Siemens Simatic S7 Series User guide

S7-200 SMART
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SIMATIC
S7
S7-200 SMART
System Manual
09/2015
A5E03822230
-AC
Preface
Product overview
1
Getting started
2
Installation
3
PLC concepts
4
Programming concepts
5
PLC device configuration
6
Program instructions
7
Communication
8
Libraries
9
Debugging and
troubleshooting
10
PID loops and tuning
11
Open loop motion control
12
Technical specifications
A
Calculating a power budget
B
Error codes
C
Special memory (SM) and
system symbol names
D
References
E
Ordering information
F

Siemens AG
Division Digital Factory
Postfach 48 48
90026 NÜRNBERG
GERMANY
A5E03822230-AC
Ⓟ
07/2015 Subject to change
Copyright © Siemens AG 2015.
All rights reserved
Legal information
Warning notice system
This manual contains notices you have to observe in order to ensure your personal safety, as well as to prevent
damage to property. The notices referring to your personal safety are highlighted in the manual by a safety alert
symbol, notices referring only to property damage have no safety alert symbol. These notices shown below are
graded according to the degree of danger.
DANGER
indicates that death or severe personal injury will result if proper precautions are not taken.
WARNING
indicates that death or severe personal injury may result if proper precautions are not taken.
CAUTION
indicates that minor personal injury can result if proper precautions are not taken.
NOTICE
indicates that property damage can result if proper precautions are not taken.
If more than one degree of danger is present, the warning notice representing the highest degree of danger will
be used. A notice warning of injury to persons with a safety alert symbol may also include a warning relating to
property damage.
Qualified Personnel
The product/system described in this documentation may be operated only by
personnel qualified
for the specific
task in accordance with the relevant documentation, in particular its warning notices and safety instructions.
Qualified personnel are those who, based on their training and experience, are capable of identifying risks and
avoiding potential hazards when working with these products/systems.
Proper use of Siemens products
Note the following:
WARNING
Siemens products may only be used for the applications described in the catalog and in the relevant technical
documentation. If products and components from other manufacturers are used, these must be recommended
or approved by Siemens. Proper transport, storage, installation, assembly, commissioning, operation and
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Disclaimer of Liability
We have reviewed the contents of this publication to ensure consistency with the hardware and software
described. Since variance cannot be precluded entirely, we cannot guarantee full consistency. However, the
information in this publication is reviewed regularly and any necessary corrections are included in subsequent
editions.

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System Manual, 09/2015, A5E03822230-AC 3
Preface
Purpose of the manual
The S7-200 SMART series is a line of micro-programmable logic controllers (Micro PLCs)
that can control a variety of automation applications. Compact design, low cost, and a
powerful instruction set make the S7-200 SMART a perfect solution for controlling small
applications. The wide variety of S7-200 SMART models and the Windows-based
programming tool give you the flexibility you need to solve your automation problems.
This manual provides information about installing and programming the S7-200 SMART
CPUs and is designed for engineers, programmers, installers, and electricians who have a
general knowledge of programmable logic controllers.
Required basic knowledge
To understand this manual, it is necessary to have a general knowledge of automation and
programmable logic controllers.
Scope of the manual
This manual describes the following products:
●STEP 7-Micro/WIN SMART V2.01
●S7-200 SMART CPU firmware release V2.1
For a complete list of the S7-200 SMART products and article numbers described in this
manual, see Technical Specifications (Page 565).
Certification, CE label and other standards
Refer to the technical specifications for more information.
Service and support
In addition to our documentation, we offer our technical expertise on the Internet on the
customer support web site (http://www.siemens.com/automation/).
Contact your Siemens distributor or sales office for assistance in answering any technical
questions, for training, or for ordering S7 products. Because your sales representatives are
technically trained and have the most specific knowledge about your operations, process
and industry, as well as about the individual Siemens products that you are using, they can
provide the fastest and most efficient answers to any problems you might encounter.

Preface
S7-200 SMART
4System Manual, 09/2015, A5E03822230-AC
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
(http://www.siemens.com/industrialsecurity).
To stay informed about product updates as they occur, sign up for a product-specific
newsletter. You can find more information on the Internet
(http://support.automation.siemens.com).

S7-200 SMART
System Manual, 09/2015, A5E03822230-AC 5
Table of contents
Preface ...................................................................................................................................................... 3
1 Product overview ..................................................................................................................................... 17
1.1 S7-200 SMART CPU ..............................................................................................................18
1.2 S7-200 SMART expansion modules.......................................................................................20
1.3 HMI devices for S7-200 SMART.............................................................................................21
1.4 Communications options ........................................................................................................22
1.5 Programming software............................................................................................................23
1.6 New features...........................................................................................................................24
2 Getting started ......................................................................................................................................... 25
2.1 Connecting to the CPU...........................................................................................................25
2.1.1 Configuring the CPU for communication ................................................................................26
2.1.1.1 Overview.................................................................................................................................26
2.1.1.2 Establishing the hardware communication connection...........................................................27
2.1.1.3 Setting up communication with the CPU ................................................................................27
2.2 Creating the sample program .................................................................................................29
2.2.1 Network 1: Starting the timer ..................................................................................................30
2.2.2 Network 2: Turning the output on ...........................................................................................31
2.2.3 Network 3: Resetting the timer ...............................................................................................32
2.2.4 Setting the CPU type and version for your project .................................................................33
2.2.5 Saving the sample project ......................................................................................................34
2.3 Downloading the sample program..........................................................................................35
2.4 Changing the operating mode of the CPU..............................................................................36
3 Installation ............................................................................................................................................... 37
3.1 Guidelines for installing S7-200 SMART devices...................................................................37
3.2 Power budget..........................................................................................................................39
3.3 Installation and removal procedures.......................................................................................41
3.3.1 Mounting dimensions for the S7-200 SMART devices...........................................................41
3.3.2 Installing and removing the CPU ............................................................................................42
3.3.3 Installing and removing an expansion module .......................................................................45
3.3.4 Installing and removing a signal board or battery board.........................................................46
3.3.5 Removing and reinstalling the terminal block connector ........................................................48
3.4 Wiring guidelines.....................................................................................................................49

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4 PLC concepts .......................................................................................................................................... 55
4.1 Execution of the control logic................................................................................................. 55
4.1.1 Reading the inputs and writing to the outputs........................................................................ 57
4.1.2 Immediately reading or writing the I/O ................................................................................... 57
4.1.3 Executing the user program................................................................................................... 58
4.2 Accessing data....................................................................................................................... 60
4.2.1 Accessing memory areas....................................................................................................... 61
4.2.2 Format for Real numbers ....................................................................................................... 68
4.2.3 Format for strings................................................................................................................... 68
4.2.4 Assigning a constant value for instructions............................................................................ 69
4.2.5 Addressing the local and expansion I/O ................................................................................ 69
4.2.6 Using pointers for indirect addressing ................................................................................... 70
4.2.7 Pointer examples ................................................................................................................... 73
4.3 Saving and restoring data...................................................................................................... 75
4.3.1 Downloading project components.......................................................................................... 75
4.3.2 Uploading project components .............................................................................................. 77
4.3.3 Types of storage .................................................................................................................... 78
4.3.4 Using a memory card............................................................................................................. 79
4.3.5 Inserting a memory card in the CPU...................................................................................... 81
4.3.6 Transferring your program with a memory card..................................................................... 81
4.3.7 Restoring data after power on................................................................................................ 84
4.4 Changing the operating mode of the CPU............................................................................. 84
5 Programming concepts............................................................................................................................ 85
5.1 Guidelines for designing a PLC system................................................................................. 85
5.2 Elements of the user program................................................................................................ 87
5.3 Creating your user program................................................................................................... 90
5.3.1 Earlier versions of STEP 7-Micro/WIN projects..................................................................... 90
5.3.2 Using STEP 7-Micro/WIN SMART user interface.................................................................. 92
5.3.3 Using STEP 7-Micro/WIN SMART to create your programs ................................................. 93
5.3.4 Using wizards to help you create your control program......................................................... 94
5.3.5 Features of the LAD editor..................................................................................................... 95
5.3.6 Features of the FBD editor..................................................................................................... 96
5.3.7 Features of the STL editor ..................................................................................................... 96
5.4 Data block (DB) editor............................................................................................................ 97
5.5 Symbol table ........................................................................................................................ 100
5.6 Variable table ....................................................................................................................... 104
5.7 PLC error reaction................................................................................................................ 109
5.7.1 Non-fatal errors and I/O errors............................................................................................. 110
5.7.2 Fatal errors........................................................................................................................... 111
5.8 Program edit in RUN mode.................................................................................................. 112
5.9 Features for debugging your program ................................................................................. 114

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6 PLC device configuration....................................................................................................................... 115
6.1 Configuring the operation of the PLC system.......................................................................115
6.1.1 System block.........................................................................................................................115
6.1.2 Configuring communication ..................................................................................................117
6.1.3 Configuring the digital inputs ................................................................................................119
6.1.4 Configuring the digital outputs ..............................................................................................121
6.1.5 Configuring the retentive ranges...........................................................................................122
6.1.6 Configuring system security..................................................................................................124
6.1.7 Configuring the startup options.............................................................................................128
6.1.8 Configuring the analog inputs...............................................................................................129
6.1.9 Reference to the analog inputs technical specifications.......................................................131
6.1.10 Configuring the analog outputs.............................................................................................132
6.1.11 Reference to the analog outputs technical specifications.....................................................133
6.1.12 Configuring the RTD analog inputs.......................................................................................134
6.1.13 Configuring the TC analog inputs .........................................................................................139
6.1.14 Configuring the RS485/RS232 CM01 communications signal board...................................143
6.1.15 Configuring the BA01 battery signal board...........................................................................144
6.1.16 Clearing PLC memory...........................................................................................................145
6.1.17 Creating a reset-to-factory-defaults memory card................................................................147
6.2 High-speed I/O......................................................................................................................148
7 Program instructions.............................................................................................................................. 149
7.1 Bit logic .................................................................................................................................149
7.1.1 Standard inputs.....................................................................................................................149
7.1.2 Immediate inputs...................................................................................................................151
7.1.3 Logic stack overview.............................................................................................................152
7.1.4 STL logic stack instructions ..................................................................................................154
7.1.5 NOT ......................................................................................................................................156
7.1.6 Positive and negative transition detectors ............................................................................157
7.1.7 Coils: output and output immediate instructions...................................................................158
7.1.8 Set, reset, set immediate, and reset immediate functions....................................................159
7.1.9 Set and reset dominant bistable ...........................................................................................160
7.1.10 NOP (No operation) instruction.............................................................................................161
7.1.11 Bit logic input examples ........................................................................................................162
7.1.12 Bit logic output examples......................................................................................................163
7.2 Clock .....................................................................................................................................165
7.2.1 Read and set real-time clock ................................................................................................165
7.2.2 Read and set real-time clock extended ................................................................................167
7.3 Communication.....................................................................................................................170
7.3.1 GET and PUT (Ethernet) ......................................................................................................170
7.3.2 Transmit and receive (Freeport on RS485/RS232)..............................................................178
7.3.3 Get port address and set port address (PPI protocol on RS485/RS232).............................190
7.3.4 Get IP address and set IP address (Ethernet)......................................................................191
7.4 Compare ...............................................................................................................................192
7.4.1 Compare number values ......................................................................................................192
7.4.2 Compare character strings ...................................................................................................196
7.5 Convert .................................................................................................................................198
7.5.1 Standard conversion instructions..........................................................................................198
7.5.2 ASCII character array conversion.........................................................................................202

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7.5.3 Number value to ASCII string conversion............................................................................ 208
7.5.4 ASCII sub-string to number value conversion ..................................................................... 212
7.5.5 Encode and decode ............................................................................................................. 215
7.6 Counters............................................................................................................................... 216
7.6.1 Counter instructions ............................................................................................................. 216
7.6.2 High-speed counter instructions .......................................................................................... 220
7.6.3 Noise reduction for high-speed inputs ................................................................................. 224
7.6.4 High-speed counter programming ....................................................................................... 226
7.6.5 Example initialization sequences for high-speed counters.................................................. 238
7.7 Pulse output ......................................................................................................................... 247
7.7.1 Pulse output instruction (PLS) ............................................................................................. 247
7.7.2 Pulse train output (PTO) ...................................................................................................... 249
7.7.3 Pulse width modulation (PWM)............................................................................................ 251
7.7.4 Using SM locations to configure and control the PTO/PWM operation............................... 252
7.7.5 Calculating the profile table values ...................................................................................... 255
7.8 Math ..................................................................................................................................... 259
7.8.1 Add, subtract, multiply, and divide ....................................................................................... 259
7.8.2 Multiply integer to double integer and divide integer with remainder................................... 262
7.8.3 Trigonometry, natural logarithm/exponential, and square root............................................ 264
7.8.4 Increment and decrement.................................................................................................... 266
7.9 PID ....................................................................................................................................... 268
7.9.1 Using the PID wizard ........................................................................................................... 269
7.9.2 PID algorithm ....................................................................................................................... 274
7.9.3 Converting and normalizing the loop inputs......................................................................... 278
7.9.4 Converting the loop output to a scaled integer value........................................................... 279
7.9.5 Forward- or reverse-acting loops......................................................................................... 279
7.10 Interrupt................................................................................................................................ 282
7.10.1 Interrupt instructions ............................................................................................................ 282
7.10.2 Interrupt routine overview and CPU model event support................................................... 284
7.10.3 Interrupt programming guidelines ........................................................................................ 285
7.10.4 Types of interrupt events that the S7-200 SMART CPU supports ...................................... 287
7.10.5 Interrupt priority, queuing, and example program................................................................ 288
7.11 Logical operations................................................................................................................ 293
7.11.1 Invert .................................................................................................................................... 293
7.11.2 AND, OR, and exclusive OR................................................................................................ 294
7.12 Move .................................................................................................................................... 296
7.12.1 Move byte, word, double word, or real................................................................................. 296
7.12.2 Block move........................................................................................................................... 297
7.12.3 Swap bytes........................................................................................................................... 298
7.12.4 Move byte immediate (read and write) ................................................................................ 299
7.13 Program control.................................................................................................................... 300
7.13.1 FOR-NEXT loop................................................................................................................... 300
7.13.2 JMP (jump to label) .............................................................................................................. 301
7.13.3 SCR (sequence control relay).............................................................................................. 303
7.13.4 END, STOP, and WDR (watchdog timer reset)................................................................... 312
7.13.5 GET_ERROR (Get non-fatal error code) ............................................................................. 313
7.14 Shift and rotate..................................................................................................................... 315
7.14.1 Shift and rotate..................................................................................................................... 315

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7.14.2 Shift register bit.....................................................................................................................317
7.15 String.....................................................................................................................................320
7.15.1 String (Get length, copy, and concatenate)..........................................................................320
7.15.2 Copy substring from string....................................................................................................322
7.15.3 Find string and first character within string ...........................................................................323
7.16 Table .....................................................................................................................................326
7.16.1 Add to table...........................................................................................................................326
7.16.2 First-in-first-out and last-in-first-out.......................................................................................328
7.16.3 Memory fill.............................................................................................................................330
7.16.4 Table find ..............................................................................................................................331
7.17 Timer.....................................................................................................................................335
7.17.1 Timer instructions..................................................................................................................335
7.17.2 Timer programming tips and examples ................................................................................337
7.17.3 Interval timers .......................................................................................................................344
7.18 Subroutine.............................................................................................................................346
7.18.1 CALL (subroutine) and RET (conditional return) ..................................................................346
8 Communication...................................................................................................................................... 353
8.1 CPU communication connections.........................................................................................354
8.2 CPU communication ports ....................................................................................................355
8.3 HMIs and communication drivers .........................................................................................355
8.4 Ethernet ................................................................................................................................357
8.4.1 Overview...............................................................................................................................357
8.4.2 TCP/IP protocol.....................................................................................................................357
8.4.3 Local/partner connection ......................................................................................................358
8.4.4 Sample Ethernet network configurations..............................................................................358
8.4.5 Assigning Internet Protocol (IP) addresses ..........................................................................359
8.4.5.1 Assigning IP addresses to programming and network devices............................................359
8.4.5.2 Configuring or changing an IP address for a CPU or device in your project........................362
8.4.5.3 Searching for CPUs and devices on your Ethernet network ................................................369
8.4.6 Locating the Ethernet (MAC) address on the CPU...............................................................370
8.4.7 HMI-to-CPU communication .................................................................................................371
8.5 PROFIBUS............................................................................................................................372
8.5.1 EM DP01 PROFIBUS DP module ........................................................................................373
8.5.1.1 Distributed Peripheral (DP) standard communications.........................................................373
8.5.1.2 Using the EM DP01 to connect an S7-200 SMART as a DP device....................................374
8.5.1.3 Configuring the EM DP01.....................................................................................................375
8.5.1.4 Data consistency...................................................................................................................376
8.5.1.5 Supported configurations......................................................................................................377
8.5.1.6 Installing the EM DP01 GSD file...........................................................................................378
8.5.1.7 Configuring the EM DP01 I/O ...............................................................................................379
8.5.1.8 Example of V memory and I/O address area .......................................................................382
8.5.1.9 User program considerations................................................................................................384
8.5.1.10 LED status indicators for the EM DP01 PROFIBUS DP.......................................................386
8.5.1.11 Using HMIs and S7-CPUs with the EM DP01 ......................................................................387
8.5.1.12 Device database file: GSD....................................................................................................388
8.5.1.13 PROFIBUS DP communications to a CPU example program .............................................392
8.5.1.14 Reference to the EM DP01 PROFIBUS DP module technical specifications ......................394

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8.6 RS485 .................................................................................................................................. 395
8.6.1 PPI protocol.......................................................................................................................... 395
8.6.2 Baud rate and network address........................................................................................... 396
8.6.2.1 Definition of baud rate and network address ....................................................................... 396
8.6.2.2 Setting the baud rate and network address for the S7-200 SMART CPU........................... 397
8.6.3 Sample RS485 network configurations................................................................................ 399
8.6.3.1 Single-master PPI networks................................................................................................. 399
8.6.3.2 Multi-master and multi-slave PPI networks.......................................................................... 399
8.6.4 Building your network........................................................................................................... 400
8.6.4.1 General guidelines ............................................................................................................... 400
8.6.4.2 Determining the distances, transmission rates, and cable lengths for your network........... 401
8.6.4.3 Repeaters on the network.................................................................................................... 401
8.6.4.4 Selection of the network cable............................................................................................. 402
8.6.4.5 Connector pin assignments ................................................................................................. 402
8.6.4.6 Biasing and terminating the network cable .......................................................................... 403
8.6.4.7 Biasing and terminating the CM01 signal board.................................................................. 405
8.6.4.8 Using HMI devices on your RS485 network ........................................................................ 405
8.6.5 Freeport mode...................................................................................................................... 406
8.6.5.1 Creating user-defined protocols with Freeport mode........................................................... 406
8.6.5.2 Using the RS232/PPI Multi-Master cable and Freeport mode with RS232 devices............ 409
8.7 RS232 .................................................................................................................................. 410
9 Libraries................................................................................................................................................. 411
9.1 Creating a user-defined library of instructions ..................................................................... 411
9.2 USS library instructions........................................................................................................ 413
9.2.1 USS communication overview ............................................................................................. 413
9.2.1.1 USS protocol overview......................................................................................................... 413
9.2.1.2 Requirements for using the USS protocol ........................................................................... 414
9.2.1.3 Calculating the time required for communicating with the drive .......................................... 415
9.2.2 USS program instructions.................................................................................................... 416
9.2.2.1 Using the USS protocol instructions .................................................................................... 416
9.2.2.2 USS_INIT instruction............................................................................................................ 417
9.2.2.3 USS_CTRL instruction ......................................................................................................... 419
9.2.2.4 USS_RPM_x instruction....................................................................................................... 422
9.2.2.5 USS_WPM_x instruction ...................................................................................................... 425
9.2.2.6 USS protocol execution error codes .................................................................................... 428
9.2.2.7 USS protocol example program........................................................................................... 429
9.3 Modbus library instructions .................................................................................................. 431
9.3.1 Modbus communication overview........................................................................................ 431
9.3.1.1 Modbus library features ....................................................................................................... 431
9.3.1.2 Initialization and execution time for Modbus protocol.......................................................... 433
9.3.1.3 Modbus addressing.............................................................................................................. 434
9.3.2 Modbus RTU master............................................................................................................ 436
9.3.2.1 Using the Modbus master instructions................................................................................. 436
9.3.2.2 MBUS_CTRL instruction (initialize master).......................................................................... 437
9.3.2.3 MBUS_MSG instruction ....................................................................................................... 438
9.3.2.4 Modbus master execution error codes ................................................................................ 442
9.3.3 Modbus RTU slave .............................................................................................................. 443
9.3.3.1 Using the Modbus slave instructions ................................................................................... 443
9.3.3.2 MBUS_INIT instruction (initialize slave)............................................................................... 445
9.3.3.3 MBUS_SLAVE instruction.................................................................................................... 446

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9.3.3.4 Modbus slave execution error codes....................................................................................448
9.3.4 Modbus master example program........................................................................................448
9.3.5 Modbus advanced user information......................................................................................450
10 Debugging and troubleshooting............................................................................................................. 453
10.1 Debugging your program ......................................................................................................453
10.1.1 Bookmark functions ..............................................................................................................453
10.1.2 Cross reference table ...........................................................................................................454
10.2 Displaying program status ....................................................................................................456
10.2.1 Displaying status in the program editor ................................................................................456
10.2.2 Configuring the STL status options.......................................................................................459
10.3 Using a status chart to monitor your program ......................................................................460
10.4 Forcing specific values .........................................................................................................462
10.5 Writing and forcing outputs in STOP mode ..........................................................................463
10.6 How to execute a limited number of scans...........................................................................464
10.7 Hardware troubleshooting guide...........................................................................................465
11 PID loops and tuning ............................................................................................................................. 467
11.1 PID loop definition table........................................................................................................468
11.2 Prerequisites.........................................................................................................................472
11.3 Auto-hysteresis and auto-deviation ......................................................................................472
11.4 Auto-tune sequence..............................................................................................................473
11.5 Exception conditions.............................................................................................................475
11.6 Notes concerning PV out-of-range (result code 3) ...............................................................476
11.7 PID Tune control panel .........................................................................................................476
12 Open loop motion control....................................................................................................................... 481
12.1 Using the PWM output..........................................................................................................482
12.1.1 Configuring the PWM output.................................................................................................482
12.1.2 PWMx_RUN subroutine........................................................................................................483
12.2 Using motion control .............................................................................................................485
12.2.1 Maximum and start/stop speeds...........................................................................................485
12.2.2 Entering the acceleration and deceleration times.................................................................486
12.2.3 Configuring the motion profiles.............................................................................................487
12.3 Features of motion control ....................................................................................................490
12.4 Programming an Axis of Motion............................................................................................492
12.5 Configuring an Axis of Motion...............................................................................................493
12.6 Subroutines created by the Motion wizard for the Axis of Motion ........................................506
12.6.1 Guidelines for using the Motion subroutines ........................................................................507
12.6.2 AXISx_CTRL subroutine.......................................................................................................507
12.6.3 AXISx_MAN subroutine ........................................................................................................509
12.6.4 AXISx_GOTO subroutine......................................................................................................510
12.6.5 AXISx_RUN subroutine ........................................................................................................512
12.6.6 AXISx_RSEEK subroutine ....................................................................................................513

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12.6.7 AXISx_LDOFF subroutine.................................................................................................... 514
12.6.8 AXISx_LDPOS subroutine ................................................................................................... 515
12.6.9 AXISx_SRATE subroutine ................................................................................................... 516
12.6.10 AXISx_DIS subroutine ......................................................................................................... 517
12.6.11 AXISx_CFG subroutine........................................................................................................ 518
12.6.12 AXISx_CACHE subroutine................................................................................................... 519
12.6.13 AXISx_RDPOS subroutine................................................................................................... 520
12.6.14 AXISx_ABSPOS subroutine................................................................................................. 521
12.7 Using the AXISx_ABSPOS subroutine to read the absolute position from a SINAMICS
servo drive............................................................................................................................ 523
12.7.1 AXISx_ABSPOS and AXISx_LDPOS subroutines usage examples ................................... 523
12.7.2 Interconnections................................................................................................................... 524
12.7.3 Commissioning..................................................................................................................... 525
12.7.3.1 Control mode........................................................................................................................ 525
12.7.3.2 Setpoint pulse input channel................................................................................................ 525
12.7.3.3 Setpoint pulse train input format .......................................................................................... 525
12.7.3.4 Common engineering units basis......................................................................................... 525
12.7.4 Important facts to know........................................................................................................ 528
12.8 Axis of Motion example programs........................................................................................ 529
12.8.1 Axis of Motion simple relative move (cut-to-length application) example............................ 529
12.8.2 Axis of Motion AXISx_CTRL, AXISx_RUN, AXISx_SEEK, and AXISx_MAN example ....... 531
12.9 Monitoring the Axis of Motion............................................................................................... 535
12.9.1 Displaying and controlling the operation of the Axis of Motion............................................ 537
12.9.2 Displaying and modifying the configuration of the Axis of Motion ....................................... 542
12.9.3 Displaying the profile configuration for the Axis of Motion................................................... 542
12.9.4 Error codes for the Axis of Motion (WORD at SMW620, SMW670, or SMW720)............... 544
12.9.5 Error codes for the Motion instruction (seven LS bits of SMB634, SMB684, or
SMB734) .............................................................................................................................. 545
12.10 Advanced topics................................................................................................................... 547
12.10.1 Understanding the configuration/profile table for the Axis of Motion ................................... 547
12.10.2 Special memory (SM) locations for the Axis of Motion ........................................................ 556
12.11 Understanding the RP Seek modes of the Axis of Motion................................................... 559
12.11.1 Selecting the work zone location to eliminate backlash ...................................................... 564
A Technical specifications......................................................................................................................... 565
A.1 General specifications.......................................................................................................... 565
A.1.1 General technical specifications .......................................................................................... 565
A.2 S7-200 SMART CPUs ......................................................................................................... 570
A.2.1 CPU ST20 and CPU SR20 .................................................................................................. 570
A.2.1.1 General specifications and features..................................................................................... 570
A.2.1.2 Digital inputs and outputs..................................................................................................... 573
A.2.1.3 CPU ST20 and CPU SR20 wiring diagrams........................................................................ 575
A.2.2 CPU ST30 and CPU SR30 .................................................................................................. 577
A.2.2.1 General specifications and features..................................................................................... 577
A.2.2.2 Digital inputs and outputs..................................................................................................... 580
A.2.2.3 CPU ST30 and CPU SR30 wiring diagrams........................................................................ 582
A.2.3 CPU ST40, CPU SR40, and CPU CR40 ............................................................................. 584
A.2.3.1 General specifications and features..................................................................................... 584
A.2.3.2 Digital inputs and outputs..................................................................................................... 587

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System Manual, 09/2015, A5E03822230-AC 13
A.2.3.3 CPU ST40, SR40 and CR40 wiring diagrams......................................................................590
A.2.4 CPU ST60, CPU SR60, and CPU CR60 ..............................................................................593
A.2.4.1 General specifications and features .....................................................................................593
A.2.4.2 Digital inputs and outputs .....................................................................................................596
A.2.4.3 CPU ST60, SR60 and CR60 wiring diagrams ......................................................................599
A.2.5 Wiring diagrams for sink and source input, and relay output ...............................................602
A.3 Digital inputs and outputs expansion modules (EMs)...........................................................603
A.3.1 EM DE08 digital input specifications.....................................................................................603
A.3.2 EM DT08 and EM DR08 digital output specifications...........................................................604
A.3.3 EM DT16, EM DR16, EM DT32, and EM DR32 digital input/output specifications..............607
A.4 Analog inputs and outputs expansion modules (EMs) .........................................................613
A.4.1 EM AE04 and EM AE08 analog input specifications............................................................613
A.4.2 EM AQ02 and EM AQ04 analog output module specifications............................................616
A.4.3 EM AM03 and EM AM06 analog input/output module specifications...................................618
A.4.4 Step response of the analog inputs ......................................................................................623
A.4.5 Sample time and update times for the analog inputs ...........................................................623
A.4.6 Measurement ranges of the analog inputs for voltage and current (SB and EM) ................624
A.4.7 Measurement ranges of the analog outputs for voltage and current (SB and EM)..............625
A.5 Thermocouple and RTD expansion modules (EMs).............................................................626
A.5.1 Thermocouple expansion modules (EMs) ............................................................................626
A.5.1.1 EM AT04 thermocouple specifications .................................................................................626
A.5.2 RTD expansion modules (EMs)............................................................................................632
A.6 Digital signal boards..............................................................................................................637
A.6.1 SB DT04 digital input/output specifications ..........................................................................637
A.7 Analog signal boards ............................................................................................................640
A.7.1 SB AE01 analog input specifications....................................................................................640
A.7.2 SB AQ01 analog output specifications .................................................................................642
A.8 RS485/RS232 signal boards ................................................................................................644
A.8.1 SB RS485/RS232 specifications ..........................................................................................644
A.9 Battery board signal boards (SBs)........................................................................................646
A.9.1 SB BA01 Battery board.........................................................................................................646
A.10 EM DP01 PROFIBUS DP module ........................................................................................648
A.10.1 S7-200 SMART CPUs that support the EM DP01 PROFIBUS DP module .........................649
A.10.2 Connector pin assignments for EM DP01 ............................................................................650
A.10.3 EM DP01 PROFIBUS DP module wiring diagram................................................................651
B Calculating a power budget ................................................................................................................... 653
B.1 Power budget........................................................................................................................653
B.2 Calculating a sample power requirement .............................................................................655
B.3 Calculating your power requirement.....................................................................................656
C Error codes............................................................................................................................................ 657
C.1 PLC non-fatal error codes.....................................................................................................657
C.2 PLC non-fatal error SM flags ................................................................................................660
C.3 PLC fatal error codes............................................................................................................661
C.4 Timestamp mismatch............................................................................................................663

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S7-200 SMART
14 System Manual, 09/2015, A5E03822230-AC
D Special memory (SM) and system symbol names ................................................................................. 665
D.1 SM (Special Memory) overview ........................................................................................... 665
D.2 SMB0: System status........................................................................................................... 667
D.3 SMB1: Instruction execution status...................................................................................... 668
D.4 SMB2: Freeport receive character....................................................................................... 669
D.5 SMB3: Freeport character error........................................................................................... 669
D.6 SMB4: Interrupt queue overflow, run-time program error, interrupts enabled, freeport
transmitter idle, and value forced......................................................................................... 670
D.7 SMB5: I/O error status ......................................................................................................... 670
D.8 SMB6-SMB7: CPU ID, error status, and digital I/O points................................................... 671
D.9 SMB8-SMB19: I/O module ID and errors ............................................................................ 672
D.10 SMW22-SMW26: Scan times .............................................................................................. 673
D.11 SMB28-SMB29: Signal board ID and errors........................................................................ 673
D.12 SMB30: (port 0) and SMB130: (port 1)................................................................................ 674
D.13 SMB34-SMB35: Time intervals for timed interrupts............................................................. 674
D.14 SMB36-45 (HSC0), SMB46-55 (HSC1), SMB56-65 (HSC2), SMB136-145 (HSC3):
high-speed counters ............................................................................................................ 675
D.15 SMB66-SMB85, SMB166-SMB169, SMB176-SMB179, and SMB566-SMB579: PTO0,
PWM0, PTO1, PWM1, PTO2, and PWM2 high-speed outputs........................................... 678
D.16 SMB86-SMB94 and SMB186-SMB194: Receive message control..................................... 681
D.17 SMW98: I/O expansion bus communication errors ............................................................. 683
D.18 SMW100-SMW114 System alarms ..................................................................................... 684
D.19 SMB130: Freeport control for port 1 (See SMB30).............................................................. 685
D.20 SMB136-SMB145: HSC3 high-speed counter..................................................................... 685
D.21 SMB186-SMB194: Receive message control (See SMB86-SMB94).................................. 685
D.22 SMB480-SMB515: Data log status ...................................................................................... 685
D.23 SMB600-SMB749: Axis (0, 1, and 2) open loop motion control .......................................... 686
D.24 SMB650-SMB699: Axis 1 open loop motion control (See SMB600-SMB740).................... 687
D.25 SMB700-SMB749: Axis 2 open loop motion control (See SMB600-SMB740).................... 687
D.26 SMB1000-SMB1049: CPU hardware/firmware ID............................................................... 688
D.27 SMB1050-SMB1099: SB (signal board) hardware/firmware ID........................................... 688
D.28 SMB1100-SMB1399: EM (expansion module) hardware/firmware ID ................................ 689
D.29 SMB1400-SMB1699: EM (expansion module) module-specific data.................................. 691

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System Manual, 09/2015, A5E03822230-AC 15
E References ............................................................................................................................................ 693
E.1 Often-used special memory bits ...........................................................................................693
E.2 Interrupt events in priority order............................................................................................694
E.3 High-speed counter summary...............................................................................................695
E.4 Instructions............................................................................................................................696
E.5 Memory ranges and features................................................................................................703
F Ordering information.............................................................................................................................. 705
F.1 CPU modules........................................................................................................................705
F.2 Expansion modules (EMs) and signal boards (SBs) ............................................................705
F.3 Programming software..........................................................................................................706
F.4 Communication.....................................................................................................................706
F.5 Spare parts and other hardware...........................................................................................706
F.6 Human Machine Interface devices .......................................................................................708
Index...................................................................................................................................................... 709

Table of contents
S7-200 SMART
16 System Manual, 09/2015, A5E03822230-AC

S7-200 SMART
System Manual, 09/2015, A5E03822230-AC 17
Product overview
1
The S7-200 SMART series of micro-programmable logic controllers (Micro PLCs) can control
a wide variety of devices to support your automation needs.
The CPU monitors inputs and changes outputs as controlled by the user program, which can
include Boolean logic, counting, timing, complex math operations, and communications with
other intelligent devices. The compact design, flexible configuration, and powerful instruction
set combine to make the S7-200 SMART a perfect solution for controlling a wide variety of
applications.

Product overview
1.1 S7-200 SMART CPU
S7-200 SMART
18 System Manual, 09/2015, A5E03822230-AC
1.1
S7-200 SMART CPU
The CPU combines a microprocessor, an integrated power supply, input circuits, and output
circuits in a compact housing to create a powerful Micro PLC. After you have downloaded
your program, the CPU contains the logic required to monitor and control the input and
output devices in your application.
①
LEDs for the I/O
②
Terminal connectors
③
Ethernet communication
port
④
Clip for installation on a
standard (DIN) rail
⑤
Ethernet status LEDs
(under door): LINK, Rx/Tx
⑥
Status LEDs: RUN, STOP
and ERROR
⑦
RS485 Communication
port
⑧
Optional signal board
(Standard models only)
⑨
Memory card connection
(under door)
The CPU provides different models with a diversity of features and capabilities that help you
create effective solutions for your varied applications. The different models of CPUs are
shown below. For detailed information about a specific CPU, see the technical specifications
(Page 570).
Table 1- 1 S7-200 SMART CPUs
CR40
CR60
SR20
ST20
SR30
ST30
SR40
ST40
SR60
ST60
Compact, non-expandable
X
X
Standard, expandable
X
X
X
X
X
X
X
X
Relay output
X
X
X
X
X
X
Transistor output (DC)
X
X
X
X
I/O points (built-in)
40
60
20
20
30
30
40
40
60
60

Product overview
1.1 S7-200 SMART CPU
S7-200 SMART
System Manual, 09/2015, A5E03822230-AC 19
Table 1- 2 Compact non-expandable CPUs
Features
CPU CR40
CPU CR60
Dimensions: W x H x D (mm)
125 x 100 x 81
175 x 100 x 81
User memory Program 12 Kbytes 12 Kbytes
User data
8 Kbytes
8 Kbytes
Retentive 10 Kbytes max.110 Kbytes max.1
On-board digital I/O •Inputs
•Outputs
•24 DI
•16 DQ Relay
36 DI
24 DQ Relay
Expansion modules
None
None
Signal board
None
None
High-speed counters 4 at 100 K Hz single phase
or
2 at 50 K Hz A/B phase
4 at 100 K Hz single phase
or
2 at 50 K Hz A/B phase
PID loops
8
8
Real-time clock with 7-day back-up
No
No
1
You can configure areas of V memory, M memory, C memory (current values), and portions of T memory (current val-
ues on retentive timers) to be retentive, up to the specified maximum amount.
Table 1- 3 Standard expandable CPUs
Features
CPU SR20, CPU
ST20
CPU SR30, CPU
ST30
CPU SR40, CPU
ST40
CPU SR60, CPU
ST60
Dimensions: W x H x D (mm)
90 x 100 x 81
110 x 100 x 81
125 x 100 x 81
175 x 100 x 81
User memory
Program
12 Kbytes
18 Kbytes
24 Kbytes
30 Kbytes
User data
8 Kbytes
12 Kbytes
16 Kbytes
20 Kbytes
Retentive
10 Kbytes max.
1
10 Kbytes max.
1
10 Kbytes max.
1
10 Kbytes max.
1
On-board digital I/O •Inputs
•Outputs
•12 DI
•8 DQ
•18 DI
•12 DQ
•24 DI
•16 DQ
•36 DI
•24 DQ
Expansion modules
6 max.
6 max.
6 max.
6 max.
Signal board
1
1
1
1
High-speed counters 4 at 200 K Hz
single phase
or
2 at 100 K Hz A/B
phase
4 at 200 K Hz sin-
gle phase
or
2 at 100 K Hz A/B
phase
4 at 200 K Hz sin-
gle phase
or
2 at 100 K Hz A/B
phase
4 at 200 K Hz sin-
gle phase
or
2 at 100 K Hz A/B
phase
Pulse outputs
2
2 at 100 KHz
3 at 100 K Hz
3 at 100 KHz
3 at 100 KHz
PID loops
8
8
8
8
Real-time clock with 7-day back-up
Yes
Yes
Yes
Yes
1
You can configure areas of V memory, M memory, C memory (current values), and portions of T memory (current val-
ues on retentive timers) to be retentive, up to the specified maximum amount.
2
The specified maximum pulse frequency is possible only for CPU models with transistor outputs. Pulse output operation
is not recommended for CPU models with relay outputs.

Product overview
1.2 S7-200 SMART expansion modules
S7-200 SMART
20 System Manual, 09/2015, A5E03822230-AC
Refer to the technical specifications (Page 565) for the power requirements of the CPU and
the expansion modules. Use the worksheets in Appendix B, Calculating a power budget
(Page 656) to calculate your power budget.
1.2
S7-200 SMART expansion modules
To better solve your application requirements, the S7-200 SMART family includes a wide
variety of expansion modules, signal boards, and a communications module. You can use
these expansion modules with the standard CPU models (SR20, ST20, SR30, ST30, SR40,
ST40, SR60 or ST60) to add additional functionality to the CPU. The following table provides
a list of the expansion modules that are currently available. For detailed information about a
specific module, see the technical specifications (Page 565).
Table 1- 4 Expansion modules and signal boards
Type
Input only
Output only
Combination In/Out
Other
Digital expan-
sion module
•8 x DC In •8 x DC Out
•8 x Relay Out
•8 x DC In / 8 x DC Out
•8 x DC In / 8 x Relay Out
•16 x DC In / 16 x DC Out
•16 x DC In / 16 x Relay Out
Analog expan-
sion modules
•4 x Analog In
•8 x Analog In
•2 x RTD In
•4 x RTD In
•4 x TC In
•2 x Analog Out
•4 x Analog Out
•4 x Analog In / 2 x Analog Out
•2 x Analog In / 1 x Analog Out
Signal boards •1 x Analog In •1 x Analog Out •2 x DC In x 2 x DC Out •RS485/RS232
•Battery Board
Table 1- 5 Communication expansion modules
Module
Type
Description
Communication expansion module
(EM)
PROFIBUS DP SMART module EM DP01 PROFIBUS DP