Maintenance | Siemens S7-400 guide

Maintenance

7

Chapter Overview

Section	Description	Page

7.1	Replacing the Backup Battery	7-2

7.2	Replacing a Power Supply Module	7-4

7.3	Replacing CPUs	7-5

7.4	Replacing Digital or Analog Modules	7-7

7.5	Changing the Fuses in the Digital Modules	7-9

7.6	Replacing Interface Modules	7-11

7.7	Replacing the Fuse of the Fan Subassembly	7-13

7.8	Replacing Fans in the Fan Subassembly During Operation	7-14

7.9	Replacing the Filter Frame of the Fan Subassembly During Operation	7-16

7.10	Replacing the Power Supply PCB and Monitoring PCB of the Fan	7-18
	Subassembly

7.11	Replacing Interface Submodules	7-19

Automation System S7-400	Hardware and Installation	7-1
A5E00850741-01		7-1

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Siemens S7-400 installation manual Maintenance

Contents

Simatic Safety Guidelines Required Basic Knowledge Purpose of the ManualScope of this Manual Approvals Recycling and Disposal NavigatingFurther Support Training Centers Technical Support Service & Support on the Internet Preface Contents Contents Assembling and Installing Systems Maintenance Figures Routing Equipotential Bonding Conductor and Signal Line Tables Overview of the S7-400 Features of the S7-400 Components Function Illustration S7-400 components Location of the order number and product version Example of a rating plate Section Description Chapter Overview Central Rack CR and Expansion Rack ER S7-400 InstallationIntroduction Connecting with a 5 V Supply Connecting the CR and ERsOverview of the Connections Local Connection Remote Connection Ways of Connecting Central and Expansion Racks Type of Connection Maximum Total Cable Length Rules for Connection Rack No. Available Application Characteristics Slots Buses Installing the Central Rack CR and Expansion Rack ERFunction of the Racks Racks in the S7-400 System Bus Electrical SupplyCommunication Bus C Bus Rack with I/O Bus and Communication Bus Properties Segmented CR Subdivided CR Characteristics Retaining Distances Between Devices Important Notes on InstallationMounting and Grounding the Racks Dimensions of the Racks Mounting the Rack Screw Type Explanation Connecting the Rack to the Chassis GroundMounting Screws Mounting Additional Racks 840 mm Cable duct/fan subassembly Reference Point M4 x Ungrounded configuration Grounded configurationConnection to the Reference Point Methods of Ventilation Methods of Ventilation Wall Changing the Ventilation Filter Mat Optional Shipping state Procedure Installing the Fan Subassembly Monitoring the Fan Subassembly Installing the Cable Duct Types and Dimensions of Cabinets Choosing and Setting up Cabinets with the S7-400Why Cabinets are Required Open Cabinets Closed Cabinets Removable Power Dissipation from Cabinets Example Type of Cabinet Max. Permissible Ambient Cabinet dimensionsExample of selecting the cabinet type Arrangement of the Modules Rules for the Arrangement of ModulesSpace Requirement of the Racks Modules Tool Installing Modules in a RackInstallation Sequence Removing the Cover Screwing the Modules in Place Attaching the Modules Fitting Slot Labels Marking the Modules with Slot LabelsSlot Number Networking Methods of Expansion and NetworkingDistributed I/Os Accessories Accessories Installing the S7-400 Addressing the S7-400 Addresses Geographical and Logical AddressesGeographical Addresses Logical Addresses Conditions for Default Addressing Default Addressing Example How to Determine the Default Address of a ModuleDefault Addresses of Digital Modules Default Addresses of Analog Modules Channel on a Digital Module How to Determine the Default Address of a Channel Channel on an Analog Module Addressing the S7-400 Wiring the S7-400 Power Supply Modules and Load Current Power Supplies Supplying Power to Modules Estimating the Power Requirement Choosing the Power Supply ModuleCalculation Example Module Quantity +5 VDC Max. Current Consumption Choosing the Load Current Power Supply Choosing the Load Current Power SupplyLoad Current Power Supplies Determining the Load Current Definition of a Grounded Supply TN-S Network Assembling an S7-400 with Process I/OsComponents and Protective Measures Rule Grounding the Load Current Circuits CPU S7-400 in the Overall Installation Application Assembling an S7-400 with Grounded Reference Potential MDischarge of Interference Currents Terminal Connection Model An S7-400 Configured with Ungrounded Reference Potential Power Supply Units Example of Ungrounded Operation Filtering the 24 VDC SupplyInsulation Monitoring Isolated Modules and Grounding Concept Assembling an S7-400 with Isolated ModulesDefinition Configuration with Isolated Modules Parallel Wiring of Digital S7-400 Outputs Ground Connections GroundingProtective Ground Device Grounding Method Mode Connection of Load Voltage Connecting the Load Voltage Ground Use only Approved Components Interference-Free Configuration for Local ConnectionsInterference-Free Configuration for Remote Connections Special Cases Lines and Tools Wiring Rules Disconnecting the Power Supply Connector Wiring the Power Supply ModulePower Supply Connector Wiring the Power Supply Connector AC DC L1 L+ 11 Plugging the power supply connector Plugging In the Power Supply Connector Three Types of Front Connector Wiring the Signal Modules 12 Preparing to wire the front connector Preparing to Wire the Front Connector 13 Wiring a Front Connector with Crimp Terminals Wiring the Front Connector, Crimping 14 Wiring a Front Connector with Screw-Type Terminals Wiring the Front Connector, Screw Terminals 15 Wiring a Front Connector with Spring-Type Terminals Wiring the Front Connector, Spring-Type Terminals 16 Principle of the spring contact Principle of the spring loaded terminal Cable Ties as Strain Relief Fitting the Strain Relief Labels and Terminal Diagram Labeling a Front Connector Labels 19 shows details for fitting a label in the front connector Order Number Description How to Label S7-400 Modules Front Connector Coding on the Signal Modules Fitting the Front ConnectorPlugging In the Front Connector Principle of a Coding Key 20 Attaching the Front Connector 21 shows how to screw on the front connector Interconnecting the Interface Modules Interconnecting the CR and ERs 23 Connection Between a Send IM and Two Receive IMs Fuse Setting the Fan Subassembly to the Line VoltageWiring the Fan Subassembly Routing Fiber-Optic Cables Cable routing in cable ducts or fan subassemblies Networking Same Configuration Configuring a NetworkConfiguring Communication Subnets Station = Node FundamentalsSegment Baud Rate Node Device Default MPI Address Default Highest MPI Default MPI AddressesNumber of Nodes MPI/PROFIBUS-DP Addresses Maximum Number of Connections via MPI Rules for MPI AddressesPG / OP -- Module communication without MPI PG Access Rules Rules for Configuring a Network Recommendation for MPI Addresses Data Packets in the MPI NetworkRecommendation for PROFIBUS-DP Addresses Components Terminating Resistor on the RS 485 Repeater Terminating Resistor on the Bus Connector Example Terminating Resistor in the MPI Network Example of an MPI Network Example of a PROFIBUS-DP Network PROFIBUS-DP Example Using a CPU Programming device access beyond network limits Programming Device Access Beyond Network Limits Routing Segment in the MPI Network Cable LengthsSegment in the PROFIBUS-DP Network Longer Cable Lengths Lengths of Spur Lines 10 Configuration of an MPI network PROFIBUS-DP Bus Cables Characteristics of the PROFIBUS-DP Bus CablePROFIBUS-DP Bus Cables Rules for Laying Cables Appearance 6ES7972-0B.20 Bus ConnectorsPurpose of the Bus Connector Removing the Bus Connector Connecting Bus Cables to Bus Connectors 6ES7972-0B.20Connecting the Bus Connector RS 485 Repeater / Diagnostics Repeater Benefits and Areas of Application PROFIBUS-DP Network with Fiber-Optic CablesElectrical/Optical Conversion Transmission Rate Optical PROFIBUS-DP Network in Partyline Topology Profibus Optical Bus Terminal OBT Features of the Fiber-Optic Cables Cable grip Prerequisite Order NumbersSimatic NET Profibus plastic fiber-optic, standard cable Simatic NET Profibus PCF fiber-optic, standard cable Structure Accessories Order Number Mixed Use of Plastic Fiber-Optic and PCF Fiber-Optic Cable Cable LengthsLaying PCF Fiber-Optic Cable Laying Plastic Fiber-Optic Cable Rules for Laying Cable Installing the Connector Adapter Networking Commissioning How to Proceed in the Case of an Error Recommended Procedure for First StartupRecommended Procedure Checks Prior to Switching On for the First Time Checks Prior to Switching On for the First TimeMounting and Wiring Modules Grounding and Chassis Ground Concept Line Voltage Module SettingsPower Supply Module If You Then Connecting a Programming Device PG to an S7-400Connecting a Programming Device PG to an S7-400 Switching On an S7-400 for the First Time Switching On an S7-400 for the First TimeSwitching On an H System for the First Time Communication between Programming Device and CPU How to Carry Out a Memory Reset Resetting the CPU with the Mode Selector SwitchWhen Should a CPU be Reset? How to Perform a Memory Reset Resetting the CPU with the Mode Selector Switch Special Case MPI Parameters What Happens in the CPU During a Memory ResetWhat Remains Following the Memory Reset Restart warm start Cold, Warm, and Hot Restarts with the Mode Selector SwitchHot restart Control sequence for restart warm restart / hot restart What Type of Memory Card Should You Use? Inserting a Memory CardMemory Card as Load Memory Inserting a Memory Card Inserting a Backup Battery Inserting a Backup Battery OptionBackup Commissioning Commissioning Reducing the Passivation Layer Removing a Backup Battery Requirements Starting Up a PROFIBUS-DP SubnetStarting Up Behavior of the CPU During Startup Available Interface Modules Installing Interface Modules Covering Unused Submodule Slots Commissioning Maintenance Replacing the Backup Battery Replacing the Backup Battery Rules for the Care of Backup Batteries Using Backup Batteries Installing a New Module Replacing a Power Supply ModuleSlot Numbering How the S7-400 Behaves after Exchanging Modules Removing the Module Replacing CPUsSaving the Data Installing a New Module Replacing Digital or Analog Modules Installing a Module Exchanging the Front Connector Removing the Front Connector Coding Key Modules with Fuses Changing the Fuses in the Digital ModulesCheck the Plant Changing the Fuses How the S7-400 Behaves after Replacing the Fuse Removing Modules / Exchanging Cables Replacing Interface ModulesHot--swapping Modules Installing a New Module Replacing the Fuse Replacing the Fuse of the Fan SubassemblyFuse Type Removing the Fans Replacing Fans in the Fan Subassembly During Operation Maintenance Replacing the Filter Frame Maintenance Exchanging the Mother Board Available Interface Submodules Installing Interface SubmodulesReplacing Interface Submodules Inserting an Interface Submodule in a CPU Assembling and Installing Systems General Basic Rules General Rules and Regulations for Operating the S7-400Specific Application Emergency OFF Devices VDC Supply 120/230 VAC SupplyProtection Against External Electrical Effects With You Must Ensure Protection against By Means Protection Against Other Electrical Effects Possible Effects of Interference Principles of System Installation for EMCDefinition EMC Capacitive Coupling Coupling MechanismsInductive Coupling Radiated Interference Rule 1 Large Area Grounding Five Basic Rules for Ensuring Electromagnetic CompatibilityRule 2 Correct Cable Routing Rule 3 Secure Cable Shields See also Rule 4 Special EMC MeasuresRule 5 Standard Reference Potential Grounding of Inactive Metal Parts During Installation Installation of Programmable Controllers for EMCEnsure the following when chassis grounding Inactive Metal Parts Example 1 Cabinet Configuration for EMC Examples of EMC-Compatible Assembly Example 2 EMC--compliant Wall Mounting Key for example Figure A-3 shows an example of wall mounting for EMC Ensure the following for frame and wall mounting Purpose of the Shielding Shielding CablesPrinciple of Operation Suitable Cables Figure A-4 Mounting Cable Shields Handling the Shields Equipotential Bonding Conductor Equipotential BondingPotential Differences Assembling and Installing Systems Cabling Inside Buildings How to Read the TableConnect Cables for Run Inside cabinets Ethernet Rules for EMC Cabling Outside BuildingsRules for Lightning Protection Outside Buildings Overvoltage Protection Devices Overview Lightning Protection and Overvoltage Protection Surges Effects of a Lightning Strike Figure A-6 Lightning Protection Zones of a Building Diagram of the Lightning Protection Zones Order No Additional MeasuresSer Cables for Equip transition point 0 With Dehn + Söhne Lightning Protection Element for the 24 VDC Supply Lightning Protection Element for Signal Modules Ser Cables for Equip transition point 1 2 with Order No Low-Voltage Protection Elements for 1 Ser Cables for Equip transition point Order No With Low-Voltage Protection Elements for 2 Lightning-protection zone Sample CircuitLightning-protection 0, field side zone Ser. No Components Description From fi Gure A-7 Components in figure A-7 Additional Overvoltage Protection Inductive Surge VoltageIntegrated Surge Arrester Suppression with AC-Operated Coils Suppression for DC-Operated CoilsSuppression with Diodes / Zener Diodes Risks Safety of Electronic Control EquipmentIntoduction Reliability Important Information Operation under Industrial Conditions Interference-Free Connection of MonitorsOperation under Low-Interference Conditions Shielding and Grounding under Industrial Conditions Isolated Section You will find What is ESD? Charging Electrostatic Charging of Persons Avoid Direct Contact Ensure Sufficient Grounding Address Backup BatteryAnalog Module Bit Memory M Configuring ConfigurationCentral module Chassis Ground Counters Default SettingCycle time Cyclic Interrupt Diagnostic Interrupt Diagnostic BufferDP Master DP Slave Function Error DisplayError Response Function Block FB Functional GroundingFunction Module FM Global Data Communication Instance Data Block Hardware InterruptInterface, Multipoint Interrupt, Cyclic Local Data Load MemoryLogic Block Manufacturer--specific interrupt Nesting Depth MPI AddressNetwork Node Number Operating State OB PriorityOperating System of the CPU Organization Block OB Priority classes Parameters, StaticProcess Image Programming Device PG Reference Ground Run-Time ErrorReference Potential Retentive Data Slave Signal ModuleStatus interrupt Substitute Value Time-Delay Interrupt System DiagnosticsSystem Function SFC System Function Block SFB Toggle switch Timer TUpdate interrupt Total Current Warm Restart VaristorWatchdog interrupt Work Memory Index Index Index-3 Index-4