Siemens SIMATIC PCS 7 User guide

CPU 410-5H Process Automation/CPU
410 SMART
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SIMATIC
PCS 7 Process Control System
CPU 410-5H Process
Automation/CPU 410 SMART
System Manual
09/2014
A5E32631667
-AB
Preface
1
Introduction to CPU 410-5H
2
Structure of the CPU 410-5H
3
I/O configuration variants
4
PROFIBUS DP
5
PROFINET IO
6
Operator controls and
operating modes of the CPU
410-5H
7
Link-up and update
8
Special functions of the CPU
410-5H
9
System modifications during
redundant operation
10
Failure and replacement of
components during
redundant operation
11
Synchronization modules
12
System expansion card
13
Technical data
14
Properties and technical
specifications of CPU 410
SMART
15
Supplementary information
16
Characteristic values of
redundant automation
systems
A
Function and communication
modules that can be used in
a redundant configuration
B
Connection examples for
redundant I/Os
C

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A5E32631667-AB
Ⓟ
09/2014 Subject to change
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editions.

CPU 410-5H Process Automation/CPU 410 SMART
System Manual, 09/2014, A5E32631667-AB 3
Table of contents
1 Preface ................................................................................................................................................. 15
1.1 Preface....................................................................................................................................15
1.2 Security information ................................................................................................................18
1.3 Documentation........................................................................................................................19
2 Introduction to CPU 410-5H .................................................................................................................. 21
2.1 Scope of application of PCS 7 ................................................................................................21
2.2 Possible applications ..............................................................................................................23
2.3 The basic system of the CPU 410-5H for stand-alone operation ...........................................24
2.4 The basic system for redundant operation .............................................................................25
2.5 Rules for the assembly of fault-tolerant stations.....................................................................27
2.6 I/O for CPU 410-5H.................................................................................................................28
2.7 I/O configuration variants of the fault-tolerant system ............................................................28
2.8 Tools for configuring (STEP 7 - HW Config, PCS 7) ..............................................................28
2.9 PCS 7 project..........................................................................................................................29
2.10 Scaling and licensing (scaling concept)..................................................................................30
3 Structure of the CPU 410-5H................................................................................................................. 33
3.1 Operator controls and display elements on the CPU 410-5H ................................................33
3.2 Monitoring functions of the CPU 410-5H ................................................................................37
3.3 Status and error displays ........................................................................................................39
3.4 PROFIBUS DP interface (X1).................................................................................................43
3.5 PROFINET IO interfaces (X5, X8) ..........................................................................................44
3.6 Overview of the parameters for the CPU 410-5H...................................................................46
4 I/O configuration variants ...................................................................................................................... 47
4.1 Stand-alone operation.............................................................................................................47
4.2 Fail-safe operation ..................................................................................................................51
4.3 Fault-tolerant automation systems (redundancy operation) ...................................................55
4.3.1 Redundant SIMATIC automation systems..............................................................................55
4.3.2 Increase of plant availability, reaction to errors ......................................................................56
4.4 Introduction to the I/O link to fault-tolerant system .................................................................59
4.5 Using single-channel switched I/O..........................................................................................60
4.6 System and media redundancy at the PROFINET IO interface .............................................66
4.6.1 System redundancy ................................................................................................................66

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4.6.2 Media redundancy ................................................................................................................. 69
4.7 Connecting redundant I/O to the PROFIBUS DP interface ................................................... 72
4.7.1 Signal modules for redundancy ............................................................................................. 72
4.7.2 Evaluating the passivation status........................................................................................... 86
5 PROFIBUS DP ..................................................................................................................................... 87
5.1 CPU 410-5H as PROFIBUS DP master ................................................................................ 87
5.2 DP address ranges of the CPU 410-5H................................................................................. 87
5.3 Diagnostics of the CPU 410-5H as PROFIBUS DP master .................................................. 88
6 PROFINET IO....................................................................................................................................... 91
6.1 Introduction ............................................................................................................................ 91
6.2 PROFINET IO systems.......................................................................................................... 93
6.3 Device replacement without removable medium/programming device ................................. 95
7 Operator controls and operating modes of the CPU 410-5H .................................................................. 97
7.1 Operating modes of the CPU 410-5H.................................................................................... 97
7.1.1 RUN mode ............................................................................................................................. 97
7.1.2 STOP mode ........................................................................................................................... 98
7.1.3 STARTUP mode .................................................................................................................... 99
7.1.4 HOLD mode ......................................................................................................................... 100
7.1.5 LINK-UP and UPDATE modes ............................................................................................ 101
7.1.6 ERROR-SEARCH mode...................................................................................................... 101
7.1.7 DEFECTIVE state ................................................................................................................ 102
7.2 System states of the redundant CPU 410-5H...................................................................... 103
7.2.1 Introduction .......................................................................................................................... 103
7.2.2 The system states of the fault-tolerant system .................................................................... 105
7.2.3 Displaying and changing the system state of a fault-tolerant system.................................. 106
7.2.4 System status change from the STOP system state ........................................................... 106
7.2.5 System status change from the standalone mode system status ....................................... 107
7.2.6 System status change from the redundant system state..................................................... 107
7.2.7 System diagnostics of a fault-tolerant system ..................................................................... 108
7.3 Self-test ................................................................................................................................ 110
7.4 Performing a memory reset ................................................................................................. 113
8 Link-up and update ..............................................................................................................................115
8.1 Effects of link-up and updating............................................................................................. 115
8.2 Link-up and update via PG command ................................................................................. 116
8.3 Time monitoring ................................................................................................................... 117
8.3.1 Time response ..................................................................................................................... 119
8.3.2 Determining the monitoring times ........................................................................................ 119
8.3.3 Performance values for link-up and update ......................................................................... 126
8.3.4 Influences on time response ................................................................................................ 126
8.4 Special features in link-up and update operations............................................................... 127
9 Special functions of the CPU 410-5H ...................................................................................................129
9.1 Security levels...................................................................................................................... 129

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9.2 Access-protected blocks .......................................................................................................131
9.3 Resetting the CPU410-5H to factory settings.......................................................................132
9.4 Reset during operation..........................................................................................................133
9.5 Updating firmware.................................................................................................................134
9.6 Firmware update in RUN mode ............................................................................................136
9.7 Reading service data ............................................................................................................137
9.8 Response to fault detection ..................................................................................................138
9.9 Time synchronization............................................................................................................138
9.10 Type update with interface change in RUN ..........................................................................140
10 System modifications during redundant operation ............................................................................... 141
10.1 System modifications during operation.................................................................................141
10.2 Possible hardware modifications ..........................................................................................143
10.3 Adding components ..............................................................................................................146
10.3.1 Step 1: Modify hardware.......................................................................................................147
10.3.2 Step 2: Modify the hardware configuration offline ................................................................147
10.3.3 Step 3: Stop the standby CPU..............................................................................................148
10.3.4 Step 4: Download new hardware configuration to the standby CPU....................................148
10.3.5 Step 5: Switch to CPU with modified configuration ..............................................................149
10.3.6 Step 6: Transition to redundant system state .......................................................................150
10.3.7 Step 7: Modify and download the user program...................................................................151
10.3.8 Use of free channels on an existing module.........................................................................152
10.3.9 Addition of interface modules ...............................................................................................153
10.4 Removal of components .......................................................................................................155
10.4.1 Step 1: Modify the hardware configuration offline ................................................................156
10.4.2 Step 2: Modify and download the user program...................................................................156
10.4.3 Step 3: Stop the standby CPU..............................................................................................157
10.4.4 Step 4: Download new hardware configuration to the standby CPU....................................158
10.4.5 Step 5: Switch to CPU with modified configuration ..............................................................158
10.4.6 Step 6: Transition to redundant system state .......................................................................159
10.4.7 Step 7: Modify hardware.......................................................................................................160
10.4.8 Removal of interface modules ..............................................................................................161
10.5 Editing CPU parameters .......................................................................................................162
10.5.1 Editing CPU parameters .......................................................................................................162
10.5.2 Step 1: Editing CPU parameters offline................................................................................164
10.5.3 Step 2: Stopping the reserve CPU........................................................................................164
10.5.4 Step 3: Downloading a new hardware configuration to the reserve CPU ............................165
10.5.5 Step 4: Switching to CPU with modified configuration..........................................................165
10.5.6 Step 5: Transition to redundant system mode......................................................................166
10.6 Re-parameterization of a module .........................................................................................167
10.6.1 Re-parameterization of a module .........................................................................................167
10.6.2 Step 1: Editing parameters offline.........................................................................................168
10.6.3 Step 2: Stopping the reserve CPU........................................................................................169
10.6.4 Step 3: Downloading a new hardware configuration to the reserve CPU ............................169
10.6.5 Step 4: Switching to CPU with modified configuration..........................................................170
10.6.6 Step 5: Transition to redundant system mode......................................................................171

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11 Failure and replacement of components during redundant operation ....................................................173
11.1 Failure and replacement of central components.................................................................. 173
11.1.1 Failure and replacement of a CPU during redundant operation .......................................... 173
11.1.2 Failure and replacement of a power supply module ............................................................ 175
11.1.3 Failure and replacement of an input/output or function module .......................................... 176
11.1.4 Failure and replacement of a communication module ......................................................... 177
11.1.5 Failure and replacement of a synchronization module or fiber-optic cable ......................... 178
11.1.6 Failure and replacement of an IM 460 and IM 461 interface module .................................. 180
11.2 Failure and replacement of components of the distributed I/Os .......................................... 181
11.2.1 Failure and replacement of a PROFIBUS DP master.......................................................... 182
11.2.2 Failure and replacement of a redundant PROFIBUS DP interface module ........................ 184
11.2.3 Failure and replacement of a PROFIBUS DP slave ............................................................ 184
11.2.4 Failure and replacement of PROFIBUS DP cables ............................................................. 185
11.3 Failure and replacement of components of PROFINET IO ................................................. 187
11.3.1 Failure and replacement of a PROFINET IO device............................................................ 187
11.3.2 Failure and replacement of PROFIBUS IO cables .............................................................. 188
12 Synchronization modules .....................................................................................................................189
12.1 Synchronization modules for the CPU 410-5H .................................................................... 189
12.2 Installation of fiber-optic cables............................................................................................ 193
12.3 Selecting fiber-optic cables .................................................................................................. 196
13 System expansion card........................................................................................................................201
13.1 Variants of the system expansion card................................................................................ 201
14 Technical data .....................................................................................................................................203
14.1 Technical specifications of the CPU 410-5H; (6ES7 410-5HX08-0AB0)............................. 203
15 Properties and technical specifications of CPU 410 SMART.................................................................215
15.1 CPU 410 SMART................................................................................................................. 215
15.2 Technical specifications of the CPU 410 SMART; (6ES7 410-5HN08-0AB0)..................... 217
16 Supplementary information ..................................................................................................................229
16.1 Supplementary information on PROFIBUS DP ................................................................... 229
16.2 Supplementary information on diagnostics of CPU 410-5H as PROFIBUS DP master...... 230
16.3 System status lists for PROFINET IO .................................................................................. 233
16.4 Configuring with STEP 7...................................................................................................... 235
16.4.1 Rules for arranging fault-tolerant station components ......................................................... 235
16.4.2 Configuring hardware........................................................................................................... 235
16.4.3 Assigning parameters to modules in a fault-tolerant station................................................ 236
16.4.4 Recommendations for setting CPU parameters, fixed settings ........................................... 236
16.4.5 Networking configuration ..................................................................................................... 237
16.5 Programming device functions in STEP 7 ........................................................................... 238
16.6 Communication services...................................................................................................... 239
16.6.1 Overview of communication services................................................................................... 239
16.6.2 PG communication............................................................................................................... 240
16.6.3 OP communication............................................................................................................... 240

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16.6.4 S7 communication ................................................................................................................241
16.6.5 S7 routing..............................................................................................................................242
16.6.6 Data set routing.....................................................................................................................246
16.6.7 SNMP network protocol ........................................................................................................247
16.6.8 Open Communication Via Industrial Ethernet ......................................................................248
16.7 Basics and terminology of fault-tolerant communication ......................................................251
16.8 Usable networks ...................................................................................................................255
16.9 Communication via S7 connections......................................................................................256
16.9.1 Communication via S7 connections - one-sided mode ........................................................257
16.9.2 Communication via redundant S7 connections ....................................................................259
16.9.3 Communication via point-to-point CP on the ET 200M ........................................................260
16.9.4 Custom connection to single-channel systems ....................................................................262
16.10 Communication via fault-tolerant S7 connections ................................................................263
16.10.1 Communication between fault-tolerant systems...................................................................265
16.10.2 Communication between fault-tolerant systems and a fault-tolerant CPU ...........................268
16.10.3 Communication between fault-tolerant systems and PCs....................................................269
16.11 Consistent data .....................................................................................................................271
16.11.1 Consistency of communication blocks and functions ...........................................................271
16.11.2 Consistency rules for SFB 14 "GET" or read variable, and SFB 15 "PUT" or write
variable .................................................................................................................................271
16.11.3 Consistent reading and writing of data from and to DP standard slaves/IO devices ...........272
16.12 Link-up and update sequence ..............................................................................................274
16.12.1 Link-up sequence..................................................................................................................277
16.12.2 Update sequence..................................................................................................................278
16.12.3 Switch to CPU with modified configuration...........................................................................281
16.12.4 Disabling of link-up and update ............................................................................................282
16.13 The user program .................................................................................................................283
16.14 Other options for connecting redundant I/Os........................................................................284
16.15 Cycle and response times of the CPU 410-5H.....................................................................287
16.15.1 Cycle time .............................................................................................................................287
16.15.2 Calculating the cycle time .....................................................................................................289
16.15.3 Cycle load due to communication.........................................................................................293
16.15.4 Response time ......................................................................................................................295
16.15.5 Calculating cycle and response times ..................................................................................300
16.15.6 Examples of calculating the cycle and response times ........................................................301
16.15.7 Interrupt response time.........................................................................................................304
16.15.8 Example of calculation of the interrupt response time..........................................................306
16.15.9 Reproducibility of delay and watchdog interrupts .................................................................307
16.16 Runtimes of the FCs and FBs for redundant I/Os ................................................................308
A Characteristic values of redundant automation systems ...................................................................... 311
A.1 Basic concepts......................................................................................................................311
A.2 Comparison of MTBF for selected configurations ................................................................315
A.2.1 System configurations with redundant CPU 410-5H ............................................................315
A.2.2 System configurations with distributed I/Os..........................................................................316
A.2.3 Comparison of system configurations with standard and fault-tolerant communication ......320

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B Function and communication modules that can be used in a redundant configuration...........................321
C Connection examples for redundant I/Os..............................................................................................323
C.1 MTA terminal modules (Marshalled Termination Assemblies) ............................................ 323
C.2 Interconnection of output modules....................................................................................... 323
C.3 8-channel HART analog input MTA ..................................................................................... 325
C.4 8-channel HART analog output MTA ................................................................................... 326
C.5 SM 321; DI 16 x DC 24 V, 6ES7 321–1BH02–0AA0 ........................................................... 327
C.6 SM 321; DI 32 x DC 24 V, 6ES7 321–1BL00–0AA0............................................................ 328
C.7 SM 321; DI 16 x AC 120/230V, 6ES7 321–1FH00–0AA0 ................................................... 329
C.8 SM 321; DI 8 x AC 120/230 V, 6ES7 321–1FF01–0AA0..................................................... 330
C.9 SM 321; DI 16 x DC 24V, 6ES7 321–7BH00–0AB0 ............................................................ 331
C.10 SM 321; DI 16 x DC 24V, 6ES7 321–7BH01–0AB0 ............................................................ 332
C.11 SM 326; DO 10 x DC 24V/2A, 6ES7 326–2BF01–0AB0 ..................................................... 333
C.12 SM 326; DI 8 x NAMUR, 6ES7 326–1RF00–0AB0.............................................................. 334
C.13 SM 326; DI 24 x DC 24 V, 6ES7 326–1BK00–0AB0 ........................................................... 335
C.14 SM 421; DI 32 x UC 120 V, 6ES7 421–1EL00–0AA0.......................................................... 336
C.15 SM 421; DI 16 x DC 24 V, 6ES7 421–7BH01–0AB0 ........................................................... 337
C.16 SM 421; DI 32 x DC 24 V, 6ES7 421–1BL00–0AB0............................................................ 338
C.17 SM 421; DI 32 x DC 24 V, 6ES7 421–1BL01–0AB0............................................................ 339
C.18 SM 322; DO 8 x DC 24 V/2 A, 6ES7 322–1BF01–0AA0 ..................................................... 340
C.19 SM 322; DO 32 x DC 24 V/0,5 A, 6ES7 322–1BL00–0AA0 ................................................ 341
C.20 SM 322; DO 8 x AC 230 V/2 A, 6ES7 322–1FF01–0AA0.................................................... 342
C.21 SM 322; DO 4 x DC 24 V/10 mA [EEx ib], 6ES7 322–5SD00–0AB0 .................................. 343
C.22 SM 322; DO 4 x DC 15 V/20 mA [EEx ib], 6ES7 322–5RD00–0AB0 .................................. 344
C.23 SM 322; DO 8 x DC 24 V/0.5 A, 6ES7 322–8BF00–0AB0 .................................................. 345
C.24 SM 322; DO 16 x DC 24 V/0.5 A, 6ES7 322–8BH01–0AB0................................................ 346
C.25 SM 332; AO 8 x 12 Bit, 6ES7 332–5HF00–0AB0 ................................................................ 347
C.26 SM 332; AO 4 x 0/4...20 mA [EEx ib], 6ES7 332–5RD00–0AB0 ......................................... 348
C.27 SM 422; DO 16 x AC 120/230 V/2 A, 6ES7 422–1FH00–0AA0 .......................................... 349
C.28 SM 422; DO 32 x DC 24 V/0.5 A, 6ES7 422–7BL00–0AB0 ................................................ 350
C.29 SM 331; AI 4 x 15 Bit [EEx ib]; 6ES7 331–7RD00–0AB0 .................................................... 351
C.30 SM 331; AI 8 x 12 Bit, 6ES7 331–7KF02–0AB0 .................................................................. 352
C.31 SM 331; AI 8 x 16 Bit; 6ES7 331–7NF00–0AB0 .................................................................. 353
C.32 SM 331; AI 8 x 16 Bit; 6ES7 331–7NF10–0AB0 .................................................................. 354
C.33 AI 6xTC 16Bit iso, 6ES7331-7PE10-0AB0 .......................................................................... 355

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C.34 SM331; AI 8 x 0/4...20mA HART, 6ES7 331-7TF01-0AB0 ..................................................356
C.35 SM 332; AO 4 x 12 Bit; 6ES7 332–5HD01–0AB0.................................................................358
C.36 SM332; AO 8 x 0/4...20mA HART, 6ES7 332-8TF01-0AB0.................................................359
Index................................................................................................................................................... 361
Tables
Table 3- 1 LED displays on the CPUs...........................................................................................................34
Table 3- 2 Possible states of the BUS1F, BUS5F, and BUS8F LEDs..........................................................40
Table 3- 3 Possible states of the LINK and RX/TX LEDs .............................................................................41
Table 4- 1 System modifications during operation........................................................................................48
Table 4- 2 Measures in PROFIsafe for error avoidance ...............................................................................54
Table 4- 3 Interface modules for use of single-channel switched I/O configuration at the PROFIBUS
DP interface .................................................................................................................................61
Table 4- 4 Bus modules for hot swapping.....................................................................................................61
Table 4- 5 Interface module for use of single-channel switched I/O configuration at the PROFINET
IO interface...................................................................................................................................63
Table 4- 6 Signal modules for redundancy ...................................................................................................72
Table 5- 1 CPU 410-5H.................................................................................................................................87
Table 5- 2 Meaning of the "BUSF" LED of the CPU 410-5H as DP master .................................................88
Table 7- 1 Causes of error leading to redundancy loss ................................................................................98
Table 7- 2 Overview of system states of the fault-tolerant system .............................................................105
Table 7- 3 Response to errors during the self-test......................................................................................110
Table 7- 4 Response to a recurring comparison error ................................................................................111
Table 7- 5 Reaction to checksum errors .....................................................................................................111
Table 7- 6 Hardware fault with one-sided call of OB 121, checksum error, second occurrence ................112
Table 8- 1 Properties of link-up and update functions ................................................................................115
Table 8- 2 PG commands for link-up and update .......................................................................................116
Table 8- 3 Typical values for the user program part ...................................................................................126
Table 9- 1 Protection levels of a CPU .........................................................................................................129
Table 9- 2 CPU properties in the factory settings .......................................................................................132
Table 9- 3 LED patterns ..............................................................................................................................133
Table 10- 1 Modifiable CPU parameters.......................................................................................................162
Table 12- 1 Accessory fiber-optic cable ........................................................................................................196
Table 12- 2 Specification of fiber-optic cables for indoor applications..........................................................197
Table 12- 3 Specification of fiber-optic cables for outdoor applications........................................................199

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Table 16- 1 Reading the diagnostics data with STEP 7................................................................................230
Table 16- 2 Event detection of the CPU 41xH as a DP master ....................................................................232
Table 16- 3 Comparison of the system status lists of PROFINET IO and PROFIBUS DP...........................233
Table 16- 4 Communication services of the CPUs .......................................................................................239
Table 16- 5 Availability of connection resources...........................................................................................240
Table 16- 6 SFBs for S7 Communication......................................................................................................242
Table 16- 7 Job lengths and "local_device_id" parameter ............................................................................250
Table 16- 8 For the monitoring times with redundant I/O..............................................................................287
Table 16- 9 Cyclic program processing.........................................................................................................288
Table 16- 10 Factors influencing cycle time ....................................................................................................290
Table 16- 11 Portion of the process image transfer time, CPU 410-5H..........................................................291
Table 16- 12 Extending the cycle time ............................................................................................................291
Table 16- 13 Operating system execution time at the cycle control point.......................................................292
Table 16- 14 Extended cycle time due to nested interrupts............................................................................292
Table 16- 15 Direct access of the CPUs to I/O modules in the central controller ...........................................299
Table 16- 16 Direct access of the CPUs to I/O modules in the expansion unit with local link ........................299
Table 16- 17 Direct access of the CPUs to I/O modules in the expansion unit with remote link, setting
100 m .........................................................................................................................................300
Table 16- 18 Example of calculating the response time .................................................................................301
Table 16- 19 Hardware and interrupt response times; maximum interrupt response time without com-
munication..................................................................................................................................304
Table 16- 20 Reproducibility of time-delay and cyclic interrupts of the CPUs ................................................307
Table 16- 21 Runtimes of the blocks for redundant I/Os.................................................................................308
Table C- 1 Interconnecting digital output modules with/without diodes.......................................................323
Figures
Figure 2-1 Overview ......................................................................................................................................23
Figure 2-2 Hardware of the S7-400H basic system ......................................................................................24
Figure 2-3 Hardware of the S7-400H basic system ......................................................................................25
Figure 3-1 Arrangement of the control and display elements on CPU 410-5H.............................................33
Figure 4-1 Overview: System structure for system modifications during operation ......................................50
Figure 4-2 Processing chain: acquire, process, output .................................................................................51
Figure 4-3 Safety-related communication .....................................................................................................53
Figure 4-4 Operating objectives of redundant automation systems..............................................................55

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Figure 4-5 Integrated automation solutions with SIMATIC............................................................................56
Figure 4-6 Example of redundancy in a network without error......................................................................57
Figure 4-7 Example of redundancy in a 1-out-of-2 system with error ...........................................................58
Figure 4-8 Example of redundancy in a 1-out-of-2 system with total failure .................................................58
Figure 4-9 Single-channel switched distributed I/O configuration at the PROFIBUS DP interface ..............60
Figure 4-10 Single-channel switched distributed I/O configuration at the PROFINET IO interface................63
Figure 4-11 S7-400H system with IO devices connected in system redundancy ...........................................66
Figure 4-12 System redundancy in different views .........................................................................................67
Figure 4-13 PN/IO with system redundancy....................................................................................................68
Figure 4-14 PN/IO with system redundancy....................................................................................................69
Figure 4-15 Configuration example of media redundancy ..............................................................................70
Figure 4-16 Fault-tolerant digital input module in 1-out-of-2 configuration with one encoder.........................78
Figure 4-17 Fault-tolerant digital input modules in 1-out-of-2 configuration with two encoders......................79
Figure 4-18 Fault-tolerant digital output modules in 1-out-of-2 configuration .................................................79
Figure 4-19 Fault-tolerant analog input modules in 1-out-of-2 configuration with one encoder......................81
Figure 4-20 Fault-tolerant analog input modules in 1-out-of-2 configuration with two encoders ....................83
Figure 4-21 Fault-tolerant analog output modules in 1-out-of-2 configuration ................................................84
Figure 7-1 Synchronizing the subsystems ..................................................................................................104
Figure 8-1 Meanings of the times relevant for updates...............................................................................118
Figure 8-2 Correlation between the minimum I/O retention time and the maximum inhibit time for
priority classes > 15 ...................................................................................................................121
Figure 12-1 Synchronization module.............................................................................................................190
Figure 12-2 Fiber-optic cables, installation using distribution boxes.............................................................200
Figure 13-1 SEC............................................................................................................................................201
Figure 16-1 Diagnostics with CPU 410 .........................................................................................................231
Figure 16-2 S7 routing...................................................................................................................................243
Figure 16-3 S7 routing gateways: PROFINET IO - DP - PROFINET IO.......................................................244
Figure 16-4 S7 routing: TeleService application example.............................................................................245
Figure 16-5 Data set routing..........................................................................................................................246
Figure 16-6 Example of an S7 connection ....................................................................................................252
Figure 16-7 Example that shows that the number of resulting partial connections depends on the con-
figuration ....................................................................................................................................254
Figure 16-8 Example of linking standard and fault-tolerant systems in a simple bus system.......................257
Figure 16-9 Example of linking standard and fault-tolerant systems in a redundant bus system.................258
Figure 16-10 Example of linking of standard and fault-tolerant systems in a redundant ring .........................258
Figure 16-11 Example of linking standard and fault-tolerant systems in a single bus system........................259

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Figure 16-12 Example of redundancy with fault-tolerant systems and a redundant bus system with re-
dundant standard connections ...................................................................................................260
Figure 16-13 Example of connecting a fault-tolerant system to a single-channel third-party system via
switched PROFIBUS DP............................................................................................................261
Figure 16-14 Example of connecting a fault-tolerant system to a single-channel third-party system via
PROFINET IO with system redundancy ....................................................................................261
Figure 16-15 Example of linking a fault-tolerant system to a single-channel third-party system ....................262
Figure 16-16 Example of redundancy with fault-tolerant system and redundant ring.....................................266
Figure 16-17 Example of redundancy with fault-tolerant system and redundant bus system.........................266
Figure 16-18 Example of fault-tolerant system with additional CP redundancy..............................................267
Figure 16-19 Example of redundancy with fault-tolerant system and fault-tolerant CPU ...............................268
Figure 16-20 Example of redundancy with fault-tolerant system and redundant bus system.........................270
Figure 16-21 Example of redundancy with a fault-tolerant system, redundant bus system and redun-
dant connection to the PC..........................................................................................................270
Figure 16-22 Sequence of link-up and update ................................................................................................275
Figure 16-23 Update sequence .......................................................................................................................276
Figure 16-24 Example of minimum signal duration of an input signal during the update ...............................277
Figure 16-25 Redundant one-sided and switched I/O.....................................................................................284
Figure 16-26 Flow chart for OB 1 ....................................................................................................................286
Figure 16-27 Elements and composition of the cycle time..............................................................................289
Figure 16-28 Formula: Influence of communication load ................................................................................293
Figure 16-29 Distribution of a time slice ..........................................................................................................293
Figure 16-30 Dependency of the cycle time on communication load..............................................................294
Figure 16-31 DP cycle times on the PROFIBUS DP network .........................................................................296
Figure 16-32 Shortest response time ..............................................................................................................297
Figure 16-33 Longest response time...............................................................................................................298
Figure A-1 MDT............................................................................................................................................312
Figure A-2 MTBF..........................................................................................................................................313
Figure A-3 Common Cause Failure (CCF) ..................................................................................................314
Figure A-4 Availability ..................................................................................................................................315
Figure C-1 Interconnection example for SM 331, Al 8 x 0/4...20mA HART.................................................325
Figure C-2 Interconnection example for SM 322, Al 8 x 0/4...20mA HART.................................................326
Figure C-3 Example of an interconnection with SM 321; DI 16 x DC 24 V..................................................327
Figure C-4 Example of an interconnection with SM 321; DI 32 x DC 24 V..................................................328
Figure C-5 Example of an interconnection with SM 321; DI 16 x AC 120/230 V.........................................329
Figure C-6 Example of an interconnection with SM 321; DI 8 x AC 120/230 V...........................................330

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Figure C-7 Example of an interconnection with SM 321; DI 16 x DC 24V ..................................................331
Figure C-8 Example of an interconnection with SM 321; DI 16 x DC 24V ..................................................332
Figure C-9 Example of an interconnection with SM 326; DO 10 x DC 24V/2A ...........................................333
Figure C-10 Example of an interconnection with SM 326; DI 8 x NAMUR....................................................334
Figure C-11 Example of an interconnection with SM 326; DI 24 x DC 24 V .................................................335
Figure C-12 Example of an interconnection with SM 421; DI 32 x UC 120 V ...............................................336
Figure C-13 Example of an interconnection with SM 421; DI 16 x 24 V........................................................337
Figure C-14 Example of an interconnection with SM 421; DI 32 x 24 V........................................................338
Figure C-15 Example of an interconnection with SM 421; DI 32 x 24 V........................................................339
Figure C-16 Example of an interconnection with SM 322; DO 8 x DC 24 V/2 A ...........................................340
Figure C-17 Example of an interconnection with SM 322; DO 32 x DC 24 V/0.5 A ......................................341
Figure C-18 Example of an interconnection with SM 322; DO 8 x AC 230 V/2 A .........................................342
Figure C-19 Example of an interconnection with SM 322; DO 16 x DC 24 V/10 mA [EEx ib].......................343
Figure C-20 Example of an interconnection with SM 322; DO 16 x DC 15 V/20 mA [EEx ib].......................344
Figure C-21 Example of an interconnection with SM 322; DO 8 x DC 24 V/0.5 A ........................................345
Figure C-22 Example of an interconnection with SM 322; DO 16 x DC 24 V/0.5 A ......................................346
Figure C-23 Example of an interconnection with SM 332, AO 8 x 12 Bit ......................................................347
Figure C-24 Example of an interconnection with SM 332; AO 4 x 0/4...20 mA [EEx ib] ...............................348
Figure C-25 Example of an interconnection with SM 422; DO 16 x 120/230 V/2 A ......................................349
Figure C-26 Example of an interconnection with SM 422; DO 32 x DC 24 V/0.5 A ......................................350
Figure C-27 Example of an interconnection with SM 331, AI 4 x 15 Bit [EEx ib]...........................................351
Figure C-28 Example of an interconnection with SM 331; AI 8 x 12 Bit ........................................................352
Figure C-29 Example of an interconnection with SM 331; AI 8 x 16 Bit ........................................................353
Figure C-30 Example of an interconnection with SM 331; AI 8 x 16 Bit ........................................................354
Figure C-31 Example of an interconnection AI 6xTC 16Bit iso......................................................................355
Figure C-32 Interconnection example 1 SM 331; AI 8 x 0/4...20mA HART...................................................356
Figure C-33 Interconnection example 2 SM 331; AI 8 x 0/4...20mA HART...................................................357
Figure C-34 Example of an interconnection with SM 332, AO 4 x 12 Bit ......................................................358
Figure C-35 Interconnection example 3 SM 332; AO 8 x 0/4...20mA HART.................................................359

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CPU 410-5H Process Automation/CPU 410 SMART
System Manual, 09/2014, A5E32631667-AB 15
Preface
1
1.1
Preface
Purpose of this manual
This manual represents a useful reference and contains information on operations,
descriptions of functions, and technical specifications of the CPU 410-5H Process
Automation and the CPU 410 SMART.
For information on installing and wiring this and other modules in order to set up an
automation system, refer to Manual
Automation System S7-400, Hardware and Installation .
Basic knowledge required
This manual requires general knowledge of automation engineering.
Moreover, it is assumed that the reader has sufficient knowledge of computers or equipment
similar to a PC, such as programming devices, running under the PCS 7 V8.1 Windows 7
(32/64-bit), Windows Server 2008, Windows Server 2008 R2 or Windows 7 operating
system. The PCS 7 Readme includes information on which operating system is suitable for
your PCS 7 configuration. The CPU 410-5H is configured using the PCS 7 software, and you
should thus be familiar in the handling of this software.
In particular when operating a CPU 410-5H in hazardous areas, observe the information on
electrical safety of electronic control systems provided in the appendix of the manual
Automation System S7-400, Hardware and Installation .
Scope of the manual
The manual is relevant to the following components:
●CPU 410–5H Process Automation; 6ES7 410-5HX08-0AB0 firmware version V8.1 and
higher
●CPU 410 SMART; 6ES7 410-5HN08-0AB0 firmware version V8.1 and higher

Preface
1.1 Preface
CPU 410-5H Process Automation/CPU 410 SMART
16 System Manual, 09/2014, A5E32631667-AB
Use of the current version of PCS 7 or the engineering tools is only required if the current
CPU has new functions compared to the last firmware version and you want to use these
functions. The same applies when an old CPU is replaced by a CPU with current firmware: If
you do not want to use any properties beyond the scope of the replaced CPU, you can use
the CPU with the old article number and old firmware version when configuring in HW
Config.
Note
CPU 410-5H and CPU 410 SMART
Except for the special features described in the section
Properties and technical
specifications of CPU 410 SMART
(Page 215), the CPU 410 SMART behaves like a CPU
410
-5H. Taking this section into consideration, the statements made in this manual about the
CPU 410
-5H also apply to the CPU 410 SMART.
Approvals
For details on certifications and standards, refer to Manual S7-400 Automation System,
Module Data
, section 1.1, Standards and Certifications. Here you will also find the technical
specification for the entire S7-400.
Online help
In addition to the manual, you will find detailed support on how to use the software in the
integrated online help system of the software.
The help system can be accessed using various interfaces:
●The
Help
menu contains several commands:
Contents
opens the Help index. You will find
help on fault-tolerant systems in
Configuring fault-tolerant systems
.
●
Using Help
provides detailed instructions on using the online help system.
●The context-sensitive help system provides information on the current context, for
example, on an open dialog or active window. You can call this help by clicking "Help" or
using the F1 key.
●The status bar provides a further form of context-sensitive help. It shows a short
description of each menu command when you position the mouse pointer over a
command.
●A short info text is also shown for the toolbar buttons when you hold the mouse pointer
briefly over a button.
If you prefer to read the information of the online help in printed form, you can print individual
topics, books or the entire help system.
Recycling and disposal
The CPU 410-5H and CPU 410 SMART contains environmentally compatible materials and
can be recycled. For ecologically compatible recycling and disposal of your old device,
contact a certificated disposal service for electronic scrap.

Preface
1.1 Preface
CPU 410-5H Process Automation/CPU 410 SMART
System Manual, 09/2014, A5E32631667-AB 17
Additional support
If you have any questions relating to the products described in this manual, and do not find
the answers in this documentation, please contact your Siemens partner at our local offices.
You will find information on who to contact at:
Contact partners (http://www.siemens.com/automation/partner)
A guide to the technical documents for the various SIMATIC products and systems is
available at:
Documentation (http://www.automation.siemens.com/simatic/portal/html_76/techdoku.htm)
You can find the online catalog and order system under:
Catalog (http://mall.automation.siemens.com/)
Functional Safety Services
Siemens Functional Safety Services is a comprehensive performance package that supports
you in risk assessment and verification all the way to plant commissioning and
modernization. We also offer consulting services for the application of fail-safe and fault-
tolerant SIMATIC S7 automation systems.
Additional information is available at:
Functional Safety Services (http://www.siemens.com/safety-services)
Submit your requests to:
Mail Functional Safety Services (mailto:[e-mail])
Training center
We offer a range of relevant courses to help you to get started with the SIMATIC S7
automation system. Please contact your local training center or the central training center.
Training (http://www.sitrain.com/index_en.html)
Technical Support
For technical support of all Industry Automation products, fill in and submit the online
Support Request:
Support Request (http://www.siemens.de/automation/support-request)
Service & Support on the Internet
In addition to our documentation, we offer a comprehensive online knowledge base on the
Internet at:
Service & Support (http://www.siemens.com/automation/service&support)
There you will find:
●The newsletter containing the latest information on your products.
●The latest documents via our search function in Service & Support.

Preface
1.2 Security information
CPU 410-5H Process Automation/CPU 410 SMART
18 System Manual, 09/2014, A5E32631667-AB
●A forum for global information exchange by users and specialists.
●Your local Automation representative.
●Information on field service, repairs and spare parts. Much more can be found under
"Services".
1.2
Security information
Siemens provides products and solutions with industrial security functions that support the
secure operation of plants, solutions, machines, equipment and/or networks. They are
important components in a holistic industrial security concept. With this in mind, Siemens’
products and solutions undergo continuous development. Siemens recommends strongly
that you regularly check for product updates.
For the secure operation of Siemens products and solutions, it is necessary to take suitable
preventive action (e.g. cell protection concept) and integrate each component into a holistic,
state-of-the-art industrial security concept. Third-party products that may be in use should
also be considered. You can find more information about industrial security on the Internet.
To stay informed about product updates as they occur, sign up for a product-specific
newsletter. You can find more information on the Internet.

Preface
1.3 Documentation
CPU 410-5H Process Automation/CPU 410 SMART
System Manual, 09/2014, A5E32631667-AB 19
1.3
Documentation
User documentation
The table below provides an overview of the descriptions of the various components and
options in the S7-400 automation system.
Topic
Documentation
See also
Setting up an automation sys-
tem
S7-400, Hardware and Installa-
tion
S7-400 Automation System
Hardware and Installation
(http://support.automation.sieme
ns.com/WW/view/en/1117849)
Data of the standard modules of
an automation system
S7-400 Module Data SIMATIC S7-400 S7-400 Auto-
mation System Module Data
(http://support.automation.sieme
ns.com/WW/view/en/1117740)
IM 153-2
IM 153-4 PN
ET 200M Distributed I/O Device SIMATIC ET 200M Distributed
I/O Device, HART Analog Mod-
ules
(http://support.automation.sieme
ns.com/WW/view/en/22063748)
IM 157
IM 153-2 FF
DP/PA Link and Y Link bus links
FF Link bus links
SIMATIC Bus Links DP/PA
Coupler, Active Field Distribu-
tors, DP/PA Link and Y Link
(http://support.automation.sieme
ns.com/WW/view/en/1142696)
Configuring, commissioning,
and operation of a PROFINET
IO system
PROFINET IO System Descrip-
tion
PROFINET system description
(http://support.automation.sieme
ns.com/WW/view/en/19292127)
Fail-safe systems
Configuring and programming of
fail-safe systems
Working with S7 F-Systems V
6.1
S7 F/FH Systems SIMATIC Industrial Software S7
F/FH Systems - Configuring and
Programming
(http://support.automation.sieme
ns.com/WW/view/en/2201072)
Solution concepts
Function mechanisms
Configurations of PCS 7
PCS 7 V8.1 technical documen-
tation
SIMATIC PCS 7 technical doc-
umentation
(http://www.automation.siemens
.com/mcms/industrial-
automation-systems-
simat-
ic/en/handbuchuebersicht/tech-
dok-pcs7/Seiten/Default.aspx)
Configuring hardware Configuring Hardware and
Communication Connections
with STEP 7
Configuring Hardware and
Communication Connections
with STEP 7
(http://support.automation.sieme
ns.com/WW/view/en/18652631)
System Modifications during
Stand-Alone Operation
Modifying the System during
Operation via CiR
Modifying the System during
Operation via CiR
(http://support.automation.sieme
ns.com/WW/view/en/14044916)

Preface
1.3 Documentation
CPU 410-5H Process Automation/CPU 410 SMART
20 System Manual, 09/2014, A5E32631667-AB