C B A 8 7 6 5 S7-400 and M7-400Programmable ControllersHardware and Installation 4 SIMATIC 3 2 1 www.PLCworld.cn

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(1)www.PLCworld.cn www.gkbpx.com Preface, Contents. SIMATIC S7-400 and M7-400 Programmable Controllers Hardware and Installation Manual. Product Overview. 1. Installing the S7-400. 2. Addressing the S7-400. 3. Wiring the S7-400. 4. Networking. 5. Starting Up. 6. 理整. Maintenance. 司公限. Assembling the M7-400 This manual is part of the documentation package with the order number:. 育教. 控帮. 有技科 Assembling and Installing Systems. A. Guidelines for Handling Electrostatically-Sensitive Devices (ESD). B. Siemens Worldwide. C. Glossary, Index. 07/99 C79000-G7076-C424 Release 01. 8. Appendices:. 6ES7498-8AA03-8BA0. 工沙长. 7.

(2) www.PLCworld.cn Safety Guidelines. www.gkbpx.com. This manual contains notices which you should observe to ensure your own personal safety, as well as to protect the product and connected equipment. These notices are highlighted in the manual by a warning triangle and are marked as follows according to the level of danger:. Danger. !. #(#.-.". ." -0, *,-)(& #($/,2 ), -/-.(.#& *,)*,.2 '! 1#&& ,-/&. # *,)*, *,/.#)(- , (). .%(. !. Warning #(#.-.". ." -0, *,-)(& #($/,2 ), -/-.(.#& *,)*,.2 '! ( ,-/&. # *,)*, *,/.#)(- , (). .%(. Caution. !. #(#.- .". '#(), *,-)(& #($/,2 ), *,)*,.2 '! ( ,-/&. # *,)*, *,/.#)(- , (). .%(. Note ,1-2)/, ..(.#)( .) *,.#/&,&2 #'*),.(. #( ),'.#)( )( ." *,)/. "(&#(! ." *,)/. ), .) *,.#/&, *,. ) ." )/'(..#)(. 理整. 司公限. Qualified Personnel. The device/system may only be set up and operated in conjunction with this manual.. 有技科. (&2

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(14) www.PLCworld.cn www.gkbpx.com. Preface. Purpose of the Manual The information given in this manual makes it possible for you to: install and wire an S7-400 memory programmable controller configure an M7-400 automation computer for mechanical and electrical installation. 理整. A description of the functions and technical specifications of the signal modules, power supply modules and interface modules can be found in the reference manual Module Specifications.. 司公限. Contents of the Manual. 有技科. The manual contains the following subjects:. 育教. Installing the S7-400/M7-400. Wiring the S7-400/M7-400 and preparing it for commissioning.. 帮控 Scope of the Documentation Package 工沙长. This manual is part of the SIMATIC S7-400, M7-400 documentation package, order number 6ES7 498-8AA03-8BA0, comprising the following manuals: Manual. Contents. S7-400 and M7-400 Programmable Controllers, Installation. Installing and starting up an S7-400 or an M7-400. S7-400 and M7-400 Programmable Controllers, Module Specifications. Data for modules and components of the S7-400 and M7-400. S7-400 Instruction List. Complete list of instructions of the S7-400 CPUs with all run times. Standards The S7-400 programmable controller meets the requirements of the IEC 1131, part 2. The S7-400 meets the requirements for CE labeling. The S7-400 has CSA, UL and FM approval.. S7-400 and M7-400 Programmable Controllers, Installation Manual C79000-G7076-C424-01. iii.

(15) www.PLCworld.cn www.gkbpx.com. Preface. Recycling and Disposal The SIMATIC S7-400/M7-400 is an environmentally friendly product. It is characterized by the following points: The plastic for the casing is coated with a halogen-free flame retardant despite its high resistance to fire. Labeling is done by laser (meaning no labels) The plastics are coded according to DIN 54840 Fewer materials are used in this compact design, fewer components are required as the result of integration in ASICs The SIMATIC S7-400/M7-400 can be recycled as a result of its minimal use of harmful substances. For environmentally compatible recycling and disposal of your old SIMATIC device in accordance with the current state of the art, please contact:. 理整. Siemens Aktiengesellschaft Technische Dienstleistungen ATD TD 3 Kreislaufwirtschaft Postfach 32 40 D-91052 Erlangen. 司公限. 有技科. Telefon: (+49) 9131 / 7-33698 Fax: (+49) 9131 / 7-26643. This Siemens department provides a comprehensive and flexible disposal service at a fixed cost with individual consultancy. You will be provided with papers documenting the breaking down of your system giving details on the fractional parts and the relevant verification papers for the materials.. 育教. Audience. 帮控工. 长沙. This manual is intended for the following audience: Installers Startup specialists Service and maintenance personnel. Where is this Package Valid? This documentation package contains the descriptions of all the modules that are valid at the time of publishing of the manuals. The order numbers of the modules and other components to which these manuals apply are specified, where appropriate, in the corresponding data sheets in the reference manual and in the chapter entitled ”Spare Parts.” We reserve the right to provide new modules and modules with a new product release with a product information containing the latest information on the module.. iv. S7-400 and M7-400 Programmable Controllers, Installation Manual C79000-G7076-C424-01.

(16) www.PLCworld.cn www.gkbpx.com. Preface. Additional Manuals Required for S7-400 This documentation package describes the hardware of the S7-400. You will need the following additional documentation for programming and starting up an S7-400:. Manual/ Manual Package. Contents. Standard Software for S7 and M7 STEP 7 Basic Information. Installing and starting up STEP 7 on a programming device / PC Working with STEP 7 with the following contents: Managing projects and files Configuring and assigning parameters to the S7-400 configuration Assigning symbolic names for user programs Creating and testing a user program in STL/LAD Creating data blocks Configuring the communication between two or more CPUs Loading, storing and deleting user programs in the CPU / programming device. 理整. Monitoring and controlling user programs Monitoring and controlling the CPU. 司公限. Guide for efficiently implementing the programming task with the programming device / PC and STEP 7 How the CPUs work (for example, memory concept, access to inputs and outputs, addressing, blocks, data management). 有技科. Description of STEP 7 data management Using data types of STEP 7. 育教. Using linear and structured programming Using block call instructions. 帮控工. Using the debug and diagnostic functions of the CPUs in the user program (for example, error OBs, status word). STEP 7 Reference Information. 长沙. Basic procedure for working with STL, LAD, or FBD (for example, structure of STL, LAD, or FBD, number formats, syntax). Statement List (STL) for S7-300 and S7-400 Ladder Logic (LAD) for S7-300 and S7-400 Function Block Diagram (FBD) for S7-300 and S7-400 System and Standard Functions. Description of all instructions in STEP 7 (with program examples). Manual. Description of the programming device hardware. PG 7xx. Connecting a programming device to various devices. Description of the various addressing methods in STEP 7 (with examples) Description of all functions integrated in the CPUs Description Descri tion of the internal registers in the CPU Description of all system functions integrated in the CPUs Description of all organization blocks integrated in the CPUs. Starting up a programming device. S7-400 and M7-400 Programmable Controllers, Installation Manual C79000-G7076-C424-01. v.

(17) www.PLCworld.cn www.gkbpx.com. Preface. Additional Manuals Required for M7-400 This documentation package describes the hardware of the M7-400. You will need the following additional documentation for programming and starting up an M7-400:. Documentation. Contents. Order No.. SIMATIC M7 Technical Overview. Describes the available components, possible structures and principles of communication. 6ES7 498-0AA00-8AA0. System Software for M7-300/400 Program Design Programming Manual. Designing, writing and testing a C program for M7 CPU/FM modules with the M7 SYS programming package, using the M7 SYS functions. 6ES7 802-0FA01-0AA0. System Software for Detailed description of the M7 SYS functions M7-300/400 System and and data structures, listing of messages Standard Functions Reference types Manual System Software for M7-300/400 Installation and Operation User Manual. Installing and configuring the operating system and system software. 理整. 司公限. Further Information. 有技科. For further information on S7-400 and memory programmable controllers, see the list in the Appendix.. 育教. CD-ROM. 帮控工. Additionally, complete SIMATIC S7 documentation is available on CD-ROM.. 沙长 Structure of this Manual. To facilitate rapid access to special information, the manual contains the following aids: At the start of the manual, you will find a complete list of contents. The appendix is followed by a glossary which defines the important technical terms used in the manual. At the end of the manual there is a detailed index to enable you to find the desired information quickly.. vi. S7-400 and M7-400 Programmable Controllers, Installation Manual C79000-G7076-C424-01.

(18) www.PLCworld.cn www.gkbpx.com. Preface. Additional Assistance If you have any questions regarding the products described in these manuals and cannot find an answer in the paper documentation or in the online help, please contact the Siemens representative in your area. You will find a list of addresses in the Appendix entitled “Siemens Worldwide” at the end of this manual. If you have any questions or comments on this manual, please fill out the remarks form at the end of the manual and return it to the address shown on the form. We would be grateful if you could also take the time to give us your personal opinion of the manual. Siemens also offers a number of training courses to introduce you to the SIMATIC S7 automation system. Please contact your regional training center or the central training center in Nuremberg, Germany for details: D-90327 Nuremberg, Tel. (+49) 911 / 895 3154.. 理整. Up-To-Date Information. You can find up-to-date information on SIMATIC products from the following sources:. 司公限. On the Internet under http://www.ad.siemens.de/. 有技科. In addition, the SIMATIC Customer Support provides up-to-date information and download facilities for users of SIMATIC products: On Internet under http://www.ad.siemens.de/simatic.cs. 育教. Via SIMATIC Customer Support Mailbox under the following number +49 (911) 895-7100. 帮控工. For dialing into the mailbox use a modem of up to V.34 (28.8 Kbps) and set the following parameters: 8, N, 1, ANSI, or alternatively use ISDN (x. 75, 64 Kbps).. 长沙. You can reach the SIMATIC Customer Support by phone using the number (+49) (911) 895-7000 and by fax using (+49) (911) 895-7002. You can also send enquiries by e-mail on the Internet or by mail to the above mailbox.. S7-400 and M7-400 Programmable Controllers, Installation Manual C79000-G7076-C424-01. vii.

(19) www.PLCworld.cn www.gkbpx.com. Preface. 理整. 司公限. 育教. 有技科. 帮控工. 长沙. viii. S7-400 and M7-400 Programmable Controllers, Installation Manual C79000-G7076-C424-01.

(20) www.PLCworld.cn www.gkbpx.com. Contents 1. Product Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1-1. 2. Installing the S7-400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 2-1. 2.1. Assembling an S7-400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 2-2. 2.2. Assembling the Central Rack (CR) and Expansion Rack (ER) . . . . . . . . .. 2-6. 2.3. Segmented CR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 2-8. 2.4. Mounting and Grounding the Racks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 2-9. 2.5. Chassis Terminal Connection in the Non-Isolated Configuration . . . . . . . .. 2-14. 2.6. Methods of Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 2-16. 2.7. Changing the Ventilation with the Cable Duct and Fan Subassembly . . .. 2-18. 2.8. Installing the Fan Subassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 2-20. 2.9. Installing the Cable Duct . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 2-22. 2.10. Choosing and Setting up Cabinets with the S7-400 . . . . . . . . . . . . . . . . . .. 2-23. 2.11. Rules for the Arrangement of Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 2-27. 2.12. Installing Modules in a Rack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 2-28. 3. 4. 理整. 公司. 限有. 育教. 科技. 控帮. 工沙长. 2.13. Marking the Modules with Slot Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 2-32. 2.14. Methods of Expansion and Networking . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 2-33. 2.15. Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 2-34. 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. Wiring the S7-400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 4-1. 4.1. General Rules and Regulations for Operating the S7-400 . . . . . . . . . . . . .. 4-2. 4.2. Supplying Power to Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 4-5. 4.3. Choosing the Power Supply Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 4-6. 4.4. Choosing the Load Current Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . .. 4-7. 4.5. Assembling an S7-400 with Process I/Os . . . . . . . . . . . . . . . . . . . . . . . . . . .. 4-8. 4.6. Assembling an S7-400 with Grounded Reference Potential (0 V) . . . . . . .. 4-10. S7-400 and M7-400 Programmable Controllers, Installation Manual C79000-G7076-C424-01. ix.

(21) www.PLCworld.cn www.gkbpx.com. Contents. 4.7. 5. x. Assembling an S7-400 with Ungrounded Reference Potential (Ungrounded Configuration) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 4-11. 4.8. Assembling an S7-400 with Isolated Modules . . . . . . . . . . . . . . . . . . . . . . .. 4-13. 4.9. Shielding Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 4-15. 4.10. Equipotential Bonding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 4-17. 4.11. Protection Against Inductive Surge Voltages . . . . . . . . . . . . . . . . . . . . . . . .. 4-19. 4.12. Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 4-21. 4.13. Interference-Free Configuration for Local and Remote Connections . . . .. 4-23. 4.14. Wiring Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 4-25. 4.15. Setting the VAC Power Supply Module to the Line Voltage . . . . . . . . . . . .. 4-27. 4.16. Wiring the Power Supply Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 4-28. 4.17. Wiring the Signal Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 4-32. 4.18. Wiring the Front Connector, Crimp Snap-On Terminals . . . . . . . . . . . . . . .. 4-34. 4.19. Wiring the Front Connector, Screw-Type Terminals . . . . . . . . . . . . . . . . . .. 4-35. 4.20. Wiring the Front Connector, Spring-Type Terminals . . . . . . . . . . . . . . . . . .. 4-36. 4.21. Fitting the Strain Relief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 4-38. 4.22. Labeling a Front Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 4-39. 4.23. Fitting the Front Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 4-41. 4.24. Interconnecting the CR and ER(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 4-44. 4.25. Setting the Fan Subassembly to the Line Voltage and Wiring It . . . . . . . .. 4-46. 4.26. Routing Cables Using Cable Ducts or Fan Subassemblies . . . . . . . . . . . .. 4-47. 4.27. Routing Cables Using Fiber-Optic Cables . . . . . . . . . . . . . . . . . . . . . . . . . . .. 4-48. 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 5-23. 5.8 5.8.1 5.8.2 5.8.3. PROFIBUS-DP network with fiber-optic cables . . . . . . . . . . . . . . . . . . . . . . Fiber-optic cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Simplex connectors and connector adapter . . . . . . . . . . . . . . . . . . . . . . . . . Connecting a fiber-optic cable to the PROFIBUS device . . . . . . . . . . . . . .. 5-25 5-27 5-29 5-31. 理整. 司公限. 技有. 育科. 帮教. 控工. 长沙. S7-400 and M7-400 Programmable Controllers, Installation Manual C79000-G7076-C424-01.

(22) www.PLCworld.cn www.gkbpx.com. 6. 7. Contents. Starting Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 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. Fitting Memory Cards in the CPU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 6-19. 6.11. Installing Interface Submodules (CPU 417 and 417 H) . . . . . . . . . . . . . . . .. 6-21. 理整. 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. 司公限. 技有. 育科. 帮教. 控工. 长沙. 8. Fan Subassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 7-18. Assembling the M7-400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 8-1. 8.1. Mechanical Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 8-2. 8.2. Addressing the M7-400 Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 8-4. 8.3. Electrical Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 8-5. 8.4 8.4.1 8.4.2 8.4.3 8.4.4 8.4.5 8.4.6 8.4.7 8.4.8. Installing the M7-400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checklist for Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Module Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fitting Memory Cards in the CPU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installing Interface Submodules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fitting the Short AT Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembling Expansion Modules on a Central Rack . . . . . . . . . . . . . . . . . . Installing a Module Assembly in the Rack . . . . . . . . . . . . . . . . . . . . . . . . . . . Inserting/Removing a Memory Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 8-7 8-8 8-9 8-10 8-12 8-14 8-16 8-23 8-27. 8.5. Connecting a Module Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 8-28. S7-400 and M7-400 Programmable Controllers, Installation Manual C79000-G7076-C424-01. xi.

(23) www.PLCworld.cn www.gkbpx.com. Contents. A. B. 8.6. Assembling an MPI Subnet or PROFIBUS-DP Subnet . . . . . . . . . . . . . . . .. 8-30. 8.7 8.7.1 8.7.2 8.7.3 8.7.4 8.7.5. 8-32 8-33 8-36 8-39 8-40. 8.7.6 8.7.7. Preparing for Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Connecting the Operator Panels and I/O Devices . . . . . . . . . . . . . . . . . . . . Connecting a Programming Device (PG) to the COM Interface . . . . . . . . Connecting a Programming Device (PG) to the M7-400 . . . . . . . . . . . . . . . Connecting a Programming Device (PG) to Two or More Nodes . . . . . . . Connecting a Programming Device (PG) to Ungrounded Nodes of an MPI Subnet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Starting Up a PROFIBUS-DP Subnet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking the Status and Error Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . .. 8-43 8-44 8-45. 8.8 8.8.1 8.8.2 8.8.3 8.8.4. Replacing Modules and Submodules/Cards . . . . . . . . . . . . . . . . . . . . . . . . . Replacing an Interface Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacing the CPU or Expansion Modules of a Module Assembly . . . . . . Replacing Memory Cards in a CPU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacing a Short AT Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 8-46 8-47 8-49 8-54 8-56. Assembling and Installing Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. A-1. Principles of System Installation for EMC . . . . . . . . . . . . . . . . . . . . . . . . . . .. A-2. A.2. Installation of Programmable Controllers for EMC . . . . . . . . . . . . . . . . . . . .. A-6. A.3. Cabling Inside Buildings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. A-10. A.4. Cabling Outside Buildings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. A-13. A.5 A.5.1 A.5.2 A.5.3. A-14 A-15 A-17. A.5.4. Lightning Protection and Overvoltage Protection . . . . . . . . . . . . . . . . . . . . . Lightning Protection Zone Concept . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rules for the Transition between Lightning Protection Zones 0 and 1 . . . Rules for the Transitions between Lightning Protection Zones greater than 0 <->1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Example Circuit for Surge Protection of Networked S7-400s . . . . . . . . . . .. A-19 A-21. A.6. Interference-Free Connection of Monitors . . . . . . . . . . . . . . . . . . . . . . . . . . .. A-23. 技有. 科育教. 帮控工. 长沙. B-1. B.1. What is ESD? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. B-2. Electrostatic Charging of Persons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. B-3. General Protective Measures Against Electrostatic Discharge Damage .. B-4. Siemens Worldwide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. C-1. B.3. xii. 司公限. Guidelines for Handling Electrostatically-Sensitive Devices (ESD) . . . . . . . . .. B.2. C. 理整. A.1. Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. Glossary-1. Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. Index-1. S7-400 and M7-400 Programmable Controllers, Installation Manual C79000-G7076-C424-01.

(24) www.PLCworld.cn www.gkbpx.com. 1. Product Overview. Overview of the S7-400 The S7-400 is a programmable controller. Almost any automation task can be implemented with a suitable choice of S7-400 components. S7-400 modules have a block design for swing-mounting in a rack. Expansion racks are available to extend the system.. 理整. In this chapter, we show you the most important components with which you can assemble an S7-400.. 司公限. Features of the S7-400. 有技科. The S7-400 programmable controller combines all the advantages of the previous system with those of a new system and new software. These are:. 育教. A graded CPU platform. Upwardly-compatible CPUs. 帮控工. Enclosed modules of rugged design Convenient terminal system for the signal modules. 长沙. 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. S7-400 and M7-400 Programmable Controllers, Installation Manual C79000-G7076-C424-01. 1-1.

(25) www.PLCworld.cn www.gkbpx.com. Product Overview. Overview of the M7-400 The SIMATIC S7 programmable controller is extended by the SIMATIC M7 automation computer with its AT-compatible computer functionality. This enables the SIMATIC user to make use of the open software world, either as an extension to an S7 programmable controller or as a stand-alone M7 computer system. The entire SIMATIC S7 range of I/O devices is available to the M7 user.. Features of the M7-400 The M7-400 automation computer is suitable for the following typical tasks: Process data acquisition Storage of large volumes of data Control of local process I/Os Communication. 理整. Closed-loop control, positioning, counting Operator interface systems.. 司公限. It offers the following features:. 有技科. Running of DOS/Windows software available on the market Free programming (high-level language). 育教. RMOS real-time multitasking operating system – running of real time-capable software. 帮控工. – event-driven program processing – multitasking. 长沙. A standard, short AT card can be plugged in Multicomputing in the non-segmented rack Full incorporation in S7-400 systems.. 1-2. S7-400 and M7-400 Programmable Controllers, Installation Manual C79000-G7076-C424-01.

(26) www.PLCworld.cn www.gkbpx.com. Product Overview. Components of an S7-400 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). ... 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.. Accessories: Backup battery. CPUs Central Processing Units (CPUs). Memory cards. ... execute the user program; communicate via the multipoint interface (MPI) with other CPUs or with a programming device (PG).. 理整. 司公限. 育教. 有技科. ... store the user program and parameters.. 控帮. 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-DP bus cables. ...connect CPUs to programming devices.. 工沙长. S7-400 and M7-400 Programmable Controllers, Installation Manual C79000-G7076-C424-01. 1-3.

(27) www.PLCworld.cn www.gkbpx.com. Product Overview. Components. Function. PG cables. ...connect a CPU to a programming device.. PROFIBUS components for example, PROFIBUS bus terminal. ... connect the S7-400 to other S7-400 devices or programming devices.. RS 485 repeaters. ...amplify data signals on bus 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.. Illustration. 理整. 司公限. Additional components of the S7-400 such as communications processors, function modules, etc., are described in separate manuals.. 育教. Components of an M7-400. 帮控工. 有技科. The most important components of the M7-400 and their functions are given in the following tables:. 长沙. Components. Central Processing Units (CPUs) Accessories: Memory Card DRAM Cards. Application Modules (FMs) Accessories: Memory Card DRAM Cards On-Board Silicon Disk. 1-4. Function. Illustration. ... function as AT-compatible processing units; execute the user program; communicate via the MPI with other CPUs or with a programming device / PC; serve to accommodate two interface submodules (IFs). ... are ISA-compatible processing units to support the CPU. (They are described in a separate manual.). S7-400 and M7-400 Programmable Controllers, Installation Manual C79000-G7076-C424-01.

(28) www.PLCworld.cn www.gkbpx.com. Components. Product Overview. Function. Illustration. Expansion Modules (EXMs). ... serve to accommodate three interface submodules (IFs).. AT Adapter Modules (ATMs). ... provide a slot for a 16-bit AT module (up to 164 mm long).. Mass Storage Modules (MSMs). ... serve to store programs and data on a hard disk (2.5”) or floppy disk (3.5”).. Interface Submodules (IFs). ... for connecting I/O devices such as VGA monitor, mouse, keyboard, printer.. 育教. 理整. 司公限. 有技科. Applicable Modules in the S7-400 Range. 帮控工. The following modules from the S7-400 range can be used with the M7-400: Power supply modules (PSs). 长沙. Function modules (FMs) Signal modules (SMs) Interface modules (IMs) Fan subassemblies. Suitable I/O Devices The following I/O devices can be connected via the appropriate interface submodules: VGA monitor Keyboard Mouse Printer Sensors and actuators Distributed I/Os. S7-400 and M7-400 Programmable Controllers, Installation Manual C79000-G7076-C424-01. 1-5.

(29) www.PLCworld.cn www.gkbpx.com. Product Overview. Connecting the M7-400 to a Programming Device / PC For the remote setup of the M7-400, you can connect a programming device or PC to the CPU of the M7-400 via a V.24 cable. A PC/PG cable is used to connect a programming device or PC and CPU of the M7-400 via the multipoint interface (MPI).. Location of Order Number and Product Version The order number and product version are printed on every module of the SIMATIC S7-400/M7-400. The 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. Module designation. 理整.

(30) . Rating plate. 司公限.

(31)

(32) . Product version Abbreviated order no. (6ES7 ...). 育教. 有技科. 帮控工. 长沙. 1-6. S7-400 and M7-400 Programmable Controllers, Installation Manual C79000-G7076-C424-01.

(33) www.PLCworld.cn www.gkbpx.com. Product Overview. Example of a Rating Plate. SIMATIC M7. .

(34) . . APPROVED CLASS 1 BE4 2 MAX. 1BC. X 2 3 4. 5. 6 7 8. T4. Product version. Order no.. Approvals and marks Module designation. 理整. 司公限. 育教. 有技科. 帮控工. 长沙. S7-400 and M7-400 Programmable Controllers, Installation Manual C79000-G7076-C424-01. 1-7.

(35) www.PLCworld.cn www.gkbpx.com. Product Overview. 理整. 司公限. 育教. 有技科. 帮控工. 长沙. 1-8. S7-400 and M7-400 Programmable Controllers, Installation Manual C79000-G7076-C424-01.

(36) www.PLCworld.cn www.gkbpx.com. 2. Installing the S7-400. Chapter Overview Section. Description. Page. 2.1. Assembling an S7-400. 2-2. 2.2. Assembling the Central Rack (CR) and Expansion Rack (ER). 2-6. 2.3. Segmented CR. 2-8. 2.4. Mounting and Grounding the Racks. 2.5. Chassis Ground Connection in the Non-Isolated Configuration. 2-14. 2.6. Methods of Ventilation. 2-16. 2.7. Changing the Ventilation with the Cable Duct and Fan Subassembly. 2-18. 2.8. Installing the Fan Subassembly. 2-20. 2.9. Installing the Cable Duct. 2-22. 2.10. Choosing and Setting up Cabinets with the S7-400. 2-23. 2.11. Rules for the Arrangement of Modules. 2-27. 2.12. Installing Modules in a Rack. 2-28. 2.13. Marking the Modules with Slot Labels. 2-32. 2.14. Methods of Expansion and Networking. 2-33. 2.15. Accessories. 2-34. 技有. 育科. 教帮控. 沙工. 长. 司公限. S7-400 and M7-400 Programmable Controllers, Installation Manual C79000-G7076-C424-01. 理整. 2-9. 2-1.

(37) www.PLCworld.cn www.gkbpx.com. Installing the S7-400. 2.1. Assembling an S7-400. Introduction An S7-400 programmable controller consists of a central rack (CR) and one or more expansion racks (ERs), as required. You use ERs when there are insufficient slots in the CR for your application, or when you wish to operate signal modules separated from the CR (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 7). The M7-400 modules function similarly to the S7-400 modules and also use the racks in the S7-400 range. Any differences in function or data can be found directly at the relevant point or in Section 8.1 “Mechanical Configuration.”. 理整. 司公限. 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).. 育教. 有技科. Shown in Figure 2-1 is a rack with 18 slots configured as a CR.. 帮控工. 长沙. PS. CPU. Figure 2-1. 2-2. SMs. Rack Fitted with Modules in the S7-400 System. S7-400 and M7-400 Programmable Controllers, Installation Manual C79000-G7076-C424-01.

(38) www.PLCworld.cn www.gkbpx.com. Installing the S7-400. 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 7.. 理整. 司公限. Overview of the Connections. Observe the connection rules at the end of this section.. 有技科. Local Connection. Send IM. Remote Connection. 460-0. 460-1. 460-3. 461-0. 461-1. 461-3. 4. 1. 4. Max. distance. 3m. 1.5 m. 102.25 m. 5 V transfer. no. yes. no. -. 5A. -. yes. no. yes. 育教. Receive IM. 控帮. Max. no. of connectable ERs per chain. 工沙长. Max. current flow per interface Communication bus transmission. S7-400 and M7-400 Programmable Controllers, Installation Manual C79000-G7076-C424-01. 2-3.

(39) www.PLCworld.cn www.gkbpx.com. Installing the S7-400. Ways of Connecting Central and Expansion Racks. Central rack CR. IM 460-3 IM 460-1 IM 460-0. Expansion without 5 V transfer, local Expansion rack ER 1 Expansion rack ER 4. IM 461-0. IM 461-0. 理整. Chain length 3 m max.. 司公限. 有技科. Expansion with 5 V transfer, local Expansion rack ER 1. 育教. 控帮. IM 461-1. 沙工. Chain length 1.5 m max.. 长. Remote expansion Expansion rack ER 4. Expansion rack ER 1. IM 461-3. IM 461-3 Chain length 102.25 m max.. 2-4. S7-400 and M7-400 Programmable Controllers, Installation Manual C79000-G7076-C424-01.

(40) www.PLCworld.cn www.gkbpx.com. Installing the S7-400. 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.. 理整. 司公限. Type of Connection. Maximum (Total) Cable Length. Local connection with 5 V transfer via IM 460-1 and IM 461-1 Local connection without 5 V transfer via IM 460-0 and IM 461-0. 1.5 m. 技有. 科育教. Remote connection via IM 460-3 and IM 461-3. 3m. 102.25 m. 帮控工. 长沙. S7-400 and M7-400 Programmable Controllers, Installation Manual C79000-G7076-C424-01. 2-5.

(41) www.PLCworld.cn www.gkbpx.com. Installing the S7-400. 2.2. Assembling the Central Rack (CR) and Expansion Rack (ER). Function of the racks The racks of the S7-400 system form the basic framework which accepts the individual modules. The modules exchange data and signals and are powered via the backplane bus. The racks are designed for wall mounting, for mounting on rails, and for installation in frames and cabinets (see Chapter 4).. Racks in the S7-400 System. Rack. No. of Slots. Available Buses. Application. Characteristics. UR1. 18. UR2. 9. I/O bus Communication bus. CR or ER. Rack for all module types in the S7-400 and as central rack for CPUs and their ex expansion ansion modules from the M7-400 range (see Section 8.1).. ER1. 18. UR2-H. 2-6. 有技科. Interrupts from modules have no effect because no interrupt lines exist.. 育教 ERs. 控帮. 9. 工沙长 CR2. 司公限. Racks for signal modules (SMs), receive IMs, and all power supply modules. The I/O bus has the following restrictions:. Restricted I/O bus ER2. 理整. 18. I/O bus, segmented Communication bus, continuous. Segmented CR. 18. I/O bus, segmented Communication bus, segmented. Fault-tolerant CR or ER. Modules are not su supplied lied 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).. Rack for all module types in the S7-400 except receive IMs and for the CPUs and their expansion ex ansion modules from the M7 M7-400 400 range (see Section 8.1). The I/O bus is subdivided into 2 I/O bus segments of 10 and 8 slots respectively. Rack for all module types in the S7-400. The I/O bus and communication bus are divided into 2 bus segments, each with 9 slots.. S7-400 and M7-400 Programmable Controllers, Installation Manual C79000-G7076-C424-01.

(42) www.PLCworld.cn www.gkbpx.com. Installing the S7-400. 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.. 理整. Communication Bus (C Bus). 司公限. 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.. 有技 Rack with I/O bus and Communication Bus 科育教帮控工沙长. 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. C bus connector. S7-400 and M7-400 Programmable Controllers, Installation Manual C79000-G7076-C424-01. 2-7.

(43) www.PLCworld.cn www.gkbpx.com. Installing the S7-400. 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.. 理整. All the modules inserted in a segmented CR are powered by the power supply module at slot 1.. 司公限. Both segments have a common backup battery.. The following figure shows a segmented CR with divided I/O bus and continuous communication bus.. . 育教.

(44) . 帮控工. . 长沙. . . . . . . . . . . . . . . . 有技科

(45) . . . . I/O bus Segment 1. . . . . . . I/O bus Segment 2. Communication bus. 2-8. S7-400 and M7-400 Programmable Controllers, Installation Manual C79000-G7076-C424-01.

(46) www.PLCworld.cn www.gkbpx.com. 2.4. 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 comply with DIN 41 494. According to the UL/CSA and the EU Directive 73/23/EEC (low-voltage directive), installation in a cabinet, a casing, or a closed operations room is necessary in order to fulfil the requirements for electrical safety (see Reference Manual, Chapter 1). In principle, the M7-400 is mounted like an S7-400 except that preassembly is required (see Section 8.4 “Installing the M7-400”).. 理整. Step 1: Retaining Distances Between Devices. 司公限. You must observe the minimum distances between the rack and neighboring devices. You need these minimum clearances during installation and operation. 有技科. For fitting and removing modules. For fitting and disconnecting the module front connectors. 育教. 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.. 帮控工. 长沙. . . 40 mm. . . . . . . . . . . . . . 20 mm. 20 mm 352 mm. . *. 22 mm 522.5 mm (18 slots) 297.5 mm (9 slots) * 40 mm facilitates the installation of a fan subassembly Mounting depth, fitted: 237 mm max.. S7-400 and M7-400 Programmable Controllers, Installation Manual C79000-G7076-C424-01. 2-9.

(47) www.PLCworld.cn www.gkbpx.com. Installing the S7-400. 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.. . . . . . . . . . . 440 mm. 理整. 司公限. Cable duct/fan subassambly. 522.5 mm (with cable duct) 542.5 (with fan subassembly) 19-inch reference level Mounting depth, fitted: 237 mm max.. 育教. Dimensions of the Racks. 有技科. 帮控工. The following figure shows the dimensions for racks with 18 and 9 slots and the positions of cutouts for screw mounting.. 长沙. The cutouts are arranged according to the 19-inch standard.. 60 mm. . . . . . . . . . . . . . . . . . . . . . . . . 290 mm 190 mm. 40 mm 465 mm. 240 mm. 482.5 mm. 257.5 mm. Depth = 27.5 mm without modules Depth = 237.0 mm with modules. 2-10. S7-400 and M7-400 Programmable Controllers, Installation Manual C79000-G7076-C424-01.

(48) www.PLCworld.cn www.gkbpx.com. Installing the S7-400. Step 2: Mounting the Rack Screw the rack to the base. Is the base material a grounded metal plate or a grounded equipment plate? If so: Establish a low-impedance connection between rack and base material. With painted and anodized metals, for example, use a suitable contact agent or special contact washers. If not: No special measures are required.. Mounting Screws You have a choice of the following types of screw for securing a rack: Screw Type M6 cylinder-head screw to ISO 1207/ISO 1580 (DIN 84/DIN 85) M6 hex. screw to ISO 4017 (DIN 4017). Explanation Choose the screw length according to your assembly. You also need “6.4” “6 4” washers to ISO 7092 (DIN 433).. 理整. 司公 Step 3: Connecting the Rack to the Chassis Ground限有技科育教帮控工沙长. 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.. S7-400 and M7-400 Programmable Controllers, Installation Manual C79000-G7076-C424-01. 2-11.

(49) www.PLCworld.cn www.gkbpx.com. Installing the S7-400. M6 threaded bolt Contact washer Terminal Plain washer M6 nut. To chassis ground. 理整. 司公限. Step 4: Mounting Additional Racks. If you assemble an S7-400 with two or more racks, you must allow additional clearance between the individual racks or install a fan subassembly or cable duct.. 有技科. The figure below shows the clearance you must allow between two racks of the S7-400 during installation.. . . . . . . 帮控工. 育教 . . . . . . . . . . . . . . 长沙. 110 mm. 2-12. S7-400 and M7-400 Programmable Controllers, Installation Manual C79000-G7076-C424-01.

(50) www.PLCworld.cn www.gkbpx.com. Installing the S7-400. 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.. . . . . . . . . . . 理整. Cable duct/fan subassambly 840 mm . . . . . . . 育教. 帮控工. . . 司公限. . 有技科. Cable duct/fan subassambly. 长沙. Mounting depth, fitted: 237 mm max.. 19-inch reference level. 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.. S7-400 and M7-400 Programmable Controllers, Installation Manual C79000-G7076-C424-01. 2-13.

(51) www.PLCworld.cn www.gkbpx.com. Installing the S7-400. 2.5. 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 location of the reference point on a rack.. . . . . . . 理整. 司公限. Reference point. 育教. 有技科. 帮控工. Chassis ground terminal. 沙长 Connecting to the Reference Point For the connection to the reference point, use a cable lug for M4, a suitable spring washer (for example, strain washer to DIN 6796) and an M4 x 6 cylinder-head screw. Note Do not use any cyclinder-head screws longer than 6 mm for the connection to the reference point. Otherwise, you may create an undesired connection between the reference point and the rack profile behind it and therefore the connection for the chassis ground.. 2-14. S7-400 and M7-400 Programmable Controllers, Installation Manual C79000-G7076-C424-01.

(52) www.PLCworld.cn www.gkbpx.com. Installing the S7-400. The following figure shows the chassis ground connection to the reference point.. Threaded hole. Terminal Spring washer M4 screw. 理整. 司公限. 育教. 有技科. 帮控工. 长沙. S7-400 and M7-400 Programmable Controllers, Installation Manual C79000-G7076-C424-01. 2-15.

(53) www.PLCworld.cn www.gkbpx.com. Installing the S7-400. 2.6. Methods of Ventilation. Methods of Ventilation Under extreme ambient conditions, particularly when operating the S7-400 modules in cabinets, you can use the cable duct or fan subassembly to optimize ventilation. There are two methods of supplying air to the modules. You draw in air either from the back or from below. The cable duct and fan subassembly can be converted for this purpose. The following figure shows the ventilation when air is drawn in from the back.. ÇÇ 理 ÇÇ 整 ÇÇ 司 ÇÇ 公 ÇÇ 限有 ÇÇ 技 ÇÇ 科 ÇÇ 育 ÇÇ 教 ÇÇ 帮 ÇÇ 控工 ÇÇ 沙 ÇÇ 长 ÇÇ ÇÇ ÇÇ ÇÇ ÇÇ ÇÇ ÇÇ ÇÇ ÇÇ Wall. Exhaust air. Modules. Cable duct or fan subassembly. Exhaust air. Modules. Supply air. 2-16. S7-400 and M7-400 Programmable Controllers, Installation Manual C79000-G7076-C424-01.

(54) www.PLCworld.cn www.gkbpx.com. Installing the S7-400. The following figure shows the ventilation when air is drawn in from the bottom.. Exhaust air. ÇÇ ÇÇ ÇÇ ÇÇ ÇÇ 理 ÇÇ 整司 ÇÇ 公限 ÇÇ 有技 ÇÇ 育科 ÇÇ教帮控 Ç 工 Ç 长沙 Wall. Modules. Cable duct or fan subassembly. Modules. Supply air. S7-400 and M7-400 Programmable Controllers, Installation Manual C79000-G7076-C424-01. 2-17.

(55) www.PLCworld.cn www.gkbpx.com. Installing the S7-400. 2.7. Changing the Ventilation with the Cable Duct and Fan Subassembly. Changing the Ventilation At the base of the cable duct and the fan subassembly, there is a cover that you can move in order to change the air duct. To do this, proceed as follows: 1. Using a screwdriver, make a quarter turn counter-clockwise to open the two quick-release locks at the front of the cable duct or fan subassembly. 2. Grasp the base with both hands; press it gently downward and pull it fully out of the cable duct or fan subassembly. 3. The cover is secured to the base with snap catches. Press the cover from below, close to the snap catches, and remove the cover. 4. At approximately right angles to the base, insert the cover in the snap hinges at the rear edge of the base. 5. Slide the base in again and push it up.. 理整. 司公限. 6. Use a screwdriver to make a quarter turn clockwise and close the two quick-release locks.. 有技科. 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.. 育教. 帮控工. 长沙. 2-18. S7-400 and M7-400 Programmable Controllers, Installation Manual C79000-G7076-C424-01.

(56) www.PLCworld.cn www.gkbpx.com. Installing the S7-400. Cover Delivered state: Cover fitted at bottom (supply air from the rear). Base. Quick-release locks Snap catches Cover Cover fitted at back. 理整. (supply air from below). 有技科 Base. 育教. 司公限. 控帮. Snap hinges. 工沙长. State When Shipped. 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.. S7-400 and M7-400 Programmable Controllers, Installation Manual C79000-G7076-C424-01. 2-19.

(57) www.PLCworld.cn www.gkbpx.com. Installing the S7-400. 2.8. 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. Snap-in mechanism of dummy covers. 理整. Plug-in contact. 司公限. 帮控工. 育教. Direction for pulling off. 长沙. 有技科. Back of cable routing. Left cover. Quick-release lock. 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.. 2-20. S7-400 and M7-400 Programmable Controllers, Installation Manual C79000-G7076-C424-01.

(58) www.PLCworld.cn www.gkbpx.com. Installing the S7-400. 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.. . . . . . . . . 理整. 司公限. Dummy plate. . . 育教. 有技科 . . . . . . 帮控工. 19-inch reference level. 长沙. 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.. S7-400 and M7-400 Programmable Controllers, Installation Manual C79000-G7076-C424-01. 2-21.

(59) www.PLCworld.cn www.gkbpx.com. Installing the S7-400. 2.9. 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.. . . . . . . . . 理整. 有技科. 育教. 帮控工. 长沙. 2-22. 司公限. . . . . . . . . . 19-inch reference level. S7-400 and M7-400 Programmable Controllers, Installation Manual C79000-G7076-C424-01.

(60) www.PLCworld.cn www.gkbpx.com. 2.10. Installing the S7-400. 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. 理整. 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 40 050.. 司公限. 育教. 有技科. 帮控工. 长沙. S7-400 and M7-400 Programmable Controllers, Installation Manual C79000-G7076-C424-01. 2-23.

(61) www.PLCworld.cn www.gkbpx.com. Installing the S7-400. 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. Types of Cabinet Closed Cabinets. Open Cabinets Through-ventilation Increased by natural through-ventilation convection. Natural convection. Forced circulation using fan subassembly, enhanced natural convection. Forced circulation using heat exchanger, external ventilation inside and outside. 理整. Heat removal primarily by natural thermal convection, small portion via the cabinet wall. Increased heat removal through increased air movement. 长沙 Degree of protection IP 20. Degree of protection IP 20. 技有. 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 54. Degree of protection IP 54. Degree of protection IP 54. 科育教. 帮控工. 司公限. 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. 2-24. up to 2700 W (1400 W with very fine filter). up to 260 W. up to 360 W. up to 1700 W. S7-400 and M7-400 Programmable Controllers, Installation Manual C79000-G7076-C424-01.

(62) www.PLCworld.cn www.gkbpx.com. Installing the S7-400. 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. Ambient temperature in oC 60. 50. 理整. 1 40. 司公限. 2. 30. 3. 育教. 20 200. 400. 有技科. 600. 800. 1000. 1200. 帮控工. Figure 2-2. 长沙. 1400 W. Power dissipation. 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. !. Warning Modules can be damaged. Modules can be damaged by subjecting them to excessively high ambient temperature. In the case of modules with hard drives, in particular, ensure that they are not subjected to an excessively high ambient temperature.. S7-400 and M7-400 Programmable Controllers, Installation Manual C79000-G7076-C424-01. 2-25.

(63) www.PLCworld.cn www.gkbpx.com. Installing the S7-400. Example for Determining the Type of Cabinet The following example clarifies the maximum ambient temperature which is permissible for a particular power dissipation with various types of cabinet. The following equipment configuration is to be installed in a cabinet: 1 central rack. 150 W. 2 expansion racks of 150 W power dissipation each. 300 W. 1 load current power supply under full load. 200 W. Total power dissipation. 650 W. From Figure 2-2, with a total power dissipation of 650 W, the ambient temperatures obtained are as follows: Type of Cabinet. Max. Permissible Ambient Temperature. Closed, with natural convection and forced circulation (Curve 3). 司公限. Open, with through-ventilation (Curve 2) Closed, with heat exchanger (Curve 1). Dimensions of Cabinet. 育教. 理整. (no operation possible) approx. 38° C approx. 45° C. 有技科. To determine the dimensions of a cabinet suitable for assembling an S7-400, you must take the following into account:. 帮控工. Space requirement of the racks Minimum clearances between racks and cabinet walls. 长沙. Minimum clearances between racks Space requirement of cable ducts or fan subassemblies Locations of rails. 2-26. S7-400 and M7-400 Programmable Controllers, Installation Manual C79000-G7076-C424-01.

(64) www.PLCworld.cn www.gkbpx.com. 2.11. Installing the S7-400. Rules for the Arrangement of Modules. Rules for S7-400 and M7-400 Given in this section are the rules you must observe when arranging modules in the S7-400. The rules for M7-400 modules can be found in Section 8.1 “Mechanical Configuration”.. Arrangement of Modules You need observe only two rules for the arrangement of modules in a rack: S. In all racks, the power supply module must always be inserted on the extreme left (beginning with slot 1). In the UR2-H from slot 1 in both segments.. S. The receive IM in the ER must always be inserted on the extreme right. In the UR2-H at slot 9 once per segment.. 理整. 司公限. Note. Establish whether there are additional regulations applying to all modules not described in this manual.. 有技科. The following table shows which modules can be used in the different racks: Modules. 育教. 控帮. 沙工. Power Supply Modules. Racks. UR1, UR2 as CR. UR1, UR2 as ER. CR2. ER1, ER2. F. F. F. F. CPUs. F. F. Send IMs. F. F. 长. F. Receive IMs Signal Modules. F. F. F F. F. Space requirement of the racks In the S7-400 system, there are modules occupying one, two, or three slots (width 25, 50, or 75 mm). Refer to the technical specifications of the module under the keyword “dimensions” to see how many slots a module occupies. The mounting depth of a rack fitted with modules is 237 mm maximum.. S7-400 and M7-400 Programmable Controllers, Installation Manual C79000-G7076-C424-01. 2-27.

(65) www.PLCworld.cn www.gkbpx.com. Installing the S7-400. 2.12. Installing Modules in a Rack. Introduction All modules are installed in a rack using the same procedure.. !. Caution Modules and racks can be damaged. If you use force when installing modules in a rack, these components may be damaged. Carefully follow the steps described below for the installation sequence.. 理整. Tool. 司公限. The tool needed to install the modules is a cylindrical screwdriver with 3.5 mm blade width.. Installation Sequence. 有技科. To install modules in a rack, follow the steps outlined below:. 育教. 1. Remove the dummy plates from the slots at which you intend to insert modules. Grasp the dummy plate at the points marked and pull it forward and off.. 帮控工. With double and triple-width modules, you must remove the dummy plates from all the slots to be covered by the relevant module.. 长沙. 2. Remove the cover, if applicable, from the module (see Figure 2-3). 3. Disconnect the power supply connector at the power supply module. 4. Attach the first module and swing it downwards (see Figure 2-4). If you feel a resistance when swinging the module down, raise it slightly and then continue. 5. Tighten the module screws top and bottom with a torque of 0.8 to 1.1 Nm (see Figure 2-5). Triple-width modules are secured with two screws at the top and at the bottom. 6. Refit the module cover, if applicable. 7. Fit the remaining modules in the same way. 8. Insert the key into the keyswitch in the CPU when you have installed all the modules (see Figure 2-6). The individual steps for installation are explained in the following. The method of removing modules is described in Chapter 7.. 2-28. S7-400 and M7-400 Programmable Controllers, Installation Manual C79000-G7076-C424-01.

(66) www.PLCworld.cn www.gkbpx.com. Installing the S7-400. Removing the Cover With modules which have a cover (for example, power supply modules and CPUs), you remove this before installing the module in the rack. Proceed as follows: 1. Press the locking lever down (1). 2. Swing the cover forward and off (2).. 理整. (1). (2) Figure 2-3. Removing the Cover. 育教. 司公限. 有技科. 帮控工. 长沙. S7-400 and M7-400 Programmable Controllers, Installation Manual C79000-G7076-C424-01. 2-29.

(67) www.PLCworld.cn www.gkbpx.com. Installing the S7-400. Attaching the Modules Attach the modules one by one (1) and swing them carefully downwards (2). If you feel a resistance when swinging the module down, raise it slightly and then continue.. (1). 理整. 司公限. (2). Figure 2-4. Attaching the Modules. 育教. Screwing the Modules in Place. 有技科. 帮控工. 长沙. Tightening torque 0.8 to 1.1 Nm. Figure 2-5. 2-30. Screwing the Modules in Place. S7-400 and M7-400 Programmable Controllers, Installation Manual C79000-G7076-C424-01.

(68) www.PLCworld.cn www.gkbpx.com. Installing the S7-400. Inserting the Keyswitch You can insert the key in the CPU in the STOP position of the switch. You can remove the key in the STOP or RUN settings.. 理整. Figure 2-6. Inserting the Key in the CPU. 育教. 司公限. 有技科. 帮控工. 长沙. S7-400 and M7-400 Programmable Controllers, Installation Manual C79000-G7076-C424-01. 2-31.

(69) www.PLCworld.cn www.gkbpx.com. Installing the S7-400. 2.13. Marking the Modules with Slot Labels. Slot Number Once the modules are installed, you should mark each one with its slot number to avoid the risk of mixing up modules during operation. If modules do get mixed up, you may have to reconfigure the assembly. The slot number is printed on the rack. Double-width modules occupy two slots and are assigned the consecutive slot numbers of both slots. Triple-width modules occupy three slots and are assigned the consecutive slot numbers of these three slots.. 理整. Fitting Slot Labels. You use slot labels to mark a module with its slot number. The slot labels are provided with the rack as a “number wheel”.. 司公限. To fit the slot labels, follow the steps outlined below:. 有技科. 1. Hold the “number wheel” on the module and rotate it to the slot number for the module inserted at this slot. 2. Use your finger to press the slot label into the module. The label will break away from the “number wheel”.. 育教. 帮控工. 长沙. Figure 2-7. 2-32. Fitting a Slot Label. S7-400 and M7-400 Programmable Controllers, Installation Manual C79000-G7076-C424-01.

(70) www.PLCworld.cn www.gkbpx.com. 2.14. Installing the S7-400. Methods of Expansion and Networking. Introduction Apart from the structures mentioned in this chapter, other expansions are possible, for example, by connecting distributed I/Os or by networking. The modules with which you can connect an M7-400 to PROFIBUS DP can be found in Section 8.7.6 “Starting Up a PROFIBUS-DP Subnet.”. 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. One of the master-capable CPUs of the S7-400, the CPU 413-2 DP, the CPU 414-2 DP, or the CPU 416-2 DP is used.. 理整. 司公限. You can use the following devices, for example, as slaves, i.e. as local inputs/outputs: ET 200M ET 200 U/B/C All DP standard slaves. 育教. Networking. 有技科. 帮控工. Two or more S7-400s can be arranged in a network for communication via the multipoint interface.. 长沙. For networking the individual S7-400s, you must interconnect their CPUs with PROFIBUS-DP bus cables. The S7-400 is connected to the communication network via the multipoint interface (MPI) of the CPU via: Bus connectors A PROFIBUS-DP RS 485 bus terminal See Chapter 7 for further details. Other networking methods require special modules.. S7-400 and M7-400 Programmable Controllers, Installation Manual C79000-G7076-C424-01. 2-33.