Siemens CPU 410-5H Process Automation 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
10/2013
A5E32631667
-AA
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-AA
Ⓟ
11/2013 Technical data subject to change
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editions.

CPU 410-5H Process Automation/CPU 410 SMART
System Manual, 10/2013, A5E32631667-AA 3
Table of contents
1 Preface ................................................................................................................................................. 15
1.1 Preface.........................................................................................................................................15
1.2 Security information .....................................................................................................................18
1.3 Documentation .............................................................................................................................18
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......................................................................................................................27
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 ...............................................................................................................................28
2.10 Scaling and licensing (scaling concept).......................................................................................30
3 Structure of the CPU 410-5H................................................................................................................. 31
3.1 Operator controls and display elements on the CPU 410-5H......................................................31
3.2 Monitoring functions of the CPU 410-5H .....................................................................................35
3.3 Status and error displays .............................................................................................................37
3.4 PROFIBUS DP interface (X1) ......................................................................................................41
3.5 PROFINET IO interface (X5, X8) .................................................................................................41
3.6 Overview of the parameters for the CPU 410-5H ........................................................................44
4 I/O configuration variants ...................................................................................................................... 45
4.1 Stand-alone operation..................................................................................................................45
4.2 Fail-safe operation .......................................................................................................................49
4.3 Fault-tolerant automation systems (redundancy operation) ........................................................53
4.3.1 Redundant SIMATIC automation systems...................................................................................53
4.3.2 Increase of plant availability, reaction to errors ...........................................................................54
4.4 Introduction to the I/O link to fault-tolerant system ......................................................................56
4.5 Using single-channel switched I/O...............................................................................................57
4.6 System and media redundancy at the PROFINET IO interface ..................................................63
4.6.1 System redundancy .....................................................................................................................63

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4.6.2 Media redundancy....................................................................................................................... 67
4.7 Connecting redundant I/O to the PROFIBUS DP interface ........................................................ 68
4.7.1 Signal modules for redundancy .................................................................................................. 68
4.7.2 Evaluating the passivation status................................................................................................ 83
5 PROFIBUS DP ..................................................................................................................................... 85
5.1 CPU 410-5H as PROFIBUS DP master ..................................................................................... 85
5.2 DP address ranges of the CPU 410-5H...................................................................................... 85
5.3 Diagnostics of the CPU 410-5H as PROFIBUS DP master........................................................ 86
6 PROFINET IO....................................................................................................................................... 87
6.1 Introduction.................................................................................................................................. 87
6.2 PROFINET IO systems ............................................................................................................... 89
6.3 Device replacement without removable medium/programming device ...................................... 90
7 Operator controls and operating modes of the CPU 410-5H .................................................................. 91
7.1 Operating modes of the CPU 410-5H ......................................................................................... 91
7.1.1 RUN mode................................................................................................................................... 91
7.1.2 STOP mode ................................................................................................................................ 92
7.1.3 STARTUP mode ......................................................................................................................... 93
7.1.4 HOLD mode ................................................................................................................................ 94
7.1.5 LINK-UP and UPDATE modes.................................................................................................... 94
7.1.6 ERROR-SEARCH mode ............................................................................................................. 95
7.1.7 DEFECTIVE state ....................................................................................................................... 96
7.2 System states of the redundant CPU 410-5H............................................................................. 97
7.2.1 Introduction.................................................................................................................................. 97
7.2.2 The system states of the fault-tolerant system ........................................................................... 99
7.2.3 Displaying and changing the system state of a fault-tolerant system....................................... 100
7.2.4 System status change from the STOP system state ................................................................ 100
7.2.5 System status change from the standalone mode system status............................................. 101
7.2.6 System status change from the redundant system state.......................................................... 102
7.2.7 System diagnostics of a fault-tolerant system........................................................................... 102
7.3 Self-test ..................................................................................................................................... 104
8 Link-up and update ..............................................................................................................................109
8.1 Effects of link-up and updating.................................................................................................. 109
8.2 Conditions for link-up and update ............................................................................................. 110
8.3 Time monitoring ........................................................................................................................ 110
8.3.1 Time response .......................................................................................................................... 113
8.3.2 Determining the monitoring times ............................................................................................. 113
8.3.3 Performance values for link-up and update .............................................................................. 120
8.3.4 Influences on time response ..................................................................................................... 121
8.4 Special features in link-up and update operations .................................................................... 121
9 Special functions of the CPU 410-5H ...................................................................................................123
9.1 Security levels ........................................................................................................................... 123
9.2 Access-protected blocks ........................................................................................................... 125

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9.3 Resetting the CPU410-5H to factory settings ............................................................................126
9.4 Reset during operation...............................................................................................................127
9.5 Updating firmware ......................................................................................................................128
9.6 Firmware update in RUN mode .................................................................................................129
9.7 Reading service data .................................................................................................................131
9.8 Response to fault detection .......................................................................................................131
9.9 Time synchronization .................................................................................................................132
10 System modifications during redundant operation ............................................................................... 135
10.1 System modifications during operation......................................................................................135
10.2 Possible hardware modifications ...............................................................................................137
10.3 Adding components ...................................................................................................................139
10.3.1 Step 1: Modify hardware ............................................................................................................140
10.3.2 Step 2: Modify the hardware configuration offline......................................................................141
10.3.3 Step 3: Stop the standby CPU ...................................................................................................142
10.3.4 Step 4: Download new hardware configuration to the standby CPU.........................................142
10.3.5 Step 5: Switch to CPU with modified configuration....................................................................143
10.3.6 Step 6: Transition to redundant system state ............................................................................144
10.3.7 Step 7: Modify and download the user program ........................................................................145
10.3.8 Use of free channels on an existing module..............................................................................146
10.3.9 Addition of interface modules.....................................................................................................147
10.4 Removal of components ............................................................................................................148
10.4.1 Step 1: Modify the hardware configuration offline......................................................................149
10.4.2 Step 2: Modify and download the user program ........................................................................149
10.4.3 Step 3: Stop the standby CPU ...................................................................................................150
10.4.4 Step 4: Download new hardware configuration to the standby CPU.........................................151
10.4.5 Step 5: Switch to CPU with modified configuration....................................................................151
10.4.6 Step 6: Transition to redundant system state ............................................................................152
10.4.7 Step 7: Modify hardware ............................................................................................................153
10.4.8 Removal of interface modules ...................................................................................................154
10.5 Editing CPU parameters ............................................................................................................155
10.5.1 Editing CPU parameters ............................................................................................................155
10.5.2 Step 1: Editing CPU parameters offline .....................................................................................157
10.5.3 Step 2: Stopping the reserve CPU.............................................................................................157
10.5.4 Step 3: Downloading a new hardware configuration to the reserve CPU .................................158
10.5.5 Step 4: Switching to CPU with modified configuration...............................................................158
10.5.6 Step 5: Transition to redundant system mode ...........................................................................159
10.6 Re-parameterization of a module...............................................................................................161
10.6.1 Re-parameterization of a module...............................................................................................161
10.6.2 Step 1: Editing parameters offline..............................................................................................162
10.6.3 Step 2: Stopping the reserve CPU.............................................................................................162
10.6.4 Step 3: Downloading a new hardware configuration to the reserve CPU .................................163
10.6.5 Step 4: Switching to CPU with modified configuration...............................................................163
10.6.6 Step 5: Transition to redundant system mode ...........................................................................164

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11 Failure and replacement of components during redundant operation ....................................................167
11.1 Failure and replacement of central components....................................................................... 167
11.1.1 Failure and replacement of a CPU during redundant operation ............................................... 167
11.1.2 Failure and replacement of a power supply module ................................................................. 168
11.1.3 Failure and replacement of an input/output or function module................................................ 169
11.1.4 Failure and replacement of a communication module .............................................................. 171
11.1.5 Failure and replacement of a synchronization module or fiber-optic cable .............................. 172
11.1.6 Failure and replacement of an IM 460 and IM 461 interface module ....................................... 175
11.2 Failure and replacement of components of the distributed I/Os ............................................... 175
11.2.1 Failure and replacement of a PROFIBUS DP master............................................................... 176
11.2.2 Failure and replacement of a redundant PROFIBUS DP interface module.............................. 177
11.2.3 Failure and replacement of a PROFIBUS DP slave ................................................................. 177
11.2.4 Failure and replacement of PROFIBUS DP cables .................................................................. 178
11.3 Failure and replacement of components of PROFINET IO ...................................................... 179
11.3.1 Failure and replacement of a PROFINET IO device................................................................. 179
11.3.2 Failure and replacement of PROFIBUS IO cables ................................................................... 179
12 Synchronization modules .....................................................................................................................181
12.1 Synchronization modules for the CPU 410-5H ......................................................................... 181
12.2 Installation of fiber-optic cables................................................................................................. 185
12.3 Selecting fiber-optic cables ....................................................................................................... 187
13 System expansion card........................................................................................................................193
13.1 Variants of the system expansion card ..................................................................................... 193
14 Technical data .....................................................................................................................................195
14.1 Technical specifications of the CPU 410-5H; (6ES7 410-5HX08-0AB0).................................. 195
15 Properties and technical specifications of CPU 410 SMART.................................................................203
15.1 CPU 410 SMART ...................................................................................................................... 203
15.2 Technical specifications of the CPU 410 SMART; (6ES7 410-5HN08-0AB0).......................... 205
16 Supplementary information ..................................................................................................................213
16.1 Supplementary information on PROFIBUS DP......................................................................... 213
16.2 Supplementary information on diagnostics of CPU 410-5H as PROFIBUS DP master........... 214
16.3 System status lists for PROFINET IO ....................................................................................... 217
16.4 Configuring with STEP 7 ........................................................................................................... 218
16.4.1 Rules for arranging fault-tolerant station components .............................................................. 218
16.4.2 Configuring hardware................................................................................................................ 219
16.4.3 Assigning parameters to modules in a fault-tolerant station ..................................................... 219
16.4.4 Recommendations for setting CPU parameters, fixed settings ................................................ 220
16.4.5 Networking configuration........................................................................................................... 221
16.5 Programming device functions in STEP 7 ................................................................................ 222
16.6 Communication services ........................................................................................................... 222
16.6.1 Overview of communication services........................................................................................ 222
16.6.2 PG communication.................................................................................................................... 224
16.6.3 OP communication.................................................................................................................... 224

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16.6.4 S7 communication .....................................................................................................................224
16.6.5 S7 routing...................................................................................................................................226
16.6.6 Data set routing..........................................................................................................................230
16.6.7 SNMP network protocol .............................................................................................................231
16.6.8 Open Communication Via Industrial Ethernet............................................................................232
16.7 Basics and terminology of fault-tolerant communication ...........................................................235
16.8 Usable networks.........................................................................................................................239
16.9 Communication via S7 connections...........................................................................................239
16.9.1 Communication via S7 connections - one-sided mode..............................................................240
16.9.2 Communication via redundant S7 connections .........................................................................242
16.9.3 Communication via point-to-point CP on the ET 200M .............................................................243
16.9.4 Custom connection to single-channel systems..........................................................................245
16.10 Communication via fault-tolerant S7 connections......................................................................246
16.10.1 Communication between fault-tolerant systems ........................................................................248
16.10.2 Communication between fault-tolerant systems and a fault-tolerant CPU ................................251
16.10.3 Communication between fault-tolerant systems and PCs .........................................................252
16.11 Consistent data ..........................................................................................................................254
16.11.1 Consistency of communication blocks and functions ................................................................254
16.11.2 Consistency rules for SFB 14 "GET" or read variable, and SFB 15 "PUT" or write variable.....255
16.11.3 Consistent reading and writing of data from and to DP standard slaves/IO devices.................256
16.12 Link-up and update sequence....................................................................................................257
16.12.1 Link-up sequence.......................................................................................................................261
16.12.2 Update sequence.......................................................................................................................262
16.12.3 Switch to CPU with modified configuration or expanded memory configuration .......................265
16.12.4 Disabling of link-up and update..................................................................................................266
16.13 The user program.......................................................................................................................267
16.14 Other options for connecting redundant I/Os.............................................................................268
16.15 Cycle and response times of the CPU 410-5H ..........................................................................272
16.15.1 Cycle time ..................................................................................................................................272
16.15.2 Calculating the cycle time ..........................................................................................................274
16.15.3 Communication load ..................................................................................................................277
16.15.4 Response time ...........................................................................................................................279
16.15.5 Calculating cycle and response times .......................................................................................285
16.15.6 Examples of calculating the cycle and response times .............................................................286
16.15.7 Interrupt response time ..............................................................................................................288
16.15.8 Example of calculation of the interrupt response time ...............................................................290
16.15.9 Reproducibility of delay and watchdog interrupts ......................................................................291
16.16 Runtimes of the FCs and FBs for redundant I/Os......................................................................292
A Characteristic values of redundant automation systems ...................................................................... 295
A.1 Basic concepts...........................................................................................................................295
A.2 Comparison of MTBF for selected configurations......................................................................299
A.2.1 System configurations with redundant CPU 410-5H .................................................................299
A.2.2 System configurations with distributed I/Os...............................................................................300
A.2.3 Comparison of system configurations with standard and fault-tolerant communication............304
B Function and communication modules that can be used in a redundant configuration.......................... 305

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8System Manual, 10/2013, A5E32631667-AA
C Connection examples for redundant I/Os..............................................................................................307
C.1 MTA terminal modules (Marshalled Termination Assemblies) ................................................. 307
C.2 Interconnection of output modules............................................................................................ 307
C.3 8-channel HART analog input MTA .......................................................................................... 309
C.4 8-channel HART analog output MTA ........................................................................................ 310
C.5 SM 321; DI 16 x DC 24 V, 6ES7 321–1BH02–0AA0 ................................................................ 311
C.6 SM 321; DI 32 x DC 24 V, 6ES7 321–1BL00–0AA0................................................................. 312
C.7 SM 321; DI 16 x AC 120/230V, 6ES7 321–1FH00–0AA0......................................................... 313
C.8 SM 321; DI 8 x AC 120/230 V, 6ES7 321–1FF01–0AA0 .......................................................... 314
C.9 SM 321; DI 16 x DC 24V, 6ES7 321–7BH00–0AB0 ................................................................. 315
C.10 SM 321; DI 16 x DC 24V, 6ES7 321–7BH01–0AB0 ................................................................. 316
C.11 SM 326; DO 10 x DC 24V/2A, 6ES7 326–2BF01–0AB0 .......................................................... 317
C.12 SM 326; DI 8 x NAMUR, 6ES7 326–1RF00–0AB0................................................................... 318
C.13 SM 326; DI 24 x DC 24 V, 6ES7 326–1BK00–0AB0 ................................................................ 319
C.14 SM 421; DI 32 x UC 120 V, 6ES7 421–1EL00–0AA0............................................................... 320
C.15 SM 421; DI 16 x DC 24 V, 6ES7 421–7BH01–0AB0 ................................................................ 321
C.16 SM 421; DI 32 x DC 24 V, 6ES7 421–1BL00–0AB0................................................................. 322
C.17 SM 421; DI 32 x DC 24 V, 6ES7 421–1BL01–0AB0................................................................. 323
C.18 SM 322; DO 8 x DC 24 V/2 A, 6ES7 322–1BF01–0AA0 .......................................................... 324
C.19 SM 322; DO 32 x DC 24 V/0,5 A, 6ES7 322–1BL00–0AA0...................................................... 325
C.20 SM 322; DO 8 x AC 230 V/2 A, 6ES7 322–1FF01–0AA0......................................................... 326
C.21 SM 322; DO 4 x DC 24 V/10 mA [EEx ib], 6ES7 322–5SD00–0AB0........................................ 327
C.22 SM 322; DO 4 x DC 15 V/20 mA [EEx ib], 6ES7 322–5RD00–0AB0 ....................................... 328
C.23 SM 322; DO 8 x DC 24 V/0.5 A, 6ES7 322–8BF00–0AB0 ....................................................... 329
C.24 SM 322; DO 16 x DC 24 V/0.5 A, 6ES7 322–8BH01–0AB0 ..................................................... 330
C.25 SM 332; AO 8 x 12 Bit, 6ES7 332–5HF00–0AB0 ..................................................................... 331
C.26 SM 332; AO 4 x 0/4...20 mA [EEx ib], 6ES7 332–5RD00–0AB0 .............................................. 332
C.27 SM 422; DO 16 x AC 120/230 V/2 A, 6ES7 422–1FH00–0AA0 ............................................... 333
C.28 SM 422; DO 32 x DC 24 V/0.5 A, 6ES7 422–7BL00–0AB0...................................................... 334
C.29 SM 331; AI 4 x 15 Bit [EEx ib]; 6ES7 331–7RD00–0AB0 ......................................................... 335
C.30 SM 331; AI 8 x 12 Bit, 6ES7 331–7KF02–0AB0 ....................................................................... 336
C.31 SM 331; AI 8 x 16 Bit; 6ES7 331–7NF00–0AB0 ....................................................................... 337
C.32 SM 331; AI 8 x 16 Bit; 6ES7 331–7NF10–0AB0 ....................................................................... 338
C.33 AI 6xTC 16Bit iso, 6ES7331-7PE10-0AB0 ............................................................................... 339
C.34 SM331; AI 8 x 0/4...20mA HART, 6ES7 331-7TF01-0AB0....................................................... 340

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C.35 SM 332; AO 4 x 12 Bit; 6ES7 332–5HD01–0AB0......................................................................342
C.36 SM332; AO 8 x 0/4...20mA HART, 6ES7 332-8TF01-0AB0......................................................343
Index................................................................................................................................................... 345
Tables
Table 3- 1 LED displays on the CPUs...........................................................................................................32
Table 3- 2 Possible states of the BUS1F, BUS5F, and BUS8F LEDs..........................................................38
Table 3- 3 Possible states of the LINK and RX/TX LEDs .............................................................................39
Table 4- 1 Measures in PROFIsafe for error avoidance ...............................................................................52
Table 4- 2 Interface modules for use of single-channel switched I/O configuration at the PROFIBUS
DP interface .................................................................................................................................58
Table 4- 3 Interface module for use of single-channel switched I/O configuration at the PROFINET
IO interface...................................................................................................................................60
Table 4- 4 Signal modules for redundancy ...................................................................................................69
Table 4- 5 Analog input modules and encoders ...........................................................................................81
Table 5- 1 CPU 410-5H.................................................................................................................................85
Table 5- 2 Meaning of the "BUSF" LED of the CPU 410-5H as DP master .................................................86
Table 7- 1 Causes of error leading to redundancy loss ................................................................................92
Table 7- 2 Overview of system states of the fault-tolerant system ...............................................................99
Table 7- 3 Response to errors during the self-test......................................................................................104
Table 7- 4 Response to a recurring comparison error ................................................................................105
Table 7- 5 Reaction to checksum errors .....................................................................................................105
Table 7- 6 Hardware fault with one-sided call of OB 121, checksum error, second occurrence ................106
Table 8- 1 Properties of link-up and update functions ................................................................................109
Table 8- 2 Conditions for link-up and update ..............................................................................................110
Table 8- 3 Typical values for the user program part ...................................................................................120
Table 9- 1 Protection levels of a CPU .........................................................................................................123
Table 9- 2 CPU properties in the factory settings .......................................................................................126
Table 9- 3 LED patterns ..............................................................................................................................127
Table 10- 1 Modifiable CPU parameters.......................................................................................................155
Table 12- 1 Accessory fiber-optic cable ........................................................................................................187
Table 12- 2 Specification of fiber-optic cables for indoor applications..........................................................188
Table 12- 3 Specification of fiber-optic cables for outdoor applications........................................................190
Table 16- 1 Reading the diagnostics data with STEP 7................................................................................214
Table 16- 2 Event detection of the CPU 41xH as a DP master ....................................................................216

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Table 16- 3 Comparison of the system status lists of PROFINET IO and PROFIBUS DP...........................217
Table 16- 4 Communication services of the CPUs .......................................................................................222
Table 16- 5 Availability of connection resources...........................................................................................223
Table 16- 6 SFBs for S7 Communication......................................................................................................225
Table 16- 7 Job lengths and "local_device_id" parameter ............................................................................234
Table 16- 8 For the monitoring times with redundant I/O..............................................................................272
Table 16- 9 Cyclic program processing.........................................................................................................273
Table 16- 10 Factors influencing cycle time ....................................................................................................274
Table 16- 11 Portion of the process image transfer time, CPU 410-5H..........................................................275
Table 16- 12 Extending the cycle time ............................................................................................................276
Table 16- 13 Operating system execution time at the cycle control point.......................................................276
Table 16- 14 Extended cycle time due to nested interrupts ............................................................................276
Table 16- 15 Direct access of the CPUs to I/O modules in the central controller...........................................283
Table 16- 16 Direct access of the CPUs to I/O modules in the expansion unit with local link ........................283
Table 16- 17 Direct access of the CPUs to I/O modules in the expansion unit with remote link, setting
100 m .........................................................................................................................................284
Table 16- 18 Example of calculating the response time .................................................................................285
Table 16- 19 Hardware and interrupt response times; maximum interrupt response time without
communication ...........................................................................................................................289
Table 16- 20 Reproducibility of time-delay and cyclic interrupts of the CPUs ................................................291
Table 16- 21 Runtimes of the blocks for redundant I/Os.................................................................................292
Table C- 1 Interconnecting digital output modules with/without diodes.......................................................307
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.............................................31
Figure 4-1 Overview: System structure for system modifications during operation ......................................48
Figure 4-2 Processing chain: acquire, process, output .................................................................................49
Figure 4-3 Safety-related communication .....................................................................................................51
Figure 4-4 Operating objectives of redundant automation systems..............................................................53
Figure 4-5 Integrated automation solutions with SIMATIC............................................................................54
Figure 4-6 Example of redundancy in a network without error......................................................................55

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Figure 4-7 Example of redundancy in a 1-out-of-2 system with error ...........................................................56
Figure 4-8 Example of redundancy in a 1-out-of-2 system with total failure .................................................56
Figure 4-9 Single-channel switched distributed I/O configuration at the PROFIBUS DP interface ..............58
Figure 4-10 Single-channel switched distributed I/O configuration at the PROFINET IO interface................60
Figure 4-11 S7-400H system with IO devices connected in system redundancy ...........................................63
Figure 4-12 System redundancy in different views .........................................................................................64
Figure 4-13 PN/IO with system redundancy....................................................................................................65
Figure 4-14 PN/IO with system redundancy....................................................................................................66
Figure 4-15 Configuration example of media redundancy ..............................................................................67
Figure 4-16 Fault-tolerant digital input module in 1-out-of-2 configuration with one encoder.........................75
Figure 4-17 Fault-tolerant digital input modules in 1-out-of-2 configuration with two encoders......................76
Figure 4-18 Fault-tolerant digital output modules in 1-out-of-2 configuration .................................................76
Figure 4-19 Fault-tolerant analog input modules in 1-out-of-2 configuration with one encoder......................78
Figure 4-20 Fault-tolerant analog input modules in 1-out-of-2 configuration with two encoders ....................80
Figure 4-21 Fault-tolerant analog output modules in 1-out-of-2 configuration ................................................81
Figure 7-1 Synchronizing the subsystems ....................................................................................................98
Figure 8-1 Meanings of the times relevant for updates...............................................................................112
Figure 8-2 Correlation between the minimum I/O retention time and the maximum inhibit time for
priority classes > 15 ...................................................................................................................115
Figure 12-1 Synchronization module.............................................................................................................182
Figure 12-2 Fiber-optic cables, installation using distribution boxes.............................................................191
Figure 13-1 SEC............................................................................................................................................193
Figure 16-1 Diagnostics with CPU 410 .........................................................................................................215
Figure 16-2 S7 routing...................................................................................................................................227
Figure 16-3 S7 routing gateways: PROFINET IO - DP - PROFINET IO.......................................................228
Figure 16-4 S7 routing: TeleService application example.............................................................................229
Figure 16-5 Data set routing..........................................................................................................................230
Figure 16-6 Example of an S7 connection ....................................................................................................236
Figure 16-7 Example that shows that the number of resulting partial connections depends on the
configuration...............................................................................................................................238
Figure 16-8 Example of linking standard and fault-tolerant systems in a simple bus system.......................240
Figure 16-9 Example of linking standard and fault-tolerant systems in a redundant bus system.................241
Figure 16-10 Example of linking of standard and fault-tolerant systems in a redundant ring .........................241
Figure 16-11 Example of redundancy with fault-tolerant systems and a redundant bus system with
redundant standard connections................................................................................................243

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12 System Manual, 10/2013, A5E32631667-AA
Figure 16-12 Example of connecting a fault-tolerant system to a single-channel third-party system via
switched PROFIBUS DP............................................................................................................244
Figure 16-13 Example of connecting a fault-tolerant system to a single-channel third-party system via
PROFINET IO with system redundancy ....................................................................................244
Figure 16-14 Example of linking a fault-tolerant system to a single-channel third-party system ....................245
Figure 16-15 Example of redundancy with fault-tolerant system and redundant ring.....................................249
Figure 16-16 Example of redundancy with fault-tolerant system and redundant bus system.........................250
Figure 16-17 Example of fault-tolerant system with additional CP redundancy..............................................250
Figure 16-18 Example of redundancy with fault-tolerant system and fault-tolerant CPU ...............................252
Figure 16-19 Example of redundancy with fault-tolerant system and redundant bus system.........................253
Figure 16-20 Example of redundancy with a fault-tolerant system, redundant bus system, and CP
redundancy on PC. ....................................................................................................................254
Figure 16-21 Sequence of link-up and update ................................................................................................259
Figure 16-22 Update sequence .......................................................................................................................260
Figure 16-23 Example of minimum signal duration of an input signal during the update ...............................261
Figure 16-24 Redundant one-sided and switched I/O.....................................................................................269
Figure 16-25 Flow chart for OB 1 ....................................................................................................................271
Figure 16-26 Elements and composition of the cycle time..............................................................................273
Figure 16-27 Formula: Influence of communication load ................................................................................277
Figure 16-28 Distribution of a time slice ..........................................................................................................277
Figure 16-29 Dependency of the cycle time on communication load..............................................................278
Figure 16-30 DP cycle times on the PROFIBUS DP network .........................................................................280
Figure 16-31 Shortest response time ..............................................................................................................281
Figure 16-32 Longest response time...............................................................................................................282
Figure A-1 MDT............................................................................................................................................296
Figure A-2 MTBF..........................................................................................................................................297
Figure A-3 Common Cause Failure (CCF) ..................................................................................................298
Figure A-4 Availability ..................................................................................................................................299
Figure C-1 Interconnection example for SM 331, Al 8 x 0/4...20mA HART.................................................309
Figure C-2 Interconnection example for SM 322, Al 8 x 0/4...20mA HART.................................................310
Figure C-3 Example of an interconnection with SM 321; DI 16 x DC 24 V..................................................311
Figure C-4 Example of an interconnection with SM 321; DI 32 x DC 24 V..................................................312
Figure C-5 Example of an interconnection with SM 321; DI 16 x AC 120/230 V.........................................313
Figure C-6 Example of an interconnection with SM 321; DI 8 x AC 120/230 V...........................................314
Figure C-7 Example of an interconnection with SM 321; DI 16 x DC 24V...................................................315
Figure C-8 Example of an interconnection with SM 321; DI 16 x DC 24V...................................................316

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Figure C-9 Example of an interconnection with SM 326; DO 10 x DC 24V/2A ...........................................317
Figure C-10 Example of an interconnection with SM 326; DI 8 x NAMUR....................................................318
Figure C-11 Example of an interconnection with SM 326; DI 24 x DC 24 V .................................................319
Figure C-12 Example of an interconnection with SM 421; DI 32 x UC 120 V ...............................................320
Figure C-13 Example of an interconnection with SM 421; DI 16 x 24 V........................................................321
Figure C-14 Example of an interconnection with SM 421; DI 32 x 24 V........................................................322
Figure C-15 Example of an interconnection with SM 421; DI 32 x 24 V........................................................323
Figure C-16 Example of an interconnection with SM 322; DO 8 x DC 24 V/2 A ...........................................324
Figure C-17 Example of an interconnection with SM 322; DO 32 x DC 24 V/0.5 A ......................................325
Figure C-18 Example of an interconnection with SM 322; DO 8 x AC 230 V/2 A .........................................326
Figure C-19 Example of an interconnection with SM 322; DO 16 x DC 24 V/10 mA [EEx ib].......................327
Figure C-20 Example of an interconnection with SM 322; DO 16 x DC 15 V/20 mA [EEx ib].......................328
Figure C-21 Example of an interconnection with SM 322; DO 8 x DC 24 V/0.5 A ........................................329
Figure C-22 Example of an interconnection with SM 322; DO 16 x DC 24 V/0.5 A ......................................330
Figure C-23 Example of an interconnection with SM 332, AO 8 x 12 Bit ......................................................331
Figure C-24 Example of an interconnection with SM 332; AO 4 x 0/4...20 mA [EEx ib] ...............................332
Figure C-25 Example of an interconnection with SM 422; DO 16 x 120/230 V/2 A ......................................333
Figure C-26 Example of an interconnection with SM 422; DO 32 x DC 24 V/0.5 A ......................................334
Figure C-27 Example of an interconnection with SM 331, AI 4 x 15 Bit [EEx ib]...........................................335
Figure C-28 Example of an interconnection with SM 331; AI 8 x 12 Bit ........................................................336
Figure C-29 Example of an interconnection with SM 331; AI 8 x 16 Bit ........................................................337
Figure C-30 Example of an interconnection with SM 331; AI 8 x 16 Bit ........................................................338
Figure C-31 Example of an interconnection AI 6xTC 16Bit iso......................................................................339
Figure C-32 Interconnection example 1 SM 331; AI 8 x 0/4...20mA HART...................................................340
Figure C-33 Interconnection example 2 SM 331; AI 8 x 0/4...20mA HART...................................................341
Figure C-34 Example of an interconnection with SM 332, AO 4 x 12 Bit ......................................................342
Figure C-35 Interconnection example 3 SM 332; AO 8 x 0/4...20mA HART.................................................343

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CPU 410-5H Process Automation/CPU 410 SMART
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CPU 410-5H Process Automation/CPU 410 SMART
System Manual, 10/2013, A5E32631667-AA 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 readership has sufficient knowledge of computers or
equipment similar to a PC, such as programming devices, running under the Windows XP,
Windows Server or Windows 7 operating system. The PCS7 Readme includes information
on which operating system is suitable for your PCS7 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 system in potentially explosive atmospheres, you
should always observe the information on the safety of electronic control systems provided in
the appendix of 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 V8.0 and
higher
●CPU 410 SMART; 6ES7 410-5HN08-0AB0 as of firmware version V8.0
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 203), 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.

Preface
1.1 Preface
CPU 410-5H Process Automation/CPU 410 SMART
16 System Manual, 10/2013, A5E32631667-AA
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 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.
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/)

Preface
1.1 Preface
CPU 410-5H Process Automation/CPU 410 SMART
System Manual, 10/2013, A5E32631667-AA 17
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.
●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".

Preface
1.2 Security information
CPU 410-5H Process Automation/CPU 410 SMART
18 System Manual, 10/2013, A5E32631667-AA
1.2
Security information
Siemens provides automation and drive products with industrial security functions that
support the secure operation of plants or machines. They are an important component in a
holistic industrial security concept. With this in mind, our products undergo continuous
development. We therefore recommend that you keep yourself informed with respect to our
product updates. Please find further information and newsletters on this subject at:
http://support.automation.siemens.com.
To ensure the secure operation of a plant or machine it is also necessary to take suitable
preventive action (e.g. cell protection concept) and to integrate the automation and drive
components into a state-of-the-art holistic industrial security concept for the entire plant or
machine. Any third-party products that may be in use must also be taken into account.
Please find further information at: http://www.siemens.com/industrialsecurity
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
system
S7-400, Hardware and
Installation
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
Automation 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
Modules
(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
Distributors, 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
Description
PROFINET system description
(http://support.automation.sieme
ns.com/WW/view/en/19292127)

Preface
1.3 Documentation
CPU 410-5H Process Automation/CPU 410 SMART
System Manual, 10/2013, A5E32631667-AA 19
Topic
Documentation
See also
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 technical documentation SIMATIC Process Control
System PCS 7 (V8.0)
(http://www.automation.siemens
.com/mcms/industrial-
automation-systems-
simatic/en/handbuchuebersicht/t
ech-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, 10/2013, A5E32631667-AA