Page 1 Preface, Contents Product Overview SIMATIC Installing the S7-400 S7-400 and M7-400 Addressing the S7-400 Programmable Controllers Hardware and Installation Wiring the S7-400 Networking Installation Manual Starting Up Maintenance Assembling the M7-400 Appendices Assembling and Installing Systems Guidelines for Handling Electrostatically-Sensitive...
Page 2 Trademarks SIMATIC, SIMATIC HMI and SIMATIC NET are registered trademarks of SIEMENS AG. Third parties using for their own purposes any other names in this document which refer to trademarks might infringe upon the rights of the trademark owners.
Page 3: A5E00069481
Where is this Manual valid? The manual is valid for the S7-400 and M7-400 programmable controllers. Changes compared to the previous version Section 2.5 and Appendix A have been updated since the previous edition of the “Hardware and Installation”...
Page 4 The SIMATIC S7-400 product range complies with the requirements of the AS/NZS 2064 standard (Australia and New Zealand). Standards The SIMATIC S7-400 product range complies with the requirements and criteria of the IEC 61131-2. Place of this Documentation in the Information Environment This manual is part of the documentation package for S7-400, M7-400.
Page 5 Working with STEP 7 with the following contents: STEP 7 Basic Managing projects and files Information 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...
Page 6 S7-300 and S7-400 System and Standard Functions • Manual Description of the programming device hardware • PG 7xx Connecting a programming device to various devices • Starting up a programming device S7-400 and M7-400 Programmable Controllers Hardware and Installation A5E00069481-04...
Page 7 Training Centers Siemens offers a number of training courses to familiarize you with the SIMATIC S7 automation system. Please contact your regional training center or our central training center in D-90327 Nuremberg, Germany for details: Telephone: +49 (911) 895-3200.
Page 8 E-Mail: simatic.hotline@ E-Mail: adsupport.asia@ E-Mail: adsupport@ sea.siemens.com siemens.com siemens.com GMT: +8:00 GMT: +1:00 GMT: –5:00 The languages of the SIMATIC Hotlines and the authorization hotline are generally German and English. S7-400 and M7-400 Programmable Controllers Hardware and Installation viii A5E00069481-04...
Page 9 • A forum, where users and experts from all over the world exchange their experiences. • Your local representative for Automation & Drives via our representatives database. • Information on field service, repairs, spare parts and more under “Services”. S7-400 and M7-400 Programmable Controllers Hardware and Installation A5E00069481-04...
Page 10 Preface S7-400 and M7-400 Programmable Controllers Hardware and Installation A5E00069481-04...
Page 11: Table Of Contents
......... . 2-25 2.11 Choosing and Setting up Cabinets with the S7-400 ....2-26 2.12...
Page 12 ......Assembling an S7-400 with Grounded Reference Potential (M) ..
Page 13 ..... . Connecting a Programming Device (PG) to an S7-400 ....
Page 14 ........8-56 S7-400 and M7-400 Programmable Controllers Hardware and Installation A5E00069481-04...
Page 15 ..... . A-25 A.9.4 Sample of a Surge Protection Circuit for Networked S7-400 PLCs ..A-28 A.10...
Page 16 Contents Figures Rack Fitted with Modules in the S7-400 System ..... Max. Cabinet Ambient Temperature as a Function of Power Dissipation of Equipment in the Cabinet .
Page 17: Memory Card
..........8-55 8-30 Removing an AT Card from the ATM 478 AT Adapter Module ..8-57 S7-400 and M7-400 Programmable Controllers Hardware and Installation xvii A5E00069481-04...
Page 18 ........A-36 Electrostatic Voltages which can Build up on a Person ....S7-400 and M7-400 Programmable Controllers Hardware and Installation xviii A5E00069481-04...
Page 19 ......... . . A-29 S7-400 and M7-400 Programmable Controllers Hardware and Installation A5E00069481-04...
Page 20 Contents S7-400 and M7-400 Programmable Controllers Hardware and Installation A5E00069481-04...
Page 21: Product Overview
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.
Page 22 – running of real time-capable software – event-driven program processing – multitasking • A standard, short AT card can be plugged in • Multicomputing in the non-segmented rack • Full incorporation in S7-400 systems. S7-400 and M7-400 Programmable Controllers Hardware and Installation A5E00069481-04...
Page 23 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 ... provide the mechanical and (UR: Universal Rack) electrical connections between (CR: Central Rack) the S7-400 modules.
Page 24 (for special areas of application) cases; can be operated with or without a filter. Additional components of the S7-400 such as communications processors, function modules, etc., are described in separate manuals. Components of an M7-400 The most important components of the M7-400 and their functions are given in the...
Page 25 ... for connecting I/O devices such as VGA monitor, mouse, keyboard, printer. Applicable Modules in the S7-400 Range The following modules from the S7-400 range can be used with the M7-400: • Power supply modules (PSs) • Function modules (FMs) • Signal modules (SMs) •...
Page 26 Location of Order Number and Product Version The order number and product version are printed on every module of the SIMATIC S7-400/M7-400. The firmware version is also printed on the CPUs. The following figure shows their locations on a module.
Page 27: Installing The S7-400
Changing the Ventilation with the Cable Duct and Fan Subassembly 2-21 Installing the Fan Subassembly 2-23 2.10 Installing the Cable Duct 2-25 2.11 Choosing and Setting up Cabinets with the S7-400 2-26 2.12 Rules for the Arrangement of Modules 2-30 2.13 Fitting Memory Cards in the CPU 2-31 2.14...
Page 28: Assembling An S7-400
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.”...
Page 29 461-4 Max. number of connectable EMs per chain Max. distance 1.5 m 102.25 m 605 m 5 V transfer Max. current transfer per inter- – – – face Communication bus transmission S7-400 and M7-400 Programmable Controllers Hardware and Installation A5E00069481-04...
Page 30 Expansion rack ER 4 Expansion rack ER 1 IM 461-3 IM 461-3 Chain length max. 102.25 m Expansion rack ER 4 Expansion rack ER 1 IM 461-4 IM 461-4 Chain length max. 605 m S7-400 and M7-400 Programmable Controllers Hardware and Installation A5E00069481-04...
Page 31 When you connect a central rack to expansion racks, you must observe the following rules: • You can connect up to 21 ERs of the S7-400 to one CR. • The ERs are assigned numbers to identify them. The rack number must be set on the coding switch of the receive IM.
Page 32: Assembling The Central Rack (Cr) And Expansion Rack (Er)
(ER) Function of the Racks The racks of the S7-400 system form the basic framework which accepts the individual modules. The modules exchange data and signals and are powered via the backplane bus. The racks are designed for wall mounting, for mounting on rails, and for installation in frames and cabinets.
Page 33 I/O bus connector and communication bus connector can be seen at each slot. When the rack is delivered, these connectors are protected by a cover. I/O bus connector Communication bus connector S7-400 and M7-400 Programmable Controllers Hardware and Installation A5E00069481-04...
Page 34: Segmented Cr
SEG1 SEG2 SEG1 SEG1 SEG1 SEG1 SEG1 SEG1 SEG1 SEG1 SEG1 SEG1 SEG2 SEG2 SEG2 SEG2 SEG2 SEG2 SEG2 SEG2 I/O bus I/O bus Segment 1 Segment 2 Communication bus S7-400 and M7-400 Programmable Controllers Hardware and Installation A5E00069481-04...
Page 35: Subdivided Cr
The following figure shows a divided CR with a divided I/O bus and communication bus. Division I Division II I/O bus I/O bus Segment 1 Segment 2 Communication bus Communication bus Segment 2 Segment 1 S7-400 and M7-400 Programmable Controllers Hardware and Installation A5E00069481-04...
Page 36: Mounting And Grounding The Racks
Installing the S7-400 Mounting and Grounding the Racks Important Notes on Installation The S7-400 racks are designed for wall mounting, mounting on rails, and for installation in frames and cabinets. Their mounting dimensions 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).
Page 37 The following figure shows the dimensions for racks with 18, 9 and 4 slots and the positions of cutouts for screw mounting. The cutouts are arranged according to the 19-inch standard. S7-400 and M7-400 Programmable Controllers Hardware and Installation 2-11 A5E00069481-04...
Page 38 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. S7-400 and M7-400 Programmable Controllers Hardware and Installation 2-12 A5E00069481-04...
Page 39 Connect the rack to the chassis ground. A threaded bolt is provided for this purpose on the bottom left of the rack. Minimum cross-section of the conductor to the chassis ground: 10 mm If the S7-400 is mounted on a mobile rack, you must provide a flexible conductor to the chassis ground. Note Always ensure that there is a low-impedance connection to the chassis ground (see the figure below).
Page 40 Installing the S7-400 Step 4: Mounting Additional Racks If you assemble an S7-400 with two or more racks, you must allow additional clearance between the individual racks or install a fan subassembly or cable duct. The figure below shows the clearance you must allow between two racks of the S7-400 during installation.
Page 41 The figure below shows how much space you must allow for when assembling an S7-400 from two racks with a cable duct or fan subassembly. This requirement is increased by a height of 400 mm for each additional rack with a cable duct or fan subassembly.
Page 42: Chassis Terminal Connection In The Non-Isolated Configuration
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. S7-400 and M7-400 Programmable Controllers Hardware and Installation 2-16 A5E00069481-04...
Page 43 Load voltage ground con- nection (reference point) Chassis ground terminal The following figure shows the ground connection to the reference point. Threaded hole Terminal Spring washer M4 screw S7-400 and M7-400 Programmable Controllers Hardware and Installation 2-17 A5E00069481-04...
Page 44 For this reason as well, leave the metallic connection on the rack and use it as a washer in an ungrounded configuration. S7-400 and M7-400 Programmable Controllers Hardware and Installation 2-18 A5E00069481-04...
Page 45: Methods Of Ventilation
Installing the S7-400 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.
Page 46 Ç Ç Ç Ç Ç Ç Modules Ç Cable duct or fan Ç subassembly Ç Ç Ç Ç Ç Ç Modules Ç Ç Ç Ç Ç Ç Ç Supply air S7-400 and M7-400 Programmable Controllers Hardware and Installation 2-20 A5E00069481-04...
Page 47: Changing The Ventilation With The Cable Duct And Fan Subassembly
6. Use a screwdriver to make a quarter turn clockwise and close the two quick-release locks. The following figure shows both methods of selecting the ventilation by appropriately fitting the cover in the base of the cable duct or fan subassembly. S7-400 and M7-400 Programmable Controllers Hardware and Installation 2-21 A5E00069481-04...
Page 48 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 Hardware and Installation 2-22 A5E00069481-04...
Page 49: Installing The Fan Subassembly
2. Remove the dummy plates which are not required by slackening the snap-in mechanisms of the covers and pulling them off. 3. Break off as many dummy plates as required. S7-400 and M7-400 Programmable Controllers Hardware and Installation 2-23 A5E00069481-04...
Page 50 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 Hardware and Installation 2-24 A5E00069481-04...
Page 51: Installing The Cable Duct
Use M6 size screws for mounting. The following figure shows how to mount the cable duct between two racks. 12 13 14 15 17 18 12 13 14 15 17 18 19-inch reference level S7-400 and M7-400 Programmable Controllers Hardware and Installation 2-25 A5E00069481-04...
Page 52: Choosing And Setting Up Cabinets With The S7-400
Why Cabinets are Required With larger installations and in an environment subject to interference or pollution, you can install the S7-400 in cabinets. The requirements of UL/CSA are met, for example, by an installation in cabinets. Types and Dimensions of Cabinets Observe the following criteria when selecting cabinet types and their dimensions: •...
Page 53: Types Of Cabinet
700 W up to 2700 W up to 260 W up to 360 W up to 1700 W (1400 W with very fine filter) S7-400 and M7-400 Programmable Controllers Hardware and Installation 2-27 A5E00069481-04...
Page 54: Max. Cabinet Ambient Temperature As A Function
600 x 600 x 2000 mm as a function of power dissipation. These values only apply if you observe the specified installation dimensions and clearances for racks. Further information can be found in Siemens catalogs NV21 and ET1.
Page 55 Closed, with heat exchanger (Curve 1) approx. 45° C Dimensions of Cabinet To determine the dimensions of a cabinet suitable for assembling an S7-400, you must take the following into account: • Space requirement of the racks • Minimum clearances between racks and cabinet walls •...
Page 56: Rules For The Arrangement Of Modules
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: •...
Page 57: Fitting Memory Cards In The Cpu
4. If necessary, insert the second memory card in slot 2 in the same way (see Figure 2-3). S7-400 and M7-400 Programmable Controllers Hardware and Installation 2-31 A5E00069481-04...
Page 58: Fitting Memory Cards In The Cpus
(see Figure 2-4). Slot 1 Slot 2 Figure 2-3 Fitting Memory Cards in the CPUs Copper flag Memory card Cutout Cutout Polarity reversal Guide support Guide support protection Slots 1 and 2 S7-400 and M7-400 Programmable Controllers Hardware and Installation 2-32 A5E00069481-04...
Page 59: Installing Modules In A Rack
3. Disconnect the power supply connector at the power supply module. 4. Attach the first module and swing it downwards (see Figure 2-6). If you feel a resistance when swinging the module down, raise it slightly and then continue. S7-400 and M7-400 Programmable Controllers Hardware and Installation 2-33 A5E00069481-04...
Page 60: Removing The Cover
Proceed as follows: 1. Press the locking lever down (1). 2. Swing the cover forward and off (2). Figure 2-5 Removing the Cover S7-400 and M7-400 Programmable Controllers Hardware and Installation 2-34 A5E00069481-04...
Page 61: Attaching The Modules
Figure 2-6 Attaching the Modules Screwing the Modules in Place Tightening torque 0.8 to 1.1 Nm Figure 2-7 Screwing the Modules in Place S7-400 and M7-400 Programmable Controllers Hardware and Installation 2-35 A5E00069481-04...
Page 62: Inserting The Key In The Cpu
You can insert the key in the CPU in the STOP position of the switch. You can remove the key in the STOP or RUN settings. Figure 2-8 Inserting the Key in the CPU S7-400 and M7-400 Programmable Controllers Hardware and Installation 2-36 A5E00069481-04...
Page 63: Marking The Modules With Slot Labels
2. Use your finger to press the slot label into the module. The label will break away from the “number wheel”. Figure 2-9 Fitting a Slot Label S7-400 and M7-400 Programmable Controllers Hardware and Installation 2-37 A5E00069481-04...
Page 64: Methods Of Expansion And Networking
M7-400 to PROFIBUS DP can be found in Section 6.9 “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.
Page 65: Accessories
For wiring the SMs strain relief for screw, crimp or spring-type terminal Extraction tool (for For rewiring SMs with a front crimp terminals) connector with crimp terminals Crimp contacts Crimping tool S7-400 and M7-400 Programmable Controllers Hardware and Installation 2-39 A5E00069481-04...
Page 66 Installing the S7-400 S7-400 and M7-400 Programmable Controllers Hardware and Installation 2-40 A5E00069481-04...
Page 67: Addressing The S7-400
Addressing the S7-400 Chapter Overview Section Description Page Geographical and Logical Addresses How to Determine the Default Address of a Module How to Determine the Default Address of a Channel S7-400 and M7-400 Programmable Controllers Hardware and Installation A5E00069481-04...
Page 68: Geographical And Logical Addresses
• Assign a logical address to the geographical address under STEP 7. This logical address is used for addressing the channel in the user program. Note If your S7-400 comprises only a CR without ER, you can also use default addressing. S7-400 and M7-400 Programmable Controllers Hardware and Installation...
Page 69 • If modules are inserted in STOP mode or during power off (modules inserted in RUN mode will not be taken into account, nor during the change from RUN ³ STOP ³ RUN) S7-400 and M7-400 Programmable Controllers Hardware and Installation A5E00069481-04...
Page 70: How To Determine The Default Address Of A Module
8 9 10 11 12 13 14 15 16 17 18 Default Addresses of Digital Modules On the S7-400, the default addresses for digital modules start from 0 (First slot in the central rack which is usually occupied by the power supply module) up to 68 (18th slot).
Page 71 Addressing the S7-400 Default Addresses of Analog Modules On the S7-400, the default addresses for analog modules start from 512 (first slot in the central rack which is usually occupied by the power supply module) up to 1600. The algorithm used to calculate the default address of an analog module is:...
Page 72: How To Determine The Default Address Of A Channel
I 46.0 I 46.1 I 46.2 I 46.3 I 46.4 I 46.5 I 46.6 I 46.7 I 47.0 I 47.1 I 47.2 I 47.3 I 47.4 I 47.5 I 47.6 I 47.7 S7-400 and M7-400 Programmable Controllers Hardware and Installation A5E00069481-04...
Page 73 8 channels at slot 6 (default address 832). With an analog input module, the first characters are IW instead of QW. Channel addresses QW 832 QW 834 QW 836 QW 838 QW 840 QW 842 QW 844 QW 846 S7-400 and M7-400 Programmable Controllers Hardware and Installation A5E00069481-04...
Page 74 Addressing the S7-400 S7-400 and M7-400 Programmable Controllers Hardware and Installation A5E00069481-04...
Page 75: Wiring The S7-400
Choosing the Power Supply Module Choosing the Load Current Power Supply Assembling an S7-400 with Process I/Os Assembling an S7-400 with Grounded Reference Potential (M) Assembling an S7-400 with Ungrounded Reference Potential (Ungrounded Configuration) Assembling an S7-400 with Isolated Modules...
Page 76: Supplying Power To Modules
Supplying Power to Modules Power Supply Modules and Load Current Power Supplies The modules of the S7-400 system are supplied with all the required operating voltages by a power supply module, via the backplane bus of the rack. Which power supply module you use in a rack depends on your system requirements (line voltage, current consumption of the modules used).
Page 77: Choosing The Power Supply Module
You should make an estimate of the power requirement for each rack of your S7-400 system in order to select the appropriate power supply module for the rack. Selection of the power supply for an M7-400 configuration is described separately in Section 8.3 “Electrical Configuration.”...
Page 78: Choosing The Load Current Power Supply
VDE 0100-410 / HD 384-4-41 S2 / IEC 60364-4-41 (as a functional extra-low voltage with isolation) or VDE 0805 / EN 60950 / IEC 60950 (as a safety extra-low voltage SELV) or VDE 0106 Part 101. S7-400 and M7-400 Programmable Controllers Hardware and Installation A5E00069481-04...
Page 79: Assembling An S7-400 With Process I/Os
The types of components and whether the protective measures are mandatory or recommended depends on the VDE specification applying to your installation, VDE 0100 or VDE 0113. The following table relates to Figure 4-1. S7-400 and M7-400 Programmable Controllers Hardware and Installation A5E00069481-04...
Page 80: Vde Specifications For Assembling A Programmable Controller
(Terminal L- or M) or on the isolating transformer (Figure 4-1, ). In the event of faults in the power distribution, this will facilitate the locating of ground faults. S7-400 and M7-400 Programmable Controllers Hardware and Installation A5E00069481-04...
Page 81: Operating The S7-400 From A Grounded Supply
Wiring the S7-400 S7-400 in the Overall Installation Shown in Figure 4-1 is the position of the S7-400 in the overall installation (load current power supply and grounding concept) with supply from a TN-S system. Note: The arrangement of supply terminals shown is not the actual arrangement; it has been chosen for reasons of clarity.
Page 82: Assembling An S7-400 With Grounded Reference Potential (M)
The terminal for the chassis ground also has an electrical connection to the frame element. Shown in Figure 4-2 is an S7-400 configured with grounded reference potential. To ground the reference potential M, you must connect the chassis ground terminal to the chassis ground and you must not remove the jumper between reference potential M and the frame element terminal on the rack.
Page 83: Assembling An S7-400 With Ungrounded Reference Potential (Ungrounded Configuration)
In this case you must remove the jumper between reference potential M and the frame element terminal on the rack. The reference potential M of the S7-400 is then connected via the RC network to the chassis ground terminal. When you connect this terminal to the chassis ground, RF interference currents will be discharged and static charges will be avoided.
Page 84 If a double fault could cause a hazardous state in the installation, you must provide insulation monitoring. Example of Ungrounded Operation If you have configured an S7-400 with a local connection and you only wish to ground the overall installation at the CR, you can operate the ERs in an ungrounded configuration.
Page 85: Assembling An S7-400 With Isolated Modules
– DC load circuits whose positive terminal (L+) is grounded (battery circuits). Isolated Modules and Grounding Concept You can use isolated modules, regardless of whether or not the reference potential of the programmable controller is grounded. S7-400 and M7-400 Programmable Controllers Hardware and Installation 4-11 A5E00069481-04...
Page 86: Simplified Representation Of Configuration With Isolated Modules
Wiring the S7-400 Configuration with Isolated Modules Shown in Figure 4-4 are the potentials of an S7-400 configured with isolated input and output modules. Racks internal Data Reference potential M Ground bus in cabinet external 230 VAC load current PS...
Page 87: Parallel Wiring Of Digital S7-400 Outputs
(difference < 0.5 V), there is no need to use diodes, see figure 4-6. Figure 4-6 Parallel Wiring of a Digital Output with Identical Rated Load Voltages S7-400 and M7-400 Programmable Controllers Hardware and Installation 4-13 A5E00069481-04...
Page 88: Grounding
Introduction Grounding in accordance with regulations and conscientiously implemented is the prerequisite for proper functioning of a programmable controller. Each individual component of the S7-400 and of the controlled system must be properly grounded. Ground Connections Low-resistance ground connections reduce the risk of electric shock in the event of a short-circuit or faults in the system.
Page 89: Grounded Connection Load Voltage
The following figure shows how the load voltage ground is connected for non-isolated operation. Metallic connection, remove for ungrounded configuration Ground terminal for load voltage Figure 4-7 Grounded connection load voltage S7-400 and M7-400 Programmable Controllers Hardware and Installation 4-15 A5E00069481-04...
Page 90: Interference-Free Configuration For Local And Remote Connections
• The racks in a grounded arrangement have a star grounding configuration • The contact springs of the racks are clean and not bent and will therefore ensure the discharge of interference currents. S7-400 and M7-400 Programmable Controllers Hardware and Installation 4-16 A5E00069481-04...
Page 91: Shielding And Grounding The Connecting Cable For A Remote Connection
For remote connections, you must use precut/preassembled connecting cables of fixed length. When the connecting cables are laid, therefore, there may be excess lengths. These must be coiled with a bifilar winding and deposited. S7-400 and M7-400 Programmable Controllers Hardware and Installation 4-17 A5E00069481-04...
Page 92: Wiring Rules
Wiring the S7-400 4.11 Wiring Rules Lines and Tools For wiring the S7-400 modules, there are some rules for the cables and for the tool you use. Information on connecting an M7-400 module assembly can be found in Section 8.5. Rules for ...
Page 93: Setting The Vac Power Supply Module To The Line Voltage
Line Voltage Set the voltage selector with 6ES7 407-0DA00-0AA0 and 6ES7 407-0RA00-0AA0 An S7-400 with VAC power supply can be operated from either a 120 V or 230 V line voltage. Check whether the voltage selector switch is set to your line voltage. To set the...
Page 94: Setting The Voltage Selector
Wiring the S7-400 Figure 4-9 Setting the voltage selector S7-400 and M7-400 Programmable Controllers Hardware and Installation 4-20 A5E00069481-04...
Page 95: Wiring The Power Supply Module
2. Detach the connector by levering it off with a suitable tool, for example, a screwdriver, at the opening provided (1). 3. Pull the connector forward and out of the power supply module (2). Figure 4-10 Disconnecting power supply connector S7-400 and M7-400 Programmable Controllers Hardware and Installation 4-21 A5E00069481-04...
Page 96 (PE) by 10 mm. 4. Strip the cores over a length of 7 mm. 5. Slacken the screw in the cover of the power supply connector and open the connector. S7-400 and M7-400 Programmable Controllers Hardware and Installation 4-22 A5E00069481-04...
Page 97: Wiring The Power Supply Connector
If you plug in or disconnect the connector with voltage applied, the power supply module or the connector may be damaged. Only plug in or disconnect the power supply connector with power removed. S7-400 and M7-400 Programmable Controllers Hardware and Installation 4-23 A5E00069481-04...
Page 98: Plugging The Power Supply Connector
4. Close the cover of the power supply module. The following figure shows how to plug the power supply connector into the power supply module. Figure 4-12 Plugging the power supply connector S7-400 and M7-400 Programmable Controllers Hardware and Installation 4-24 A5E00069481-04...
Page 99: Wiring The Signal Modules
2. Plugging the front connector into the module. The Three Types of Front Connector There are three types of front connector for signal modules in the S7-400 series: • Front connector with crimp snap-on terminals • Front connector with screw-type terminals •...
Page 100: Preparing To Wire The Front Connector
5. Isolate the wires according to the table in Section 4.11. Note The front connectors contain a jumper needed for functioning of some signal modules. Do not remove this jumper. S7-400 and M7-400 Programmable Controllers Hardware and Installation 4-26 A5E00069481-04...
Page 101: Wiring The Front Connector, Crimp Snap-On Terminals
The order number for crimp contacts can be found in Appendix C of the Reference Manual . Â Â Â Â Figure 4-14 Wiring a Front Connector with Crimp Snap-On Terminals S7-400 and M7-400 Programmable Controllers Hardware and Installation 4-27 A5E00069481-04...
Page 102: Wiring The Front Connector, Screw-Type Terminals
0.6 to 0.8 Nm. Also tighten the unwired terminals. 0.6 ... 0.8 Nm Â Â Â Â Â Â Â Â Â Figure 4-15 Wiring a Front Connector with Screw-Type Terminals S7-400 and M7-400 Programmable Controllers Hardware and Installation 4-28 A5E00069481-04...
Page 103: Wiring The Front Connector, Spring-Type Terminals
Â Â Â Â Â Â Releasing a spring contact from the front Releasing a spring contact from the side Figure 4-16 Wiring a Front Connector with Spring-Type Terminals S7-400 and M7-400 Programmable Controllers Hardware and Installation 4-29 A5E00069481-04...
Page 104: Principle Of The Spring Contact
2. Insert the wire into the spring contact as far as it will go 3. Withdraw the screwdriver: the wire is trapped by the contact Figure 4-17 Principle of the spring contact S7-400 and M7-400 Programmable Controllers Hardware and Installation 4-30 A5E00069481-04...
Page 105: Fitting The Strain Relief
There are three ways of fitting the strain relief, according to the thickness of the cable. Three openings are provided at the bottom of the front connector. Figure 4-18 Fitting a Strain Relief (Viewed from Below) S7-400 and M7-400 Programmable Controllers Hardware and Installation 4-31 A5E00069481-04...
Page 106: Labeling A Front Connector
4. Slide the label with the terminal diagram of the inputs or outputs into the interior of the cover of the front connector. 5. Slide a label externally into the cover of the front connector. S7-400 and M7-400 Programmable Controllers Hardware and Installation 4-32 A5E00069481-04...
Page 107: Fitting A Label In The Front Connector
• The labeling sheets are single-color, tear-proof and dirt-resistant. They are available in petrol, light beige, red, and yellow. • SIMATIC S7-400 I/O modules can be easily labeled application-specifically by machine using a standard laser printer in one of the following two ways: –...
Page 108 MODULES, MATERIAL: FOIL, PERFORATED FOR PRINTING WITH A LASER PRINTER, 10 SHEETS PER PACKAGE 6ES7492-2DX00-0AA0 SIMATIC S7-400, 10 A4 LABELING SHEETS, COLOR RED, 4 LABELING STRIPS/SHEETS FOR SIGNAL MODULES, MATERIAL: FOIL, PERFORATED FOR PRINTING WITH A LASER PRINTER, 10 SHEETS PER PACKAGE...
Page 109 2. Download The download contains templates for the labeling of S7-400 modules. The templates for S7-400 make the labeling strips available for the outside of the front connector cover and the terminal diagrams for the inside of the front connector cover.
Page 110: Fitting The Front Connector
When plugging in the front connector, ensure that the module and front connector are matched. S7-400 and M7-400 Programmable Controllers Hardware and Installation 4-36 A5E00069481-04...
Page 111: Attaching The Front Connector
2. Swing the front connector upwards. The two parts of the coding key will then be separated. 3. Screw the front connector on. Coding key Figure 4-21 Attaching the Front Connector S7-400 and M7-400 Programmable Controllers Hardware and Installation 4-37 A5E00069481-04...
Page 112: Screwing On The Front Connector
Wiring the S7-400 Figure 4-22 shows how to screw on the front connector. Figure 4-22 Screwing On the Front Connector S7-400 and M7-400 Programmable Controllers Hardware and Installation 4-38 A5E00069481-04...
Page 113: Interconnecting The Cr And Er(S)
5. If you wish to connect two chains with ERs to this send IM, plug the connector of the second connecting cable into the other port of the send IM. 6. Close the cover of the send IM. S7-400 and M7-400 Programmable Controllers Hardware and Installation 4-39 A5E00069481-04...
Page 114: Connection Between A Send Im And Two Receive Ims
Connection Between a Send IM and Two Receive IMs 10.Plug the terminator into the lower female connector of the receive IM in the last ER of the chain (see Reference Manual Module Specifications, Chapter 6). S7-400 and M7-400 Programmable Controllers Hardware and Installation 4-40 A5E00069481-04...
Page 115: Setting The Fan Subassembly To The Line Voltage And Wiring It
3. The small cover serves as a strain relief for the power cable. Choose one of the three sizes provided to suit your cable cross-section. 4. Screw the strain relief on. S7-400 and M7-400 Programmable Controllers Hardware and Installation 4-41 A5E00069481-04...
Page 116: Wiring The Fan Subassembly
Wiring the S7-400 Fit the small cover as a strain relief Power terminals (spring contacts) Voltage selector switch Fuse cap Figure 4-25 Wiring the Fan Subassembly S7-400 and M7-400 Programmable Controllers Hardware and Installation 4-42 A5E00069481-04...
Page 117: Routing Cables Using Cable Ducts Or Fan Subassemblies
The maximum strain load when assembling is 1000 N and during operation 150 N. Bending Radius When laying cables, you should maintain the following minimum bending radii: • Next to connector: 55 mm • Otherwise: 30 mm S7-400 and M7-400 Programmable Controllers Hardware and Installation 4-43 A5E00069481-04...
Page 119: Networking
Description Page Configuring a Network Fundamentals Rules for Configuring a Network Cable Lengths 5-15 PROFIBUS-DP Bus Cables 5-18 Bus Connectors 5-19 RS 485 Repeater 5-23 PROFIBUS-DP Network with Fiber-Optic Cables 5-25 S7-400 and M7-400 Programmable Controllers Hardware and Installation A5E00069481-04...
Page 120: Configuring A Network
Networking Configuring a Network Subnets You can connect an S7-400 device to various subnets: • Via a Simatic Net CP Ethernet to an Industrial Ethernet subnet • Via a Simatic Net CP PROFIBUS to a PROFIBUS-DP subnet • Via the integrated multipoint interface to an MPI subnet •...
Page 121: Fundamentals
CPU. Connectable Nodes PROFIBUS DP Programming devices (PGs) Programming devices (PGs) Operator interfaces (SIMATIC-OP), Operator panels (OPs)* WinCC S7-400/M7-400 PROFIBUS-DP master S7-300/M7-300 PROFIBUS-DP slaves Not recommended in DP operation S7-400 and M7-400 Programmable Controllers Hardware and Installation A5E00069481-04...
Page 122 • The highest possible MPI address must be w the highest actual MPI address and must be set to the same value for all nodes. (Exception: connecting a programming device to two or more nodes.) S7-400 and M7-400 Programmable Controllers Hardware and Installation A5E00069481-04...
Page 123: Communication Between Programming Device/Operator Panel And A Module Without Mpi
Communication from PG/OP to Module without MPI If one of the programming devices or operator panels connected to a multipoint interface (MPI) communicates with an S7-400 module which does not have an MPI connection (for example, SIMATIC NET CPs, FM 456 etc.), this module can be reached via the CPU to whose MPI the programming device or operator panel is connected.
Page 124: Data Exchange
The CPUs have different characteristics. One of these characteristics is their communication performance. If the communication resources of a CPU are occupied completely by process communication, this can severely hamper access to the CPU from the programming device. S7-400 and M7-400 Programmable Controllers Hardware and Installation A5E00069481-04...
Page 125: Rules For Configuring A Network
Up to ten segments can be connected in series. • Switch on the terminating resistor at the first and last node of a segment. To ensure the bus operates without interference, you should not switch off these nodes. S7-400 and M7-400 Programmable Controllers Hardware and Installation A5E00069481-04...
Page 126 Remember to provide a bus connector with PG female port for nodes into which a programming device may be plugged if required. Use RS 485 repeaters for the connection between segments and for extending the cable. S7-400 and M7-400 Programmable Controllers Hardware and Installation A5E00069481-04...
Page 127: Terminating Resistor On Bus Connector
L+ M PE M 5.2 A1 B1 A1 B1 Terminating resistor for bus segment 1 Terminating resistor SIEMENS for bus segment 2 RS 485-REPEATER A2 B2A2 B2 Figure 5-4 Terminating resistor on RS 485 repeater S7-400 and M7-400 Programmable Controllers Hardware and Installation A5E00069481-04...
Page 128: Terminating Resistor On Mpi Network
MPI network. S7-400 À S7-400 S7-400 À S7-300 RS 485 repeater À À Spur line Programming device À Terminating resistor switch on Figure 5-5 Terminating resistor on MPI network S7-400 and M7-400 Programmable Controllers Hardware and Installation 5-10 A5E00069481-04...
Page 129: Example Of An Mpi Network
** Connected to the MPI later on (with default MPI address) 0 ... x MPI address of nodes À Terminating resistor switch on Figure 5-6 Example of an MPI network S7-400 and M7-400 Programmable Controllers Hardware and Installation 5-11 A5E00069481-04...
Page 130: Example Of A Profibus Dp Network
* Only connected via spur line for startup/maintenance (with default PROFIBUS-DP address = 0) 0 ... x PROFIBUS DP addresses of nodes À Terminating resistor switched on Figure 5-7 Example of a PROFIBUS DP network S7-400 and M7-400 Programmable Controllers Hardware and Installation 5-12 A5E00069481-04...
Page 131: Example With Cpu
ET 200B S7-200 À ET 200B PROFIBUS-DP MPI network network À * Only connected via spur line for startup/maintenance À Terminating resistor switched on Figure 5-8 Example with CPU 414-2 S7-400 and M7-400 Programmable Controllers Hardware and Installation 5-13 A5E00069481-04...
Page 132: Programming Device Access Beyond Network Limits
• Use STEP 7 from version 5.0 onwards • Assign STEP 7 to a programming device or PC on the network (SIMATIC Manager, Assign programming device/PC) • The network limits are bridged by modules with routing capability. S7-400 and M7-400 Programmable Controllers Hardware and Installation 5-14 A5E00069481-04...
Page 133: Cable Lengths
Note that you must count an RS 485 repeater as a node of the MPI network in the total number of all nodes to be connected, even if it is not assigned its own MPI number. The use of RS 485 repeaters reduces the number of nodes. S7-400 and M7-400 Programmable Controllers Hardware and Installation 5-15 A5E00069481-04...
Page 134: Lengths Of Spur Lines Per Segment
To connect a programming device or PC, use the connecting cable for the programming with theorder number 6ES7 901-4BD00-0XA0. You can use several connecting cable with this order number for programming devices in one bus configuration. S7-400 and M7-400 Programmable Controllers Hardware and Installation 5-16 A5E00069481-04...
Page 135: Configuration Of An Mpi Network
50m À Terminating resistor switched on Á Programming device connected via spur line for maintenance 0 ... x MPI addresses of nodes Figure 5-10 Configuration of an MPI network S7-400 and M7-400 Programmable Controllers Hardware and Installation 5-17 A5E00069481-04...
Page 136: Profibus-Dp Bus Cables
Networking PROFIBUS-DP Bus Cables PROFIBUS-DP Bus Cables Siemens supply the following PROFIBUS-DP bus cables (see catalog ST 70): PROFIBUS-DP bus cable 6XV1 830-0AH10 PROFIBUS-DP cable for burying in ground 6XV1 830-3AH10 PROFIBUS-DP trailing cable 6XV1 830-3BH10 PROFIBUS-DP bus cable with PE sheath (for foodstuffs and...
Page 137: Bus Connectors
MPI or station PROFIBUS-DP interface Switch for terminating resistor Housing screw PG connector (only with 6ES7 972-0BB20-0XA0) Clamp hinge for vertical or 30° cable routing Figure 5-11 Bu s connector S7-400 and M7-400 Programmable Controllers Hardware and Installation 5-19 A5E00069481-04...
Page 138: Strip Bus Cable
3. Slacken the clamp hinge cover. 4. The bus connector with order number 6ES7 972-0B.20 is supplied with an angled outgoing cable unit and used as it is in the S7-400. If the cable is to be routed vertically out of the housing: –...
Page 139: Inserting Cores Into The Screw Termninal Blocks
Ensure that the bare cable shield is under the shield clamp. 7. Tighten the screw terminals for the green and red cores. 8. Close the cover of the bus connector. 9. Screw the housing on. S7-400 and M7-400 Programmable Controllers Hardware and Installation 5-21 A5E00069481-04...
Page 140: Switch On Terminating Resistant
Since the bus connector is powered by the station, the terminating resistor has no effect. Ensure that the stations at which the terminating resistor is switched on are always under power. S7-400 and M7-400 Programmable Controllers Hardware and Installation 5-22 A5E00069481-04...
Page 141: Rs 485 Repeater
Terminal “M5.2” should not be wired because it is only needed during maintenance. Terminal “M5.2” is the reference ground you require when measuring the voltage between terminals “A1” and “B1”. S7-400 and M7-400 Programmable Controllers Hardware and Installation 5-23 A5E00069481-04...
Page 142: Turning Back Braided Shield Over Cable
A or B (for example, green conductor always connected to terminal A and red conductor to terminal B). 4. Tighten the shield clamps so that the bare shield makes contact under the shield clamp. S7-400 and M7-400 Programmable Controllers Hardware and Installation 5-24 A5E00069481-04...
Page 143: Profibus-Dp Network With Fiber-Optic Cables
Module (OLM). • PROFIBUS nodes with an integrated fiber-optic cable interface (e.g. ET 200M (IM 153-2 FO), S7-400 (IM 467 FO)) can be directly integrated in the optical network. How to set up optical networks with the Optical Link Module (OLM) is described in detail in the SIMATIC NET PROFIBUS Networks manual.
Page 144: Optical Profibus-Dp Network With Nodes That Have An Integrated Fiber-Optic Cable Interface
The programming device/PC is connected to the RS 485 interface of the OBT by means of the PROFIBUS cable. The OBT is integrated in the optical PROFIBUS-DP line by means of its fiber-optic cable interface. S7-400 and M7-400 Programmable Controllers Hardware and Installation 5-26 A5E00069481-04...
Page 145: Fiber-Optic Cables
Networking 5.8.1 Fiber-Optic Cables Features of the Fiber-Optic Cables Use Siemens plastic and PCF fiber-optic cables with the following features: Table 5-4 Features of the Fiber-Optic Cables Description SIMATIC NET PROFIBUS Plastic Fiber-Optic Plastic Fiber-Optic PCF Fiber-Optic Duplex Conductor Standard Cable...
Page 146 2.2 4.4 mm Diameter: Diameter: " 0.01 mm 7.8 " 0.3 mm 4.7 " 0.3 mm Weight 7.8 kg/km 65 kg/km 22 kg/km Please ask your Siemens contact about specific applications. S7-400 and M7-400 Programmable Controllers Hardware and Installation 5-28 A5E00069481-04...
Page 147: Simplex Connectors And Connector Adapter
Prerequisite The PROFIBUS device must be equipped with a fiber-optic cable interface, such as the ET 200M (IM153-2 FO) or the IM 467 FO for S7-400. S7-400 and M7-400 Programmable Controllers Hardware and Installation 5-29 A5E00069481-04...
Page 148: Order Numbers - Simplex Connectors And Connector Adapters
100 Simplex connectors and 5 polishing sets for fitting SIMATIC NET PROFIBUS plastic fiber-optic cables with connectors Connector adapters 6ES7195-1BE00-0XA0 Pack of 50 for fitting plastic Simplex connectors with the IM 467 FO and the IM 153-2 FO S7-400 and M7-400 Programmable Controllers Hardware and Installation 5-30 A5E00069481-04...
Page 149: Connecting A Fiber-Optic Cable To The Profibus Device
You can easily fit connectors to and install plastic fiber-optic cables yourself. Please read the following information on how to do this and on the rules for laying the cable. S7-400 and M7-400 Programmable Controllers Hardware and Installation 5-31 A5E00069481-04...
Page 150 Rules for Laying Cable When you lay plastic fiber-optic cable, please adhere to the following rules: • Use only the Siemens fiber-optic cables specified in Section 5.8.1 • Never exceed the maximum permissible stresses (tensile load, crushing, etc.) of the cable you are using specified in Table 5-4. Impermissible crushing can occur, for example, when screw clamps are used to fix the cable in place.
Page 151: Starting Up
Page Recommended Procedure for First Startup Checks Prior to Switching On for the First Time Connecting a Programming Device (PG) to an S7-400 Switching On an S7-400 for the First Time Resetting the CPU with the Mode Selector Switch Cold, Warm, and Hot Restarts with the Mode Selector Switch...
Page 152: Recommended Procedure For First Startup
Due to the modular assembly and the many expansion options, an S7-400 can be very extensive and complex. A first startup of an S7-400 with two or more racks and all modules inserted is therefore not advisable. Instead, a startup in stages is recommended.
Page 153: Checklist To Be Used Before Switching On For The First Time
After installing and wiring your S7-400, it is advisable to check the steps carried out so far, before switching on for the first time. Table 6-1 contains a guide in the form of a checklist for your S7-400, and refers to the chapters containing additional information on the subject.
Page 154 Line Voltage Is the available line voltage correct? According to the backup concept, Table 6-2 shows how you must set the battery monitoring switch on the different power supply modules. S7-400 and M7-400 Programmable Controllers Hardware and Installation A5E00069481-04...
Page 155: Setting The Battery Monitoring Switch
Figure 6-1 Connecting PG to an S7-400 Note The programming device is not ungrounded. To operate the S7-400 in an ungrounded configuration, you must connect the programming device via an RS 485 repeater (see Reference Manual Module Specifications, Chapter 10).
Page 156: Switching On An S7-400 For The First Time
A description of operator control of communication between CPUs and programming devices can be found in the STEP 7 manuals. Switching On an S7-400 for the First Time Switching On an S7-400 for the First Time First switch on the power cutout.
Page 157: Resetting The Cpu With The Mode Selector Switch
There are two ways of resetting the CPU: • Reset with the mode selector switch • Reset from the programming device (see STEP 7) Resetting the CPU with the mode selector is described in the following section. S7-400 and M7-400 Programmable Controllers Hardware and Installation A5E00069481-04...
Page 158 Turn the switch to the MRES setting and back to the STOP setting. Result:The STOP LED flashes for at least 3 seconds at 2 Hz (reset is being executed) and then remains lit. S7-400 and M7-400 Programmable Controllers Hardware and Installation A5E00069481-04...
Page 159 MPI parameters are valid following a memory reset. Memory Reset ... MPI Parameters ... with Flash card inserted ... on the Flash card are valid. without Flash card inserted ... are retained in the CPU and are valid. S7-400 and M7-400 Programmable Controllers Hardware and Installation A5E00069481-04...
Page 160: Cold, Warm, And Hot Restarts With The Mode Selector Switch
2. Turn the switch to the MRES setting and keep it at this setting. Result: The STOP LED is dark for one second, bright for one second, dark for one second and then remains lit. 3. Turn the switch to the RUN/RUNP setting. S7-400 and M7-400 Programmable Controllers Hardware and Installation 6-10 A5E00069481-04...
Page 161: Inserting A Memory Card
Inserting a Memory Card The Memory Card as Load Memory You can insert a memory card in all CPUs of the S7-400. It is the load memory of the CPU. Depending on the type of memory card, the user program is retained on the memory card even when power is removed.
Page 162: Inserting A Memory Card In A Cpu
CPU requests a memory reset by slow flashing of the STOP indicator at 0.5 Hz. If you insert or remove the memory card with the controller switched off, the CPU will execute an automatic reset after power on. S7-400 and M7-400 Programmable Controllers Hardware and Installation 6-12 A5E00069481-04...
Page 163: Inserting A Backup Battery (Option)
To insert the backup battery (batteries) in the power supply module, proceed as follows: 1. Discharge any static charge by touching a grounded metal part of the S7-400. 2. Open the cover of the power supply module. 3. Insert the backup battery/batteries in the battery compartment.
Page 164 Starting Up The following figure shows how to insert a backup battery in the single-width power supply module. S7-400 and M7-400 Programmable Controllers Hardware and Installation 6-14 A5E00069481-04...
Page 165 (max. temperature 100° C). Do not recharge, there is a risk of explosion. Do not open the battery, and only replace it with one of the same type. Obtain the replacement via Siemens (see the Reference Manual, Module specifications Chapter 11 for the order number). This will ensure that you have a short-circuit protected type.
Page 166 Reducing the Passivation Layer Lithium batteries (lithium/thionyl chloride) are used as backup batteries for the S7-400. In lithium batteries of this technology, a passivation layer can develop after storage for a very long time, and the immediate functional capability of the battery may not be certain.
Page 167: Starting Up A Profibus-Dp Subnet
In this case, check whether all slaves are switched on or display the content of the diagnostic buffer (see Configuring Hardware and Communication Connections with STEP 7 V 5.2). S7-400 and M7-400 Programmable Controllers Hardware and Installation 6-17 A5E00069481-04...
Page 168 6.10 Installing Interface Submodules (CPU 414-2, 414-3, 416-3, 417-4 and 417-4H) Available Interface Submodules Note Only use interface submodules that are explicitly released for use in S7-400 devices. Installing Interface Submodules Warning The modules can be damaged. When inserting or removing interface submodules with power applied, the CPU and interface submodules can be damaged (exception: using synchronization submodules in an H system).
Page 169: Inserting Interface Submodules In The Cpu
On delivery, all the submodule slots are secured with a submodule cover. The cover is attached to the frame of the card slot with screws. Leave unused submodule slots secured. S7-400 and M7-400 Programmable Controllers Hardware and Installation 6-19 A5E00069481-04...
Page 170 Starting Up S7-400 and M7-400 Programmable Controllers Hardware and Installation 6-20 A5E00069481-04...
Page 171: Maintenance
Replacing the Filter Frame of the Fan Subassembly During Operation 7-16 7.10 Replacing the Power Supply PCB and Monitoring PCB of the Fan 7-18 Subassembly 7.11 Replacing Memory Cards 7-19 7.12 Replacing Interface Submodules 7-22 S7-400 and M7-400 Programmable Controllers Hardware and Installation A5E00069481-04...
Page 172: Replacing The Backup Battery
Replacing the Backup Battery Replacing the Backup Battery 1. Discharge any static charge by touching a grounded metal part of the S7-400. 2. Open the cover of the power supply module. 3. Using the loop(s), pull the backup battery/batteries out of the battery compartment.
Page 173 Backup batteries can ignite or explode if they are heated or damaged. Backup batteries must not be • Recharged • Heated • Burned • Drilled into • Crushed Store the backup batteries in a cool, dry place. S7-400 and M7-400 Programmable Controllers Hardware and Installation A5E00069481-04...
Page 174: Replacing A Power Supply Module
10.Set the CPU mode switch to RUN if applicable. How the S7-400 Behaves after Exchanging Modules If an error occurs after replacing a module, you can read out the cause of the error from the diagnostic buffer. S7-400 and M7-400 Programmable Controllers Hardware and Installation A5E00069481-04...
Page 175: Replacing Cpus
4. Disconnect the MPI connector, if applicable. 5. Disconnect the connector at the EXT. BATT. socket, if applicable. 6. Remove the memory card. 7. Loosen the mounting screws of the module. 8. Swing the module out. S7-400 and M7-400 Programmable Controllers Hardware and Installation A5E00069481-04...
Page 176 Close the cover. How the S7-400 Behaves after Exchanging Modules If an error occurs after replacing a module, you can read out the cause of the error from the diagnostic buffer. S7-400 and M7-400 Programmable Controllers Hardware and Installation A5E00069481-04...
Page 177: Replacing Digital Or Analog Modules
Note In order that the removal and insertion of digital or analog modules can be detected by the CPU, a minimum time of two seconds must elapse between removal and insertion. S7-400 and M7-400 Programmable Controllers Hardware and Installation A5E00069481-04...
Page 178 3. Remove the labels from the front connector and insert them into the new front connector. 4. Wire the new front connector. 5. Insert the front connector in the module. 6. Screw the front connector on. 7. Switch on the load voltage. S7-400 and M7-400 Programmable Controllers Hardware and Installation A5E00069481-04...
Page 179: Changing The Fuses In The Digital Modules
Before you open these covers, ensure that either the front connector for the module is removed or the module is disconnected from the voltage supply. S7-400 and M7-400 Programmable Controllers Hardware and Installation A5E00069481-04...
Page 180 12.After fitting, each programmable module will be reinitialized by the CPU with parameters. How the S7-400 Behaves after Replacing the Fuse If an error occurs after replacing a fuse, you can read out the cause of the error from the diagnostic buffer.
Page 181: Replacing Interface Modules
(0 V output voltages). 4. Remove the cover. 5. Disconnect the connecting cables. 6. Disconnect the terminator, if applicable. 7. Loosen the mounting screws of the module. 8. Swing the module out. S7-400 and M7-400 Programmable Controllers Hardware and Installation 7-11 A5E00069481-04...
Page 182 9. Set the CPU mode switch to RUN mode. How the S7-400 Behaves after Exchanging Modules If an error occurs after replacing a module, you can read out the cause of the error from the diagnostic buffer. S7-400 and M7-400 Programmable Controllers Hardware and Installation 7-12 A5E00069481-04...
Page 183: Replacing The Fuse Of The Fan Subassembly
3. Remove the blown fuse from the fuse cap. 4. Insert the new fuse in the fuse cap and screw the cap into the fan subassembly. 5. Connect the power cable of the fan subassembly to the supply. S7-400 and M7-400 Programmable Controllers Hardware and Installation 7-13 A5E00069481-04...
Page 184: Replacing Fans In The Fan Subassembly During Operation
Fan 2 Fan 3 Ä Ä Ä Ä Ä Base Quick-release locks Reset button LEDs: F 1 = Fan 1 F 2 = Fan 2 F 3 = Fan 3 S7-400 and M7-400 Programmable Controllers Hardware and Installation 7-14 A5E00069481-04...
Page 185 7. Use a screwdriver to make a quarter turn clockwise and close the two quick-release locks. 8. Use a pointed object to press the RESET button. The fault LED will go off and the fan will start running. S7-400 and M7-400 Programmable Controllers Hardware and Installation 7-15 A5E00069481-04...
Page 186: Replacing The Filter Frame Of The Fan Subassembly During Operation
– The filter frame is secured at the rear edge of the base: With the flat of your hand, press the filter frame away from the base of the fan subassembly. This will release the filter frame from the snap hinges. S7-400 and M7-400 Programmable Controllers Hardware and Installation 7-16 A5E00069481-04...
Page 187 6. Use a screwdriver to make a quarter turn clockwise and close the two quick-release locks. 7. Replacing the filter frame will not trigger an interrupt. There is therefore no need to press the RESET button. S7-400 and M7-400 Programmable Controllers Hardware and Installation 7-17 A5E00069481-04...
Page 188: Replacing The Power Supply Pcb And Monitoring Pcb Of The Fan Subassembly
If you do not observe the ESD guidelines when handling printed-circuit boards with electronic components, the components can be damaged by a static discharge. Observe the ESD guidelines (see Appendix). S7-400 and M7-400 Programmable Controllers Hardware and Installation 7-18 A5E00069481-04...
Page 189: Replacing Memory Cards
4. If necessary, insert the second memory card in slot 2 in the same way (see Figure 7-1). 5. Fit the cover on the upper left side of the CPU by securing it with three screws. S7-400 and M7-400 Programmable Controllers Hardware and Installation 7-19 A5E00069481-04...
Page 190: Fitting Memory Cards In The Cpus
7. Fit the cover on the upper left side of the CPU by securing it with three screws. Slot 1 Slot 2 Figure 7-1 Fitting Memory Cards in the CPUs S7-400 and M7-400 Programmable Controllers Hardware and Installation 7-20 A5E00069481-04...
Page 191: Memory Card
Lightly press the guide supports out to remove the memory cards (see Figure 7-2). Copper flag Memory card Cutout Cutout Polarity reversal Guide support Guide support protection Slots 1 and 2 Figure 7-2 Memory Card S7-400 and M7-400 Programmable Controllers Hardware and Installation 7-21 A5E00069481-04...
Page 192: Replacing Interface Submodules
Maintenance 7.12 Replacing Interface Submodules Available Interface Submodules Note Only use interface submodules that are explicitly released for use in S7-400 devices. Installing Interface Submodules Warning The modules can be damaged. When inserting or removing interface submodules with power applied, the CPU and interface submodules can be damaged (exception: using synchronization submodules in an H system).
Page 193: Inserting An Interface Submodule In A Cpu
Inserting an Interface Submodule in a CPU Installing Interface Submodules In order to install an interface submodule, proceed in reverse order. For further information, see section 6.10 ”Installing Interface Submodules”. S7-400 and M7-400 Programmable Controllers Hardware and Installation 7-23 A5E00069481-04...
Page 194 Maintenance S7-400 and M7-400 Programmable Controllers Hardware and Installation 7-24 A5E00069481-04...
Page 195: Assembling The M7-400
S7-400 programmable controller. Most of the instructions in the S7-400 chapters can therefore be applied to the M7-400. Wherever details relate specifically to the M7-400, these are pointed out to you at the beginning of each S7-400 chapter with a cross-reference to the corresponding M7-400 section.
Page 196: Mechanical Configuration
M7-400 automation computer. All other information which is important for the mechanical configuration applies both to the S7-400 and the M7-400, and is described in Chapter 2. Rules for the Arrangement of Modules You must observe the following rules for the arrangement of modules in a rack: •...
Page 197: Sequence In The Module Subassembly
ER1, ER2 Modules Central Expansion Rack Rack Central Processing Units (CPUs) Expansion Module (EXM) AT Adapter Module (ATM) Mass Storage Module (MSM) Can only be inserted in conjunction with the CPU. S7-400 and M7-400 Programmable Controllers Hardware and Installation A5E00069481-04...
Page 198: Dimensions Of Modules In The M7-400 System
290 mm (227.5 mm) Mass Storage Module MSM 478 AT Adapter Module 230 mm* ATM 478 (247.5 mm*) * The mounting depth is governed by the installed AT card and its connector. S7-400 and M7-400 Programmable Controllers Hardware and Installation A5E00069481-04...
Page 199: Addressing The M7-400 Modules
The EXM 478 expansion module, ATM 478 AT adapter module and MSM 478 mass storage module cannot be accessed via the S7-400 backplane bus. Communication between these modules and the CPU is exclusively via the ISA bus.
Page 200: Electrical Configuration
• The additional facilities for expansion with PROFIBUS DP. All other important information for the electrical configuration applies both to the S7-400 and to the M7-400 modules and is described in Chapter 4. Choosing the Power Supply Module This section uses an example to show how you can estimate the current consumption of a rack.
Page 201 If you wish to connect an expansion rack to the central rack via a send IM with current transfer, you must take into account the current consumption of this expansion rack when choosing the power supply module. S7-400 and M7-400 Programmable Controllers Hardware and Installation A5E00069481-04...
Page 202: Installing The M7-400
• How to fit expansion modules on a CPU • How to install a module assembly in a rack All other important information for installation applies both to S7-400 and M7-400 modules and is described in Chapter 5. S7-400 and M7-400 Programmable Controllers Hardware and Installation...
Page 203: Checklist For Installation
10.Insert the memory card, if applicable, in the memory card slot of the CPU (page 8-28). 11. Fit and wire the required S7-400 modules (Chapters 5 and 6). 12.Mark the installed modules with a slot number (Chapter 5). S7-400 and M7-400 Programmable Controllers Hardware and Installation...
Page 204: Module Accessories
(EXM 478) (fitted) per expansion unit. All Expansion 2 connecting clips To secure the modules in a Modules module assembly, top and bottom. S7-400 and M7-400 Programmable Controllers Hardware and Installation 8-10 A5E00069481-04...
Page 205: Fitting Memory Cards In The Cpu
5. Fit the cover on the upper left side of the CPU by securing it with three screws. Note The connectors to accept the memory cards are coded (see Figure 8-2). Do not apply force when fitting the memory cards. S7-400 and M7-400 Programmable Controllers Hardware and Installation 8-11 A5E00069481-04...
Page 206: Fitting Memory Cards In The Cpus
Slot 1 Slot 2 Figure 8-1 Fitting Memory Cards in the CPUs 3.3 V DRAM memory card (for main memory) Recess Slots 1 and 2 Figure 8-2 3.3 V Memory Card S7-400 and M7-400 Programmable Controllers Hardware and Installation 8-12 A5E00069481-04...
Page 207: Installing Interface Submodules
3. Slowly push the interface submodule into the slot until the front plate rests on the frame of the card slot. 4. Secure the front plate with the two fitted, captive M2.5 x 10 slot-head screws on the left frame of the card slot. S7-400 and M7-400 Programmable Controllers Hardware and Installation 8-13 A5E00069481-04...
Page 208: Inserting An Interface Submodule In An Expansion Module
All other card slots are covered. The cover is secured to the frame of the card slot with screws. Loosen the screws and remove the cover to insert more than one interface submodule in an expansion module. S7-400 and M7-400 Programmable Controllers Hardware and Installation 8-14 A5E00069481-04...
Page 209: Fitting The Short At Card
6. Fit the mounting bracket over the angled part of the support plate of the AT card and screw it onto the support plate of the AT card and to the ATM 478. 7. Fit the cover on the upper left side of the ATM 478. S7-400 and M7-400 Programmable Controllers Hardware and Installation 8-15 A5E00069481-04...
Page 210: Fitting An At Card In The Atm 478 At Adapter Module
Assembling the M7-400 Figure 8-4 Fitting an AT Card in the ATM 478 AT Adapter Module S7-400 and M7-400 Programmable Controllers Hardware and Installation 8-16 A5E00069481-04...
Page 211: Assembling Expansion Modules On A Central Rack
4. Position the modules on a level surface and plug them into each other. 5. Use connecting clips top and bottom to interconnect the modules. The individual stages for installing an expansion assembly are explained below. S7-400 and M7-400 Programmable Controllers Hardware and Installation 8-17 A5E00069481-04...
Page 212: Locations Of The Expansion Socket And Plug
CPU 488-3 e. g. EXM 478 Expansion plug Expansion socket Figure 8-5 Locations of the Expansion Socket and Plug S7-400 and M7-400 Programmable Controllers Hardware and Installation 8-18 A5E00069481-04...
Page 213: Exm 478 Expansion Module Fitted With Connecting Clips
Removing the Connecting Clips Connecting clips are fitted at the top and bottom of expansion modules. Pull these off upward and downward respectively. Figure 8-6 EXM 478 Expansion Module Fitted with Connecting Clips S7-400 and M7-400 Programmable Controllers Hardware and Installation 8-19 A5E00069481-04...
Page 214: Removing The Cover
Proceed as follows: 1. Press the locking lever down (1). 2. Swing the cover forward and off (2). Figure 8-7 shows how to remove the cover. Figure 8-7 Removing the Cover S7-400 and M7-400 Programmable Controllers Hardware and Installation 8-20 A5E00069481-04...
Page 215: Interconnecting A Cpu And Expansion Modules
Note that there are rules on the number of connectable expansion modules and on the sequence of the modules following the CPU. These rules are listed in the Reference Manual under the chapter on M7-400 expansion. S7-400 and M7-400 Programmable Controllers Hardware and Installation 8-21 A5E00069481-04...
Page 216: Module Assembly Comprising Cpu And Expansion Modules
2. Align the connecting clips so that each bent clip end is situated over a grid hole of the module housing cover. Here, the first bent terminal end should be over the fifth notch space, counting from the back of the modules. S7-400 and M7-400 Programmable Controllers Hardware and Installation 8-22 A5E00069481-04...
Page 217: Connecting Clip
4. Carry out steps 1 to 3 similarly on the bottom of the modules to be secured. Clip end bent 90° Bent clip end Figure 8-10 Connecting Clip Fifth grid hole Figure 8-11 Securing the Modules with Connecting Clips (Schematic Diagram) S7-400 and M7-400 Programmable Controllers Hardware and Installation 8-23 A5E00069481-04...
Page 218 Installing a Module Assembly in the Rack Introduction The installation of an M7-400 CPU together with modules from the S7-400 series in a rack is carried out as described in Chapter 5. If the M7-400 central rack has expansion racks, this must be preassembled with its expansion racks into a module group (see also Section 8.4.6 ”Assembling Expansion Modules on a Central...
Page 219: Attaching A Module Assembly Comprising Cpu And Expansion Modules And Swinging It Into Position
Note Do not push the module assembly down whilst swinging it into position. Figure 8-12 Attaching a Module Assembly Comprising CPU and Expansion Modules and Swinging it into Position S7-400 and M7-400 Programmable Controllers Hardware and Installation 8-25 A5E00069481-04...
Page 220: Screwing The Modules On
Assembling the M7-400 Screwing On the Modules Figure 8-13 shows how to screw on the modules. Tightening torque 0.8 to 1.1 Nm Figure 8-13 Screwing the Modules On S7-400 and M7-400 Programmable Controllers Hardware and Installation 8-26 A5E00069481-04...
Page 221: Inserting The Key In The Cpu
Figure 8-14 shows how to insert the key in the CPU at the STOP position of the switch. You can remove the key at the STOP or RUN settings. Figure 8-14 Inserting the Key in the CPU S7-400 and M7-400 Programmable Controllers Hardware and Installation 8-27 A5E00069481-04...
Page 222: Inserting/Removing A Memory Card
If you are not sure whether write operations onto the memory card are taking place, only change it with power removed. Figure 8-15 Inserting a Memory Card in a CPU S7-400 and M7-400 Programmable Controllers Hardware and Installation 8-28 A5E00069481-04...
Page 223: Connecting A Module Assembly
The pin assignments of the subminiature D connectors can be found in the description of the relevant interface submodule in the chapter on interface submodules of the Reference Manual. S7-400 and M7-400 Programmable Controllers Hardware and Installation 8-29 A5E00069481-04...
Page 224: Assembling An Mpi Subnet Or Profibus-Dp Subnet
Example of Operation in 2 Subnets Shown in Figure 8-16 is an example of a configuration with M7-400 CPU, integrated in an MPI subnet, and simultaneously acting as DP master in a PROFIBUS-DP subnet. S7-400 and M7-400 Programmable Controllers Hardware and Installation 8-30 A5E00069481-04...
Page 225: Example Of A Configuration With The Cpu In An Mpi Subnet And Profibus-Dp Subnet
À * Only connected via spur line for startup/maintenance À Terminating resistance switched on Figure 8-16 Example of a Configuration with the CPU in an MPI Subnet and PROFIBUS-DP Subnet S7-400 and M7-400 Programmable Controllers Hardware and Installation 8-31 A5E00069481-04...
Page 226: Preparing For Operation
• How to check the status and error display by switching on for the first time All other information which is important for preparing for operation applies (except for the reset) both to the S7-400 and M7-400 modules and is described in Chapter 8.
Page 227: Connecting The Operator Panels And I/O Devices
For reasons of noise immunity of the entire system, we recommend that you use the standard connecting cables available from Siemens for connecting the I/O devices. Note If the monitor cable and connecting cables between the CPU and the keyboard or printer, etc.
Page 228 IF 962-COM interface submodule. We recommend you use a Siemens printer. Note Only a connecting cable with the shield grounded at both ends should be used between an M7-400 component and a printer. S7-400 and M7-400 Programmable Controllers Hardware and Installation 8-34 A5E00069481-04...
Page 229: Maximum Cable Lengths For Operator Panels And I/O Devices
Maximum Cable Lengths for Operator Panels and I/O Devices Device Maximum Length Keyboard • via IF 962-VGA 2.5 m Monitor • via IF 962-VGA 2.5 m Printer • via IF 962-LPT parallel port 3.0 m S7-400 and M7-400 Programmable Controllers Hardware and Installation 8-35 A5E00069481-04...
Page 230: Connecting A Programming Device (Pg) To The Com Interface
E1 / GND E1 / GND M5 / DCD M5 / DCD D2 / RxD connected to D1 / TxD D1 / TxD connected to D2 / RxD S7-400 and M7-400 Programmable Controllers Hardware and Installation 8-36 A5E00069481-04...
Page 231: Null Modem Cable For Connecting A Cpu Via If To The Com Interface
M3 / RI M3 / RI 9-pin sub. 25-pin sub. D female conn. D male conn. Pin U = housing (shield) (COM1 for IF) (COMx for Length: 10 m max. programming device) S7-400 and M7-400 Programmable Controllers Hardware and Installation 8-37 A5E00069481-04...
Page 232: Pin Assignments Of The Cable For Connecting A Cpu Via If To The Com Interface Of A Programming Device With 9-Pin Sub. D Male Connector
E2 / GND E2 / GND 9-pin sub. 25-pin sub. Pin U = housing (shield) D female conn. D male conn. Length: 10 m max. (COM1 for IF) (COMx for PG) S7-400 and M7-400 Programmable Controllers Hardware and Installation 8-38 A5E00069481-04...
Page 233: Connecting A Programming Device (Pg) To The M7-400
(see Chapter 5). Shown in Figure 8-17 are the components for connecting a programming device to the M7-400. M7-400 PG cable Programming device Figure 8-17 Connecting a Programming Device to the M7-400 S7-400 and M7-400 Programmable Controllers Hardware and Installation 8-39 A5E00069481-04...
Page 234: Connecting A Programming Device (Pg) To Two Or More Nodes
Connection Programming device permanently installed Directly incorporated in the MPI subnet in the network Programming device connected for startup Programming device connected via spur or maintenance cable to a node S7-400 and M7-400 Programmable Controllers Hardware and Installation 8-40 A5E00069481-04...
Page 235: Connecting A Programming Device To Two Or More M7-400S
• Highest MPI address: 126. Then determine, via M7 Configuration, the highest MPI address in the MPI subnet and adjust the highest MPI address in the programming device to that of the MPI subnet. S7-400 and M7-400 Programmable Controllers Hardware and Installation 8-41 A5E00069481-04...
Page 236: Connecting A Programming Device To An M7-400 Subnet
Figure 8-19 shows a network with two M7-400s, to which a programming device is connected. Programmin M7-400 g device PG cable = spur line M7-400 PROFIBUS-DP bus cable Figure 8-19 Connecting a Programming Device to an M7-400 Subnet S7-400 and M7-400 Programmable Controllers Hardware and Installation 8-42 A5E00069481-04...
Page 237: Connecting A Programming Device (Pg To Ungrounded Nodes Of An Mpi Subnet
Figure 8-20 shows the RS 485 repeater as an interface between a grounded and an ungrounded node of an MPI subnet. Bus Segment 1 Grounded signals M7-400 Programming device Bus Segment 2 Grounded signals Figure 8-20 Ungrounded Operation of the M7-400 Network S7-400 and M7-400 Programmable Controllers Hardware and Installation 8-43 A5E00069481-04...
Page 238: Starting Up A Profibus-Dp Subnet
(preset configuration) created with STEP 7 into the CPU. This procedure is described in the manual Configuring Hardware and Communication Connections STEP 7 V 5.2. 2. Switch on all DP slaves. 3. Switch the CPU from STOP to RUN. S7-400 and M7-400 Programmable Controllers Hardware and Installation 8-44 A5E00069481-04...
Page 239: Checking The Status And Error Indicators
Otherwise the module boots up. In the event of a fault, the INTF indicator lights up. If this is not the case with your modules, please consult your Siemens contact at a maintenance and repair center or call the SIMATIC hotline.
Page 240: Replacing Modules And Submodules/Cards
• How to replace CPUs or expansion modules of a module assembly, • How to replace memory cards, • How to replace a short AT card. All other important information for replacing modules applies both to the S7-400 and the M7-400 modules and is described in Chapter 7. Tool To replace modules and submodules/cards, you need a cylindrical screwdriver with 3.5 mm blade width.
Page 241: Replacing An Interface Module
6 mm. 6. Carefully withdraw the interface submodule from the guide of the card slot (see Figure 8-21). S7-400 and M7-400 Programmable Controllers Hardware and Installation 8-47 A5E00069481-04...
Page 242: Removing An Interface Submodule From The Card Slot Of An Expansion Module
Removing an Interface Submodule from the Card Slot of an Expansion Module Fitting an Interface Submodule Fit the new interface submodule in the reverse order. Further information can be found in Section 8.4.4, “Installing Interface Submodules” from page 8-13. S7-400 and M7-400 Programmable Controllers Hardware and Installation 8-48 A5E00069481-04...
Page 243: Replacing The Cpu Or Expansion Modules Of A Module Assembly
– Press the locking lever down (1). – Swing the cover forward and off (2). Figure 8-22 Removing the Cover 5. Disconnect the interface connections at the module assembly, including all interface submodules. S7-400 and M7-400 Programmable Controllers Hardware and Installation 8-49 A5E00069481-04...
Page 244: Unscrewing Modules
7. Ensure that all the mounting screws of the module assembly are undone. 8. Swing the module assembly forward out of the bus connectors and lift it upward and out of the guides of the rack (Figure 8-24). S7-400 and M7-400 Programmable Controllers Hardware and Installation 8-50 A5E00069481-04...
Page 245: Swinging A Module Assembly Out And Lifting It Up And Out
Swinging a Module Assembly Out and Lifting it Up and Out 9. Place the module assembly on a level surface (Figure 8-25). Level surface Figure 8-25 Module Assembly Comprising CPU and Expansion Modules S7-400 and M7-400 Programmable Controllers Hardware and Installation 8-51 A5E00069481-04...
Page 246: Removing The Connecting Clips From The Module To Be Replaced
Warning The connector pins can be damaged. If you misalign the modules when pulling them apart, the connector pins may be damaged. Pull the modules apart carefully without misaligning them. S7-400 and M7-400 Programmable Controllers Hardware and Installation 8-52 A5E00069481-04...
Page 247: Separating The Modules, For Example When The Mass Storage Module Is To Be Replaced
If a data medium such as the on-board silicon disk, memory card, or hard disk has been replaced with the module replacement, it may be necessary to reinstall the operating system, user programs, etc. (see the corresponding sections in the M7-SYS User Manual). S7-400 and M7-400 Programmable Controllers Hardware and Installation 8-53 A5E00069481-04...
Page 248: Replacing Memory Cards In A Cpu
5. Press the new memory card on the protruding side in the direction of the PCB until it engages with the two retaining springs (see Figure 8-28). 6. Fit the cover on the upper left side of the CPU by securing it with three screws. S7-400 and M7-400 Programmable Controllers Hardware and Installation 8-54 A5E00069481-04...
Page 249: Removing Memory Cards From The Cpus
The connectors to accept the memory cards are coded (see Figure 8-29). Do not apply force when fitting the memory cards. 3.3 V DRAM memory card (for main memory) Recess Slots 1 and 2 Figure 8-29 3.3 V Memory Card S7-400 and M7-400 Programmable Controllers Hardware and Installation 8-55 A5E00069481-04...
Page 250: Replacing A Short At Card
Then refit the AT adapter module in the module assembly and install the latter in the rack (see Section 8.4.6 “Assembling Expansion Modules on a Central Rack” and Section 8.4.7 “Installing a Module Assembly in the Rack” on pages 8-17 and 8-24). S7-400 and M7-400 Programmable Controllers Hardware and Installation 8-56 A5E00069481-04...
Page 251: Removing An At Card From The Atm 478 At Adapter Module
Assembling the M7-400 Figure 8-30 Removing an AT Card from the ATM 478 AT Adapter Module S7-400 and M7-400 Programmable Controllers Hardware and Installation 8-57 A5E00069481-04...
Page 252 Assembling the M7-400 S7-400 and M7-400 Programmable Controllers Hardware and Installation 8-58 A5E00069481-04...
Page 253 A-23 A.9.3 Rules for the Transitions between Lightning Protection Zones 1 <-> 2 A-25 and Greater A.9.4 Sample of a Surge Protection Circuit for Networked S7-400 PLCs A-28 A.10 How to Protect Digital Output Modules against Inductive Surge A-30 A.11...
Page 254: Assembling And Installing Systems
S7-400 General Basic Rules On account of the many possible applications of the S7-400, this chapter can only cover the basic rules for the electrical configuration. You must at least comply with these basic rules to ensure fault-free operation of the S7-400. The M7-400 modules operate similarly to the S7-400 modules.
Page 255 S7-400 and M7-400 Programmable Controllers Hardware and Installation A5E00069481-04...
Page 256 S7-400 and M7-400 Programmable Controllers Hardware and Installation A5E00069481-04...
Page 257: Principles Of System Installation For Emc
Introduction Although the S7-400 and its components were developed for operation in an industrial environment and meet high EMC requirements, you should carry out EMC planning before installing your control system, taking possible interference sources into account and incorporating them in your observations.
Page 258 Local transmitters (for example, conductor is subjected to an two-way radios) • electromagnetic wave. Impinging of Spark gaps (spark plugs, the wave results in induced currents collectors of electric motors, and voltages. welders) S7-400 and M7-400 Programmable Controllers Hardware and Installation A5E00069481-04...
Page 259 Route the grounded shield as far as the module without interruption, but do not ground it there again. • There must be a low-impedance connection between shield/protective ground bar and cabinet/housing. • Use metal or metallized connector cases for shielded data lines. S7-400 and M7-400 Programmable Controllers Hardware and Installation A5E00069481-04...
Page 260 Rule 4: Special EMC Measures Employ special EMC measures for particular applications (see Section 4.11). • Fit suppressors to all inductors which are not controlled by S7-400 modules. • Use incandescent bulbs or suppressed fluorescent lamps in the immediate vicinity of your controller for illuminating cabinets or housings.
Page 261: Installation Of Programmable Controllers For Emc
Grounding of Inactive Metal Parts During Installation When installing the S7-400, ensure large-area grounding of all inactive metal parts. Properly implemented chassis grounding creates a standard reference potential for the control system, and reduces the effects of picked-up interference.
Page 262: Examples Of Emc-Compatible Assembly
(grounding of inactive metal parts and connection of cable shields) have been applied. However, this example only applies to grounded operation. Observe the points marked in the figure when installing your system. Figure A-2 Example of Cabinet Installation for EMC S7-400 and M7-400 Programmable Controllers Hardware and Installation A-10 A5E00069481-04...
Page 263: Key For Example 1
If you operate your S7-400 in a low-interference environment in which the permissible ambient conditions are complied with (see Reference Manual, Chapter 1), you can mount your S7-400 in frames or on the wall. Picked-up interference must be given a path to large metal surfaces. You should therefore secure standard mounting channels, shield, and protective ground bars to metal structural elements.
Page 264 • Cover the AC supply conductors in a shockproof arrangement. Figure A-3 shows an example of wall mounting for EMC Figure A-3 Wall Mounting an S7-400 for EMC S7-400 and M7-400 Programmable Controllers Hardware and Installation A-12 A5E00069481-04...
Page 265: Shielding Cables
In the event of potential differences between grounding points, a circulating current may flow via the shield connected at both ends. In this case, install an additional equipotential bonding conductor (see Section A.6). S7-400 and M7-400 Programmable Controllers Hardware and Installation A-13 A5E00069481-04...
Page 266 Shown in the figure A-4 are some methods of securing shielded cables with cable clamps. Figure A-4 Mounting Cable Shields S7-400 and M7-400 Programmable Controllers Hardware and Installation A-14 A5E00069481-04...
Page 267: Equipotential Bonding
• Lay the equipotential bonding conductor in such a way that the surface between the conductor and the signal lines is as small as possible. (see Figure A-5). S7-400 and M7-400 Programmable Controllers Hardware and Installation A-15 A5E00069481-04...
Page 268: A-5 Routing Equipotential Bonding Conductor And Signal Line
Assembling and Installing Systems Figure A-5 Routing Equipotential Bonding Conductor and Signal Line S7-400 and M7-400 Programmable Controllers Hardware and Installation A-16 A5E00069481-04...
Page 269: Cabling Inside Buildings
Inside cabinets: (u400 V), unshielded in separate bundles or cable ducts (no minimum clearance necessary) Outside cabinets: on separate cable racks with a clearance of at least 10 cm (3.93 in.) S7-400 and M7-400 Programmable Controllers Hardware and Installation A-17 A5E00069481-04...
Page 270: Cabling Inside Buildings
(u400 V), unshielded (u400 V), unshielded ducts ETHERNET ETHERNET in common bundles or cable ducts Others in separate bundles or cable ducts with a clearance of at least 50 cm (19.65 in.) S7-400 and M7-400 Programmable Controllers Hardware and Installation A-18 A5E00069481-04...
Page 271: Cabling Outside Buildings
An individual appraisal of the entire plant is necessary before initiating any lightning protection measures (see Section A.9). Further Information on Lightning Protection You will find further information in the following sections. S7-400 and M7-400 Programmable Controllers Hardware and Installation A-19 A5E00069481-04...
Page 272: Lightning Protection And Overvoltage Protection
This refers especially to constructional measures for the building already in the planning phase. If you wish to obtain detailed information on overvoltage protection, we therefore recommend you to address your Siemens contact or a company specialized in lightning protection. S7-400 and M7-400 Programmable Controllers Hardware and Installation...
Page 273: Lightning Protection Zone Concept
Surges In lightning protection zones 1 and higher, surges can result from switching operations and interference. S7-400 and M7-400 Programmable Controllers Hardware and Installation A-21 A5E00069481-04...
Page 274 Lines that can carry lightning stroke current include: • Metal pipelines (for example, water, gas and heat) • Power cables (for example, line voltage, 24 V supply) • Data cables (for example, bus cable). S7-400 and M7-400 Programmable Controllers Hardware and Installation A-22 A5E00069481-04...
Page 275: High-Voltage Protection Of Cables With The Help
DEHNgap B/n N-PE light- 900 130* ning conductor N to PE AC TN-S system 2 pieces DEHNbloc/1 lightning con- 900 111* ductor 5SD7 032 phase L1 + N to PE S7-400 and M7-400 Programmable Controllers Hardware and Installation A-23 A5E00069481-04...
Page 276 919 506* and to 12 V +/– ductor, 919 510* type B You can order these components directly at: DEHN + SÖHNE GmbH + Co. KG Elektrotechnische Fabrik Hans-Dehn-Str. 1 D-92318 Neumarkt S7-400 and M7-400 Programmable Controllers Hardware and Installation A-24 A5E00069481-04...
Page 277: Rules For The Transitions Between Lightning Protection Zones 1 <-> 2 And Greater
You should only use the lightning conductor KT, type 24 VAD SIMATIC for the 24 VDC power supply of the S7-400. All other surge protection components do not meet the required tolerance range of 20.4 V to 28.8 V of the S7-400’s power supply.
Page 278: Low-Voltage Protection Components For Lightning Protection Zones 1
12 V +/– Blitzductor CT type MD 12 V 919 541* You can order these components directly at: DEHN + SÖHNE GmbH + Co. KG Elektrotechnische Fabrik Hans-Dehn-Str. 1 D-92318 Neumarkt S7-400 and M7-400 Programmable Controllers Hardware and Installation A-26 A5E00069481-04...
Page 279: Surge Protection Components For Lightning Protection Zones 2
For the transition points between lightning protection zones 2 <–> 3 we recommend the surge protection components listed in the table below. This low-voltage protection must be used in S7-400 for CE compliance. Table A-5 Surge Protection Components for Lightning Protection Zones 2 <–> 3 Ser.
Page 280: Sample Of A Surge Protection Circuit For Networked S7-400 Plcs
Assembling and Installing Systems A.9.4 Sample of a Surge Protection Circuit for Networked S7-400 PLCs Sample Circuit The sample in the figure A-7 shows you how install an effective surge protection for 2 networked S7-400 PLCs: L1 L2 L3 N PE Lightning-protection 0, field side zone À...
Page 281: Example Of A Circuit Conforming To Lightning Protection Requirements (Legend To Figure A-7)
0 <–> 1 order number: 919 506* and 919 510* You can order these components directly at: DEHN + SÖHNE GmbH + Co. KG Elektrotechnische Fabrik Hans-Dehn-Str. 1 D-92318 Neumarkt S7-400 and M7-400 Programmable Controllers Hardware and Installation A-29 A5E00069481-04...
Page 282: How To Protect Digital Output Modules Against Inductive Surge
Overvoltage occurs when inductive devices are switched off. Examples are relay coils and contactors Integrated Surge Arrester S7-400 digital output modules are equipped with an integrated surge arrester Additional Overvoltage Protection Inductive devices require additional surge arresters only in following cases: •...
Page 283 • The steepness of the surge voltage remains the same. • Low turn-off delay. Suppression with an RC element exhibits the following characteristics: • The amplitude and steepness of the switching overvoltage are reduced. • Low turn-off delay. S7-400 and M7-400 Programmable Controllers Hardware and Installation A-31 A5E00069481-04...
Page 284: Safety Of Electronic Control Equipment
• Monitoring of major control compoments, using on-line tests (watchdog for the CPU, etc.). These measures are referred to in safety technology as basic measures. They prevent or rectify a large proportion of possible faults. S7-400 and M7-400 Programmable Controllers Hardware and Installation A-32 A5E00069481-04...
Page 285 The entire installation is implemented with a fail-safe control system. • For control equipment with mainly safety-relevant functions (e.g. burner control systems) The entire control system is implemented with fail-safe technology S7-400 and M7-400 Programmable Controllers Hardware and Installation A-33 A5E00069481-04...
Page 286: Interference-Free Connection Of Monitors
Note that the braided shield of the coaxial cable serves as the return conductor and must not be connected to the shield bus. The monitor and communications processor (CP) are interconnected without additional shielding and grounding. S7-400 and M7-400 Programmable Controllers Hardware and Installation A-34 A5E00069481-04...
Page 287 – Fit touch protection to the video sockets, because when the grounds have been separated, a dangerous touch voltage of more than 40 V may be present at the sockets. S7-400 and M7-400 Programmable Controllers Hardware and Installation A-35 A5E00069481-04...
Page 288: A-11 Shielding And Grounding With A Great Distance Between Monitor And Programmable Controller
Outer shield connected to ground Shield bus clamp Ó Ó Ó Figure A-11 Shielding and Grounding with a Great Distance between Monitor and Programmable Controller S7-400 and M7-400 Programmable Controllers Hardware and Installation A-36 A5E00069481-04...
Page 289 Guidelines for Handling Electrostatically-Sensitive Devices (ESD) Chapter Overview Section Description Page What is ESD? Electrostatic Charging of Persons General Protective Measures Against Electrostatic Discharge Damage S7-400 and M7-400 Programmable Controllers Hardware and Installation A5E00069481-04...
Page 290: Guidelines For Handling Electrostatically-Sensitive Devices (Esd)
In most cases, the damage caused by an overvoltage is not immediately noticeable and results in total damage only after a prolonged period of operation. S7-400 and M7-400 Programmable Controllers Hardware and Installation A5E00069481-04...
Page 291: Electrostatic Charging Of Persons
5 10 20 30 40 50 60 70 80 90 100 Relative air humidity in % Figure B-1 Electrostatic Voltages which can Build up on a Person S7-400 and M7-400 Programmable Controllers Hardware and Installation A5E00069481-04...
Page 292: General Protective Measures Against Electrostatic Discharge Damage
If you have to carry out measurements on a module, you must discharge your body before you start the measurement by touching grounded metallic parts. Use grounded measuring devices only. S7-400 and M7-400 Programmable Controllers Hardware and Installation A5E00069481-04...
Page 293 The backup battery ensures that the user program in the CPU is not lost in the event of a power failure and that defined data areas, bit memory, timers, and counters are also retained. S7-400 and M7-400 Programmable Controllers Hardware and Installation Glossary-1 A5E00069481-04...
Page 294 The PG online function “Compress” is used to shift all valid blocks in the RAM of the CPU evenly and without any gaps to the beginning of the user memory. All gaps caused by deleting or correcting blocks are thus removed. S7-400 and M7-400 Programmable Controllers Hardware and Installation Glossary-2 A5E00069481-04...
Page 295 Central processing unit of the S7 or M7 programmable controller with processor, arithmetic unit, memory, operating system, and programming device interface. Cyclic Interrupt A cyclic interrupt is generated by the S7-400 CPU periodically according to a programmable time interval. A corresponding organization block is then executed. Data Block (DB) Data blocks are areas in the user program which contain user data.
Page 296 Diagnostics ³ System Diagnostics Diagnostic Buffer The diagnostic buffer is a retentive area of memory within the S7-400 CPU which stores the diagnostic events in the order they occurred. Diagnostic Interrupt Modules with diagnostics capability signal system errors to the S7-400 CPU by means of diagnostic interrupts.
Page 297 With regard to their characteristic to retain data in the case of a power failure, FEPROMs correspond to the electrically erasable EEPROMs, but can be erased much faster (FEPROM = Flash Erasable Programmable Read Only Memory). They are used on the memory cards. S7-400 and M7-400 Programmable Controllers Hardware and Installation Glossary-5 A5E00069481-04...
Page 298 GD identifier. GD Packet A GD packet can consist of one or more GD elements which are transmitted together in a message frame. S7-400 and M7-400 Programmable Controllers Hardware and Installation Glossary-6 A5E00069481-04...
Page 299 Interrupt-triggering modules trigger a hardware interrupt in the case of a certain event in the process. The hardware interrupt is signalled to the CPU. In accordance with the priority of this interrupt, the corresponding organization block is then executed. S7-400 and M7-400 Programmable Controllers Hardware and Installation Glossary-7 A5E00069481-04...
Page 300 Glossary Instance Data Block With the S7-400, each call of a function block in the STEP 7 user program is assigned a data block which is generated automatically. In the instance data block, the values of the input, output and in/out parameters as well as the local block data are stored.
Page 301 The keyswitch is the mode selector switch of the CPU. The keyswitch is operated with a key which can be withdrawn. Load Memory The load memory is part of the S7-400 CPU. It contains objects created by the programming device. It can be either a plug-in memory card or an integrated memory.
Page 302 ³ Multipoint Interface (MPI) Nesting Depth A block can be called from another block by means of block calls. The nesting depth is the number of simultaneously called logic blocks. S7-400 and M7-400 Programmable Controllers Hardware and Installation Glossary-10 A5E00069481-04...
Page 303 ³ Organization Block OB Priority The operating system of the S7-400 CPU differentiates between various priority classes, for example, cyclic program processing, process interrupt-controlled program processing. Each priority class is assigned organization blocks (OBs), where the S7 user can program a reaction.
Page 304 CPU which are not connected to a specific control task. Organization Block (OB) Organization blocks form the interface between the operating system of the S7-400 CPU and the user program. The sequence in which the user program should be processed is laid down in the organization blocks.
Page 305 Glossary Process Image The process image is a component part of the system memory of the S7-400 CPU. At the beginning of the cyclic program, the signal states of the input modules are transferred to the process-image input table (PII). At the end of the cyclic program, the process-image output table (PIQ) is transferred to the output modules as the signal state.
Page 306 The scan cycle time is the time the CPU takes to run the user program once through. Scan Rate The scan rate defines how often GD packets are sent and received on the basis of the CPU cycle. ³ System Function Block ³ System Function S7-400 and M7-400 Programmable Controllers Hardware and Installation Glossary-14 A5E00069481-04...
Page 307 A system function block (SFB) is a function block integrated in the CPU operating system which can be called in the STEP 7 user program when required, just like a function block (FB). S7-400 and M7-400 Programmable Controllers Hardware and Installation Glossary-15 A5E00069481-04...
Page 308 Time-Delay Interrupt The time-delay interrupt belongs to one of the priority classes in SIMATIC S7-400 program processing. It is generated after expiry of a time started in the user program. A corresponding organization block is then executed.
Page 309 The work memory is the RAM (Random Access Memory) in the CPU to which the STEP 7 user program is automatically reloaded from the load memory. The processor executes the program in the work memory in RUN mode. S7-400 and M7-400 Programmable Controllers Hardware and Installation Glossary-17 A5E00069481-04...
Page 310 Glossary S7-400 and M7-400 Programmable Controllers Hardware and Installation Glossary-18 A5E00069481-04...
Page 311 Connection, M7-400 setting the terminating resistor, 5-22 keyboard, 8-33 terminating resistor, 5-9 VGA monitor, 8-33 Bus connectors, assembling bus cables, 5-20 Connector, M7-400, removing the cover, 8-18 Bus segment. See Segment S7-400 and M7-400 Programmable Controllers Hardware and Installation Index-1 A5E00069481-04...
Page 312 Interface submodules, M7-400, installing, 6-18, replacing fans, 7-14 7-22, 8-13 replacing the filter frame, 7-16 Interference, radiated, A-6 replacing the fuse, 7-13 replacing the monitoring PCB, 7-18 replacing the power supply PCB, 7-18 S7-400 and M7-400 Programmable Controllers Hardware and Installation Index-2 A5E00069481-04...
Page 313 8-29 installing in the rack, 8-24 Modules installing, 2-33 Operator panels, M7-400, connecting, 8-33 isolated, 4-10 Overall installation, in the TN-S system, 4-6 signal, 2-7 Overvoltage, A-20 slot numbers, 2-37 S7-400 and M7-400 Programmable Controllers Hardware and Installation Index-3 A5E00069481-04...
Page 314 2-29 in the MPI subnet, 8-41 of the racks, 2-30 via spur line to MPI subnet, 8-42 with fan subassembly, 2-11 Protection against overvoltage, A-20 Protective measures, 4-5 S7-400 and M7-400 Programmable Controllers Hardware and Installation Index-4 A5E00069481-04...
Page 315 Surges, A-21 Ungrounded configuration, M7-400, connecting Switching on, checks prior to switching on for a programming device, 8-43 the first time, 6-3 Switching on an S7-400, for the first time, 6-6 S7-400 and M7-400 Programmable Controllers Hardware and Installation Index-5 A5E00069481-04...
Page 316 Index S7-400 and M7-400 Programmable Controllers Hardware and Installation Index-6 A5E00069481-04...

This manual is also suitable for:

M7-400

Siemens S7-400 Installation Manual

1 Product Overview

2 Installing the S7-400

5 Networking

3 Addressing the S7-400

4 Wiring the S7-400

6 Starting up

7 Maintenance

8 Assembling the M7-400

Assembling and Installing Systems

Guidelines for Handling Electrostatically-Sensitive Devices (ESD)

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Summary of Contents for Siemens S7-400