9 10 11 12 13 14 15 16 17 18

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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.

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Table 2-1 provides an overview of the most common types of cabinet. You will also find the principle of heat removal, as well as the estimated, maximum achievable power loss removal and the degree of protection.

Table 2-1 Cabinet types

Open Cabinets Closed Cabinets

Through-ventilatio n by natural convection

Increased

through-ventilation

Natural convection Forced circulation using fan

subassembly, enhanced natural convection

Forced circulation using heat exchanger, external ventilation inside and outside

Heat removal primarily by natural thermal

convection, small portion via the cabinet wall

Increased heat removal through increased air movement

Heat removal only through the cabinet wall; only low power dissipation permissible. Heat accumulation usually occurs in the top of the cabinet.

Heat removal only through the cabinet wall.

Forced ventilation of the internal air results in improved heat removal and prevention of heat accumulation.

Heat removal through exchange between heated internal air and cold external air.

The increased surface of the folded-area sectional wall of the heat exchanger and forced circulation of internal and external air permit good heat output.

Degree of

protection IP 20 Degree of

protection IP 20 Degree of

protection IP 54 Degree of

protection IP 54 Degree of protection IP 54 Typical removable power dissipation under the following boundary conditions:

Cabinet size 2200 x 600 x 600 mm

Difference between external and internal temperature of the cabinet: 20° C (for other temperature differences, you must refer to the temperature characteristics of the cabinet manufacturer) up to 700 W up to 2700 W

(1400 W with very fine filter)

up to 260 W up to 360 W up to 1700 W

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Removable Power Dissipation from Cabinets (Example)

The removable power dissipation from a cabinet is governed by the type of cabinet, its ambient temperature, and the arrangement of equipment in the cabinet.

Figure 2-2 shows a diagram with guide values for the permissible ambient temperature of a cabinet measuring 600 x 600 x 2000 mm as a function of power dissipation. These values only apply if you observe the specified installation dimensions and clearances for racks. Further information can be found in Siemens catalogs NV21 and ET1.

200 400 600 800 1000 1200 1400 W

Power dissipation 20

30 40 50 60

Ambient temperature in °C

1 2

3

Figure 2-2 Max. Cabinet Ambient Temperature as a Function of Power Dissipation of Equipment in the Cabinet

Legend for Figure 2-2:

1. Closed cabinet with heat exchanger;

heat exchanger size 11/6 (920 x 460 x 111 mm) 2. Cabinet with through-ventilation by natural convection

3. Closed cabinet with natural convection and forced circulation by equipment fans

!

WarningRisk of damage to the modules.

Modules may be damaged as a result of excess ambient temperature.

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Example of selecting the cabinet type

The example below clarifies the maximum permissible ambient temperature at a particular power loss for various cabinet types.

Equipment suitable for installation in a cabinet:

1 central rack 150 W

2 expansion racks, 150 Watts each 300 W

1 load current power supply under full load 200 W

Accumulated power loss 650 W

Permissible ambient temperatures at an accumulated power loss as shown in Figure 2-2:

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

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

• Space requirement of cable ducts or fan subassemblies

• Locations of rails

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數據

Figure 2-1 Rack Fitted with Modules in the S7-400 System
Figure 2-4 Attaching the Modules
Figure 4-1 Operating the S7-400 from a Grounded Supply
Figure 4-4 Simplified Representation of Configuration with Isolated Modules
+7

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