The S7-400 is the most powerful PLC in the family of SIMATIC controllers. It enables successful automation solutions with Totally Integrated Automation (TIA). The S7-400 is an automation platform for system solutions in production and process engineering, and it is characterized primarily by its modularity and performance reserves.
• The power PLC for the mid to high-end performance ranges. • The solution for even the most demanding tasks. • With a comprehensive range of modules and performancegraded CPUs for optimal adaptation to the automation task. • Flexible in use through simple implementation of distributed structures. • User-friendly connections. • Optimal communication and networking options. • User-friendly handling and uncomplicated design without a fan. • Can be expanded without problems when the tasks increase. • Multicomputing: Simultaneous operation of several CPUs in one S7-400 central controller. Multicomputing distributes the overall performance power of an S7-400. For example, complex tasks can be divided into technologies such as open-loop control, computing or communication, and assigned to different CPUs. And every CPU can be assigned its own local I/O. • Modularity: The powerful backplane bus of the S7-400 and the communication interfaces that can be connected direct to the CPU enable high-performance operation of a host of communication lines. This enables, for example, division into one communication path for HMI and programming tasks, one for high-performance and equidistant motion control components, and one for a “normal” I/O fieldbus. Additionally required connections to MES/ERP systems or the Internet can also be implemented. • Engineering and diagnostics: The S7-400 is configured and programmed extremely efficiently together with the SIMATIC Engineering Tools particularly in the case of extensive automation solutions with a high engineering component. For this purpose, high-level languages such as SCL and graphical engineering tools for sequential controls, state graph programs and technologyoriented diagrams are available, for example.
• Fault-tolerant automation system with redundant design. • For applications with high fail-safety requirements. Processes with high restart costs, expensive downtimes, little supervision, and few maintenance options. • Redundant central functions. • Increases availability of I/O: switched I/O configuration. • Also possible to use I/Os with standard availability: singlesided configuration. • Hot stand-by: automatic reaction-free switching to the standby unit in the event of a fault. • Configuration with two separate or one divided central rack. • Connection of switched I/O via redundant PROFIBUS DP or via system reduntant PROFINET IO.
• Failsafe automation system for plants with increased safety requirements • Complies with safety requirements to SIL 3 in accordance with IEC 61508, AK6 in accordance with DIN V 19250 and Cat. 4 in accordance with EN 954-1 • If required, also fault tolerant through redundant design • Without additional wiring of the safety-related I/O • Safety-relevant communication via PROFIBUS DP with PROFIsafe profile • Based on S7-400H and distributed IOs ET 200M with fail-safe modules • Standard modules for non-safety-related applications can also be used in the automation system • Isolation module for joint use of fail-safe and standard modules in safety mode in one ET 200M
SIEMENS SIMATIC S7-400 CPUs
The S7-400 is especially suitable for data-intensive tasks in the process industry. High processing speeds and deterministic response times guarantee short machine cycle times on high-speed machines in the manufacturing industry.
The S7-400 is used preferably to coordinate overall plants and to control lower-level systems. This is guaranteed by the high communication power and the integral interfaces.
Many of the S7-400 components are also available in a SIPLUS version for extreme environmental conditions.
S7-400 finds successful application here:
Standard mechanical equipment manufacture incl. custom mechanical equipment manufacture
Power generation and distribution
Paper and printing industries
Food and beverages industries
Process engineering, e.g. water and wastewater utilities
Chemical industry and petrochemicals
There is a graded range of CPUs from the entry-level CPU right up to the high-performance CPU for configuring the controller. All CPUs control large quantity structures; several CPUs can work together in a multicomputing configuration to boost performance. Thanks to their high processing speed and deterministic response times, the CPUs enable short machine cycle times.The different CPUs are distinguished by, for example, work memory, address range, number of connections and execution time. As well as the standard CPUs, there are also two failsafe and three fault-tolerant CPUs available.
With the Version 7 the continuous advancement of the series will be continued. Among others, storage, performance and quantity structure have been innovated. Furthermore the focus was on the new expansion of the Profinet communication performance. The complementary systems are still the high-end controller for all industries.
The power of the S7-400 is scalable thanks to a graded range of CPUs; the capacity for I/O is almost unlimited.
The power reserves of the CPUs enable new functions to be integrated without further hardware investment, e.g. processing of quality data, user-friendly diagnosis, integration into higher-level MES solutions or high-speed communication via bus systems.
The S7-400 can be structured in a modular way; there is a widely varied range of modules available both for centralized configurations and distributed structures. This results in very cost-effective spare parts handling.
The configuration of the distributed I/O of the S7-400 can be modified during operation (Configuration in Run). In addition signal modules can be removed and inserted while live (hot swapping). This makes it very easy to expand the system or replace modules in the event of a fault.
The storage of the complete project data including symbols and comments on the CPU simplifies service and maintenance calls.
Safety engineering and standard automation can be integrated into a single S7-400 controller; plant availability can be increased through the redundant structure of the S7-400.
Many of the S7-400 components are also available in a SIPLUS version for external environmental conditions, e.g. extended temperature range (-25 +60°C) and for use where there is aggressive atmosphere/condensation.
The high-speed backplane bus of S7-400 ensures efficient linking of central I/O modules
Design and function
The powerful backplane bus of the S7-400 and the DP communication interfaces that can be plugged directly onto the CPU allow the high-performance operation of many communication lines. This permits, for example, the division into one communications line for HMI and programming tasks, one line for high-performance and equidistant motion control components, and one “normal” I/O fieldbus. Additionally required connections to MES-/ERP systems or the Internet via SIMATIC IT can also be implemented. The S7-400 can be expanded centrally or in a distributed configuration depending on the task. Add-on devices and interface modules are available centrally for this purpose. Distributed expansion is possible over the PROFIBUS or PROFINET interfaces integrated in the CPUs. If required, communication processors (CPs) can also be used.DesignAn S7-400 system basically comprises a rack, power supply, and central processing unit. It can be installed and expanded in a modular way. All modules can be positioned freely next to the power supply plugged in on the left. The S7-400 has a rugged design without a fan. Signal modules can be hotswapped. A multi-faceted module range can be used for central expansions as well as for simple configuration of distributed topologies with ET 200. In a centralized expansion, additional mounting racks are connecteddirect to the central controller.
In addition to the standard mounting racks, aluminum mounting racks with 9 and 18 slots are also available. These aluminum racks are highly resistant to unfavorable environmental conditions, and they are more rigid and around 25% lighter.
Multicomputing, that is, the simultaneous operation of several CPUs in one S7-400 central controller, offers users different benefits:
The overall performance of an S7-400 can be shared by means of multicomputing. For example, complex tasks in technologies such as open-loop control, computing or communication can be split and assigned to different CPUs. Each CPU is assigned its own, local I/O for this purpose.
Some tasks can also be disconnected from each other in multicomputing, that is, one CPU processes the time-critical process tasks and another handles the non-time-critical tasks.
In multicomputing operation, all CPUs behave like a single CPU, that is, when one CPU goes to STOP, the others are also halted. The actions of several CPUs can be coordinated selectively by instruction via synchronization calls.In addition, data exchange between the CPUs takes place at an extremely high speed via the “global data” mechanism.
The size of the work memory is determined CPU that can be selected from a finely graded range of CPUs.The integral load memory (RAM) is sufficient for small to mediumsized programs. For larger programs, the load memory is enlarged by plugging in RAM or FEPROM memory cards (64 KB to 64 MB).
The S7-400 CPUs have some highly useful special functions:
Simpler and faster upgrade due to firmware update via network from an engineering workstation
Additional write-protection (for e.g. no component download from PC to CPU) via a system function
Optional know-how protection by reading the serial number of the memory card, so that it is ensured that the program runs only with the particular memory card
An integrated data record gateway permits integrated accessto data records across different bus systems and networkboundaries e.g. a control-level PC can communicate via PROFINETwith a lower-level S7-400 controller and the field devicesconnected to it via PROFIBUS.
SIEMENS SIMATIC S7-400 Signal modules
Signal modules are the interface of the controller to the process. A host of different digital and analog modules provide exactly the inputs/outputs required for each task. Digital and analog modules differ as regards the number of channels, voltage and current ranges, electrical isolation, diagnostics and alarm functions, etc. However, the S7-400 signal modules are only a subset of the modules that can be connected to the S7-400 via PROFIBUS DP. Centrally connected signal modules can be connected and disconnected during operation. This makes module replacement extremely easy.
Design and function
Easy installation The sensors/actuators are connected through front connectors. When a module is replaced, the connector is simply plugged into the new module of the same type; the wiring is retained. The coding of the front connector avoids mistakes. The S7-400 is also able to detect whether the front connector is plugged in.
Fast connection SIMATIC TOP connect makes connection even simpler and faster. Preassembled front connectors with single cores and a complete plug-in modular system comprising a front connector module, connecting cable and terminal block are available.
High packing density The high number of channels on the modules is a reason for the space-saving design. For example, modules with 8 to 32 digital channels or 8 to 16 analog channels are available.
Simple parameterization The modules are configured and parameterized using STEP 7, and there are no inconvenient switch settings to be made. The data are stored centrally and, following module replacement, they are automatically transferred to the new module so that no setting errors can occur. No software upgrade is requiredwhen using new modules. A configuration can be copied as often as required, e.g. for standard machines.
Diagnostics, interrupts Many modules additionally monitor signal acquisition (diagnostics) and the signals from the process (process interrupt. e.g. edge evaluation). This makes it possible to react immediately to process errors, e.g. wire breaks or short circuits, and any process event, e.g. rising or falling edge at a digital input. The response of the controller can easily be programmed with STEP 7. On the digital input modules, several interrupts per module are possible.
SIEMENS SIMATIC S7-400 Function modules
The multi-facetted module range of S7-400 allows modular customization to suit the most varied tasks. Apart from the CPUs with integrated functions and interfaces, there is a wide range of special modules in S7-400 design for technology.
Range of application
Wood, glass, stone and metal processing
General machine manufacturing
Rubber and plastic industry
High degree of accuracy and dynamic response
Specialized and universal modules with a wide range of functions
CPU is not involved since the functionality is stored in the firmware of each module
Quick reaction times (deterministic dynamic response)
Engineering with configuring tool, integrated into STEP 7
Design and function
Function modules are intelligent modules that independently execute the technological tasks and thus reduce the load on the CPU. They are used when a high level of accuracy and dynamic response is required.
SIEMENS SIMATIC S7-400 Communication processors
Communication processors are used for connecting S7-400 to the different bussystems / communication networks as well for point-to- point link.
Point-to-point connection Point-to-point link via communications processors (CPs) is an extremely powerful and low-cost alternative to bus systems. The advantage of point-to-point links over bus systems is especially pronounced when only a few (RS 485) devices are to be connected to the SIMATIC S7. The CPs can also easily link third-party systems to the SIMATIC S7. Thanks to the great flexibility of the CPs, different physical transmission media, transmission rates or even customized transmission protocols can be implemented. For each CP, there is a configuring package on CD with electronic manual, parameterization screen forms and standard function blocks for communication between the CPU and the CP. The configuration data are stored in a system block and backed up in the CPU. When modules are replaced, the new module is therefore immediately ready for use. With the S7-400 point-to-point link modules, adaptation to the physical transmission media is achieved by plugging in the relevant interface submodules, without the need for external converters.
Communication modules allow connection of the SIMATIC S7-400 for instance to:
SIMATIC S7 and SIMATIC S5 programmable controllers, and systems from many other manufacturers
PCs, programming devices, hmi devices
Scanners, bar code readers
• Reduced start-up times due to the easy configuration with STEP 7 • Reduced downtimes and service times in the event of a fault through LED displays
Design and function
The CPs have a rugged plastic housing with LEDs for displaying operating states and faults. They show all advantages of the SIMATIC S7-300- Design, e.g. • Compact design • Easy installation • User friendly wiring, etc.