Siemens SIMATIC PCS 7 User manual

Preface, Contents
Hardware structure 1
Installation of the software 2
Commissioning 3
Configuration 4
Interface module TPM 478-2 5
Migration rack II 6
Appendices
Technical Data A
Abbreviations B
Literature index C
Glossary
SIMATIC
01/2007
C79000-G8076-C710-04
Process Control System PCS 7
Connecting TM I/O to PCS 7
Manual
SIMATIC

Index-2 Process Control System PCS 7Connecting TM I/O to PCS 7
C79000-G8076-C710-04
!Danger
indicates that death, severe personal injury or substantial property damage will result if proper precautions
are not taken.
!Warning
indicates that death, severe personal injury or substantial property damage can result if proper
precautions are not taken.
!Caution
indicates that minor personal injury can result if proper precautions are not taken.
Caution
indicates that property damage can result if proper precautions are not taken.
Notice
draws your attention to particularly important information on the product, handling the product, or to a
particular part of the documentation.
Qualified Personnel
Only qualified personnel should be allowed to install and work on this equipment. Qualified persons are
defined as persons who are authorized to commission, to ground and to tag circuits, equipment, and
systems in accordance with established safety practices and standards.
Correct Usage
Note the following:
!Warning
This device and its components may only be used for the applications described in the catalog or the
technical description, and only in connection with devices or components from other manufacturers which
have been approved or recommended by Siemens.
This product can only function correctly and safely if it is transported, stored, set up, and installed
correctly, and operated and maintained as recommended.
Trademarks
SIMATIC®, SIMATIC HMI®and SIMATIC NET®are registered trademarks of SIEMENS AG.
Third parties using for their own purposes any other names in this document which refer to trademarks
might infringe upon the rights of the trademark owners.
Safety Guidelines
This manual contains notices intended to ensure personal safety, as well as to protect the products and
connected equipment against damage. These notices are highlighted by the symbols shown below and
graded according to severity by the following texts:
We have checked the contents of this manual for agreement
with the hardware and software described. Since deviations
cannot be precluded entirely, we cannot guarantee full
agreement. However, the data in this manual are reviewed
regularly and any necessary corrections included in
subsequent editions. Suggestions for improvement are
welcomed.
Disclaim of LiabilityCopyright WSiemens AG 2007 All rights reserved
The reproduction, transmission or use of this document or its
contents is not permitted without express written authority.
Offenders will be liable for damages. All rights, including rights
created by patent grant or registration of a utility model or
design, are reserved.
Siemens AG
Bereich Automation and Drives
Geschaeftsgebiet Industrial Automation Systems
Postfach 4848, D- 90327 Nuernberg
©Siemens AG 2007
Technical data subject to change.
Siemens Aktiengesellschaft C79000-G8076-C710

iii
Connecting TM I/O to PCS 7
C79000-G8076-C710-04
Preface
This manual provides information on hardware components you can use to
interconnect an existing TELEPERM M I/O installation and the process con-
trol system SIMATIC PCS 7.
A combination of corresponding tools and programs enables communication
(Configuration and Operation) with the C&O system WinCC.
The information in this manual enables you to:
•commission the TPM 478-2 interface module
•operate migration rack II with PCS7/TM.
This documentation describes system-specific functions of the TPM 478-2
interface module and the use of migration rack II with PCS7/TM.
Topics included:
•Hardware assembly
•Software installation
•Commissioning
•Configuration
•TPM 478-2 interface module
•Migration rack II
•Technical data, abbreviations list, literatur listing, glossary.
The target group of readers is occupied in programming and process techno-
logy engineering.
Prerequisite is basic knowledge on handling PCs and
working with WinCC/TM.
Also required is knowledge of the process control system TELEPERM M,
PCS7 and SIMATIC S7.
A number of technical descriptions and manuals are available for consolida-
tion of this information. Please refer to the literature index in Appendix C.
Purpose of this
manual
Manual
content
Readers
Prerequisites

iv Connecting TM I/O to PCS 7
C79000-G8076-C710-04
Siemens offers you a number of training courses for the SIMATIC PCS7
automation system. For details, please contact your regional training center
or our central training center in:
1. D-90327 Nuremberg, Germany,
Phone 0911 / 895 3202 , Fax: 0911 / 895 3252
2. D-78187 Karlsruhe, Germany,
Phone 0721 / 595 2917, Fax: 0721 / 595 6087
Further support
Preface

v
Connecting TM I/O to PCS 7
C79000-G8076-C710-04
Available worldwide 24 hours:
Johnson City
Nuremberg
Singapore
SIMATIC Hotline
Worldwide (Nuremberg)
Technical Support
(Free Contact)
Local time: Mon.-Fri. 7:00 to 17:00
Phone: [phone]
Fax: [phone]
E-Mail: techsupport@
ad.siemens.de
GMT: +1:00
Worldwide (Nuremberg)
Technical Support
(fee based, only with
SIMATIC Card)
Local time: Mon.-Fri. 0:00 to 24:00
Phone: [phone]
Fax: [phone]
GMT: +01:00
Europe / Africa (Nuremberg)
Authorization
Local time: Mon.-Fri. 7:00 to 17:00
Phone: [phone]
Fax: [phone]
E-mail: authorization@
nbgm.siemens.de
GMT: +1:00
America (Johnson City)
Technical Support and
Authorization
Local time: Mon.-Fri. 8:00 to 19:00
Phone: [phone]
Fax: [phone]
E-mail: simatic.hotline@
sea.siemens.com
GMT: -5:00
Asia / Australia (Singapore)
Technical Support and
Authorization
Local time: Mon.-Fri. 8:30 to 17:30
Phone: [phone]
Fax: [phone]
E-mail: simatic.hotline@
sae.siemens.com.sg
GMT: +8:00
The languages of the SIMATIC Hotlines are generally German and English, in addition, French, Italian and Spanish are
spoken on the authorization hotline.
Automation and
Drives, Service &
Support
Preface

vi Connecting TM I/O to PCS 7
C79000-G8076-C710-04
In addition to our documentation, we offer our Know-how online on the In-
ternet under
http://www.ad.siemens.de/support
Here you will find:
•Current product information leaflets, FAQs (Frequently Asked Questions),
Downloads, Tipps and Tricks.
•A newsletter providing up-to-date information on our products.
•The Knowledge Manager helps you find the documents you need.
•Users and specialists from all over the world share information in the
forum.
•Your local customer service representative for Automation & Drives in
our customer service representative data bank.
•Information on field service, repairs, spare parts and more under
”Services”.
Service & Support
on the Internet
Preface

vii
Connecting TM I/O to PCS 7
C79000-G8076-C710-04
Contents
Preface iii. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Contents vii. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1 Hardware structure 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.1 Interface module TPM 478-2 1-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.2 Migration rack II 1-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 Installation of the software 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.1 Installing and uninstalling the block library 2-2. . . . . . . . . . . . . . . . . . . . . . . . . .
3 Commissioning 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.1 PCS7/TM in M7-400 installation technique 3-2. . . . . . . . . . . . . . . . . . . . . . . . . .
3.2 Supply conception 3-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 Configuration 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.1 General 4-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2 Configuration input 4-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2.1 Configuring the Memory Card of the FM456 4-3. . . . . . . . . . . . . . . . . . . . . . . . .
4.3 Example of how to use the block editor to configure I/O 4-5. . . . . . . . . . . . . . .
4.4 Extended module configuration 4-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.5 Special features for the configuration of transparent
connection modules 4-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.5.1 Configuration Notes for the Coupling Modules 6DS1333, 6DS1318 4-10. . . . .
4.6 Configuring the connection modules 6DS1310-8AA/-8AB 4-12. . . . . . . . . . . . .
4.7 Substitute configuration for 6DS1504-8AA / 6DS1505-8AA 4-13. . . . . . . . . . . .
4.7.1 Rules for PCS7/TM 4-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.7.2 Substitute configuration for PCS7/TM 4-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.8 Table of TELEPERM M modules for input at ”Module type” 4-15. . . . . . . . . . . .
4.9 FM456-4 configuration 4-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.9.1 Display elements of FM456-4 4-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.9.2 Diagnostics 4-18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.9.3 Reaction of the Output Modules in STOP or HALT State 4-19. . . . . . . . . . . . . .
4.9.4 Diagnosis Function: Time Measurement at FM456-4 4-19. . . . . . . . . . . . . . . . .
4.9.5 Mutual Monitoring between CPU and TPM 478-2 4-20. . . . . . . . . . . . . . . . . . . .

viii Connecting TM I/O to PCS 7
C79000-G8076-C710-04
5 Interface module TPM 478-2 5-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.1 Product overview 5-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2 Fields of application 5-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.3 Configuration 5-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.3.1 Configuration of the PCS7/TM with TELEPERM M I/O 5-9. . . . . . . . . . . . . . .
5.4 Operating method 5-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.4.1 Implementation of TELEPERM M I/O in PCS7/TM 5-14. . . . . . . . . . . . . . . . . . .
5.5 Configuration 5-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.6 I/O modules 5-18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.7 Note on orders 5-20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6 Migration rack II 6-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.1 Product overview 6-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.1.1 Use of the migration rack on PCS7/TM 6-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.2 Wiring 6-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.2.1 Supply and signals 6-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.2.2 Grounding 6-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.3 I/O bus system 6-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.3.1 Configuration of the I/O bus system 6-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.3.2 Configuration of the I/O slots 6-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.4 Connector pin-out 6-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.4.1 Pin-out 64-pole G-connector, all slots 6-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.4.2 Pin-out X30, 25-pole Sub-D connector, process control signals 6-10. . . . . . . .
6.4.3 Migration rack connector panel 6-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.4.4 Rear view of the bus PCB 6-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.4.5 Front view of the bus PCB 6-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.5 Operating conditions 6-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A Technical Data A-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A.1 Technical data of the TPM 478-2 interface module A-2. . . . . . . . . . . . . . . . . . .
A.2 TPM 478-2 connector and socket pin-out A-4. . . . . . . . . . . . . . . . . . . . . . . . . . .
B Abbreviations B-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C Literature List C-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Glossary Glossary-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Contents

1-1
Connecting TM I/O to PCS 7
C79000-G8076-C710-04
Hardware structure
This chapter provides brief information which gives you a quick overview of
the TPM 478-2 interface module and migration carrier II.
In Chapter you find on page
1.1 Interface module TPM 478-2 1-2
1.2 Migration carrier II 1-4
Contents
1

1-2 Connecting TM I/O to PCS 7
C79000-G8076-C710-04
1.1 Interface module TPM 478-2
TPM 478-2 is an interface module with the M7-400 technological structure
of the SIMATIC M7 product family. It represents an expansion unit for the
central module FM 456-4, and it is used in the PCS7/TM PLC.
The following functions are integrated in the TPM 478-2 interface module:
•TELEPERM M I/O functionality.
A highly efficient processor controls the access functions to TELE-
PERM M I/O modules via a periodically updated process image. This
process image fetches input process data it writes them to the outputs of
the hardware I/O.
Process image data is transferred from the TPM 478-2 to the user pro-
gram via driver blocks.
•two I/O bus interfaces for the TELEPERM M basic and expansion cabinet
•I/O bus logic supply with a +5 V bus.
The TPM 478-2 interface module interconnects existing TELEPERM M I/O
hardware of the basic and expansion cabinet of an AS 220/230/235 system.
Here, the basic central unit is replaced with a preinstalled module rack - na-
mely the migration rack - which contains a system PCS7/TM and the add-on
components TPM 478-2 and FM456-4.
It provides the I/O bus connections A and B for existing expansion units.
Data are exchanged with existing expansion unit via I/O bus A and B of
TPM 478-2. See Figure 1-1.
PROFIBUS /
Ethernet
PCS7/TM
I/O bus A
I/O bus B Basic cabinet
Expansion cabinet
TPM478-2
Migration rack
AS 220/230/235
PS
CPU416-2DP
TPM Interface module
PS Power supply module
CPU Central module
FM456-4 CP443-5 /
CP443-1
Figure 1-1 TPM 478-2 for the connection of TELEPERM M I/O modules
General
functions
Connecting
TELEPERM M I/O
Hardware structure

1-3
Connecting TM I/O to PCS 7
C79000-G8076-C710-04
All connection and display elements of the TPM 478-2 interface module are
mounted on the front panel of the module, see Figure 1-2.
LED displays
connection
TPM 478-2
connection
connection
Connecting cable
+
SV: 5 V-Bus
-
I/O bus
I/O bus A
I/O bus B
FEA
PAA
PAB
RUN
X2
Figure 1-2 Arrangement of the connections and display modules of the TPM 478-2
interface module
Elements of
TPM 478-2
Hardware structure

1-4 Connecting TM I/O to PCS 7
C79000-G8076-C710-04
For additional information on the TPM 478-2 interface modules refer to
Chapter 5 in this manual.
1.2 Migration rack II
The migration rack II is a preassembled module rack with the dimensions of
the panel-mount system ES 902 which is required for operating a PCS7/TM
system in a TELEPERM M cabinet.
All system components such as DC power supply, CPU, FM456-4 and I/O
bus interface can be operated on the short backplane PCB.
The additional five I/O slots the migration rack II is equipped with can hold
TELEPERM M I/O modules taken from an AS 220 S-/AS 235 basic unit and
can be assigned freely to I/O bus A and B.
For the PCS7/TM system, migration rack II provides five TELEPERM M
I/O slots for the installation of TELEPERM M I/O modules taken from an
AS 220 S-/AS 235 basic unit. All slots can be operated on I/O bus A or split
up in a 3 : 2 ratio between I/O bus A and B.
Other features are the simplified wiring (supply and process control messa-
ges) and the possibility of replacing certain mechanical components (connec-
tors) in case of error.
The wiring features no loose ends, that is, installation technique is adapted to
AS 230/235.
The integrated backplane also provides distribution of specific signals and
voltages. Process control monitoring signals are now terminated on the back-
plane terminal blocks - same as in the AS 235. The existing cabinet wiring
can be used almost completely.
The front panel fuses for L+ (16A) and PM (4A) can be replaced from the
front in case of error. Due to the fastening mechanism on the side, the I/O bus
connectors can be replaced in case of error without having to remove the mi-
gration rack.
The migration rack is equipped with by-pass capacitors for the L+, PM, M24
and MZ voltages for the derivation of electrical disturbance to the shielding
and, thus to the metal case.
All position addresses of the slots are equipped with filters.
Information
General
Features
Hardware structure

1-5
Connecting TM I/O to PCS 7
C79000-G8076-C710-04
Further information on Migration Rack II is found in Chapter 6 of this ma-
nual.
PS
405
CPU
416 FM
456
CP
443
TPM
478-2
SIMATIC PCS7
with
TELEPERM M I/O
Figure 1-3 Front view of migration rack II
Information
Hardware structure

1-6 Connecting TM I/O to PCS 7
C79000-G8076-C710-04
Hardware structure

2-1
Connecting TM I/O to PCS 7
C79000-G8076-C710-04
Installation of the software
In this Chapter you are shown how you can install the block library with the
help of a setup routine.
This chapter treats the following topics:
In Chapter you find on Page
2.1 Installing and uninstalling the block library 2-2
Software operating requirements are:
•Windows NT operating system
•Programming device or PC with
– 80486 CPU (or higher) and
– RAM memory
•Color monitor, keyboard and mouse, supported by Microsoft Windows
NT
•STEP 7 Basic software
•Free space u4 Mbytes on hard disk drive
•At least 1 MB space on drive C: for
Setup (Setup files are deleted after installation).
Overview
In this Chapter
Installation requi-
rements
2

2-2 Connecting TM I/O to PCS 7
C79000-G8076-C710-04
2.1 Installing and uninstalling the block library
The setup program of the included software installs the block library automa-
tically.
Installation is menu controlled. Call the setup program with the usual
Windows 95 standard procedure for software installation.
Setup installs the basic blocks for the PLC in the PCS 7 Basis Blocks library
of the SIMATIC S7 catalog.
If setup detects an existing installation on the system, a corresponding
prompt pops up, offering you the following choices:
•Abort installation (in order to uninstall the old software version under
Windows95 and the restart installation) or
•Continue installation and overwrite the old version with the new one.
Considering clean software maintenance, you should uninstall an existing old
version before you install the new one. To simply overwrite an old version
and then to uninstall it bears the risk that some components of the old instal-
lation might not be deleted.
Details on installing and uninstalling STEP 7 software is found in
Chapter 2.3 of the STEP 7 documentation /31/.
Setup also installs the screen software in systems operating with WinCC.
Information on the use of blocks in CFC is found in the ”CFC for S7 and M7,
Graphic connection of technological functions” User Manual.
Overview
If a Software ver-
sion is already
installed ...
Installing or unin-
stalling
STEP 7-Software
Systems with
WinCC
Use in CFC
Installation of the software

3-1
Connecting TM I/O to PCS 7
C79000-G8076-C710-04
Commissioning
In this Chapter you are shown how to
•mount the modules on profile rails
•commission a PCS7/TM.
This is found on the following pages:
In Chapter you find on Page
3.1 PCS7/TM in M7-400 installation technique 3-2
3.2 Supply conception 3-7
In this Chapter
Contents
3

3-2 Connecting TM I/O to PCS 7
C79000-G8076-C710-04
3.1 PCS7/TM in M7-400 installation technique
A PCS7/TM PLC in M7-400 installation technique is mounted in the same
way as a SIMATIC M7-400 PLC.
Note
Details on how to mount a SIMATIC M7-400 PLC are found in Manual /31/.
Here a brief overview of the most important steps for mounting a PCS7/TM
PLC in M7-400 installation technique:
Mount the module rack in the cabinet.
Ground the module rack.
Remove the covers of the power supply and central module.
Remove the covers and insert the interface modules in the central module.
See also Figure 3-1 showing the arrangement:
•IF 961-DIO for acquisition and output of process control signals, e.g. ca-
binet lamp
•IF 962-COM for diagnostics with remote terminal
Note when inserting an interface module:
•Hold the interface module on the longitudinal sides of the front panel
•Slide the ends of the interface module into the lower and upper guide rail
of the slot
•Slide it in slowly until the front panel of the interface module is flush on
the module slot frame
•Screw-tighten the interface module.
!Warning
Always switch off power when you insert or remove an interface module.
The bottom of interface modules is not covered. This is why you must al-
ways conform with EGB rules when handling these modules.
Introduction
M7-400 mounting
and installatio
technology
Mounting modules
Grounding modu-
les
Removing the co-
ver hood
Installing interface
modules
Commissionin
g

3-3
Connecting TM I/O to PCS 7
C79000-G8076-C710-04
Remove the cover from the expansion connector on the TPM 478-2 interface
and the cover of the expansion socket on the central module FM 456-4.
See Figure 3-1.
TPM 478-2
Expansion
connector
FM 456-4
Expansion socket
Figure 3-1 Positions of the expansion connector/socket with corresponding cover.
Removing connec-
tor/socket covers
Commissionin
g

3-4 Connecting TM I/O to PCS 7
C79000-G8076-C710-04
Place the central module FM 456-4 and the TPM 478-2 interface module on a
plane surface and carefully plug them together. Engage the included connec-
tion clamps on the upper and lower side of the modules.
TPM 478-2
plane surface
FM 456-4
Figure 3-2 Interconnecting the central module and interface module
Remove the blind covers from the module rack slots required.
Interconnecting
modules
Blind covers
Commissionin
g