Siemens SIMATIC PCS 7 CPU 410-5H User guide

CPU 410-5H Process Automation
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SIMATIC
PCS 7 process control system
CPU 410-5H Process Automation
System Manual
09/2014
A5E31622160
-AB
Preface
1
Introduction to CPU 410-5H
2
Structure of the CPU 410-5H
3
I/O configuration variants
4
PROFIBUS DP
5
PROFINET IO
6
Operator controls and
operating modes of the
CPU 410-5H
7
Link-up and update
8
Special functions of the
CPU 410-5H
9
System modifications during
redundant operation
10
Failure and replacement of
components during
redundant operation
11
Synchronization modules
12
System expansion card
13
Technical data
14
Supplementary information
15
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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A5E31622160-AB
Ⓟ
09/2014 Subject to change
Copyright © Siemens AG 2014.
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editions.

CPU 410-5H Process Automation
System Manual, 09/2014, A5E31622160-AB 3
Table of contents
1 Preface .................................................................................................................................................... 15
1.1 Preface....................................................................................................................................15
1.2 Security information ................................................................................................................18
1.3 Documentation........................................................................................................................19
2 Introduction to CPU 410-5H..................................................................................................................... 21
2.1 Scope of application of PCS 7................................................................................................21
2.2 Possible applications ..............................................................................................................23
2.3 The basic system of the CPU 410-5H for stand-alone operation ...........................................25
2.4 The basic system for redundant operation .............................................................................27
2.5 Rules for the assembly of fault-tolerant stations.....................................................................29
2.6 I/O for CPU 410-5H.................................................................................................................29
2.7 I/O configuration variants of the fault-tolerant system ............................................................30
2.8 Tools for configuring (STEP 7 - HW Config, PCS 7) ..............................................................30
2.9 PCS 7 project..........................................................................................................................31
2.10 Scaling and licensing (scaling concept)..................................................................................32
3 Structure of the CPU 410-5H................................................................................................................... 35
3.1 Operator controls and display elements on the CPU 410-5H ................................................35
3.2 Monitoring functions of the CPU 410-5H ................................................................................39
3.3 Status and error displays ........................................................................................................41
3.4 PROFIBUS DP interface (X1).................................................................................................45
3.5 PROFINET IO interfaces (X5, X8) ..........................................................................................45
3.6 Overview of the parameters for the CPU 410-5H...................................................................48
4 I/O configuration variants......................................................................................................................... 49
4.1 Stand-alone operation ............................................................................................................49
4.2 Fail-safe operation ..................................................................................................................54
4.3 Fault-tolerant automation systems (redundancy operation) ...................................................57
4.3.1 Redundant SIMATIC automation systems .............................................................................57
4.3.2 Increase of plant availability, reaction to errors ......................................................................59
4.4 Introduction to the I/O link to fault-tolerant system .................................................................62
4.5 Using single-channel switched I/O..........................................................................................63

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4.6 System and media redundancy at the PROFINET IO interface ............................................ 70
4.6.1 System redundancy ............................................................................................................... 70
4.6.2 Media redundancy ................................................................................................................. 74
4.7 Connecting redundant I/O to the PROFIBUS DP interface ................................................... 76
4.7.1 Signal modules for redundancy ............................................................................................. 76
4.7.2 Evaluating the passivation status........................................................................................... 90
5 PROFIBUS DP ........................................................................................................................................ 91
5.1 CPU 410-5H as PROFIBUS DP master ................................................................................ 91
5.2 DP address ranges of the CPU 410-5H................................................................................. 91
5.3 Diagnostics of the CPU 410-5H as PROFIBUS DP master .................................................. 92
6 PROFINET IO.......................................................................................................................................... 95
6.1 Introduction ............................................................................................................................ 95
6.2 PROFINET IO systems.......................................................................................................... 97
6.3 Device replacement without removable medium/programming device ................................. 98
7 Operator controls and operating modes of the CPU 410-5H.................................................................... 99
7.1 Operating modes of the CPU 410-5H.................................................................................... 99
7.1.1 RUN mode ............................................................................................................................. 99
7.1.2 STOP mode ......................................................................................................................... 101
7.1.3 STARTUP mode .................................................................................................................. 102
7.1.4 HOLD mode ......................................................................................................................... 103
7.1.5 LINK-UP and UPDATE modes ............................................................................................ 104
7.1.6 ERROR-SEARCH mode...................................................................................................... 104
7.1.7 DEFECTIVE state ................................................................................................................ 105
7.2 System states of the redundant CPU 410-5H...................................................................... 106
7.2.1 Introduction .......................................................................................................................... 106
7.2.2 The system states of the fault-tolerant system .................................................................... 109
7.2.3 Displaying and changing the system state of a fault-tolerant system.................................. 110
7.2.4 System status change from the STOP system state ........................................................... 111
7.2.5 System status change from the standalone mode system status ....................................... 112
7.2.6 System status change from the redundant system state..................................................... 113
7.2.7 System diagnostics of a fault-tolerant system ..................................................................... 114
7.3 Self-test ................................................................................................................................ 116
7.4 Performing a memory reset ................................................................................................. 120
8 Link-up and update................................................................................................................................ 121
8.1 Effects of link-up and updating............................................................................................. 121
8.2 Link-up and update via PG command ................................................................................. 122
8.3 Time monitoring ................................................................................................................... 123
8.3.1 Time response ..................................................................................................................... 125
8.3.2 Determining the monitoring times ........................................................................................ 126
8.3.3 Performance values for link-up and update......................................................................... 133
8.3.4 Influences on time response................................................................................................ 134
8.4 Special features in link-up and update operations............................................................... 135

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9 Special functions of the CPU 410-5H..................................................................................................... 137
9.1 Security levels.......................................................................................................................137
9.2 Access-protected blocks.......................................................................................................140
9.3 Resetting the CPU410-5H to factory settings.......................................................................141
9.4 Reset during operation .........................................................................................................143
9.5 Updating firmware.................................................................................................................144
9.6 Firmware update in RUN mode ............................................................................................146
9.7 Reading service data ............................................................................................................148
9.8 Response to fault detection ..................................................................................................148
9.9 Time synchronization............................................................................................................149
9.10 Type update with interface change in RUN..........................................................................150
10 System modifications during redundant operation ................................................................................. 151
10.1 System modifications during operation.................................................................................151
10.2 Possible hardware modifications ..........................................................................................153
10.3 Adding components ..............................................................................................................156
10.3.1 Step 1: Modify hardware.......................................................................................................157
10.3.2 Step 2: Modify the hardware configuration offline ................................................................158
10.3.3 Step 3: Stop the standby CPU..............................................................................................159
10.3.4 Step 4: Download new hardware configuration to the standby CPU....................................159
10.3.5 Step 5: Switch to CPU with modified configuration ..............................................................160
10.3.6 Step 6: Transition to redundant system state .......................................................................161
10.3.7 Step 7: Modify and download the user program...................................................................163
10.3.8 Use of free channels on an existing module.........................................................................164
10.3.9 Addition of interface modules ...............................................................................................165
10.4 Removal of components .......................................................................................................166
10.4.1 Step 1: Modify the hardware configuration offline ................................................................167
10.4.2 Step 2: Modify and download the user program...................................................................168
10.4.3 Step 3: Stop the standby CPU..............................................................................................169
10.4.4 Step 4: Download new hardware configuration to the standby CPU....................................169
10.4.5 Step 5: Switch to CPU with modified configuration ..............................................................170
10.4.6 Step 6: Transition to redundant system state .......................................................................171
10.4.7 Step 7: Modify hardware.......................................................................................................172
10.4.8 Removal of interface modules ..............................................................................................173
10.5 Editing CPU parameters .......................................................................................................174
10.5.1 Editing CPU parameters .......................................................................................................174
10.5.2 Step 1: Editing CPU parameters offline................................................................................176
10.5.3 Step 2: Stopping the reserve CPU........................................................................................176
10.5.4 Step 3: Downloading a new hardware configuration to the reserve CPU ............................177
10.5.5 Step 4: Switching to CPU with modified configuration..........................................................177
10.5.6 Step 5: Transition to redundant system mode......................................................................179

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10.6 Re-parameterization of a module......................................................................................... 180
10.6.1 Re-parameterization of a module......................................................................................... 180
10.6.2 Step 1: Editing parameters offline........................................................................................ 181
10.6.3 Step 2: Stopping the reserve CPU....................................................................................... 181
10.6.4 Step 3: Downloading a new hardware configuration to the reserve CPU ........................... 182
10.6.5 Step 4: Switching to CPU with modified configuration......................................................... 183
10.6.6 Step 5: Transition to redundant system mode..................................................................... 184
11 Failure and replacement of components during redundant operation .................................................... 185
11.1 Failure and replacement of central components.................................................................. 185
11.1.1 Failure and replacement of a CPU during redundant operation.......................................... 185
11.1.2 Failure and replacement of a power supply module............................................................ 187
11.1.3 Failure and replacement of an input/output or function module .......................................... 188
11.1.4 Failure and replacement of a communication module......................................................... 190
11.1.5 Failure and replacement of a synchronization module or fiber-optic cable ......................... 191
11.1.6 Failure and replacement of an IM 460 and IM 461 interface module .................................. 193
11.2 Failure and replacement of components of the distributed I/Os.......................................... 194
11.2.1 Failure and replacement of a PROFIBUS DP master.......................................................... 195
11.2.2 Failure and replacement of a redundant PROFIBUS DP interface module ........................ 196
11.2.3 Failure and replacement of a PROFIBUS DP slave ............................................................ 197
11.2.4 Failure and replacement of PROFIBUS DP cables ............................................................. 198
11.3 Failure and replacement of components of PROFINET IO ................................................. 199
11.3.1 Failure and replacement of a PROFINET IO device............................................................ 199
11.3.2 Failure and replacement of PROFIBUS IO cables .............................................................. 200
12 Synchronization modules....................................................................................................................... 201
12.1 Synchronization modules for the CPU 410-5H .................................................................... 201
12.2 Installation of fiber-optic cables............................................................................................ 206
12.3 Selecting fiber-optic cables.................................................................................................. 209
13 System expansion card ......................................................................................................................... 215
13.1 Variants of the system expansion card................................................................................ 215
14 Technical data ....................................................................................................................................... 217
14.1 Technical specifications of the CPU 410-5H; (6ES7 410-5HX08-0AB0)............................. 217
15 Supplementary information.................................................................................................................... 231
15.1 Supplementary information on PROFIBUS DP ................................................................... 231
15.2 Supplementary information on diagnostics of CPU 410-5H as PROFIBUS DP master...... 232
15.3 System status lists for PROFINET IO.................................................................................. 235
15.4 Configuring with STEP 7...................................................................................................... 237
15.4.1 Rules for arranging fault-tolerant station components......................................................... 237
15.4.2 Configuring hardware........................................................................................................... 238
15.4.3 Assigning parameters to modules in a fault-tolerant station................................................ 238
15.4.4 Recommendations for setting CPU parameters, fixed settings ........................................... 239
15.4.5 Networking configuration ..................................................................................................... 240

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15.5 Programming device functions in STEP 7 ............................................................................241
15.6 Communication services.......................................................................................................242
15.6.1 Overview of communication services ...................................................................................242
15.6.2 PG communication................................................................................................................243
15.6.3 OP communication................................................................................................................244
15.6.4 S7 communication ................................................................................................................244
15.6.5 S7 routing..............................................................................................................................246
15.6.6 Data set routing.....................................................................................................................249
15.6.7 SNMP network protocol ........................................................................................................251
15.6.8 Open Communication Via Industrial Ethernet ......................................................................252
15.7 Basics and terminology of fault-tolerant communication ......................................................256
15.8 Usable networks ...................................................................................................................260
15.9 Communication via S7 connections......................................................................................260
15.9.1 Communication via S7 connections - one-sided mode ........................................................261
15.9.2 Communication via redundant S7 connections ....................................................................264
15.9.3 Communication via point-to-point CP on the ET 200M ........................................................266
15.9.4 Custom connection to single-channel systems ....................................................................268
15.10 Communication via fault-tolerant S7 connections ................................................................269
15.10.1 Communication between fault-tolerant systems...................................................................272
15.10.2 Communication between fault-tolerant systems and a fault-tolerant CPU...........................275
15.10.3 Communication between fault-tolerant systems and PCs....................................................276
15.11 Consistent data.....................................................................................................................279
15.11.1 Consistency of communication blocks and functions ...........................................................279
15.11.2 Consistency rules for SFB 14 "GET" or read variable, and SFB 15 "PUT" or write
variable .................................................................................................................................280
15.11.3 Consistent reading and writing of data from and to DP standard slaves/IO devices ...........280
15.12 Link-up and update sequence ..............................................................................................283
15.12.1 Link-up sequence..................................................................................................................287
15.12.2 Update sequence..................................................................................................................288
15.12.3 Switch to CPU with modified configuration...........................................................................291
15.12.4 Disabling of link-up and update ............................................................................................292
15.13 The user program .................................................................................................................293
15.14 Other options for connecting redundant I/Os........................................................................294
15.15 Cycle and response times of the CPU 410-5H.....................................................................298
15.15.1 Cycle time .............................................................................................................................298
15.15.2 Calculating the cycle time .....................................................................................................300
15.15.3 Cycle load due to communication.........................................................................................304
15.15.4 Response time......................................................................................................................307
15.15.5 Calculating cycle and response times ..................................................................................313
15.15.6 Examples of calculating the cycle and response times ........................................................314
15.15.7 Interrupt response time.........................................................................................................317
15.15.8 Example of calculation of the interrupt response time..........................................................319
15.15.9 Reproducibility of delay and watchdog interrupts.................................................................320
15.16 Runtimes of the FCs and FBs for redundant I/Os ................................................................321

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A Characteristic values of redundant automation systems........................................................................ 323
A.1 Basic concepts..................................................................................................................... 323
A.2 Comparison of MTBF for selected configurations................................................................ 328
A.2.1 System configurations with redundant CPU 410-5H ........................................................... 328
A.2.2 System configurations with distributed I/Os......................................................................... 330
A.2.3 Comparison of system configurations with standard and fault-tolerant communication...... 333
B Function and communication modules that can be used in a redundant configuration .......................... 335
C Connection examples for redundant I/Os............................................................................................... 337
C.1 MTA terminal modules (Marshalled Termination Assemblies) ............................................ 337
C.2 Interconnection of output modules....................................................................................... 337
C.3 8-channel HART analog input MTA ..................................................................................... 339
C.4 8-channel HART analog output MTA................................................................................... 340
C.5 SM 321; DI 16 x DC 24 V, 6ES7 321–1BH02–0AA0 ........................................................... 341
C.6 SM 321; DI 32 x DC 24 V, 6ES7 321–1BL00–0AA0............................................................ 342
C.7 SM 321; DI 16 x AC 120/230V, 6ES7 321–1FH00–0AA0 ................................................... 343
C.8 SM 321; DI 8 x AC 120/230 V, 6ES7 321–1FF01–0AA0..................................................... 344
C.9 SM 321; DI 16 x DC 24V, 6ES7 321–7BH00–0AB0 ............................................................ 345
C.10 SM 321; DI 16 x DC 24V, 6ES7 321–7BH01–0AB0 ............................................................ 346
C.11 SM 326; DO 10 x DC 24V/2A, 6ES7 326–2BF01–0AB0 ..................................................... 347
C.12 SM 326; DI 8 x NAMUR, 6ES7 326–1RF00–0AB0.............................................................. 348
C.13 SM 326; DI 24 x DC 24 V, 6ES7 326–1BK00–0AB0 ........................................................... 349
C.14 SM 421; DI 32 x UC 120 V, 6ES7 421–1EL00–0AA0.......................................................... 350
C.15 SM 421; DI 16 x DC 24 V, 6ES7 421–7BH01–0AB0 ........................................................... 351
C.16 SM 421; DI 32 x DC 24 V, 6ES7 421–1BL00–0AB0............................................................ 352
C.17 SM 421; DI 32 x DC 24 V, 6ES7 421–1BL01–0AB0............................................................ 353
C.18 SM 322; DO 8 x DC 24 V/2 A, 6ES7 322–1BF01–0AA0 ..................................................... 354
C.19 SM 322; DO 32 x DC 24 V/0,5 A, 6ES7 322–1BL00–0AA0 ................................................ 355
C.20 SM 322; DO 8 x AC 230 V/2 A, 6ES7 322–1FF01–0AA0.................................................... 356
C.21 SM 322; DO 4 x DC 24 V/10 mA [EEx ib], 6ES7 322–5SD00–0AB0 .................................. 357
C.22 SM 322; DO 4 x DC 15 V/20 mA [EEx ib], 6ES7 322–5RD00–0AB0 .................................. 358
C.23 SM 322; DO 8 x DC 24 V/0.5 A, 6ES7 322–8BF00–0AB0 .................................................. 359
C.24 SM 322; DO 16 x DC 24 V/0.5 A, 6ES7 322–8BH01–0AB0................................................ 360
C.25 SM 332; AO 8 x 12 Bit, 6ES7 332–5HF00–0AB0 ................................................................ 361
C.26 SM 332; AO 4 x 0/4...20 mA [EEx ib], 6ES7 332–5RD00–0AB0......................................... 362
C.27 SM 422; DO 16 x AC 120/230 V/2 A, 6ES7 422–1FH00–0AA0 .......................................... 363
C.28 SM 422; DO 32 x DC 24 V/0.5 A, 6ES7 422–7BL00–0AB0 ................................................ 364

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C.29 SM 331; AI 4 x 15 Bit [EEx ib]; 6ES7 331–7RD00–0AB0.....................................................365
C.30 SM 331; AI 8 x 12 Bit, 6ES7 331–7KF02–0AB0 ...................................................................366
C.31 SM 331; AI 8 x 16 Bit; 6ES7 331–7NF00–0AB0...................................................................367
C.32 SM 331; AI 8 x 16 Bit; 6ES7 331–7NF10–0AB0...................................................................368
C.33 AI 6xTC 16Bit iso, 6ES7331-7PE10-0AB0 ...........................................................................369
C.34 SM331; AI 8 x 0/4...20mA HART, 6ES7 331-7TF01-0AB0 ..................................................370
C.35 SM 332; AO 4 x 12 Bit; 6ES7 332–5HD01–0AB0.................................................................372
C.36 SM332; AO 8 x 0/4...20mA HART, 6ES7 332-8TF01-0AB0.................................................373
Index...................................................................................................................................................... 375
Tables
Table 3- 1 LED displays on the CPUs...........................................................................................................36
Table 3- 2 Possible states of the BUS1F, BUS5F, and BUS8F LEDs..........................................................42
Table 3- 3 Possible states of the LINK and RX/TX LEDs .............................................................................43
Table 4- 1 System modifications during operation........................................................................................50
Table 4- 2 Measures in PROFIsafe for error avoidance ...............................................................................56
Table 4- 3 Interface modules for use of single-channel switched I/O configuration at the PROFIBUS
DP interface .................................................................................................................................64
Table 4- 4 Bus modules for hot swapping.....................................................................................................64
Table 4- 5 Interface module for use of single-channel switched I/O configuration at the PROFINET
IO interface...................................................................................................................................66
Table 4- 6 Signal modules for redundancy ...................................................................................................76
Table 5- 1 CPU 410-5H.................................................................................................................................91
Table 5- 2 Meaning of the "BUSF" LED of the CPU 410-5H as DP master .................................................92
Table 7- 1 Causes of error leading to redundancy loss ..............................................................................100
Table 7- 2 Overview of system states of the fault-tolerant system .............................................................109
Table 7- 3 Response to errors during the self-test......................................................................................116
Table 7- 4 Response to a recurring comparison error ................................................................................117
Table 7- 5 Reaction to checksum errors .....................................................................................................117
Table 7- 6 Hardware fault with one-sided call of OB 121, checksum error, second occurrence................118
Table 8- 1 Properties of link-up and update functions ................................................................................121
Table 8- 2 PG commands for link-up and update .......................................................................................122
Table 8- 3 Typical values for the user program part ...................................................................................133
Table 9- 1 Protection levels of a CPU.........................................................................................................137
Table 9- 2 CPU properties in the factory settings .......................................................................................141

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Table 9- 3 LED patterns ..............................................................................................................................142
Table 10- 1 Modifiable CPU parameters.......................................................................................................174
Table 12- 1 Accessory fiber-optic cable ........................................................................................................209
Table 12- 2 Specification of fiber-optic cables for indoor applications..........................................................210
Table 12- 3 Specification of fiber-optic cables for outdoor applications........................................................212
Table 15- 1 Reading the diagnostics data with STEP 7................................................................................232
Table 15- 2 Event detection of the CPU 41xH as a DP master ....................................................................234
Table 15- 3 Comparison of the system status lists of PROFINET IO and PROFIBUS DP...........................235
Table 15- 4 Communication services of the CPUs .......................................................................................242
Table 15- 5 Availability of connection resources...........................................................................................243
Table 15- 6 SFBs for S7 Communication......................................................................................................245
Table 15- 7 Job lengths and "local_device_id" parameter ............................................................................254
Table 15- 8 For the monitoring times with redundant I/O..............................................................................297
Table 15- 9 Cyclic program processing.........................................................................................................298
Table 15- 10 Factors influencing cycle time....................................................................................................300
Table 15- 11 Portion of the process image transfer time, CPU 410-5H..........................................................301
Table 15- 12 Extending the cycle time ............................................................................................................302
Table 15- 13 Operating system execution time at the cycle control point.......................................................302
Table 15- 14 Extended cycle time due to nested interrupts............................................................................303
Table 15- 15 Direct access of the CPUs to I/O modules in the central controller...........................................311
Table 15- 16 Direct access of the CPUs to I/O modules in the expansion unit with local link........................311
Table 15- 17 Direct access of the CPUs to I/O modules in the expansion unit with remote link, setting
100 m .........................................................................................................................................312
Table 15- 18 Example of calculating the response time .................................................................................313
Table 15- 19 Hardware and interrupt response times; maximum interrupt response time without com-
munication..................................................................................................................................317
Table 15- 20 Reproducibility of time-delay and cyclic interrupts of the CPUs ................................................320
Table 15- 21 Runtimes of the blocks for redundant I/Os.................................................................................321
Table C- 1 Interconnecting digital output modules with/without diodes.......................................................337

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Figures
Figure 2-1 Overview ......................................................................................................................................23
Figure 2-2 Hardware of the S7-400H basic system ......................................................................................25
Figure 2-3 Hardware of the S7-400H basic system ......................................................................................27
Figure 3-1 Arrangement of the control and display elements on CPU 410-5H.............................................35
Figure 4-1 Overview: System structure for system modifications during operation......................................52
Figure 4-2 Processing chain: acquire, process, output.................................................................................54
Figure 4-3 Safety-related communication .....................................................................................................55
Figure 4-4 Operating objectives of redundant automation systems..............................................................57
Figure 4-5 Integrated automation solutions with SIMATIC............................................................................59
Figure 4-6 Example of redundancy in a network without error......................................................................60
Figure 4-7 Example of redundancy in a 1-out-of-2 system with error ...........................................................61
Figure 4-8 Example of redundancy in a 1-out-of-2 system with total failure.................................................61
Figure 4-9 Single-channel switched distributed I/O configuration at the PROFIBUS DP interface ..............63
Figure 4-10 Single-channel switched distributed I/O configuration at the PROFINET IO interface................66
Figure 4-11 S7-400H system with IO devices connected in system redundancy...........................................70
Figure 4-12 System redundancy in different views .........................................................................................71
Figure 4-13 PN/IO with system redundancy....................................................................................................72
Figure 4-14 PN/IO with system redundancy....................................................................................................73
Figure 4-15 Configuration example of media redundancy ..............................................................................75
Figure 4-16 Fault-tolerant digital input module in 1-out-of-2 configuration with one encoder.........................82
Figure 4-17 Fault-tolerant digital input modules in 1-out-of-2 configuration with two encoders......................83
Figure 4-18 Fault-tolerant digital output modules in 1-out-of-2 configuration .................................................83
Figure 4-19 Fault-tolerant analog input modules in 1-out-of-2 configuration with one encoder......................85
Figure 4-20 Fault-tolerant analog input modules in 1-out-of-2 configuration with two encoders ....................87
Figure 4-21 Fault-tolerant analog output modules in 1-out-of-2 configuration................................................88
Figure 7-1 Synchronizing the subsystems ..................................................................................................107
Figure 8-1 Meanings of the times relevant for updates...............................................................................124
Figure 8-2 Correlation between the minimum I/O retention time and the maximum inhibit time for
priority classes > 15 ...................................................................................................................127
Figure 12-1 Synchronization module.............................................................................................................202
Figure 12-2 Fiber-optic cables, installation using distribution boxes.............................................................213
Figure 13-1 SEC............................................................................................................................................215
Figure 15-1 Diagnostics with CPU 410 .........................................................................................................233
Figure 15-2 S7 routing...................................................................................................................................246
Figure 15-3 S7 routing gateways: PROFINET IO - DP - PROFINET IO.......................................................247

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Figure 15-4 S7 routing: TeleService application example.............................................................................248
Figure 15-5 Data set routing..........................................................................................................................250
Figure 15-6 Example of an S7 connection ....................................................................................................257
Figure 15-7 Example that shows that the number of resulting partial connections depends on the con-
figuration.....................................................................................................................................258
Figure 15-8 Example of linking standard and fault-tolerant systems in a simple bus system.......................261
Figure 15-9 Example of linking standard and fault-tolerant systems in a redundant bus system.................262
Figure 15-10 Example of linking of standard and fault-tolerant systems in a redundant ring .........................263
Figure 15-11 Example of linking standard and fault-tolerant systems in a single bus system........................264
Figure 15-12 Example of redundancy with fault-tolerant systems and a redundant bus system with re-
dundant standard connections...................................................................................................265
Figure 15-13 Example of connecting a fault-tolerant system to a single-channel third-party system via
switched PROFIBUS DP............................................................................................................266
Figure 15-14 Example of connecting a fault-tolerant system to a single-channel third-party system via
PROFINET IO with system redundancy ....................................................................................267
Figure 15-15 Example of linking a fault-tolerant system to a single-channel third-party system ....................268
Figure 15-16 Example of redundancy with fault-tolerant system and redundant ring.....................................272
Figure 15-17 Example of redundancy with fault-tolerant system and redundant bus system.........................273
Figure 15-18 Example of fault-tolerant system with additional CP redundancy..............................................273
Figure 15-19 Example of redundancy with fault-tolerant system and fault-tolerant CPU ...............................275
Figure 15-20 Example of redundancy with fault-tolerant system and redundant bus system.........................277
Figure 15-21 Example of redundancy with a fault-tolerant system, redundant bus system and redun-
dant connection to the PC..........................................................................................................277
Figure 15-22 Sequence of link-up and update ................................................................................................284
Figure 15-23 Update sequence .......................................................................................................................285
Figure 15-24 Example of minimum signal duration of an input signal during the update ...............................286
Figure 15-25 Redundant one-sided and switched I/O.....................................................................................294
Figure 15-26 Flow chart for OB 1 ....................................................................................................................296
Figure 15-27 Elements and composition of the cycle time..............................................................................299
Figure 15-28 Formula: Influence of communication load ................................................................................304
Figure 15-29 Distribution of a time slice ..........................................................................................................304
Figure 15-30 Dependency of the cycle time on communication load..............................................................306
Figure 15-31 DP cycle times on the PROFIBUS DP network .........................................................................308
Figure 15-32 Shortest response time ..............................................................................................................309
Figure 15-33 Longest response time...............................................................................................................310
Figure A-1 MDT............................................................................................................................................324

Table of contents
CPU 410-5H Process Automation
System Manual, 09/2014, A5E31622160-AB 13
Figure A-2 MTBF .........................................................................................................................................325
Figure A-3 Common Cause Failure (CCF) ..................................................................................................326
Figure A-4 Availability ..................................................................................................................................327
Figure C-1 Interconnection example for SM 331, Al 8 x 0/4...20mA HART.................................................339
Figure C-2 Interconnection example for SM 322, Al 8 x 0/4...20mA HART.................................................340
Figure C-3 Example of an interconnection with SM 321; DI 16 x DC 24 V .................................................341
Figure C-4 Example of an interconnection with SM 321; DI 32 x DC 24 V .................................................342
Figure C-5 Example of an interconnection with SM 321; DI 16 x AC 120/230 V.........................................343
Figure C-6 Example of an interconnection with SM 321; DI 8 x AC 120/230 V...........................................344
Figure C-7 Example of an interconnection with SM 321; DI 16 x DC 24V ..................................................345
Figure C-8 Example of an interconnection with SM 321; DI 16 x DC 24V ..................................................346
Figure C-9 Example of an interconnection with SM 326; DO 10 x DC 24V/2A ...........................................347
Figure C-10 Example of an interconnection with SM 326; DI 8 x NAMUR....................................................348
Figure C-11 Example of an interconnection with SM 326; DI 24 x DC 24 V .................................................349
Figure C-12 Example of an interconnection with SM 421; DI 32 x UC 120 V ...............................................350
Figure C-13 Example of an interconnection with SM 421; DI 16 x 24 V........................................................351
Figure C-14 Example of an interconnection with SM 421; DI 32 x 24 V........................................................352
Figure C-15 Example of an interconnection with SM 421; DI 32 x 24 V........................................................353
Figure C-16 Example of an interconnection with SM 322; DO 8 x DC 24 V/2 A ...........................................354
Figure C-17 Example of an interconnection with SM 322; DO 32 x DC 24 V/0.5 A ......................................355
Figure C-18 Example of an interconnection with SM 322; DO 8 x AC 230 V/2 A .........................................356
Figure C-19 Example of an interconnection with SM 322; DO 16 x DC 24 V/10 mA [EEx ib].......................357
Figure C-20 Example of an interconnection with SM 322; DO 16 x DC 15 V/20 mA [EEx ib].......................358
Figure C-21 Example of an interconnection with SM 322; DO 8 x DC 24 V/0.5 A ........................................359
Figure C-22 Example of an interconnection with SM 322; DO 16 x DC 24 V/0.5 A ......................................360
Figure C-23 Example of an interconnection with SM 332, AO 8 x 12 Bit ......................................................361
Figure C-24 Example of an interconnection with SM 332; AO 4 x 0/4...20 mA [EEx ib] ...............................362
Figure C-25 Example of an interconnection with SM 422; DO 16 x 120/230 V/2 A ......................................363
Figure C-26 Example of an interconnection with SM 422; DO 32 x DC 24 V/0.5 A ......................................364
Figure C-27 Example of an interconnection with SM 331, AI 4 x 15 Bit [EEx ib]...........................................365
Figure C-28 Example of an interconnection with SM 331; AI 8 x 12 Bit........................................................366
Figure C-29 Example of an interconnection with SM 331; AI 8 x 16 Bit........................................................367
Figure C-30 Example of an interconnection with SM 331; AI 8 x 16 Bit........................................................368
Figure C-31 Example of an interconnection AI 6xTC 16Bit iso......................................................................369
Figure C-32 Interconnection example 1 SM 331; AI 8 x 0/4...20mA HART...................................................370
Figure C-33 Interconnection example 2 SM 331; AI 8 x 0/4...20mA HART...................................................371

Table of contents
CPU 410-5H Process Automation
14 System Manual, 09/2014, A5E31622160-AB
Figure C-34 Example of an interconnection with SM 332, AO 4 x 12 Bit ......................................................372
Figure C-35 Interconnection example 3 SM 332; AO 8 x 0/4...20mA HART.................................................373

CPU 410-5H Process Automation
System Manual, 09/2014, A5E31622160-AB 15
Preface
1
1.1
Preface
Purpose of this manual
This manual represents a useful reference and contains information on operator inputs,
descriptions of functions, and technical specifications of the CPU 410-5H Process
Automation.
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 V8.1 and
higher
Approvals
For details on certifications and standards, refer to Manual S7-400 Automation System,
Module Data
, Chapter 1.1, Standards and Certifications. Here you will also find the technical
specification for the entire S7-400.

Preface
1.1 Preface
CPU 410-5H Process Automation
16 System Manual, 09/2014, A5E31622160-AB
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
System Manual, 09/2014, A5E31622160-AB 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
18 System Manual, 09/2014, A5E31622160-AB
1.2
Security information
Siemens provides products and solutions with industrial security functions that support the
secure operation of plants, solutions, machines, equipment and/or networks. They are
important components in a holistic industrial security concept. With this in mind, Siemens’
products and solutions undergo continuous development. Siemens recommends strongly
that you regularly check for product updates.
For the secure operation of Siemens products and solutions, it is necessary to take suitable
preventive action (e.g. cell protection concept) and integrate each component into a holistic,
state-of-the-art industrial security concept. Third-party products that may be in use should
also be considered. You can find more information about industrial security on the Internet.
To stay informed about product updates as they occur, sign up for a product-specific
newsletter. You can find more information on the Internet.

Preface
1.3 Documentation
CPU 410-5H Process Automation
System Manual, 09/2014, A5E31622160-AB 19
1.3
Documentation
User documentation
The table below provides an overview of the descriptions of the various components and
options in the S7-400 automation system.
Topic
Documentation
See also
Setting up an automation sys-
tem
S7-400, Hardware and Instal-
lation
S7-400 Automation System Hard-
ware and Installation
(http://support.automation.siemens.
com/WW/view/en/1117849)
Data of the standard modules of
an automation system
S7-400 Module Data SIMATIC S7-400 S7-400 Automa-
tion System Module Data
(http://support.automation.siemens.
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.siemens.
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 Cou-
pler, Active Field Distributors,
DP/PA Link and Y Link
(http://support.automation.siemens.
com/WW/view/en/1142696)
Configuring, commissioning,
and operation of a PROFINET
IO system
PROFINET IO System De-
scription
PROFINET system description
(http://support.automation.siemens.
com/WW/view/en/19292127)
Fail-safe systems
Configuring and programming of
fail-safe systems
Working with S7 F-Systems V
6.1
S7 F/FH Systems SIMATIC Industrial Software S7
F/FH Systems - Configuring and
Programming
(http://support.automation.siemens.
com/WW/view/en/2201072)
Solution concepts
Function mechanisms
Configurations of PCS 7
PCS 7 V8.1 technical docu-
mentation
SIMATIC Process Control System
PCS 7 (V8.0)
(http://www.automation.siemens.co
m/mcms/industrial-automation-
systems-
simat-
ic/en/handbuchuebersicht/tech-
dok-pcs7/Seiten/Default.aspx)
Configuring hardware Configuring Hardware and
Communication Connections
with STEP 7
Configuring Hardware and Com-
munication Connections with
STEP 7
(http://support.automation.siemens.
com/WW/view/en/18652631)
System Modifications during
Stand-Alone Operation
Modifying the System during
Operation via CiR
Modifying the System during Op-
eration via CiR
(http://support.automation.siemens.
com/WW/view/en/14044916)

Preface
1.3 Documentation
CPU 410-5H Process Automation
20 System Manual, 09/2014, A5E31622160-AB