Siemens S7-400 Maintenance

7-1

AutomationSystem S7-400 Hardwareand Installation

A5E00850741-01

Maintenance

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

Subassembly

7-18

7.11 ReplacingInterface Submodules 7-19

Contents

Main ! Caution Notice Qualified Personnel Prescribed Usage ! Trademarks Safety Guidelines Preface Navigating Recycling and Disposal Further Support TrainingCenters TechnicalSupport Service & Support on the Internet Page Contents Page Page Page Page Page Product Overview Overview of the S7-400 Features of the S7-400 Product Overview 1-2 S7-400 components The most important components of the S7-400 and their functions are given in the following tables: Location of the order number and product version Page 2-1 Installing the S7-400 2.1 S7-400 Installation Central Rack (CR) and Expansion Rack (ER) Connecting the CR and ER(s) Connecting witha5VSupply Overview of the Connections 2-4 Ways of Connecting Central and Expansion Racks Rules for Connection 2-6 2.2 Installing the Central Rack (CR) and Expansion Rack (ER) Function of the Racks Racks in the S7-400 System Electrical Supply I/O Bus Communication Bus (C Bus) Rack with I/O Bus and Communication Bus 2.3 Segmented CR Properties 2.4 Subdivided CR Characteristics 2.5 Mounting and Grounding the Racks Important Notes on Installation Step 1: Retaining Distances Between Devices Space Required When Using Cable Channels and Fan Subassemblies Dimensions of the Racks Step 2: Mounting the Rack 2-13 Mounting Screws Youhave a choice of the following types of screw for securing a rack: Step 3: Connecting the Rack to the Chassis Ground Step 4: Mounting Additional Racks Page 2.6 Chassis Terminal Connection in the Non-Isolated Configuration Reference Point Connection to the Reference Point 2.7 Methods of Ventilation Methods of Ventilation Page 2.8 Changing the Ventilation with the Cable Duct and Fan Subassembly Changing the Ventilation Shipping state Filter Mat (Optional) 2.9 Installing the Fan Subassembly Monitoring the Fan Subassembly 2.10 Installing the Cable Duct 2.11 Choosing and Setting up Cabinets with the S7-400 Why Cabinets are Required Typesand Dimensions of Cabinets 2-26 Removable Power Dissipation from Cabinets (Example) Example of selecting the cabinet type Cabinet dimensions 2.12 Rules for the Arrangement of Modules Arrangement of the Modules Space Requirement of the Racks 2.13 Installing Modules in a Rack Tool Installation Sequence Removing the Cover Attaching the Modules Screwing the Modules in Place 2.14 Marking the Modules with Slot Labels Slot Number Fitting Slot Labels 2.15 Methods of Expansion and Networking Distributed I/Os Networking 2-35 2.16 Accessories Accessories Page 3-1 Addressing the S7-400 3.1 Geographical and Logical Addresses Addresses Geographical Addresses Logical Addresses The TwoStages of Addressing Default Addressing Conditions for Default Addressing 3.2 How to Determine the Default Address of a Module Default Addressing Default Addresses of Digital Modules Page 3.3 How to Determine the Default Address of a Channel Channel on a Digital Module Channel on an Analog Module Page 4-1 Wiring the S7-400 4.1 Supplying Power to Modules Power Supply Modules and Load Current Power Supplies 4.2 Choosing the Power Supply Module Estimating the Power Requirement Calculation Example 4.3 Choosing the Load Current Power Supply Choosing the Load Current Power Supply Load Current Power Supplies Determining the Load Current 4.4 Assembling an S7-400 with Process I/Os Definition of a Grounded Supply (TN-S Network) Components and Protective Measures Rule: Grounding the Load Current Circuits S7-400 in the Overall Installation 4.5 Assembling an S7-400 with Grounded Reference Potential (M) Discharge of Interference Currents TerminalConnection Model 4.6 Assembling an S7-400 with Ungrounded Reference Potential (Ungrounded Configuration) Discharge of Interference Currents TerminalConnection Model Power Supply Units Page 4.7 Assembling an S7-400 with Isolated Modules Definition Isolated Modules and Grounding Concept Configuration with Isolated Modules 4.8 Parallel Wiring of Digital S7-400 Outputs Parallel Wiring of a Digital Output with Different Rated Load Voltages Parallel Wiring of a Digital Output with Identical Rated Load Voltages 4.9 Grounding Ground Connections Protective Ground Connecting the Load VoltageGround 4.10 Interference-Free Configuration for Local and Remote Connections Use only Approved Components Interference-Free Configuration for Local Connections Interference-Free Configuration for Remote Connections Special Cases Wiring the S7-400 4-17 4.11 Wiring Rules Lines and Tools For wiring the S7-400 modules, there are some rules for the cables and tools to use. 4.12 Wiring the Power Supply Module Power Supply Connector Disconnecting the Power Supply Connector Wiring the Power Supply Connector Page Plugging In the Power Supply Connector 4.13 Wiring the Signal Modules The Three Typesof Front Connector Preparing to Wire the Front Connector 4.14 Wiring the Front Connector, Crimping 4.15 Wiring the Front Connector, Screw Terminals 4.16 Wiring the Front Connector, Spring-TypeTerminals Principle of the spring loaded terminal 4.17 Fitting the Strain Relief Cable Ties as Strain Relief 4.18 Labeling a Front Connector Labels and TerminalDiagram Labels Notes on Ordering Labeling Sheets for S7-400 How to Label S7-400 Modules 4.19 Fitting the Front Connector Principle of a Coding Key Front Connector Coding on the Signal Modules Plugging In the Front Connector Page Page 4.20 Interconnecting the CR and ER(s) Interconnecting the Interface Modules Page 4.21 Setting the Fan Subassembly to the Line Voltage and Wiring It Setting the Fan Subassembly to the Line Voltage Fuse Wiring the Fan Subassembly 4.22 Cable routing in cable ducts or fan subassemblies Cable Routing Securing Cables Shield Contact 4.23 Routing Fiber-Optic Cables Networking 5.1 Configuring a Network Subnets Same Configuration Multipoint Interface (MPI) Configuring Communication 5.2 Fundamentals Station = Node Segment Baud Rate Connectable Nodes Number of Nodes MPI/PROFIBUS-DP Addresses Default MPI Addresses Rules for MPI Addresses PG / OP --Module communication without MPI Maximum Number of Connections via MPI PG Access 5.3 Rules for Configuring a Network Rules Data Packets in the MPI Network Recommendation for MPI Addresses Recommendation for PROFIBUS-DP Addresses Components 5-9 TerminatingResistor on the Bus Connector TerminatingResistor on the RS 485 Repeater Example: TerminatingResistor in the MPI Network 5-11 Example of an MPI Network 5-12 Example of a PROFIBUS-DP Network Example Using a CPU 414-2 Programming Device Access Beyond Network Limits (Routing) 5.4 Cable Lengths Segment in the MPI Network Segment in the PROFIBUS-DP Network Longer Cable Lengths Lengths of Spur Lines 5-17 5.5 PROFIBUS-DP Bus Cables PROFIBUS-DP Bus Cables Characteristics of the PROFIBUS-DP Bus Cable Rules for Laying Cables 5.6 Bus Connectors Purpose of the Bus Connector Appearance (6ES7972-0B.20 ...) Connecting Bus Cables to Bus Connectors ( Connecting the Bus Connector Removing the Bus Connector 5.7 RS 485 Repeater / Diagnostics Repeater 5.8 PROFIBUS-DP Network with Fiber-Optic Cables Electrical/Optical Conversion Benefits and Areas of Application Optical PROFIBUS-DP Network in Partyline Topology TransmissionRate 5-24 PROFIBUS Optical Bus Terminal(OBT) 5.8.1 Fiber-Optic Cables Features of the Fiber-Optic Cables Use Siemens plastic and PCF fiber-optic cables with the following features: 5.8.2 Simplex Connectors and Connector Adapter Definition Prerequisite Structure Order Numbers 5.8.3 Connecting a Fiber-Optic Cable to the PROFIBUS Device Cable Lengths Mixed Use of Plastic Fiber-Optic and PCF Fiber-Optic Cable Laying PCF Fiber-Optic Cable Laying Plastic Fiber-Optic Cable Installation Instructions for Plastic Fiber-Optic Cable (with Photos) Rules for Laying Cable Installing the Connector Adapter Page 6-1 Commissioning 6.1 Recommended Procedure for First Startup Recommended Procedure How to Proceed in the Case of an Error Commissioning 6-3 6.2 Checks Prior to Switching On for the First Time Checks Prior to Switching On for the First Time Commissioning 6-4 6.3 Connecting a Programming Device (PG) to an S7-400 Connecting a Programming Device (PG) to an S7-400 Communication between Programming Device and CPU Operator Control 6.4 Switching On an S7-400 for the First Time Switching On an S7-400 for the First Time Switching On an H System for the First Time 6.5 Resetting the CPU with the Mode Selector Switch How to Carry Out a Memory Reset When Should a CPU be Reset? How to Perform a Memory Reset Resetting the CPU with the Mode Selector Switch What Happens in the CPU During a Memory Reset What Remains Following the Memory Reset... Special Case MPI Parameters 6.6 Cold, Warm, and Hot Restarts with the Mode Selector Switch Restart (warm start) Hot restart Control sequence for restart (warm restart) / hot restart 6.7 Inserting a Memory Card The Memory Card as Load Memory What Typeof Memory Card Should You Use? Inserting a Memory Card 6.8 Inserting a Backup Battery (Option) Backup Inserting a Backup Battery Page Page Reducing the Passivation Layer Removing a Backup Battery 6.9 Starting Up a PROFIBUS-DP Subnet Requirements Starting Up Behavior of the CPU During Startup 6.10 Installing Interface Modules (CPU 414-2, 414-3, 416-3, 417-4 and 417-4H) Available Interface Modules Installing Interface Modules Covering Unused Submodule Slots Page 7-1 Maintenance 7.1 Replacing the Backup Battery Replacing the Backup Battery Using Backup Batteries Rules for the Care of Backup Batteries 7.2 Replacing a Power Supply Module Removing the Module (Ignore Steps 1 and 2 When Using Redundant Power Supply Modules) 7.3 Replacing CPUs Saving the Data Removing the Module Page 7.4 Replacing Digital or Analog Modules Installing a Module Removing the Front Connector Coding Key Exchanging the Front Connector 7.5 Changing the Fuses in the Digital Modules ! Modules with Fuses Check the Plant Changing the Fuses How the S7-400 Behaves after Replacing the Fuse 7.6 Replacing Interface Modules Hot--swappingModules Removing Modules / Exchanging Cables Page 7.7 Replacing the Fuse of the Fan Subassembly Fuse Type Replacing the Fuse 7.8 Replacing Fans in the Fan Subassembly During Operation Removing the Fans Page 7.9 Replacing the Filter Frame of the Fan Subassembly During Operation Replacing the Filter Frame Page 7.10 Replacing the Power Supply PCB and Monitoring PCB of the Fan Subassembly Exchanging the Mother Board 7.11 Replacing Interface Submodules Available Interface Submodules Installing Interface Submodules A A-1 Assembling and Installing Systems A.1 General Rules and Regulations for Operating the S7-400 General Basic Rules Specific Application EMERGENCY OFF Devices Reactions of the Plant after Certain Events 120/230 VACSupply 24 VDC Supply The following table shows the points you must observe when connecting the S7-400 to a 24 VDC supply. Protection Against External Electrical Effects The following table shows what you must observe for protection against external electrical effects. Protection Against Other Electrical Effects A.2 Principles of System Installation for EMC Definition: EMC Possible Effects of Interference Page Five Basic Rules for Ensuring Electromagnetic Compatibility Rule 1: Large Area Grounding Rule 2: Correct Cable Routing Rule 3: Secure Cable Shields Rule 4: Special EMC Measures Rule 5: Standard Reference Potential See also A.3 Installation of Programmable Controllers for EMC Inactive Metal Parts Grounding of Inactive Metal Parts During Installation Ensure the following when chassis grounding: A.4 Examples of EMC-Compatible Assembly Example 1: Cabinet Configuration for EMC Key for example 1 Example 2: EMC--compliantWall Mounting Ensure the following for frame and wall mounting: A.5 Shielding Cables Purpose of the Shielding Principle of Operation Suitable Cables Grounding the Cable Shields Handling the Shields A.6 Equipotential Bonding Potential Differences Equipotential Bonding Conductor Page A-17 A.7 Cabling Inside Buildings How to Read the Table A-18 A.8 Cabling Outside Buildings A.9 Lightning Protection and Overvoltage Protection Overview A.9.1 Lightning Protection Zone Concept Principle of the Lightning Protection Zone Concept According to IEC 61312-1/DIN VDE 0185 T103 Effects of a Lightning Strike Surges Diagram of the Lightning Protection Zones Principle of Transitionsbetween the Lightning Protection Zones A.9.2 Rules for the Transition between Lightning Protection Zones 0and1 Rule for the Transition0 < ->1 (Lightning Protection Equipotential Bonding) Additional Measures A-24 A.9.3 Rules for the Transitions between Lightning Protection Zones 1 <-> 2 and Greater Rules for Transitions1 <-> 2 and Above (Local Equipotential Bonding) ). Additional Measures Lightning Protection Element for the 24 VDC Supply Low-VoltageProtection Elements for 1 < --> 2 A-27 Low-VoltageProtection Elements for 2< --> 3 Page A-29 Components in figure A-7 The table A-6 explains consecutive numbers in the figure A-7: A.10 How to Protect Digital Output Modules against Inductive Surge Inductive Surge Voltage Integrated Surge Arrester Additional Overvoltage Protection Suppression for DC-Operated Coils Suppression with Diodes / Zener Diodes Suppression with AC-Operated Coils A.11 Safety of Electronic Control Equipment Intoduction Reliability Risks Splitting the group into safety-relevant areas and areas which are not savety-relevant Important Information A.12 Interference-Free Connection of Monitors Operation under Low-Interference Conditions Operation under Industrial Conditions Shielding and Grounding under Industrial Conditions Page B B.1 What is ESD? Definition: B.2 Electrostatic Charging of Persons Charging B.3 General Protective Measures Against Electrostatic Discharge Damage Ensure Sufficient Grounding Avoid Direct Contact Glossary A B C D E F G H I L M N O P Page R S Page T U V W Index A B C D H I L M N R S T W