Siemens Simatic S7-1500 User manual

SIMATIC TOP connect for S7-1500 and
ET200MP
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SIMATIC TOP connect for S7-1500
and ET200MP
Manual
Preface
Safety notes
1
Documentation guide
2
Product overview
3
Connecting
4
Wiring SIMATIC TOP
connect to the I/O modules
5
Technical specifications
6
Environment
7
Dimension drawings
A
Circuit diagrams
B
Spare parts / Accessories
C
Service and Support
D

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Ⓟ
04/2014 Subject to change
Copyright © Siemens AG .
All rights reserved
Legal information
Warning notice system
This manual contains notices you have to observe in order to ensure your personal safety, as well as to prevent
damage to property. The notices referring to your personal safety are highlighted in the manual by a safety alert
symbol, notices referring only to property damage have no safety alert symbol. These notices shown below are
graded according to the degree of danger.
DANGER
indicates that death or severe personal injury will result if proper precautions are not taken.
WARNING
indicates that death or severe personal injury may result if proper precautions are not taken.
CAUTION
indicates that minor personal injury can result if proper precautions are not taken.
NOTICE
indicates that property damage can result if proper precautions are not taken.
If more than one degree of danger is present, the warning notice representing the highest degree of danger will
be used. A notice warning of injury to persons with a safety alert symbol may also include a warning relating to
property damage.
Qualified Personnel
The product/system described in this documentation may be operated only by
personnel qualified
for the specific
task in accordance with the relevant documentation, in particular its warning notices and safety instructions.
Qualified personnel are those who, based on their training and experience, are capable of identifying risks and
avoiding potential hazards when working with these products/systems.
Proper use of Siemens products
Note the following:
WARNING
Siemens products may only be used for the applications described in the catalog and in the relevant technical
documentation. If products and components from other manufacturers are used, these must be recommended
or approved by Siemens. Proper transport, storage, installation, assembly, commissioning, operation and
maintenance are required to ensure that the products operate safely and without any problems. The permissible
ambient conditions must be complied with. The information in the relevant documentation must be observed.
Trademarks
All names identified by ® are registered trademarks of Siemens AG. The remaining trademarks in this publication
may be trademarks whose use by third parties for their own purposes could violate the rights of the owner.
Disclaimer of Liability
We have reviewed the contents of this publication to ensure consistency with the hardware and software
described. Since variance cannot be precluded entirely, we cannot guarantee full consistency. However, the
information in this publication is reviewed regularly and any necessary corrections are included in subsequent
editions.

SIMATIC TOP connect for S7-1500 and ET200MP
Manual, 3
Preface
Purpose of this documentation
This documentation provides important information on wiring the I/O modules (input and
output modules) of the S7-1500 SIMATIC controller and the ET 200MP modular I/O system
with SIMATIC TOP connect system cabling.
Basic knowledge required
General knowledge about automation is needed to understand this documentation.
Scope of this documentation
This documentation applies to all SIMATIC products in the S7-1500 product family with
ET 200MP.
Conventions
Please also observe the notes marked as follows:
Note
A note contains important information about the product described,
about handling the
product or about a specific section of the documentation that requires particular attention.
Recycling and disposal
The products can be recycled as their components are low in pollutants. For the
environmentally friendly recycling and disposal of your old device, please contact a
certificated disposal service for electronic scrap.
Additional support
●You will find information on the technical support service in the appendix to this
documentation.
●The technical documentation for the various SIMATIC products and systems is available
on the Internet (http://www.siemens.com/simatic-tech-doku-portal).
●You will find the online catalog and online ordering system on the Internet
(http://mall.automation.siemens.com).

SIMATIC TOP connect for S7-1500 and ET200MP
Manual, 5
Table of contents
Preface ........................................................................................................................................3
1 Safety notes .................................................................................................................................7
2 Documentation guide .....................................................................................................................9
3 Product overview......................................................................................................................... 11
3.1 What is SIMATIC TOP connect system cabling?..................................................................... 11
3.2 Components........................................................................................................................... 14
3.3 Connectable I/O modules ....................................................................................................... 17
4 Connecting ................................................................................................................................. 19
4.1 Safety regulations................................................................................................................... 19
4.2 Wiring rules ............................................................................................................................ 21
4.3 Connecting components......................................................................................................... 22
4.3.1 Assembling the round-sheath ribbon cable ............................................................................. 24
4.3.2 Wiring the front connector module .......................................................................................... 26
4.3.3 Connecting the connecting cable and supply voltage to the front connector module................ 27
4.3.4 Connecting the connecting cable to the terminal module......................................................... 31
4.3.5 Connecting the actuators/sensors to the terminal module ....................................................... 32
4.4 Labeling terminal modules...................................................................................................... 32
5 Wiring SIMATIC TOP connect to the I/O modules............................................................................ 33
5.1 SIMATIC TOP connect components and selection guide ........................................................ 33
5.2 Note on connecting digital I/O modules................................................................................... 39
5.3 Note on connecting the 2 A output module ............................................................................. 41
5.4 Note on connecting analog I/O modules ................................................................................. 43
5.5 Shield connection of the signal cables .................................................................................... 45
6 Technical specifications ............................................................................................................... 49
6.1 Standards and approvals........................................................................................................ 49
6.2 Electromagnetic compatibility ................................................................................................. 51
6.3 Shipping and storage conditions ............................................................................................. 52
6.4 Mechanical and climatic ambient conditions............................................................................ 52
6.5 Technical specifications for front connector modules .............................................................. 54
6.6 Technical specifications for connecting cables........................................................................ 56
6.7 Technical specifications for terminal modules ......................................................................... 57
7 Environment ............................................................................................................................... 69
A Dimension drawings .................................................................................................................... 71

Table of contents
SIMATIC TOP connect for S7-1500 and ET200MP
6Manual,
A.1 Front connector modules.........................................................................................................71
A.2 Terminal modules for 16-pin connecting cable.........................................................................80
A.3 Terminal modules for 50-pin connecting cable.........................................................................86
B Circuit diagrams.......................................................................................................................... 89
B.1 Circuit diagrams for front connector modules...........................................................................89
B.2 Circuit diagrams, terminal modules for 16-pin connecting cable ...............................................94
B.3 Circuit diagrams, terminal modules for 50-pin connecting cable .............................................105
C Spare parts / Accessories ...........................................................................................................111
C.1 Accessories ..........................................................................................................................111
D Service and Support...................................................................................................................113
Index ........................................................................................................................................115

SIMATIC TOP connect for S7-1500 and ET200MP
Manual, 7
Safety notes
1
Warning
When electrical devices are operated, parts of these devices will necessarily carry
dangerous voltages.
If these devices are not correctly handled/operated, this can result in death or severe injury
as well as significant material damage.
Only appropriately qualified personnel may work on or in the vicinity of this device.
This device can only function correctly and safely if it is transported, stored, set up and
installed correctly.
Before installation or maintenance work can begin, the system's main switch must be
switched off and measures taken to prevent it being switched on again.
If this instruction is not followed, touching live parts can result in death or serious injury.

SIMATIC TOP connect for S7-1500 and ET200MP
Manual, 9
Documentation guide
2
Introduction
The documentation for the SIMATIC products is modular in structure and covers a wide
range of subjects relating to your automation system.
The complete documentation for SIMATIC products in the S7-1500 product family with
ET 200MP comprises the system manual, the function manuals and the product manuals.
The TIA Selection Tool will also help you to select and order the right system cabling for your
SIMATIC S7-1500.

Documentation guide
SIMATIC TOP connect for S7-1500 and ET200MP
10 Manual,
Overview of documentation for SIMATIC S71500 / ET200MP
The tables below set out the documentation for SIMATIC S7-1500 / ET 200MP with the
relevant content for system cabling.
Table 2- 1 Documentation for SIMATIC S7-1500 / ET 200MP system cabling
Subject
Documentation
Key content
System description S7-1500 Automation System system manual
(http://support.automation.siemens.com/WW/view/en/59191792)
ET 200MP distributed I/O device system manual
(http://support.automation.siemens.com/WW/view/en/59193214)
•Connecting
Digital modules DQ 16 x 24 V DC/0.5A ST digital output module
(http://support.automation.siemens.com/WW/view/en/59193401)
•Block diagram
•Connecting
•Technical specifications
•Dimension drawings
DQ 32 x 24 V DC/0.5A ST digital output module
(http://support.automation.siemens.com/WW/view/en/59193400)
DQ 8 x 24 V DC/2A HF digital output module
(http://support.automation.siemens.com/WW/view/en/59193089)
DI 16 x 24 V DC HF digital input module
(http://support.automation.siemens.com/WW/view/en/59193001)
DI 16 x 24 V DC SRC BA digital input module
(http://support.automation.siemens.com/WW/view/en/59191844)
DI 32 x 24 V DC HF digital input module
(http://support.automation.siemens.com/WW/view/en/59192896)
Analog modules AQ 4 x U/I ST analog output module
(http://support.automation.siemens.com/WW/view/en/59191850)
•Block diagram
•Connecting
•Technical specifications
•Dimension drawings
AQ 8 x U/I HS analog output module
(http://support.automation.siemens.com/WW/view/en/59193551)
AI 8 x U/I/RTD/TC ST analog input module
(http://support.automation.siemens.com/WW/view/en/59193205)
AI 8 x U/I HS analog input module
(http://support.automation.siemens.com/WW/view/en/59193206)
SIMATIC manuals
The latest versions of all SIMATIC manuals are available on the Internet
(http://www.siemens.com/automation/service&support) for download.

SIMATIC TOP connect for S7-1500 and ET200MP
Manual, 11
Product overview
3
3.1
What is SIMATIC TOP connect system cabling?
Introduction
SIMATIC TOP connect system cabling is an efficient way to connect the I/O modules (input
and output modules) of the SIMATIC controller S7-1500 I/O and ET 200MP.
SIMATIC TOP connect uses standardized connectors and reduces the wiring work required.
There are two types of connection:
●Fully modular connection:
for connecting sensors and actuators in the field.
●Flexible connection:
for simple wiring inside the control cabinet.
Area of application
SIMATIC TOP connect allows you to wire actuators and sensors "locally" to one or more
terminal modules. Connection to the I/O modules takes place via connecting cable.
Figure 3-1 SIMATIC TOP connect with an S7-1500

Product overview
3.1 What is SIMATIC TOP connect system cabling?
SIMATIC TOP connect for S7-1500 and ET200MP
12 Manual,
Installation
System cabling with SIMATIC TOP connect always consists of the following components:
●The front connector module with either
–One or more 16-pin male connectors for connecting the connecting cables or
–One 50-pin male connector for connecting the connecting cable
●One or more terminal modules
●One or more connecting cables with plug connectors at the ends
Fully modular connection
The fully modular connection for the system cabling comprises the following components:
●A front connector module ①for connection to the SIMATIC S7-1500 or
ET200MP I/O modules
●Connecting cables ②, pre-assembled or by the meter
●Terminal modules ③, for connection to sensors and actuators in the field ④
Figure 3-2 Fully modular connection
The components can be combined to suit the application and connected with simple plug-in
connections. The terminal modules are used instead of conventional terminal blocks and act
as the interface to the sensors and actuators.
In addition to the terminal module versions with screw-type terminals or push-in systems,
there are also versions with LED signaling and signal conditioning, for example, from
230 V AC to 24 V DC.

Product overview
3.1 What is SIMATIC TOP connect system cabling?
SIMATIC TOP connect for S7-1500 and ET200MP
Manual, 13
Flexible connection
The flexible connection for the system cabling comprises a front connector module ①for
connection to the SIMATIC S7-1500 or ET200MP digital I/O modules. The front connector is
already wired with 20 or 40 single wires ②which connect the SIMATIC S7-1500 or
ET200MP digital I/O modules directly to the sensors and actuators in the control cabinet.
Figure 3-3 Flexible connection
The single wires (cross-section: 0.5 mm²) are available in different lengths and in the
following designs:
●H05V-K cable (PVC insulation)
●H05Z-K (halogen-free insulation)
●UL/CSA approval

Product overview
3.2 Components
SIMATIC TOP connect for S7-1500 and ET200MP
14 Manual,
3.2
Components
This section gives you an overview of the components of the SIMATIC TOP connect system
cabling.
Components for fully modular connection
The table below lists the components for fully modular connection of the
SIMATIC TOP connect system cabling.
Table 3- 1 Components for fully modular connection of SIMATIC TOP connect
Component
Function
Figure
Front connector module Front connector modules are modified
front connectors and are plugged into
the I/O module to be wired. The front
connector module has IDC female
connectors for connecting the
connecting cables. Front connector
modules are available in the following
designs:
•For DI/DO digital modules (power
supply with push-in or screw-type
terminals)
•For 2A digital output 1 x 8 DO
(power supply with push-in or screw-
type terminals)
•For analog modules

Product overview
3.2 Components
SIMATIC TOP connect for S7-1500 and ET200MP
Manual, 15
Component
Function
Figure
Connecting cable Connecting cables connect the front
connector module with the terminal
modules. Connecting cables are
available in the following versions:
•16-pin and 50-pin round cable
(shielded or unshielded), pre-
assembled¹
Max. length 10 m
•16-pin round-sheath ribbon cable
(shielded or unshielded), for
assembly by the user²
Max. length 30 m
•2 x 16-pin round-sheath ribbon
cable (unshielded), for assembly by
the user²
Max. length 30 m
¹Pre-assembled: One IDC connector (insulation
displacement connector) (flat socket) at each end.
²For assembly by the user. See "Assembling round-sheath
ribbon cables".
Terminal module Digital and analog terminal modules in
S7-1500 design are available for
connecting the I/O signals. These are
attached to the standard mounting rail.
The terminal modules are available in
the following connecting systems:
•Push-in system
•Screw-type terminals
All digital terminal modules also have
LED for channel display.

Product overview
3.2 Components
SIMATIC TOP connect for S7-1500 and ET200MP
16 Manual,
Accessories for fully modular connection
The following components can be ordered separately or as spare part:
Table 3- 2 Accessories for fully modular connection of SIMATIC TOP connect
Accessories
Function
Labels Labels (20 x 7 mm, pale turquoise) in the
S7-1500 design are available for labeling the
terminal modules.
Shield plate The shield plate can be fitted onto the terminal
module for analog signals. The terminal module
with the fitted shield plate is fastened to the
standard mounting rail.
Shield connection clamps for the shield plate The shield connection clamps provide contact
plating for cable shields on the shield plate.
IDC connector (insulation displacement
connector), 16-pin
Round-sheath ribbon cables only:
The IDC connector (insulation displacement
connector) is crimped onto the pre-assembled
round-sheath ribbon cable.
Crimping pliers for IDC connectors (insulation
displacement connectors)
The IDC connectors (insulation displacement
connectors) are crimped onto the pre-assembled
round-sheath ribbon cable using the crimping
pliers.
Components for flexible connection
The table below lists the components for flexible connection of the SIMATIC TOP connect
system cabling.
Table 3- 3 Components for flexible connection of SIMATIC TOP connect
Component
Function
Figure
Front connector with single
wires
Up to 16 or 32 digital input and
output channels can be
connected directly to the I/O
with a front connector with
single wires. The single wires
are fitted with screw-type
contacts in the front connector
and are cut off straight at the
other end.
The wires can be easily
identified as they are marked at
regular intervals in accordance
with the pin designations on the
front connector. The front
connectors are available in the
following designs:
•For 16 DI/DO modules
•For 32 DI/DO modules

Product overview
3.3 Connectable I/O modules
SIMATIC TOP connect for S7-1500 and ET200MP
Manual, 17
3.3
Connectable I/O modules
The tables below list all input and output modules of the SIMATIC controller S7-1500 and
ET 200MP that can be connected with the SIMATIC TOP connect fully modular connection.
Table 3- 4 Connectable I/O modules, for terminal modules with 16-pin connecting cables
I/O module (digital, analog)
Article number
DI 16x24 VDC, 0.05 ms … 20 ms, type 3
6ES7 521-1BH00-0AB0
DI 16x24 VDC, 3 ms type 1; sourcing 6ES7 521-1BH50-0AB0
DI 32x24 VDC, 0.05 ms … 20 ms, type 3
6ES7 521-1BL00-0AB0
DO 16x24 VDC, 0.5 A, substitute values
6ES7 522-1BH00-0AB0
DQ 8x24 VDC, 2 amperes
6ES7 522-1BF00-0AB0
DO 32x24 VDC, 0.5 A, substitute values
6ES7 522-1BL00-0AB0
AO 4xU, I, 16-bit, 0.3 %
6ES7 532-5HD00-0AB0
AQ 8xU, I, HS correct
6ES7 532-5HF00-0AB0
AI 8xU, I, 14-bit, 0.3 %
6ES7 531-7NF10-0AB0
AI 8xU, I, R, RTD, TC, 16-bit, 0.3 %
6ES7 531-7KF00-0AB0
Table 3- 5 Connectable I/O modules, for terminal modules with 50-pin connecting cables
I/O module (digital, analog)
Article number
DI 16x24 VDC, 0.05 ms … 20 ms, type 3
6ES7 521-1BH00-0AB0
DI 16x24 VDC, 3 ms type 1; sourcing
6ES7 521-1BH50-0AB0
DI 32x24 VDC, 0.05 ms … 20 ms, type 3
6ES7 521-1BL00-0AB0
DO 16x24 VDC, 0.5 A, substitute values
6ES7 522-1BH00-0AB0
DO 32x24 VDC, 0.5 A, substitute values 6ES7 522-1BL00-0AB0
AO 4xU, I, 16-bit, 0.3 %
6ES7 532-5HD00-0AB0
AQ 8xU, I, HS correct 6ES7 532-5HF00-0AB0
AI 8xU, I, 14-bit, 0.3 %
6ES7 531-7NF10-0AB0
AI 8xU, I, R, RTD, TC, 16-bit, 0.3 % 6ES7 531-7KF00-0AB0

SIMATIC TOP connect for S7-1500 and ET200MP
Manual, 19
Connecting
4
4.1
Safety regulations
Introduction
When used in plants or systems, SIMATIC TOP connect system cabling is subject to special
rules and regulations in line with the area of application.
This section provides an overview of the most important rules for connecting SIMATIC TOP
connect.
Rules and regulations governing the integration of the S7-1500 into a plant or system can
also be found under "Rules and regulations" in the S7-1500 system manual
(http://support.automation.siemens.com/WW/view/en/59191792).
Specific application
Please observe the safety and accident prevention regulations that apply to specific
applications, for example, the machinery directives.
Supply voltage
Please note the following points about line voltage:
●For stationary plants and systems without an all-pole line disconnector, there must be a
disconnector unit (all-pole) fitted in the building installation.
●Any fluctuation/deviation in the line voltage from the rated value must be within the
permitted tolerance for all S7-1500 electric circuits.
24 V DC supply
Please note the following points for 24 V DC supply:
●Power supplies for 24 V DC must have secure electrical isolation in accordance with IEC
60364-4-41.
●Surge arrestors must be fitted to protect against lighting and overvoltage.
You will find components for lightning and overvoltage protection in the "Designing
interference-free controllers" function manual
(http://support.automation.siemens.com/WW/view/en/59193566).

Connecting
4.1 Safety regulations
SIMATIC TOP connect for S7-1500 and ET200MP
20 Manual,
Protection from electric shock
The S7-1500 automation system mounting rail must be connected (conductive connection)
to the protective conductor to prevent electric shock.
Protection from external electrical interference
The following section details the points to note to prevent electrical interference and faults:
●You must make sure that each plant or system fitted with an S7-1500 is connected to a
protective conductor with a sufficient cross-section to deal with electromagnetic
interference.
●For supply, signal and bus cables, you must make sure that the cables are correctly
routed and installed.
●For signal and bus cables, you must make sure that an open circuit or crossover will not
result in undefined plant or system states.
Reference
Further information is available in the "Designing interference-free controllers" function
manual.