Siemens Simatic S7-400 User manual

Preface, Contents
Product Overview 1
Installing the S7-400 2
Addressing the S7-400 3
Wiring the S7-400 4
Networking 5
Starting Up 6
Maintenance 7
Assembling the M7-400 8
Appendices
Assembling and Installing
Systems A
Guidelines for Handling
Electrostatically-Sensitive
Devices (ESD) B
Glossary, Index
S7-400 and M7-400
Programmable Controllers
Hardware and Installation
Installation Manual
SIMATIC
This manual is part of the documentation
package with the order number
6ES7498-8AA03-8BA0
Edition 12/2002
A5E00069481-04

Index-2 S7-400 and M7-400 Programmable Controllers Hardware and Installation
A5E00069480-02
!Danger
indicates that death, severe personal injury or substantial property damage will result if proper precau-
tions are not taken.
!Warning
indicates that death, severe personal injury or substantial property damage can result if proper
precautions are not taken.
!Caution
indicates that minor personal injury can result if proper precautions are not taken.
Caution
indicates that property damage can result if proper precautions are not taken.
Notice
draws your attention to particularly important information on the product, handling the product, or to a
particular part of the documentation.
Qualified Personnel
Only qualified personnel should be allowed to install and work on this equipment. Qualified persons
are defined as persons who are authorized to commission, to ground and to tag circuits, equipment, and
systems in accordance with established safety practices and standards.
Correct Usage
Note the following:
!Warning
This device and its components may only be used for the applications described in the catalog or the
technical description, and only in connection with devices or components from other manufacturers
which have been approved or recommended by Siemens.
This product can only function correctly and safely if it is transported, stored, set up, and installed
correctly, and operated and maintained as recommended.
Trademarks SIMATIC, SIMATIC HMIand SIMATIC NETare registered trademarks of SIEMENS AG.
Third parties using for their own purposes any other names in this document which refer to trademarks
might infringe upon the rights of the trademark owners.
Safety Guidelines
This manual contains notices intended to ensure personal safety, as well as to protect the products and
connected equipment against damage. These notices are highlighted by the symbols shown below and
graded according to severity by the following texts:
We have checked the contents of this manual for agreement
with the hardware and software described. Since deviations
cannot be precluded entirely, we cannot guarantee full
agreement. However, the data in this manual are reviewed
regularly and any necessary corrections included in
subsequent editions. Suggestions for improvement are
welcomed.
Disclaim of Liability
Copyright W Siemens AG 1999-2002 All rights reserved
The reproduction, transmission or use of this document or its
contents is not permitted without express written authority.
Offenders will be liable for damages. All rights, including
rights created by patent grant or registration of a utility model
or design, are reserved.
Siemens AG
Bereich Automation and Drives
Geschaeftsgebiet Industrial Automation Systems
Postfach 4848, D- 90327 Nuernberg Siemens AG 1999– 2002
Technical data subject to change.
Siemens Aktiengesellschaft A5E00069481-04

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Preface
Purpose of the Manual
The information given in this manual makes it possible for you to:
•install and wire an S7-400 memory programmable controller
•configure an M7-400 automation computer for mechanical and electrical
installation
A description of the functions and technical specifications of the signal modules,
power supply modules and interface modules can be found in the reference
manual Module Specifications.
Required Basic Knowledge
General knowledge of the field of automation engineering is required in order to
understand the manual.
Target Group
This manual is aimed at people with the required qualifications to commission,
operate and maintain the products described.
Where is this Manual valid?
The manual is valid for the S7-400 and M7-400 programmable controllers.
Changes compared to the previous version
Section 2.5 and Appendix A have been updated since the previous edition of the
“Hardware and Installation” manual.
Note: You can recognize the previous edition of this ”Hardware and Installation”
manual by the number that appears in the footer: A5E00069480-03.
The number of the current edition is: A5E00069480-04.

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iv S7-400 and M7-400 Programmable Controllers Hardware and Installation
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Certification
The SIMATIC S7-400 product range has the following certificates and approvals:
•Underwriters Laboratories, Inc.: UL 508 (Industrial Control Equipment)
•Canadian Standards Association: CSA C22.2 Nummer 142, tested (Process
Control Equipment)
•Factory Mutual Research: Approval Standard Class Number 3611.
You can find details on the certificates and approvals in the “Module Specifications”
manual.
CE Labeling
The SIMATIC S7-400 product range complies with the requirements and protection
objectives of the following EU directives:
•EC low voltage directive 73/23/EEC
•EC electromagnetic compatibility directive 89/336/EEC
C-Tick Mark
The SIMATIC S7-400 product range complies with the requirements of the
AS/NZS 2064 standard (Australia and New Zealand).
Standards
The SIMATIC S7-400 product range complies with the requirements and criteria of
the IEC 61131-2.
Place of this Documentation in the Information Environment
This manual is part of the documentation package for S7-400, M7-400.
System Documentation Packages
S7-400/M7-400 •S7-400, M7-400 Programmable Controller;
Hardware and Installation
•S7-400, M7-400 Programmable Controllers; Module Specifications
•S7-400 Instruction List
•S7 400, CPU Data Programmable Controller

Preface
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S7-400 and M7-400 Programmable Controllers Hardware and Installation
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Finding Your Way
The manual offers the following access aids to make it easy for you to find specific
information quickly:
•At the beginning of the manual you will find a complete table of contents and
lists of the figures and tables contained in the manual.
•In each chapter you will find information in the left-hand margin on each page
that gives you an overview of the contents of the relevant section.
•After the appendices you will find a glossary containing definitions of important
terms and concepts that are used in the manual.
•At the end of the manual you will find a detailed index, allowing you to quickly
find the information you are looking for.
Specific Information for S7-400
You require the following manuals and manual packages in order to program and
commission an S7-400:
Manual/
Manual Package Contents
Standard Software
for S7 and M7
STEP 7 Basic
Information
•Installing and starting up STEP 7 on a programming device / PC
•Working with STEP 7 with the following contents:
Managing projects and files
Configuring and assigning parameters to the S7-400 configuration
Assigning symbolic names for user programs
Creating and testing a user program in STL/LAD
Creating data blocks
Configuring the communication between two or more CPUs
Loading, storing and deleting user programs in the CPU / programming device
Monitoring and controlling user programs
Monitoring and controlling the CPU
•Guide for efficiently implementing the programming task with the programming
device / PC and STEP 7
•How the CPUs work (for example, memory concept, access to inputs and
outputs, addressing, blocks, data management)
•Description of STEP 7 data management
•Using data types of STEP 7
•Using linear and structured programming
•Using block call instructions
•Using the debug and diagnostic functions of the CPUs in the user program
(for example, error OBs, status word)

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Manual/
Manual Package Contents
STEP 7 Reference
Information
Statement List (STL)
for S7-300 and
S7-400
Ladder Logic (LAD)
•Basic procedure for working with STL, LAD, or FBD (for example, structure of
STL, LAD, or FBD, number formats, syntax)
•Description of all instructions in STEP 7 (with program examples)
•Description of the various addressing methods in STEP 7 (with examples)
•Description of all functions integrated in the CPUs
•Description of the internal registers in the CPU
for S7-300 and
S7-400
Function Block
Diagram (FBD) for
S7-300 and S7-400
System and
Standard Functions
Description of the internal registers in the CPU
•Description of all system functions integrated in the CPUs
•Description of all organization blocks integrated in the CPUs
Manual
PG 7xx
•Description of the programming device hardware
•Connecting a programming device to various devices
•Starting up a programming device

Preface
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S7-400 and M7-400 Programmable Controllers Hardware and Installation
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Specific Information for M7-400
This documentation package describes the hardware of the M7-400. You will need
the following additional documentation for programming and starting up an M7-400:
Documentation Contents Order No.
System Software for
M7-300/400 Program Design
Programming Manual
Designing, writing and testing a C program
for M7 CPU/FM modules with the M7 SYS
programming package, using the M7 SYS
functions
6ES7802-0FA14-0BA0
System Software for
M7-300/400 System and
Standard Functions
Reference Manual
Detailed description of the M7 SYS functions
and data structures, listing of messages
types
System Software for
M7-300/400 Installation and
Operation
User Manual
Installing and configuring the operating
system and system software
Recycling and Disposal
The S7-400 is environmentally friendly and can thus recyclable. Consult a certified
disposal agency for electronics junk to recycle and dispose of your old equipment
in an environmentally friendly manner.
Further Support
If you have any technical questions, please get in touch with your Siemens
representative or agent responsible.
http://www.siemens.de/partner
Training Centers
Siemens offers a number of training courses to familiarize you with the SIMATIC S7
automation system. Please contact your regional training center or our central
training center in D-90327 Nuremberg, Germany for details:
Telephone: [phone].
Internet: http://www.sitrain.com

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viii S7-400 and M7-400 Programmable Controllers Hardware and Installation
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A&D Technical Support
Worldwide, available 24 hours a day:
Johnson City
Nuernberg
Beijing
Technical Support
Worldwide (Nuernberg)
Technical Support
24 hours a day, 365 days a year
Phone: [phone]
Fax: [phone]
E-Mail: adsupport@
siemens.com
GMT: +1:00
Europe / Africa (Nuernberg)
Authorization
Local time: Mon.-Fri. 8:00 to 17:00
Phone: [phone]
Fax: [phone]
E-Mail: adsupport@
siemens.com
GMT: +1:00
United States (Johnson City)
Technical Support and
Authorization
Local time: Mon.-Fri. 8:00 to 17:00
Phone: [phone]
Fax: [phone]
E-Mail: simatic.hotline@
sea.siemens.com
GMT: –5:00
Asia / Australia (Beijing)
Technical Support and
Authorization
Local time: Mon.-Fri. 8:00 to 17:00
Phone: [phone]
Fax: [phone]
E-Mail: adsupport.asia@
siemens.com
GMT: +8:00
The languages of the SIMATIC Hotlines and the authorization hotline are generally German and English.

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Service & Support on the Internet
In addition to our documentation, we offer our Know-how online on the internet at:
http://www.siemens.com/automation/service&support
where you will find the following:
•The newsletter, which constantly provides you with up–to–date information on
your products.
•The right documents via our Search function in Service & Support.
•A forum, where users and experts from all over the world exchange their
experiences.
•Your local representative for Automation & Drives via our representatives
database.
•Information on field service, repairs, spare parts and more under “Services”.

Preface
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Contents
1 Product Overview 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 Installing the S7-400 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.1 Assembling an S7-400 2-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.2 Assembling the Central Rack (CR) and Expansion Rack (ER) 2-6. . . . . . . . .
2.3 Segmented CR 2-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.4 Subdivided CR 2-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.5 Mounting and Grounding the Racks 2-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.6 Chassis Terminal Connection in the Non-Isolated Configuration 2-16. . . . . . . .
2.7 Methods of Ventilation 2-19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.8 Changing the Ventilation with the Cable Duct and Fan Subassembly 2-21. . . .
2.9 Installing the Fan Subassembly 2-23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.10 Installing the Cable Duct 2-25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.11 Choosing and Setting up Cabinets with the S7-400 2-26. . . . . . . . . . . . . . . . . . .
2.12 Rules for the Arrangement of Modules 2-30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.13 Fitting Memory Cards in the CPU 2-31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.14 Installing Modules in a Rack 2-33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.15 Marking the Modules with Slot Labels 2-37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.16 Methods of Expansion and Networking 2-38. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.17 Accessories 2-39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 Addressing the S7-400 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.1 Geographical and Logical Addresses 3-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2 How to Determine the Default Address of a Module 3-4. . . . . . . . . . . . . . . . . .
3.3 How to Determine the Default Address of a Channel 3-6. . . . . . . . . . . . . . . . . .

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4 Wiring the S7-400 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.1 Supplying Power to Modules 4-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2 Choosing the Power Supply Module 4-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3 Choosing the Load Current Power Supply 4-4. . . . . . . . . . . . . . . . . . . . . . . . . . .
4.4 Assembling an S7-400 with Process I/Os 4-5. . . . . . . . . . . . . . . . . . . . . . . . . . .
4.5 Assembling an S7-400 with Grounded Reference Potential (M) 4-7. . . . . . . .
4.6 Assembling an S7-400 with Ungrounded Reference Potential
(Ungrounded Configuration) 4-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.7 Assembling an S7-400 with Isolated Modules 4-10. . . . . . . . . . . . . . . . . . . . . . . .
4.8 Parallel Wiring of Digital S7-400 Outputs 4-12. . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.9 Grounding 4-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.10 Interference-Free Configuration for Local and Remote Connections 4-15. . . .
4.11 Wiring Rules 4-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.12 Setting the VAC Power Supply Module to the Line Voltage 4-18. . . . . . . . . . . . .
4.13 Wiring the Power Supply Module 4-20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.14 Wiring the Signal Modules 4-24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.15 Wiring the Front Connector, Crimp Snap-On Terminals 4-26. . . . . . . . . . . . . . . .
4.16 Wiring the Front Connector, Screw-Type Terminals 4-27. . . . . . . . . . . . . . . . . . .
4.17 Wiring the Front Connector, Spring-Type Terminals 4-28. . . . . . . . . . . . . . . . . . .
4.18 Fitting the Strain Relief 4-30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.19 Labeling a Front Connector 4-31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.20 Fitting the Front Connector 4-35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.21 Interconnecting the CR and ER(s) 4-38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.22 Setting the Fan Subassembly to the Line Voltage and Wiring It 4-40. . . . . . . . .
4.23 Routing Cables Using Cable Ducts or Fan Subassemblies 4-42. . . . . . . . . . . .
4.24 Routing Cables Using Fiber-Optic Cables 4-42. . . . . . . . . . . . . . . . . . . . . . . . . . .

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5 Networking 5-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.1 Configuring a Network 5-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2 Fundamentals 5-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.3 Rules for Configuring a Network 5-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.4 Cable Lengths 5-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.5 PROFIBUS-DP Bus Cables 5-18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.6 Bus Connectors 5-19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.7 RS 485 Repeater 5-23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.8 PROFIBUS-DP Network with Fiber-Optic Cables 5-25. . . . . . . . . . . . . . . . . . . . .
5.8.1 Fiber-Optic Cables 5-27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.8.2 Simplex Connectors and Connector Adapter 5-29. . . . . . . . . . . . . . . . . . . . . . . .
5.8.3 Connecting a Fiber-Optic Cable to the PROFIBUS Device 5-31. . . . . . . . . . . . .
6 Starting Up 6-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.1 Recommended Procedure for First Startup 6-2. . . . . . . . . . . . . . . . . . . . . . . . . .
6.2 Checks Prior to Switching On for the First Time 6-3. . . . . . . . . . . . . . . . . . . . . .
6.3 Connecting a Programming Device (PG) to an S7-400 6-5. . . . . . . . . . . . . . . .
6.4 Switching On an S7-400 for the First Time 6-6. . . . . . . . . . . . . . . . . . . . . . . . . .
6.5 Resetting the CPU with the Mode Selector Switch 6-7. . . . . . . . . . . . . . . . . . . .
6.6 Cold, Warm, and Hot Restarts with the Mode Selector Switch 6-10. . . . . . . . . .
6.7 Inserting a Memory Card 6-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.8 Inserting a Backup Battery (Option) 6-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.9 Starting Up a PROFIBUS-DP Subnet 6-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.10 Installing Interface Submodules
(CPU 414-2, 414-3, 416-3, 417-4 and 417-4H) 6-18. . . . . . . . . . . . . . . . . . . . . . .
7 Maintenance 7-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.1 Replacing the Backup Battery 7-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.2 Replacing a Power Supply Module 7-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.3 Replacing CPUs 7-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.4 Replacing Digital or Analog Modules 7-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.5 Changing the Fuses in the Digital Modules 7-9. . . . . . . . . . . . . . . . . . . . . . . . . .
7.6 Replacing Interface Modules 7-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.7 Replacing the Fuse of the Fan Subassembly 7-13. . . . . . . . . . . . . . . . . . . . . . . .
7.8 Replacing Fans in the Fan Subassembly During Operation 7-14. . . . . . . . . . . .
7.9 Replacing the Filter Frame of the Fan Subassembly During Operation 7-16. .
7.10 Replacing the Power Supply PCB and Monitoring PCB
of the Fan Subassembly 7-18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.11 Replacing Memory Cards 7-19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.12 Replacing Interface Submodules 7-22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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xiv S7-400 and M7-400 Programmable Controllers Hardware and Installation
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8 Assembling the M7-400 8-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.1 Mechanical Configuration 8-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.2 Addressing the M7-400 Modules 8-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.3 Electrical Configuration 8-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.4 Installing the M7-400 8-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.4.1 Checklist for Installation 8-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.4.2 Module Accessories 8-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.4.3 Fitting Memory Cards in the CPU 8-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.4.4 Installing Interface Submodules 8-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.4.5 Fitting the Short AT Card 8-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.4.6 Assembling Expansion Modules on a Central Rack 8-17. . . . . . . . . . . . . . . . . . .
8.4.7 Installing a Module Assembly in the Rack 8-24. . . . . . . . . . . . . . . . . . . . . . . . . . .
8.4.8 Inserting/Removing a Memory Card 8-28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.5 Connecting a Module Assembly 8-29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.6 Assembling an MPI Subnet or PROFIBUS-DP Subnet 8-30. . . . . . . . . . . . . . . .
8.7 Preparing for Operation 8-32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.7.1 Connecting the Operator Panels and I/O Devices 8-33. . . . . . . . . . . . . . . . . . . .
8.7.2 Connecting a Programming Device (PG) to the COM Interface 8-36. . . . . . . . .
8.7.3 Connecting a Programming Device (PG) to the M7-400 8-39. . . . . . . . . . . . . . .
8.7.4 Connecting a Programming Device (PG) to Two or More Nodes 8-40. . . . . . . .
8.7.5 Connecting a Programming Device (PG)
to Ungrounded Nodes of an MPI Subnet 8-43. . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.7.6 Starting Up a PROFIBUS-DP Subnet 8-44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.7.7 Checking the Status and Error Indicators 8-45. . . . . . . . . . . . . . . . . . . . . . . . . . .
8.8 Replacing Modules and Submodules/Cards 8-46. . . . . . . . . . . . . . . . . . . . . . . . .
8.8.1 Replacing an Interface Module 8-47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.8.2 Replacing the CPU or Expansion Modules of a Module Assembly 8-49. . . . . .
8.8.3 Replacing Memory Cards in a CPU 8-54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.8.4 Replacing a Short AT Card 8-56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Contents
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S7-400 and M7-400 Programmable Controllers Hardware and Installation
A5E00069481-04
A Assembling and Installing Systems A-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A.1 General Rules and Regulations for Operating the S7-400 A-2. . . . . . . . . . . . .
A.2 Principles of System Installation for EMC A-5. . . . . . . . . . . . . . . . . . . . . . . . . . .
A.3 Installation of Programmable Controllers for EMC A-9. . . . . . . . . . . . . . . . . . . .
A.4 Examples of EMC-Compatible Assembly A-10. . . . . . . . . . . . . . . . . . . . . . . . . . .
A.5 Shielding Cables A-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A.6 Equipotential Bonding A-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A.7 Cabling Inside Buildings A-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A.8 Cabling Outside Buildings A-19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A.9 Lightning Protection and Overvoltage Protection A-20. . . . . . . . . . . . . . . . . . . . .
A.9.1 Lightning Protection Zone Concept A-21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A.9.2 Rules for the Transition between Lightning Protection Zones 0 and 1 A-23. . .
A.9.3 Rules for the Transitions between
Lightning Protection Zones 1 <-> 2 and Greater A-25. . . . . . . . . . . . . . . . . . . . . .
A.9.4 Sample of a Surge Protection Circuit for Networked S7-400 PLCs A-28. . . . . .
A.10 How to Protect Digital Output Modules against Inductive Surge A-30. . . . . . . .
A.11 Safety of Electronic Control Equipment A-32. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A.12 Interference-Free Connection of Monitors A-34. . . . . . . . . . . . . . . . . . . . . . . . . . .
B Guidelines for Handling Electrostatically-Sensitive Devices (ESD) B-1. . . . . . . . . .
B.1 What is ESD? B-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
B.2 Electrostatic Charging of Persons B-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
B.3 General Protective Measures Against Electrostatic Discharge Damage B-4.
Glossary
Index

Contents
xvi S7-400 and M7-400 Programmable Controllers Hardware and Installation
A5E00069481-04
Figures
2-1 Rack Fitted with Modules in the S7-400 System 2-2. . . . . . . . . . . . . . . . . . . . .
2-2 Max. Cabinet Ambient Temperature as a Function
of Power Dissipation of Equipment in the Cabinet 2-28. . . . . . . . . . . . . . . . . . . .
2-3 Fitting Memory Cards in the CPUs 2-32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-4 Memory Card 2-32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-5 Removing the Cover 2-34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-6 Attaching the Modules 2-35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-7 Screwing the Modules in Place 2-35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-8 Inserting the Key in the CPU 2-36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-9 Fitting a Slot Label 2-37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1 Operating the S7-400 from a Grounded Supply 4-6. . . . . . . . . . . . . . . . . . . . . .
4-2 An S7-400 Configured with Grounded Reference Potential 4-7. . . . . . . . . . . .
4-3 An S7-400 Configured with Ungrounded Reference Potential 4-8. . . . . . . . . .
4-4 Simplified Representation of Configuration with Isolated Modules 4-11. . . . . . .
4-5 Parallel Wiring of a Digital Output with Different Rated Load Voltages 4-12. . .
4-6 Parallel Wiring of a Digital Output with Identical Rated Load Voltages 4-12. . .
4-7 Grounded connection load voltage 4-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-8 Shielding and Grounding the Connecting Cable for
a Remote Connection 4-16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-9 Setting the voltage selector 4-19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-10 Disconnecting power supply connector 4-20. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-11 Wiring the power supply connector 4-22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-12 Plugging the power supply connector 4-23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-13 Preparing to wire the front connector 4-25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-14 Wiring a Front Connector with Crimp Snap-On Terminals 4-26. . . . . . . . . . . . . .
4-15 Wiring a Front Connector with Screw-Type Terminals 4-27. . . . . . . . . . . . . . . . .
4-16 Wiring a Front Connector with Spring-Type Terminals 4-28. . . . . . . . . . . . . . . . .
4-17 Principle of the spring contact 4-29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-18 Fitting a Strain Relief (Viewed from Below) 4-30. . . . . . . . . . . . . . . . . . . . . . . . . .
4-19 Fitting the Labels on the Front Connector 4-31. . . . . . . . . . . . . . . . . . . . . . . . . . .
4-20 Fitting a Label in the Front Connector 4-32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-21 Attaching the Front Connector 4-36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-22 Screwing On the Front Connector 4-37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-23 Plugging a Connecting Cable into a Send IM 4-38. . . . . . . . . . . . . . . . . . . . . . . .
4-24 Connection Between a Send IM and Two Receive IMs 4-39. . . . . . . . . . . . . . . .
4-25 Wiring the Fan Subassembly 4-41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1 Communication between Programming Device/Operator Panel
and a Module without MPI 5-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-2 Data Exchange 5-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-3 Terminating resistor on bus connector 5-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-4 Terminating resistor on RS 485 repeater 5-9. . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-5 Terminating resistor on MPI network 5-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-6 Example of an MPI network 5-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-7 Example of a PROFIBUS DP network 5-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-8 Example with CPU 414-2 5-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-9 Programming device access beyond network limits 5-14. . . . . . . . . . . . . . . . . . .
5-10 Configuration of an MPI network 5-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-11 Bu s connector 5-19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-12 Strip bus cable 5-20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-13 Inserting cores into the screw termninal blocks 5-21. . . . . . . . . . . . . . . . . . . . . .
5-14 Switch on terminating resistant 5-22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Contents
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S7-400 and M7-400 Programmable Controllers Hardware and Installation
A5E00069481-04
5-15 Turning back braided shield over cable 5-24. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-16 Optical PROFIBUS-DP Network with Nodes
that have an Integrated Fiber-Optic Cable Interface 5-26. . . . . . . . . . . . . . . . . .
5-17 Simplex Connectors and a Special Connector Adapter
for the IM 153-2 FO and IM 467 FO (installed) 5-30. . . . . . . . . . . . . . . . . . . . . . .
6-1 Connecting PG to an S7-400 6-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-2 Inserting a Memory Card in a CPU 6-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-3 Inserting Interface Submodules in the CPU 6-19. . . . . . . . . . . . . . . . . . . . . . . . . .
7-1 Fitting Memory Cards in the CPUs 7-20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-2 Memory Card 7-21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-3 Inserting an Interface Submodule in a CPU 7-23. . . . . . . . . . . . . . . . . . . . . . . . .
8-1 Fitting Memory Cards in the CPUs 8-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-2 3.3 V Memory Card 8-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-3 Inserting an Interface Submodule in an Expansion Module 8-14. . . . . . . . . . . .
8-4 Fitting an AT Card in the ATM 478 AT Adapter Module 8-16. . . . . . . . . . . . . . . .
8-5 Locations of the Expansion Socket and Plug 8-18. . . . . . . . . . . . . . . . . . . . . . . .
8-6 EXM 478 Expansion Module Fitted with Connecting Clips 8-19. . . . . . . . . . . . .
8-7 Removing the Cover 8-20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-8 Interconnecting a CPU and Expansion Modules 8-21. . . . . . . . . . . . . . . . . . . . .
8-9 Module Assembly Comprising CPU and Expansion Modules 8-22. . . . . . . . . . .
8-10 Connecting Clip 8-23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-11 Securing the Modules with Connecting Clips (Schematic Diagram) 8-23. . . . .
8-12 Attaching a Module Assembly Comprising CPU and Expansion Modules
and Swinging it into Position 8-25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-13 Screwing the Modules On 8-26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-14 Inserting the Key in the CPU 8-27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-15 Inserting a Memory Card in a CPU 8-28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-16 Example of a Configuration with the CPU in an MPI Subnet
and PROFIBUS-DP Subnet 8-31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-17 Connecting a Programming Device to the M7-400 8-39. . . . . . . . . . . . . . . . . . . .
8-18 Connecting a Programming Device to Two or More M7-400s 8-41. . . . . . . . . .
8-19 Connecting a Programming Device to an M7-400 Subnet 8-42. . . . . . . . . . . . .
8-20 Ungrounded Operation of the M7-400 Network 8-43. . . . . . . . . . . . . . . . . . . . . .
8-21 Removing an Interface Submodule from the Card Slot
of an Expansion Module 8-48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-22 Removing the Cover 8-49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-23 Unscrewing Modules 8-50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-24 Swinging a Module Assembly Out and Lifting it Up and Out 8-51. . . . . . . . . . . .
8-25 Module Assembly Comprising CPU and Expansion Modules 8-51. . . . . . . . . . .
8-26 Removing the Connecting Clips from the Module to be Replaced 8-52. . . . . . .
8-27 Separating the Modules, for Example When the
Mass Storage Module is to be Replaced 8-53. . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-28 Removing Memory Cards from the CPUs 8-55. . . . . . . . . . . . . . . . . . . . . . . . . . .
8-29 3.3 V Memory Card 8-55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-30 Removing an AT Card from the ATM 478 AT Adapter Module 8-57. . . . . . . . . .

Contents
xviii S7-400 and M7-400 Programmable Controllers Hardware and Installation
A5E00069481-04
A-1 The Possible Routes for Electromagnetic Interference A-5. . . . . . . . . . . . . . . .
A-2 Example of Cabinet Installation for EMC A-10. . . . . . . . . . . . . . . . . . . . . . . . . . . .
A-3 Wall Mounting an S7-400 for EMC A-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A-4 Mounting Cable Shields A-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A-5 Routing Equipotential Bonding Conductor and Signal Line A-16. . . . . . . . . . . . .
A-6 Lightning Protection Zones of a Building A-22. . . . . . . . . . . . . . . . . . . . . . . . . . . .
A-7 Sample Circuitry for Networked S7-400 PLCs A-28. . . . . . . . . . . . . . . . . . . . . . .
A-8 Relay Contact for EMERGENCY OFF in the Output Circuit A-30. . . . . . . . . . . .
A-9 Suppression for DC-Operated Coils A-31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A-10 Suppression with AC-Operated Coils A-31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A-11 Shielding and Grounding with a Great Distance between Monitor
and Programmable Controller A-36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
B-1 Electrostatic Voltages which can Build up on a Person B-3. . . . . . . . . . . . . . . .

Contents
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S7-400 and M7-400 Programmable Controllers Hardware and Installation
A5E00069481-04
Tables
2-1 Types of Cabinet 2-27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2 Modules in the different racks 2-30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-3 Accessories for Modules and Racks 2-39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1 VDE Specifications for Assembling a Programmable Controller 4-5. . . . . . . .
4-2 Methods of Protective Grounding 4-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-3 Grounded connection load voltage 4-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-4 Front connector coding elements 4-35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1 Permitted Cable Length of a Segment in an MPI Network 5-15. . . . . . . . . . . . .
5-2 Permitted Cable Length of a Segment in the PROFIBUS-DP Network
Depending on the Transmisson Rate 5-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-3 Lengths of Spur Lines per Segment 5-16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-4 Features of the Fiber-Optic Cables 5-27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-5 Order Numbers - Fiber-Optic Cables 5-29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-6 Order Numbers - Simplex connectors and connector adapters 5-30. . . . . . . .
5-7 Permissible Cable Lengths on the Optical PROFIBUS-DP Network
(Partyline Topology) 5-31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-1 Checklist to be Used Before Switching On for the First Time 6-3. . . . . . . . . .
6-2 Setting the Battery Monitoring Switch 6-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-1 Sequence in the Module Subassembly 8-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-2 Possible Applications of the M7-400 Modules 8-3. . . . . . . . . . . . . . . . . . . . . . . .
8-3 Dimensions of Modules in the M7-400 System 8-4. . . . . . . . . . . . . . . . . . . . . . .
8-5 Accessories for Modules and Racks 8-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-6 Maximum Cable Lengths for Operator Panels and I/O Devices 8-35. . . . . . . . .
8-7 Null Modem Cable for Connecting a CPU via IF to the COM Interface
of a Programming Device with 9-pin Sub. D Male Connector 8-36. . . . . . . . . .
8-8 Null Modem Cable for Connecting a CPU via IF to the COM Interface
of a Programming Device with 25-pin Sub. D Male Connector 8-37. . . . . . . . . .
8-9 Pin Assignments of the Cable for Connecting a CPU via IF
to the COM Interface of a Programming Device
with 9-pin Sub. D Male Connector 8-38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-10 Pin Assignments of the Cable for Connecting a CPU via IF
to the COM Interface of a Programming Device with 25-pin
Sub. D Female Connector 8-38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A-1 Key for Example 1 A-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A-2 Cabling Inside Buildings A-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A-3 High-Voltage Protection of Cables with the Help
of Surge Protection Equipment A-23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A-4 Low-Voltage Protection Components
for Lightning Protection Zones 1 <–> 2 A-26. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A-5 Surge Protection Components for Lightning Protection Zones 2 <–> 3 A-27. .
A-6 Example of a Circuit Conforming to Lightning Protection Requirements
(Legend to Figure A-7) A-29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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xx S7-400 and M7-400 Programmable Controllers Hardware and Installation
A5E00069481-04