simatic s7-400 - the plc with excellent dynamic ... · the plc with excellent dynamic...

Pro

du

ct B

rie

f · N

ov

em

be

r 2

00

3

The PLC with excellent dynamic characteristics

2

Introduction, application, advantages

Machine and plant constructors have been experiencing excessive competitive pressure for many years already, and are attempting to retain or expand the profit situation by reducing times and saving costs. Although sales prices are being reduced in certain cases, they are still expected to offer machines which are more powerful and pro-ductive, thus placing new demands on the implemented automation systems. Modular automation sys-tems are expected with a large scope of functions and high perfor-mance at favorable prices. The net-working facilities should be improved at the same time, but the engineering requirements should be reduced.

Numerous users therefore trust Totally Integrated Automation with its many successful reference appli-cations worldwide from many differ-ent industrial sectors. They there-fore profit from the experience, the global servicing facilities and the quality of SIMATIC® systems and products.

This is the basis for increasing profits and improving competitiveness using innovative automation solu-tions.

Within this range of PLCs, the SIMATIC S7-400® has been designed for system solutions in production and process automation. The S7-400 primarily features a high processing speed and communica-tions performance as well as a large quantity breakdown, e.g. memories.

Areas of application

Application areas are found in• the automobile industry (e.g.

production lines)

• mechanical engineering, includ-ing specialist machine construc-tion

• warehousing

• building systems automation

• the steel industry

• energy generation and energy dis-tribution

• the paper and printing industry

• woodworking

• textile manufacture

• pharmaceuticals

• the food and beverages industry

• process engineering, e.g. water supply and disposal

• the chemical and petrochemical industries

Special applications

There are other versions of the S7-400 available for specialist appli-cations:• Applications requiring fault toler-

ance can be implemented with the S7-400H

• For fail-safe applications, there is the S7-400F that is also available in a fault-tolerant version (S7-400 HF)

• S7-400 CPUs are available as PC plug-in cards for PC-based solu-tions (WinAC Slot)

Reduction of engineering costs

In conjunction with the SIMATIC Engineering Tools, the S7-400 results in extremely efficient config-uring and programming, particularly in extensive automation solutions with a high proportion of engineer-ing. Examples include high-level lan-guages like SCL and graphical Engi-neering Tools for sequential controls, state diagrams and tech-nology-oriented diagrams.

Reduction of operating costs

Saving of the complete project data including symbols and comments on the CPU facilitates and simplifies servicing and maintenance.

In addition, powerful integrated sys-tem diagnostics functions guaran-tee increased availability of the con-troller and therefore greater productivity. To this are added con-figurable process diagnostics func-tions for analysis of process faults in order to reduce downtimes and fur-ther boost productivity.

Increase in machine cycle rates

The significantly innovated CPUs set new standards with respect to pro-cessing speed and communications performance. As a result of the sig-nificantly improved performance, the new CPUs provide the basis for shorter machine cycle times.

New functions

The reserve capacity of the inno-vated CPUs means that it is possible to integrate new functions without further hardware investments, e.g. processing of quality data, conve-nient diagnostics, integration into host MES solutions, or fast commu-nications via bus systems.

‡

‡

3

Communications interface modules

Communications interface modules can be optionally used in the S7-400 CPUs in order to adapt the latter to the requirements of the respective application.

For this purpose, the CPUs 414-3 and 416-3 have one vacant slot and the CPU 417 has two vacant slots. By adding such interface modules, additional DP lines can be config-ured as masters or slaves whose functionality corresponds to that of the integral interface.

Design, modularity, networking

Design

An S7-400 system consists basically of a backplane, a power supply, and a CPU. A modular design is possible, and only simple slot rules have to be observed. The S7-400 is character-ized by rugged fan-free operation with hot swapping of signal mod-ules.

A diverse range of modules can be used both for centralized expan-sions and for easy setup of distrib-uted structures with the ET 200®; this results in extremely low-cost spare parts inventory.

Modularity

Modularity is an important feature of the S7-400. The powerful back-

plane bus of the S7-400, and the communications interfaces that can be connected direct to the CPU, allow high-performance operation of a large number of communica-tions lines.

This makes it possible, for example, to break up the system into a line for HMI and programming tasks, one for high-performance and equidis-tant motion control components, and one for the "normal" I/O field bus. Additionally required connec-tions to MES/ERP systems or to the Internet can also be implemented.

Powerful, flexible networking

Interfaces that are directly inte-grated into the CPUs permit the con-figuration of a powerful communi-cations landscape that employs standard bus technologies, e.g. for HMI and programming device func-tions. Sufficient connectivity is pro-vided for numerous HMI devices. A routing function enables a program-ming device to be connected at any point in the network and to address all network nodes.

Multi-point interface MPI

MPI is the low-cost solution for com-munications with programming devices and PCs, HMI systems and other SIMATIC S7/C7/WinAC control-lers. A total of 125 MPI stations can be connected at transmission rates up to 12 Mbit/s, e.g. for exchanging process data between various con-trollers or for HMI functions without any programming overhead. The MPI can also be used as a PROFIBUS DP interface and permits the config-uration of a further DP line.

PROFIBUS DP

For the economical configuration of larger distributed structures, the SIMATIC S7-400 can be connected to the open PROFIBUS DP fieldbus (IEC 61158 / EN 50170). This opens up communications options with a vari-ety of partners from the SIMATIC controller up to third-party field devices. Communication using existing SIMATIC S5 or SIMATIC 505 systems is also possible. Distributed I/Os can be configured with STEP® 7 like centralized I/Os which saves a lot of engineering overhead.

Support of the DP V1 functionality permits programming and optimiza-tion of field devices during opera-tion, and therefore also shorter machine setup times. Detailed device diagnostics additionally reduce plant down times.

Powerful networking with integral interfaces of the CPU and communications processor

Easy assembly of S7-400 by hooking module into backplane

CPU performance

CPU spectrum

There is a graded range of CPUs available for controller design, from the entry-level CPU right up to the high-performance CPU. All CPUs have large quantity structures, and several CPUs can work together in multicomputing configurations in order to boost performance. The CPUs enable short machine cycle times, thanks to their efficient pro-cessing speed and deterministic response times.

The CPUs differ in their quantity breakdowns, e.g. RAM, address range, number of connections and processing time.

Multicomputing

Multi-computing, i.e. running more than one CPU in a S7-400 central controller, has a number of benefits to the user.

• Multi-computing means that the overall performance of an S7-400 can be split up. For example, com-plex technical functions, such as controlling, computing or com-municating, can be separated and assigned to different CPUs. And each CPU can be assigned its own, local I/O.

• Multi-computing also enables dif-ferent functions to be separated from one another, so, for exam-ple, one CPU can process the time- critical processing functions and another CPU the non-time critical functions.

In multi-computing mode, all the CPUs together act as a single CPU, i.e. if one CPU goes into STOP mode, all the other CPUs stop at the same time. Synchronization calls enable the actions of multiple CPUs to be coordinated for each individual instruction.

At the same time, data transfer be-tween the CPUs is extremely fast thanks to the “Global Data” mecha-nism.

Seven CPUs of graded performance for the S7-400

Performance

The S7-400 stands out not only for its short response times, but also for its large performance reserves. Very short response times can be attained, even when simultaneous communication is required, or other unforeseeable loads occur. This, in turn, makes it possible to obtain spe-cific response times, e.g. the response of an output signal to a change in input signal.

Diagnostics

The CPUs’ intelligent diagnostics sys-tem continuously monitors the func-tionality of the system and the pro-cess, and registers errors and specific system events (CPU black-box); there is also the option of adding extra diagnostic mes-sages.

The diagnostics function can deter-mine whether the signal logging (for digital modules) or analog pro-cessing (analog modules) functions of the module are in good working order. In the event of a diagnostics message (e.g. “no supply to encoder”), the module triggers a diagnostics interrupt

The CPU then interrupts the process-ing of the user program and exe-cutes the appropriate diagnostics interrupt block.

Process interrupts mean that pro-cess signals can be monitored and reactions to signal changes can be triggered

4

Memory in MB

20

Processing timeBinary command in µs

Address range Inputs/outputs in KB

4

8

16

0.030.10 0.040.06

Number of connections

163264

CPU 412-2

CPU 412-1

CPU 414-2

CPU 414-3

CPU 416-2

CPU 416-3

CPU 417

5.6

2.8

1.4

0.5

0.25

0.14

The S7-400 CPUs are being inno-vated and will receive significantly more powerful processors. New CPUs featuring maximum dynamic characteristics will be available from March 2004. In addition to a larger quantity breakdown (more RAM, uniformly high quantity of timers and counters), they will particularly feature a significantly increased per-formance. This will not only be evi-dent in significantly higher process-ing speeds, but also in a greater communications performance.

The increased features permit the integration of additional functions or an increase in machine cycle rates without further hardware invest-ments. Examples of new functions include the saving and processing of quality data, convenient diagnos-tics, or the vertical integration into host MES solutions. The improved communications performance per-mits fast Ethernet communication as well as efficient interfacing of the field level using PROFIBUS, e.g. for isochronous functions.

The most evident feature of the new CPUs is the significant increase in processing speed. With bit com-mands, the execution times are approximately halved. With more complex commands, the increase in speed is between factors of 13 and 70! Since the execution times of the complex commands could be reduced over-proportionally, the bandwidth of all command execu-tion times has become significantly smaller. Thus these complex com-mands have a far smaller influence on the total execution time of the user program, and the processing of programs with many arithmetic functions is accelerated accordingly.

The new CPUs are compatible with the previous ones with respect to spare parts and programs, i.e. a pre-vious CPU can be replaced by a new one without problem, without nega-tive effects, and without having to change the program. The previous memory cards can also be used fur-ther.

Innovative interface modules are also available to configure further DP lines for the CPUs 414-3, 416-3 and 417-4.

Furthermore, the new S7-400 CPUs can also replace the CPU 945 of the SIMATIC S5 with respect to process-ing speed.

Further features of the new CPUs include:

• As with the S7-300® CPUs, the S7-400 will also be provided with a toggle switch in the future.

• Only one row of LEDs is required to display the CPU status (except for the fault-tolerant CPUs)

CPU innovation

5

Increase in processing speeds of the CPU 417-4 compared to the previous version

Factor

Type of command

Increase in RAM of new CPUs compared to previous version

RAM

412-1 412-2 414-2 414-3 416-2 416-3 417-4

96

d 1

44

KB

14

4 d

25

6 K

B

25

6 d

51

2 K

B

76

8 K

B d

1.4

MB

1.6

d 2

.8 M

B 3.2

d 5

.6 M

B

4 d

20

MB

Fixed-point

addition Fixed-point

multiplicatio

n

Floating-point

addition Floatin

g-point

multiplicatio

n

Complex

arithmetic fu

nctions

20

10

30

40

50

70

6

All S7-400 CPUs have separate memories for data and pro-gram.This division of the main memory results in an increase in performance by 100% for certain constellations. While a standard pro-cessor accesses its RAM at least twice, the special S7-400 processor accesses the code memory and the data memory simultaneously in a single cycle. This is made possible by the separate code and data bus. This is direct performance which is of benefit to the customer!

The size of the main memory is determined by selecting the appro-priate CPU from the finely graded range of CPUs.

The integrated memory (RAM) is adequate for small to medium-sized programs. For larger programs, the memory can be increased by slot-ting in extra RAM. Additional plug-in flash memory cards are available to enable retentive memory without the use of a battery.

Memory concept

Memory types for the SIMATIC S7-400

External load memory

• battery-backed RAM or reten-tive Flash Memory

Integrated load memory• battery-backed RAM

Main memory, code• 50 % for program

• non-backed RAM

Main memory, data• 50 % for data

• battery-backed RAM

Load memory• for project data (blocks,

symbols, comments, con-figuration, parameteriza-tion data, etc.)

• customer files

Main memory

• for process-related modules, process image, local data

Isochrone mode

The S7-400 is now capable of pro-viding distributed I/O solutions with the capability to handle extremely fast processes with very high preci-sion. Consequently, production can be enhanced while at the same time increasing quality. This was made possible by the new system function denoted "isochrone mode" (not with fault-tolerant CPUs).

This is understood to be the synchro-nous coupling of signal acquisition and output by the distributed I/O sig-nal transmission via PROFIBUS, and program processing at the clock rate of the equidistant PROFIBUS. This results in a system which records its input signals, processes them, and passes on the output signals at con-stant intervals. The S7-400 thus guarantees exactly reproducible and defined process response times as well as equidistant and synchronous signal processing for the distributed I/O.

Exact repeatability of all timing sequences means that even fast pro-cesses can be handled reliably. A comprehensive range of compo-nents is available which supports isochrone mode in order to solve many applications from the motion control, measurement or control sectors.

Hardware configuration changes in RUN (Configuration in RUN, CiR)

Another feature is that SIMATIC S7-400 now allows hardware recon-figurations without any adverse ef-fects while in run mode, e.g. to im-plement new sensors or actuators. CiR - Configuration in RUN - reduces time needed for commissioning and retrofit because these changes can now be undertaken while the plant is in full operation. Also, this new system function makes it possible for technicians to respond to pro-cess changes and implement pro-cess optimizations very easily since the plant must not be re-initialized and synchronized when hardware is changed.

It is possible to add and remove dis-tributed I/O stations (PROFIBUS DP and PROFIBUS PA slaves), to add and remove individual I/O modules in the I/O system ET 200M, and to assign new parameters (e.g. to select other interrupt thresholds).

Isochrone mode and changes in configuration in RUN mode

System clock

ET 200

CPU

Distributed automation structure with isochronous and strictly real-time response

The system clock applies to the complete automation structure

7

8

Based on standard S7-400 units, the S7-400H is a fault-tolerant (redun-dant) PLC which greatly reduces the risk of production failures.

Its fault-tolerant structure means that the S7-400H is optimally suit-able for applications in which fail-ures and down times must be largely avoided, e.g. for power genera-tion/distribution, the chemical industry, mining, transportation etc.

Fault tolerance is achieved using two parallel central controllers whose CPUs are linked via fiber-optic cables and control the I/Os via redundant PROFIBUS DP lines. The I/Os themselves can be redundant in addition, permitting compensation of I/O module failures in addition to failure of CPU and PROFIBUS.

A bumpless switchover is carried out in the event of a failure, i.e. the intact unit takes over processing at the point of interruption without loss of information.

When configuring a fault-tolerant S7-400H PLC, the user can concen-trate completely on the actual task:

• The S7-400H is programmed like a standard, non-redundant S7-400 system using all STEP 7 lan-guages. All functions specific to the redundancy are conveniently programmed using a STEP 7 option package (integrated in STEP 7 V 5.3 from 01/2004).Furthermore, a program written for a standard, non-redundant system can easily be transferred to a redundant system (and vice versa).

• Standard components from the SIMATIC S7 range are almost ex-clusively used for the S7-400H, and the latter is a component of Totally Integrated Automation (TIA).

Further information can be found in the Product Brief "Fault tolerance using fault-tolerant SIMATIC S7 sys-tems".

Fault-tolerant S7-400H PLC

Fault-tolerant SIMATIC S7-400H PLC

Configuration of the SIMATIC S7-400H with switched connection of I/Os

SIMATIC S7-400H

I/O station with redundant interface

Y link

PA link

9

Fail-safe S7-400F/FH PLC

Should a fault occur, fail-safe SIMATIC S7-400F PLCs immediately enter a safe state or remain in a safe state. They thus guarantee maxi-mum safety for persons, machines, processes and the environment. The safety functions are executed by the safety program in the CPU together with fail-safe I/O modules. Standard I/Os and fail-safe I/Os can also be used in a mixed configurations.

Standard automation and safety engineering are therefore growing together in one controller. The CPU 416F is particularly suitable for the production industry, and is based on a standard CPU whose operating system has been expanded to execute safety pro-grams and various protective mea-sures. No limitations exist when exe-cuting programs without safety functions. All programming is car-ried out in the standard LAD and FBD languages. The software package "Distributed Safety" supports param-eterization of the fail-safe I/O and programming by means of pre-defined software blocks approved of by the German Technical Inspec-torate (TÜV).

The fault-tolerant CPUs 414H and 417H are available for use in pro-cess automation, where the oper-ating system has been expanded by a so-called fail-safe library. Program-ming is carried out by calling and linking function blocks in the Con-tinuous Function Chart (CFC). The software package "S7 F Systems" supports parameterization of the fail-safe I/O and programming by means of predefined and certified standard blocks.

When using two fault-tolerant CPUs, a fail-safe and fault-tolerant S7-400FH can be configured with which the redundant CPU takes over control when a fault occurs in order to continue the production process. The ET 200S and ET 200M are used in both cases as the fail-safe I/O sys-tems.

Fail-safe and fault-tolerant PLC SIMATIC S7-400FH

Standard PROFIBUS DP link to I/Os with additional fail-safe DP communication (PROFIsafe)

S7-400H CPU with fail-safe capability(CPU 417-4H)

Standard SMs F-SMs (DI, DO, AI)

Both the safety-based and standard communication between the cen-tral processing unit and I/O (safety-based or standard) take place using PROFIBUS DP and the PROFIsafe profile.

Further information can be found in the Product Brief "SIMATIC fail-safe PLCs".

10

CPUs - Technical specifications

CPU 412-1 CPU 412-2 CPU 414-2 CPU 414-3

Main memory• integrated• in instructions• for program• for data

96 KB 144 KB32 K 48 K48 KB 72 KB48 KB 72 KB

144 KB 256 KB32 K 84 K72 KB 128 KB72 KB 128 KB

256 KB 512 KB84 K 170 K128 KB 256 KB128 KB 256 KB

768 KB 1.4 MB256 K 470 K384 KB 700 KB384 KB 700 KB

load memory• integrated• expandable to

256 KB RAM64 MB

Backup ✓

Number of blocks• FB• FC• DB

256256511 (DB 0 reserved)

204820484095 (DB 0 reserved)

Program execution• free cycle• timed interrupts• delay interrupts• time interrupts• process interrupts• multi-computing interrupt• startup

1222213

1444413

Execution times• bit operations• word operations• fixed point arithmetic• floating point arithmetic

0.2 µs 0.1 µs0.2 µs 0.1 µs0.2 µs 0.1 µs0.6 µs 0.3 µs


Bit memories/timers/counter• Bit memories• S7 timers/S7 counters• IEC timers/IEC counters

4 KB256/256 2048/2048SFB/SFB

8 KB256/256 2048/2048SFB/SFB

Design• Number of expansion units• Num. of DP masters, through CP• Number of FMs• Number of CPs

21max. 10limited by number of slots and number of connectionslimited by number of slots and number of connections

MPI/DP interface• Number of DP slaves• Transmission speed

32max. 12 Mbit/s

32max. 12 Mbit/s

DP interfaces• Number• Number of DP slaves• Transmission speed• Interface modules for insertion

––––

164max. 12 Mbit/s–


296 eachmax. 12 Mbit/s1 x DP

Address ranges• Total I/O address area• I/O process image• Total digital channels• Total analog channels

4 KB/4 KB4 KB/4 KB32768/327682048/2048

8 KB/8 KB8 KB/8 KB65536/655364096/4096

MLFB group 6ES7412-1XF... 6ES7412-2XG... 6ES7414-2XG... 6ES7414-3XJ...

‡

In b

lue:

va l

ues

fo

r n

e w g

e ner

atio

n, s

tart

of

del

iver

y M

arc h

20

04‡ ‡ N

11

CPUs - Technical specifications

CPU 416-2 CPU 416-3 CPU 417-4

Main memory• integrated• in instructions• for program• for data

1.6 MB 2.8 MB530 K 930 K0.8 MB 1.4 MB0.8 MB 1.4 MB

3.2 MB 5.6 MB1065 K 1.9 M1.6 MB 2.8 MB1.6 MB 2.8 MB

4 MB 20 MB1335 K 6.7 M2 MB 10.0 MB2 MB 10.0 MB

Load memory• integrated• expandable to

256 KB RAM64 MB

Backup ✓

Number of blocks• FB• FC• DB

204820484095 (DB 0 reserved)

614461448191 (DB 0 reserved)

Program execution• free cycle• timed interrupts• delay interrupts• time interrupts• process interrupts• multi-computing interrupt• startup

1849813

1849813

Execution times• bit operations• word operations• fixed point arithmetic• floating point arithmetic



Bit memories/timers/counter• Bit memories• S7 timers/S7 counters• IEC timers/IEC counters

16 KB512/512 2048/2048SFB/SFB

Design• Number of expansion units• Num. of DP masters, through CP• Number of FMs• Number of CPs

21max. 10limited by number of slots and number of connectionslimited by number of slots and number of connections

MPI/DP interface• Number of DP slaves• Transmission speed

32max. 12 Mbit/s

DP interfaces• Number• Number of DP slaves• Transmission speed• Interface modules for insertion




Address ranges• Total I/O address area• I/O process image• Total digital channels• Total analog channels

16 KB/16 KB16 KB/16 KB131072/1310728192/8192

MLFB group 6ES7416-2XK... 6ES7416-3XL... 6ES7417-4XL...

‡ ‡ ‡

In b

lue:

va l

ues

fo

r n

e w g

e ner

atio

n, s

tart

of

del

iver

y M

arc h

20

04

12

Programming

The basis for the configuration and programming of the new CPUs of the S7-400 is the current STEP 7 ver-sion (Version 5.2, SP1, MM).

STEP 7 offers functions for every phase of an automation project – from configuration to startup, test-ing and servicing.

STEP 7

STEP 7 incorporates the SIMATIC Manager, the central tool for the software-related handling of the project. This relates not only to a sin-gle CPU, but to the whole plant – irrespective of how many control-lers, drives and HMI devices the solution consists of. Using STEP 7 also ensures that the data is kept consistent throughout the project.

STEP 7 incorporates both the hard-ware configuration of the plant and the parameterization of the mod-ules, so there are no more hardware settings to be made. STEP 7 also in-cludes the three basic languages: statement list (STL), ladder diagram (LAD) and function block diagram (FBD). STEP 7 also makes it possible to parameterize high-speed data communications between net-worked CPUs.

Engineering Tools

As the S7-400 is generally used for executing large programs, there are also higher-level languages and graphical engineering tools based on STEP 7. These have the additional functionality to enable you to pro-gram automation solutions in a function-oriented manner and using a user-friendly interface.

The following tools are available for programming:

S7-SCL

(Structured Control Language), PASCAL-based higher-level language for programming SIMATIC S7/C7 controllers

S7-GRAPH

enables graphical configuration of sequential control systems for SIMATIC S7/C7

S7-HiGraph®

for graphical description of sequen-tial or asynchronous process with status diagrams for SIMATIC S7/C7

CFC

(Continuous Function Chart), the technology-oriented diagram which enables graphical interconnection of complex functions for SIMATIC S7

Data storage

STEP 7 allows any data to be saved to the CPU, i.e. if you are servicing or upgrading the system, the person-nel can still access not only the pro-grams running, but also the whole project, including any comments and symbols. If you are using higher-level languages or graphical engineering tools, the program source code is also immediately available in its original form or in graphical format. Last but not least, it is also possible to save cus-tomer-specific operating instruc-tions, manuals and machine docu-mentation directly on the CPU in all standard file formats.

Memory requirements of the engineering tools

Memory requirements

ProductivitySTL

LAD

FBD

S7-SCLCFC

S7-

GRAPH

S7-

HIGRAPH

13

Communication

Totally Integrated Automation

A single, completely integrated and consistent system with which you can execute any automation func-tions!

An element of central importance within the system is the communi-cations network:

Industrial Ethernet (IEEE 802-3 and 802.3u) – the international standard for area and cell networking – with a connection to the IT environment.

PROFIBUS (IEC 61158/EN 50170) – the international standard for the cell and field levels.

AS-Interface (EN 50295) – the inter-national standard for communica-tions with sensors and actuators.

EIB (EN 50090, ANSI EIA 776) – the global standard building installation system and the basis for building ser-vices automation.

Point to point connection – for communication between two sta-tions with special protocols. The point to point structure represents the simplest form of communica-tion. Various different special proto-cols are used (e.g. RK 512, 3694(R) and ASCII).

Process or field communications

Process or field communication are used to connect actuators/sensors to a CPU. Process or field communica-tion with the S7-400 is supported by PROFIBUS DP. To make this possible, the S7-400 can be connected to PROFIBUS DP as a master – either by means of the interface integrated into each CPU, a special interface module or a communications pro-cessor (CP). The AS interface and EIB networks and other bus systems are accessible from the S7-400 through the PROFIBUS gateways.

Data communications

Data communications enable data transfer between automation sys-tems or between an automation sys-tem and an intelligent partner (PC, computer, etc.).This is achieved either through the programming interface or by means of PROFIBUS and Industrial Ethernet.

The programming interface enables simple cyclical data transfer on the one hand (no acknowledgment) and programmed transfer of relatively large volumes of data on the other (with or without acknowledgment).

Specific communications processors (CP) are used for the connection to PROFIBUS and Industrial Ethernet; which means that the TCP/IP proto-col can be accessed direct from the program.

Communications options of the SIMATIC S7-400

PC

OS

OSS7-300®

S7-400

S7-400Scanner

Network access

Link Link

ET 200

Fire alarmSensors

Da

ta c

om

mu

nic

ati

on

Pro

cess

/fie

ld c

om

mu

nic

ati

on

14

Expansion options,module spectrum

The S7-400 allows central or distrib-uted expansion depending on the task. Expansion units are available for central expansion, or the PROFIBUS for distributed expansion.

Central expansion

With central expansion, additional racks are connected directly to the central controller. A distance up to 600 m is possible; the full perfor-mance of the backplane bus is nev-ertheless available. The power sup-ply can also be looped on over shorter distances.

Racks with 4, 9 or 18 slots are avail-able as the central controller. Inter-face modules can be used to con-nect up to 21 expansion units, each with 18 or 9 slots for S7-400 mod-ules.

S7-400 I/Os

A wide variety of S7-400 I/O mod-ules are available for the central and expansion units:

• intelligent power supplies (redun-dant, diagnostics-compatible) to secure the supply of all operating voltages

• digital and analog I/O modules for nearly all signal types, including some with interrupt processing and diagnostics

• function modules for counting/ measurement, all types of posi-tioning functions, cam control, motion control and computing

• communications modules for serial point to point connection and bus communications by means of PROFIBUS and Industrial Ethernet

• interface modules for connecting expansion units to the central controller

PROFIBUS is used for the distributed expansion. The S7-400 provides the connection to the PROFIBUS world via the PROFIBUS DP connection integrated on the CPU. Thus a large number of I/O modules are available with which the S7-400 can be adapted to highly versatile tasks. Both PROFIBUS DP modules from Siemens and modules from other vendors can be used.

Interfacing to the IT world

The S7-400 permits simple interfac-ing of the modern IT world to the automation technology. The follow-ing functions are possible using the plug-in CP 443-1 IT® communica-tions processor:• Creation of your own web pages

using any HTML tools, and the process variables for the S7-400 can simply be assigned to the HTML objects

• Monitoring of the S7-400 through these web pages using a standard browser

• Sending of e-mails from the user program of the S7-400 by means of function calls

• Remote programming through the telephone network (e.g. ISDN) using the WAN properties of TCP/IP.

The following publications contain additional information on the mod-ule spectrum and for communica-tions:

• Product Brief "SIMATIC technology"

• Product Brief "Counting and measuring with SIMATIC"

• Product Brief "Positioning with SIMATIC"

• Product Brief "Loop control with SIMATIC"

• Product Brief "Cam control with SIMATIC"

• Product Brief "FM 458-1DP for SIMATIC S7-400“

• Product Brief "Point-to-point coupler modules"

• Overview "Industrial communication for Automation & Drives”

Communications

• Point to point connection with data rates of up to 115 Kbit/s and various protocols, e.g. for connecting modems, printers, scanners, drives, external devices, etc.

• Connection to PROFIBUS using either the DP or the FMS protocol (DP V0 and DP V1)

• Connection to Industrial Ethernet using the ISO/TCP or TCP/IP data communications protocol

• Connection to the Internet through Ethernet for loading websites and using e-mail

Technology

• Counting in various modes, up to 500 kHz

• Cam control for up to 16 cam lines per module

• Any type of positioning function: controlled positioning using the rapid/creep feed process (3 axes per module)

• Point to point positioning and veloc-ity profiles (position control) with stepper and servo motors (3 axes per module)

• PID controller with backup function-ality and integrated online self-con-figuration for various types of controller (continuous controllers, stepper controllers, pulse control-lers)

• Freely programmable, highly dynamic controller for up to 100 axes per module

15

I/Os - features

Signal modules are the interface of the SIMATIC S7-400 to the process. A wide range of different digital and analog modules make those I/Os available which are required for the respective task. However, the S7-400 signal modules only repre-sent a subset of those modules which can be connected to the S7-400 using PROFIBUS DP. Hot swapping is possible for central sig-nal modules.

Easy to install

The sensors/actuators simply con-nect to the front connector. When replacing the module, all you need to do is plug the connector into the new module of the same type. You do not need to change the wiring. The coding of the front connector prevents confusing of modules.

Fast connection

Using SIMATIC TOP connect makes it even easier to connect. You can choose between prewired front con-nectors with individual strands and a completely modular building block system, consisting of front connec-tor module, cable and terminal block.

High level of packaging density

The large number of channels on the modules is one reason for the space-saving design of the S7-400: Modules are available with 8 to 32 channels (digital) or 8 to 16 chan-nels (analog) per module.

Simple to configure

The modules are configured and parameterized using STEP 7, there are no fiddly switch settings. The data is stored centrally and automat-ically transferred to the new module after a module is replaced, which prevents transfer errors. No soft-ware upgrade is required when new modules are installed.

Alarms

Many modules also monitor signal acquisition (diagnostics interrupt) and the signals from the process (process interrupt). This means the system can react quickly to any irreg-ularities and to every process event. How and whether the controller reacts can be configured in STEP 7. For the digital input modules, a pro-cess interrupt can be triggered on a rising edge, a falling edge or both edges of a signal status change, or based on channel groups.

The following pages list criteria to help you select the appropriate sig-nal module for a given application.

Regularly updated, extensive techni-cal information can be found in the interactive CA 01 catalog at any time:

www.siemens.com/automation/ca01

SM 422 32-channel digital output module

http://www.siemens.com/automation/ca01

16

Selection guide for digital inputs/outputs

Module type Selection guide for digital inputs

Special features of this module

Very fast, inter-rupt-capable 24 V DC input module

24 V DC standard input module – extremely high pack-aging density

Highest packaging density for the 120 V market

Input module for higher, variable volt-ages

Interrupt-capable input module for lower, variable volt-ages 1)

Type of voltage DC DC AC/DC AC/DC AC/DC

Input voltage 24 V 24 V 120 V 120/230 V 24 to 60 V

Interrupt capability ✓ – – – ✓

Input delay 0.05 to 3 ms 2) 3 ms < 25 ms < 25 ms 0,5 to 20 ms 2)

Num. of channels 16 32 32 16 16

MLFB group:6ES7 421- 7BH -... 1BL..-... 1EL..-...

1FH..-...

7DH..-...

Module type Selection guide for digital outputs


DC output module for high currents

24 V DC standard output module – highest possible packaging density

Very fast, interrupt-capable 24 V DC input module

AC standard output module

Relay output module

Type of voltage DC DC DC AC Relay

Output voltage 24 V 24 V 24 V 120/230 V 5-125 V DC

Output current 2 A 0,5 A 0,5 A 2 A 5 A

Interrupt capability ✓ – ✓ – –

Num. of channels 16 32 32 16 16

MLFB group:6ES7 422- 1BH..-... 1BL..-... 7BL..-...

1FH..-... 1HH..-...

1) can also be used as an active low module2) can be set with parameters

17

I/O modules – selection guide for analog inputs

Selection guide for analog inputs

Physicalmeasured variable

Voltage


Standard module with 16 inputs


Numerous voltage ranges

Very rapid analog value acquisition

Generation of diagnostics and process value inter-rupts at 16 bit resolution

Channel-oriented isola-tion and gener-ation of diagnostic and process value interrupts

Measurement rangeEncoder

±1 V1 - 5 V

±1 V±10 V1 - 5 V

±80 mV±250 mV±500 mV±1 V±2,5 V±5 V±10 V1 - 5 V

±1 V1 - 5 V±10 V

±25 mV±50 mV±80 mV±250 mV±500 mV±1 V±2,5 V±5 V±10 V1 - 5 V

±25 mV±50 mV±80 mV±250 mV±500 mV±1 V±2,5 V±5 V±10 V1 - 5 V

Interrupt capability – – – – ✓ ✓

Isolation – ✓ ✓ ✓ ✓ ✓

Number of channels 16 8 8 8 16 8

Resolution 13 Bit 13 Bit 14 Bit 14 Bit 16 Bit 16 Bit

Conversion time per channel

55/65 ms 23/25 ms 20/23 ms 52 �s 6/21/23 ms –

MLFB group 6ES7 431- 0HH..-....

6ES7 431- 1KF0..-....

6ES7 431- 1KF1..-....

6ES7 431- 1KF2..-....

6ES7 431- 7QH..-....

6ES7 431- 7KF0..-....


Physical measured variable

Current





Very rapid analog value acquisition

Generation of diagnostics and process value inter-rupts at 16 bit resolution

Channel-oriented isola-tion and generation of diagnostic and process value interrupts

Measurement rangeEncoder

4-20 mA±20 mA

4 - 20 mA±20 mA

4 - 20 mA0 - 20 mA

4 - 20 mA±20 mA

4 - 20 mA0 - 20 mA±5 mA±10 mA±20 mA

4 - 20 mA0 - 20 mA±5 mA±10 mA±20 mA±3,2 mA

Interrupt capability – – – – ✓ ✓

Isolation – ✓ ✓ ✓ ✓ ✓

Number of channels 16 8 8 8 16 8

Resolution 13 Bit 13 Bit 14 Bit 14 Bit 16 Bit 16 Bit

Conversion time per channel

55/65 ms 23/25 ms 20/23 ms 52 �s 6/21/23 ms –

MLFB group 6ES7 431- 0HH..-....

6ES7 431- 1KF0..-....

6ES7 431- 1KF1..-....

6ES7 431- 1KF2..-....

6ES7 431- 7QH..-....

6ES7 431- 7KF0..-....

18

I/O modules – selection guide for analog inputs


Physical variable Resistance


Standard module Numerous measurement ranges

High-speed analog value acquisition and generation of process interrupts

Many measurement ranges and generation of process and diag-nostics interrupts

Encoder measurement range

0 - 600 � 0 - 48 ��0 - 150 ��

0 - 300 ��0 - 600 ��0 - 6000 �

0 - 600 � 0 - 48 ��0 - 150 �

0 - 300 ��0 - 600 ��0 - 6000 �

Interrupt capability – – – ✓

Isolation ✓ ✓ ✓ ✓

Number of channels 4 4 4 8

Resolution 13 Bit 14 Bit 14 Bit 16 Bit

Conv. time per channel 23/25 ms 20/23 ms 52 �s 6/21/23 ms

MLFB group 6ES7 431-1KF0..-.... 6ES7 431-1KF1..-.... 6ES7 431-1KF2..-.... 6ES7 431-7QH..-....


Physical variable Thermocouples


Standard module with 8 channels

16 channels with 16 bit resolu-tion and generation of process and diagnostics interrupts

Channel-oriented isolation and generation of process and diagnostics interrupts

Types B, E, N, J, K, L, R, S, T, U B, E, N, J, K, L, R, S, T, U B, E, N, J, K, L, R, S, T, U

Interrupt capability – ✓ ✓

Isolation ✓ ✓ ✓

Number of channels 8 16 8

Resolution 14 Bit 16 Bit 16 Bit

Conv. time per channel 20/23 ms 6/21/23 ms –

MLFB group 6ES7 431-1KF1..-.... 6ES7 431-7QH..-.... 6ES7 431-7KF0..-....


Physical variable Resistance thermometer


Standard module with 4 channels

Generation of process and diagnostics interrupts

Generation of process and diagnostics interrupts

Types Pt 100, Pt 200, Pt 500, Pt 1000,Ni 100

Pt 100, Pt 200, Pt 500, Pt 1000,Ni 100, Ni 1000

Pt 100, Pt 200, Pt 500, Pt 1000, Ni 100, Ni 1000

Interrupt capability – ✓ ✓

Isolation ✓ ✓ ✓

Number of channels 4 8 8

Resolution 14 Bit 16 Bit 16 Bit

Conv. time per channel 20/23 ms 6/21/23 ms –

MLFB group 6ES7 431-1KF1..-.... 6ES7 431-7QH..-.... 6ES7 431-7KF1..-...

19

I/O modules – selection guide for analog outputsStandards


Physical measured variable Voltage, current

Encoder measurement range ±10 V, 0 - 10 V, 1 - 5 V,±20 mA, 0 - 20 mA, 4 - 20 mA

Interrupt capability –

Isolation 3

Number of channels 8

Resolution 13 Bit

Conversion time per channel 420 ms

MLFB group 6ES7 432-1HF..-....

Standards

The SIMATIC S7-400 fulfills the following national and interna-tional standards:

• DIN, EN, IEC

• UL certificate

• CSA certificate

• FM class 1 div. 2; group A, B, C and D

• Temperature group T4 (� 135 °C)

• Marine approvals from:

– American Bureau of Shipping

– Bureau Veritas

– Des Norske Veritas

– Germanischer Lloyd

– Lloyds Register of Shipping

• Ambient temperature 0 to 60 °C for all components

• Earthquake-proof

20

Further information regarding SIMATIC S7-400 can be found in the Internet:www.siemens.com/simatic-s7-400

To get in touch with your contact person near you, look in the Internet under:

www.siemens.com/automation/partner

With the A&D Mall you can order electronically using the Internet:

www.siemens.com/automation/mall

Siemens AGAutomation and DrivesPostfach 4848, D-90327 NürnbergFederal Republic of Germany

Order No.: 6ZB5310-0JD02-0BA9Printed in the Federal Republic of Germany26100/401148 KB 0104 5. MAN En

© Siemens AG 2004Subject to change without prior notice

All designations marked in this Product Brief with ® are registered trademarks of Siemens AG.

www.siemens.com/simatic-s7-400

The information provided in this bro-chure contains descriptions or charac-teristics of performance which in case ofactual use do not always apply asdescribed or which may change as aresult of further development of the

products. An obligation to provide therespective characteristics shall only existif expressly agreed in the terms of con-tract. Availability and technical specifi-cations are subject to change withoutnotice.

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

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

http://www.siemens.com/simatic-s7-400

http://www.siemens.com/simatic-s7-400

simatic s7-400 - the plc with excellent dynamic ... · the plc with excellent dynamic...

Documents