IO/DG/COO/SCOD/CSD/PCI

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1 IDM UID 333J63 VERSION CREATED ON / VERSION / STATUS 11 Aug 2017 / 4.1 / Approved EXTERNAL REFERENCE / VERSION How To ITER catalogue for I&C products - Slow controllers PLC This document contains the list of Siemens S7 components to be used within Plant Systems for slow controls and SIL-2 and 3 purposes. Approval Process Name Action Affiliation Author Simelio A. 11 Aug 2017:signed IO/DG/COO/SCOD/CSD/PCI Co-Authors Bhamare A. Evrard B. Wagner R. Reviewers Fernandez Robles C. Patel J. Soni J. Wallander A. 11 Aug 2017:signed 11 Aug 2017:signed 11 Aug 2017:signed 11 Aug 2017:recommended 11 Aug 2017:recommended 11 Aug 2017:recommended 11 Aug 2017:recommended TATA Consultancy Services France SA (EU) IO/DG/COO/SCOD/CSD/PCI IO/DG/COO/SCOD/CSD/PCI IO/DG/COO/SCOD/CSD/PCI IO/DG/COO/SCOD/CSD/CDC IO/DG/COO/SCOD/CSD/PCI IO/DG/COO/SCOD/CSD Approver Petitpas P. 11 Aug 2017:approved IO/DG/COO/SCOD/CSD/PCI Document Security: Internal Use RO: Simelio Antoni Read Access LG: PLC group, LG: CODAC team, AD: ITER, AD: External Collaborators, AD: IO_Director-General, AD: EMAB, AD: OBS - Plant Control and Instrumentation Section (PCI), AD: Auditors, AD: ITER Management Assessor, project administrator, RO, AD: OBS - Control System Division (CSD) - EXT, AD: OBS - CODAC Sec... PDF generated on 11 Aug 2017 DISCLAIMER : UNCONTROLLED WHEN PRINTED PLEASE CHECK THE STATUS OF THE DOCUMENT IN IDM

2 Change Log ITER catalogue for I&C products - Slow controllers PLC (333J63) Version Latest Status Issue Date Description of Change v1.0 Signed 10 Dec 2009 v1.1 Approved 01 Feb 2010 Updated for version %5.1 of PCDH v1.2 Signed 31 Aug 2010 Update of documentation links, minor syntax changes, change of module references: Replace 6ES EK13-0AB0 by 6ES EK14-0AB0 within section Replace 353-1AH01-0AE0 by 6ES7353-1AH01-0AE0 within section Replace 6ES MA11 by 6ES5710-8MA11 within section Replace 6ES7 8GL11-0AA0 by 6ES7 8LG11-0AA0 within section Replace 6ES PN 3ER05-0AB0 by 6ES ER05-0AB0 within section Replace 6GK EX20-0EX0 by 6GK EX20-0XE0 within section Replace 6ES7 414-FH by 6ES7414HM14-0AB0 within section Replace 6ES AA04-5BK0 by 6ES AA04-0XA0 within section Replace 6ES7153-1BK00-0AB0 by 6ES7153-1BK00-0XB0 within section Replace 6ES7326-1BK01-0AB0 by 6ES7326-1BK02-0AB0 within section Replace 6ES7326-2BF01-0AB0 by 6ES7326-2BF10-0AB0 within section Replace 6ES7650-1KA11-7XX0 by 6ES7650-1AK11-7XX0 within section Replace 6ES CF02-0AA0 by 6ES7138-4CF03-0AB0 within section Replace 6ES GL11-0AA0 by 6ES7953-8LG11-0AA0 within section v1.3 Signed 22 Oct 2010 Replace 6ES7390-1BC00-0AA0 by 6ES7390-1AJ30-0AA0 within section Replace 6ES7341-1CH02 by 6ES7341-1CH02-0AE0 within section Replace 6ES7193-4CC20-0AA0 by 6ES7193-4CC30-0AA0 within section v1.4 Signed 28 Oct 2010 Replace 6ES7307-1EA00-0AA0 by 6ES7307-1EA01-0AA0 within section Add reference S7 PLC ordering process ( v1.5 Signed 17 Nov 2010 Add 6ES7971-0BA00 within section Add 6ES7952-1AM00-0AA0 within section Add 6ES7960-1AA04-0XA0 within section Add section Add 6ES7922-3BD00-0AS0 within section Add 6ES7922-3BD00-0AN0 within section v1.6 Signed 06 Jan 2011 New RO: B Evrard v1.7 Approved 09 Feb 2011 Version updated after PCDH review. v2.0 In Work 22 Oct 2012 Catalog organization completely Re-shuffled. TAble of Content is different. v3.0 Signed 03 Dec 2012 Complete Re-shuffling. References moved to another living document Addition of gudielines for architectures v3.1 Approved 13 Dec Update of Satelite Documents picture. - Update Reviewers and Approver PDF generated on 11 Aug 2017 DISCLAIMER : UNCONTROLLED WHEN PRINTED PLEASE CHECK THE STATUS OF THE DOCUMENT IN IDM

3 - Addition of Exploded view for s7-400 Rack v3.2 Revision 31 Jul 2013 Modification of Chapter 7: Software Packages Required v3.3 Approved 04 Jul 2014 Solve problem with cover page v3.4 In Work 02 Feb 2016 Addition of Network Section Addition of exploded views. v4.0 Signed 10 Aug 2017 Major modification of the Document: Software : o Reshape of the chapter o TIA Portal Added v4.1 Approved 11 Aug 2017 Typo mistakes corrected. Reference System : o SIEMENS Reference List is the main document referenced Systems Selection : o Main reshape of the chapter adapted to the current philosophy o 1500 CPUs added o Controller, CPU Range subchapters reformulated, CPU and communication performance is taking in account o Remote IO Selection sub reformulated o Network selection subchapter reshaped, detailed and enlarged taking in account new needs of the Plant Systems o Cubicle Monitoring system selection added o Accessing point selection added System Composition : o Main reshape of the chapter adapted to the current philosophy o Inclusion of 1500 Family devices Network Composition : o Main reshape of the chapter adapted to the current philosophy o Added devices taking in account the new needs of the Plant Systems Major modification of the document regarding version 3.X: -Reference System: - SIEMENS Reference List settled as the main reference of the catalogue. -Systems Selection: - Main reshape of the chapter, adapted to the current philosophy CPUs added. - Controllers and CPU Range subchapters reformulated, CPU and communication performance is taken in account. - Remote IO Selection subchapter reformulated. - Network selection subchapter reshaped, detailed and enlarged taking in account new needs of the Plant Systems. - Cubicle monitoring system selection added. - Accessing point selection added. -System Composition: - Main reshape of the chapter, adapted to the current philosophy. - Inclusion of 1500 Family devices. - Network Composition : - Main reshape of the chapter, adapted to the current philosophy. PDF generated on 11 Aug 2017 DISCLAIMER : UNCONTROLLED WHEN PRINTED PLEASE CHECK THE STATUS OF THE DOCUMENT IN IDM

4 - Added devices taking in account the new needs of the Plant Systems. -Software: - Reshape of the chapter. - TIA Portal Added. PDF generated on 11 Aug 2017 DISCLAIMER : UNCONTROLLED WHEN PRINTED PLEASE CHECK THE STATUS OF THE DOCUMENT IN IDM

5 Table of Contents 1 PURPOSE SCOPE PCDH context DEFINITIONS Acronyms Definitions Reference Documents REFERENCE SYSTEM SYSTEM SELECTION Controller type selection CPU Rack Selection...9 A. Standard System(no designation)...10 B. High Availability System( H )...10 C. Fail-Safe System( F ): CPU Range Selection...11 A. Processor Performance and Memory Size...11 B. Communication Performance Expected...14 C. Sample System (example) Remote IO Devices Selection Network Selection...19 A. Technology Selection...20 B. Field Network Architectures B.1 FieldBus (Profibus) B.2 Field Net (Profinet) using Central I&C Systems Physical Infrastructure B.3 FieldNet (Profinet) using independent physical infrastructure B.4 Modbus...28 C. Plant System Local (Private) Network Architecture C.1 Inter-Controllers communications using the Central I&C Networks C.2 Inter-Controllers communications using independent physical architecture Central I&C Network accessing point Selection...33 A. Analysis of the Arguments...33 B. Outcome of the analysis Cubicle Monitoring System Selection...36 A. Complete Solution for 1 cubicle...36 B. Partial Solution for 2 to 11 cubicles SYSTEMS COMPOSITION Slow Controllers Range...40 A. Low (distributed) Range of Slow Controllers A.1 Low (Distributed) Range PLCs: [S7-1500] CPU + IO Rack...40 B. Medium Range of Slow Controllers B.1 Mid-range PLCs: [S7-300 or S7-1500] CPU Rack B.1.1 S7-300: CPU Rack...42 Page 1 of 83

6 6.1.B.1.2 S7-1500: CPU Rack B.2 Mid-range PLC with local IO: [S7-300 or S7-1500] CPU+IO Rack B.2.1 S7-300: CPU+IO Rack B.2.2 S7-1500: CPU+IO Rack B.3 Mid-range Fail Safe PLCs: [S7-300 or S7-1500] CPU rack B.3.1 S7-300 F CPU rack B.3.2 S F CPU rack...53 C. High Range of Slow Controllers C.1 High range PLCs: S C.2 High range Fail Safe PLCs: S7-400 F CPU rack C.3 High Range, High Availability PLCs: S7-400 H CPU Rack Remote I/O Modules Range...63 A. Small I/O modules [S7-300 or S7-1500] A.1 S7-300 Family: ET200S A.2 S Family: ET200SP...65 B. Medium I/O modules [S7-300 or S7-1500] B.1 S7-300 Family: ET200M B.2 S Family: ET200MP...69 C. Medium I/O Fail-Safe modules [S7-300 or S7-1500] C.1 S7-300 Family: ET200M F C.2 S Family: ET200MP F Accessories NETWORK COMPOSITION Field Network Architecture equipment...76 A. Field Bus (Profibus) components...76 B. Field Net (Profinet) components Plant System Local (Private) Network Architecture equipment SOFTWARE : STEP7 & TIA Portal STEP A. Dependencies...79 B. Versions compatibility TIA Portal...81 A. Dependencies...81 B. Versions compatibility What version to install? Applications portability between versions...83 Page 2 of 83

7 Table of Figures Figure 1: PCDH documents 5 Figure 2: Hardware selection flowchart 9 Figure 3: SIMATIC S7-300 CPU PN/DP 11 Figure 4: SIMATIC S7-400, CPU PN/DP 12 Figure 5: SIMATIC S7-1500, CPU PN/DP 13 Figure 6: ET200M 15 Figure 7: ET200MP 15 Figure 8: ET200S 16 Figure 9: ET200SP 16 Figure 4: Network Functional Segregation 19 Figure 5: FieldBus (Profibus) Network using independent infrastructure 23 Figure 6: FieldNet Network (Profinet) using Central I&C Network infrastructure 25 Figure 7: FieldNet Network (Profinet) using independent infrastructure 27 Figure 10 : Modbus RTU Network Layout 28 Figure 8 : Inter-Controllers (S7 communication) using the Central I&C Network 30 Figure 9: Inter-Controllers (S7 Communication) using independent infrastructure 32 Figure 30 : Target of the solution for the monitoring of one single cubicle 36 Figure 31 : SIEMENS Hardware for CUB MON SYS 1 Single Cubicle 37 Figure 32 : Target of the solution for the monitoring of 2 to 11 Cubicles 37 Figure 33 : SIEMENS Hardware for CUB MON SYS From 2 to 11 cubicles 38 Figure 11 : Distributed Rack [S IO] exploded view 41 Figure 12: Rack s7-300 exploded view. 43 Figure 13: Rack S exploded view 46 Figure 14: Rack S IO exploded view 48 Figure 15 : Rack S IO exploded view 50 Figure 16: Fail Safe, High range PLCs S7300F 52 Figure 17 : Fail Safe, High range PLCs S71500F 53 Figure 18: Rack S7-400 exploded view. 55 Figure 19: Fail Safe, High range PLCs S7400F 57 Figure 20: High availability PLCs architecture 59 Figure 21: High availability PLCs S7-400H 60 Figure 22: ET200S Modules exploded view 63 Figure 23: ET200SP Modules exploded view 65 Figure 24: ET200M Modules 67 Figure 25: ET200M Modules to use with s7-400 H 68 Figure 26: ET200MP Modules 69 Figure 27: ET200M F Modules 71 Figure 28: ET200M F Modules for S7-400FH 72 Figure 29: ET200MP F Modules 73 Figure 34: Software and Applications Dependency Tree for STEP7 79 Figure 35: Software and Applications Dependency Tree for TIA Portal 81 Page 3 of 83

8 1 PURPOSE This catalogue has been created and is constantly maintained to help the Plant System manufacturers and system integrators in their work. The primary objective is to promote the usage of identical equipment in all Plant Systems so that the integration and interoperability with the ITER Instrumentation and Control system would be seamless. The secondary objective is to coordinate site-wide maintenance of the equipment. The third objective is to provide tools for the obsolescence management. The objectives will be met by a careful selection of industrial COTS products which will comply with existing standards, defined by the Plant Control Design Handbook (PCDH, [RD1]). Page 4 of 83

9 2 SCOPE This document addresses the needs for Plant Control Systems developed using COTS system devices, named Slow Controllers in the Plant Control Design Handbook. This document is applicable to Conventional, Interlock and Occupational Safety I&C systems based on slow controllers. Slow controllers used for the nuclear safety I&C systems are out of scope of this document and are described in [RD9]. ITER Catalogue of I&C Products - Slow Controllers PLC gives a list of COTS products recommended by ITER Organization for Slow I/O systems. ITER Catalogue of I&C Products - Slow Controllers PLC is a living document, which is released at regular intervals throughout the lifetime of ITER. Versions of standards and products are subject to updates and extensions as the ITER project progresses. 2.1 PCDH context The Plant Control Design Handbook (PCDH) [RD1] defines methodology, standards, specifications and interfaces applicable to ITER Plant Systems Instrumentation & Control (I&C) system life cycle. I&C standards are essential for ITER in order to: Integrate all plant systems into one integrated control system. Maintain all plant systems after delivery acceptance. Contain cost by economy of scale. PCDH comprises a core document which presents the plant system I&C life cycle and recaps the main rules to be applied to the plant system I&Cs for conventional controls, interlocks and safety controls. Some I&C topics will be explained in greater detail in dedicated documents associated with PCDH as presented in the picture below. This document is one of them. PCDH core and satellite documents: v7 PS CONTROL DESIGN INTERLOCK CONTROLS Guidelines for PIS design (3PZ2D2) Guidelines for PIS integration & config. (7LELG4) Management of local interlock functions (75ZVTY) PIS Operation and Maintenance (7L9QXR) Plant system I&C architecture (32GEBH) Methodology for PS I&C specifications (353AZY) CODAC Core System Overview (34SDZ5) I&C CONVENTIONS I&C Signal and variable naming (2UT8SH) ITER CODAC Glossary (34QECT) ITER CODAC Acronym list (2LT73V) OCCUPATIONAL SAFETY CONTROLS Guidelines for PSS design (C99J7G) NUCLEAR PCDH (2YNEFU) CATALOGUES for PS CONTROL Slow controllers products (333J63) Fast controller products (345X28) Cubicle products (35LXVZ) Integration kit for PS I&C (C8X9AE) Core PCDH (27LH2V) Plant system control philosophy Plant system control Life Cycle Plant system control specifications CODAC interface specifications Interlock I&C specification Safety I&C specification PS CONTROL DEVELOPMENT I&C signal interface (3299VT) PLC software engineering handbook (3QPL4H) Guidelines for fast controllers (333K4C) Software engineering and QA for CODAC (2NRS2K) Guidelines for I&C cubicle configurations (4H5DW6) CWS case study specifications (35W299) PS SELF DESCRIPTION DATA Self description schema documentation (34QXCP) PS CONTROL INTEGRATION The CODAC -PS Interface (34V362) PS I&C integration plan (3VVU9W) ITER alarm system management (3WCD7T) ITER operator user interface (3XLESZ) Guidelines for PON archiving (B7N2B7) PS Operating State management (AC2P4J) Guidelines for Diagnostic data structure (354SJ3) Legend This document Available and approved (XXXXXX) IDM ref. Figure 1: PCDH documents Page 5 of 83

10 3 DEFINITIONS 3.1 Acronyms AI Analogue Input AO Analogue Output CIN Central Interlock Network CIS Central Interlock System CODAC COntrol Data Access and Communications COTS Commercial Off the Shelf CNP CODAC Network Panel DA Domestic Agency DC Direct Current DI Digital Input DO Digital Output I&C Instrumentation & Control I/O Input / Output IO ITER Organization IEC International Electro technical Commission IM Interface Module (Profibus or Profinet) IP Internet Protocol LED Light Emitting Diode NTP Network Time Protocol PCDH Plant Control Design Handbook PLC Programmable Logic Controller PLN Plant System Local Network PS Plant System PSH Plant System Host SIL Safety Integrity Level TBC To Be Confirmed TBD To Be Defined TS Transceiver UPS Uninterruptible Power Supply WMC Wall Mounted Cubicle 1oo2 One out Of Two 2oo3 Two out Of Three 3.2 Definitions Central I&C Systems Dark Fiber CNP Central Control System including the CODAC (Conventional Control), the CIS (Interlock) and the CSS (Safety) Network-device-free optical fiber link between two locations CODAC Network Panel Wall mounted cubicle that perform passive patch cabling between optical fiber patch panels. Page 6 of 83

11 3.3 Reference Documents IDM Number Title [RD1] ITER_D_27LH2V Plant Control Design Handbook [RD2] ITER_D_6M58M9 CODAC DDD [Network Infrastructure Chapter] [RD2] ITER_D_C8X9AE Integration Kit for PS I&C [RD3] ITER_D_3QPL4H PLC Software Engineering Handbook [RD4] ITER_D_AWYQ5G SIEMENS Reference List [RD6] ITER_D_32GEBH Plant System I&C Architecture [RD7] ITER_D_4H5DW6 I&C Cubicle Internal Configuration [RD8] ITER_D_UBZTCW Guide for Development of the Modbus protocol programming [RD9] ITER_D_JHQLDP ITER catalogue for Nuclear Safety I&C products [RD10] ITER_D_UVYE98 Benchmark information about the communication performance between CODAC and the PLCs [RD11] ITER_D_DZJ4ZT Occupational Safety Cubicle Monitoring System based on S Page 7 of 83

12 4 REFERENCE SYSTEM In the document, no Manufacture Reference will be mentioned. Every product will be associated to a Short Designation. All Manufacture references are specified in another document: [RD4]. The reason is that references may change frequently and would make this document obsolete almost every 3 months. So the products are designed by a Short Designation, itself pointing to a Manufacturer reference in the other document. Example: Short Designation Description Product Reference Status CPU317-2 CPU PN/DP (2x Eth) 6ES7317-2EK14-0AB0 Active Page 8 of 83

13 5 SYSTEM SELECTION This chapter provides guidance to aid in the selection of slow controller hardware. CPU, CP, power supplies, I/O modules and Field Network technology should all be selected in parallel for homogenous system design. START Controller Type Selection (Standard, H, F ) PLC Range Selection (S7-300, 400, 1500) Central Processing Unit (CPU) Communication Processor (CP) Power Supply I/O Selections Network Selection END 5.1 Controller type selection Figure 2: Hardware selection flowchart Selection between fast and slow control is out of scope of this document. Refer to the PCDH [RD1] for guidance related to fast or slow control selection and network performance criteria. This catalogue has been developed to provide guidance in selecting you PLC system hardware. 5.2 CPU Rack Selection The following information provides guidance for the selection of a conventional CPU. It is recommended that you consult your ITER Control System Division representative if you require more information than the given below. These factors should be considered when selecting a CPU rack: o Standard System o High Availability System ( H ) o Fail-safe System ( F ) The first step in selecting your CPU is to determine your rack requirements. Select the type of system in development; Standard, High Availability, Fail-safe, or High Availability Fail-safe. Page 9 of 83

14 A. Standard System(no designation) The following standard CPUs are found in the Siemens Reference List [RD4]. CPU PN/DP CPU PN CPU 1512SP-1 PN for Rail DIN CPU PN/DP Standard CPUs will be used in an estimated 90% of all ITER conventional control systems. Notes: (1) The CPU 1214C is included in the Siemens Reference List [RD4]. The CPU 1214C must be used, only, in the cubicle monitoring system and forbidden for use in conventional control systems. (2) The ITER Control System Division recommends using the S7-400 for master control functions. B. High Availability System( H ) The S7-400H is suitable as a controller for high-availability processes, with two H CPUs of the same type; in the event of a fault, changeover takes place from the master system to the standby station. For more information regarding H CPUs, see: SIMATIC S7-400H High-availability CPUs The following H high availability CPUs are found in the Siemens Reference List: CPU 414-5H PN/DP CPU 416-5H PN/DP CPU 417-5H PN/DP In Siemens CPU references, an H is integrated in the short description and in the Siemens reference number: i.e. CPU414-5H, and 6ES7414-5HM06-0AB0. Notes: (1) An H CPU also qualifies as High Availability FailSafe, or FH. (2) The ITER Control System Division recommends using the S7-400H for master control functions. C. Fail-Safe System( F ): The following F Fail-safe CPUs are found in the Siemens Reference List: CPU 315F-2 PN/DP Fail Safe CPU CPU 1516F-3 PN/DP Fail Safe CPU In Siemens CPU references, an F is integrated in the short description and in the Siemens reference number: i.e. CPU315F-2, and 6ES7315-2FJ14-0AB0 Note: (1) F CPUs are used in interlock and safety systems only and are not required for use in conventional control systems. The fail-safe controllers are used to guarantee the functional safety of machines. For more information regarding F CPUs, see: Fail-safe SIMATIC CPUs See the Siemens Reference List [RD4] for the latest information regarding ITER approved CPUs. Page 10 of 83

15 5.3 CPU Range Selection A. Processor Performance and Memory Size The second step in selecting your CPU is to determine your performance and memory requirements for the system. The following tables provided for the S7-300, S7-400 and S ranges were extracted from Siemens Online resources. SIMATIC S7-300 CPU PN/DP CPU Processing Time for bit operations, typ µs for word operations, typ µs for fixed point arithmetic, typ µs for floating point arithmetic, typ µs CPU - blocks Number of blocks (total) 2048 (DBs, FCs, FBs) Size, max. 64 kbyte Digital channels Inputs Outputs Inputs, of which central 1024 Outputs, of which central 1024 Analog channels Inputs 4096 Outputs 4096 Inputs, of which central 256 Outputs, of which central 256 Hardware Configuration Racks, max. 4 Modules per rack, max. 8 Expansion devices, max. 3 Interfaces Number of other interfaces 1; Ethernet, 2-port switch, 2*RJ45 PROFINET IO Controller Transmission rate, max. 100 Mbit/s number of connectable IO devices, max. 128 PROFIBUS proxy functionality number of linked PROFIBUS devices 16 Data length per connection, max. 240 byte; slave-dependent Work memory integrated 1024 kbyte expandable No size of retentive memory for DBs 256 kbyte Load memory Pluggable (MMC), max. 8 Mbyte Software TIA Portal and STEP 7 Figure 3: SIMATIC S7-300 CPU PN/DP Page 11 of 83

16 SIMATIC S7-400, CPU PN/DP CPU Processing Time for bit operations, typ µs for word operations, typ µs for fixed point arithmetic, typ µs for floating point arithmetic, typ µs CPU - blocks DB number, max. 10,000 FB number, max. 5,000 FC number, max. 5,000 Size, max. 64 kbyte Digital channels Inputs 131,072 Outputs 131,072 Inputs, of which central 131,072 Outputs, of which central 131,072 Analog channels Inputs 8,192 Outputs 8,192 Inputs, of which central 8,192 Outputs, of which central 8,192 Hardware Configuration Racks, max. 21 connectable Ops 95 multi-computing Yes, 4 CPUs max. (with UR1 and UR2) Interfaces Interfaces/bus type 1xMPI/PROFIBUS DP, 1xPROFINET (2 ports), number of RS 485 interfaces 1; combined MPI / PROFIBUS DP number of other interfaces 1; PROFIBUS DP with IF 964-DP PROFINET IO Controller Transmission rate, max. 100 Mbit/s number of connectable IO devices, max. 256 PROFIBUS DP Master Transmission rate, max. 12 Mbit/s number of linked PROFIBUS devices 32 Work memory integrated 16 Mbyte expandable No Load memory expandable FEPROM, max. 64 Mbyte integrated RAM, max. 1 Mbyte Software TIA Portal & STEP 7 Figure 4: SIMATIC S7-400, CPU PN/DP Page 12 of 83

17 SIMATIC S7-1500, CPU PN/DP CPU Processing Time for bit operations, typ µs for word operations, typ µs for fixed point arithmetic, typ µs for floating point arithmetic, typ µs CPU - blocks Number of elements (total) 6,000 Size, max. 5 MB Address area number of IO modules 8,192; max. number of modules Inputs 32 kbyte; All in the process image Outputs 32 kbyte; All in the process image Number of distributed IO systems 64 Hardware Configuration modules per rack, max 32; CPU + 31 modules number of lines max 1 limited only by the number of PtP CM available slots Interfaces number of PROFINET interfaces 2 number of PROFIBUS interfaces 1 number of other interfaces 1; PROFIBUS DP with IF 964-DP 1st PROFINET IO Controller Number of connectable IO devices, max. 2nd PROFINET IO Controller Number of connectable IO devices, max. PROFIBUS; RJ 45 (Ethernet), RS 485 Transmission rate, max. number of linked PROFIBUS devices Work memory integrated (for program) integrated (for data) Load memory Plug-in (SIMATIC Memory Card), max 256; in total, up to 1,000 distributed I/O devices can be connected via AS-I PROFIBUS or PROFINET 32; in total, up to 1,000 distributed I/O devices can be connected via AS-I PROFIBUS or PROFINET 12 Mbit/s 256, via integrated interfaces of the CPU and connected CPs / CMs 1 Mbyte 5 Mbyte 32 Gbyte Software TIA Portal Figure 5: SIMATIC S7-1500, CPU PN/DP Page 13 of 83

18 B. Communication Performance Expected Another important point in order to determine the CPU is the Communication Performance expected. This performance is in straight relation with the quantity of data your application is going to manage (send/receive). Logically bigger quantity of data needs more powerful CPUs to achieve an acceptable communication rate. Moreover, ITER standards advice to use the CP as a device connecting to the High Network and this has also an impact in the communication performance towards the Central I&C System Please refer to the document [RD10] to have detailed information about the communication performances of the ITER PLC Configurations in relation with the quantity of data sent towards the Central I&C System. C. Sample System (example) With the information provided above, a determination can be made for the conventional system CPU based on rack requirements and performance and memory requirements. For example, a system has the following requirement: [CSD1] The PLC shall perform standard process control and monitoring This requires a standard rack leaving us with the following CPUs to select from: CPU PN/DP CPU PN CPU 1512SP-1 PN for Rail DIN CPU PN/DP Next, the system has the following performance requirement: [CSD2] The PLC shall perform bit operations in less than 0.02 µs. From the notes above, the CPU 1214C must only be used in the cubicle monitoring system. The CPU 1512SP-1 PN for Rail DIN is a distributed controller. From the tables above the minimum bit operation time for the CPU PN/DP is µs. This excludes the CPU PN/DP from consideration; it does not meet the [CSD2] performance requirement. Two CPUs meet the above requirements, the CPU PN or the CPU PN/DP. Selection of CPU can be based on other considerations. The CPU PN is programmed in STEP 7 or TIA Portal while the CPU PN/DP can be programmed only in TIA Portal. These programming platforms are described in the chapter: [Software]. Other system requirements can be used to make a final CPU selection. It is recommended that you consult your ITER Control System Division representative should you require assistance in selecting your CPU range. Refer to chapter [Systems Composition] of this document for more information regarding each of the CPU ranges. [CSD3] The Application needs to send 16K of process variables with a communication rate of 150ms towards the Central I&C System. Last point is to confirm that the communication performance provided for the selected PLC Configuration matches with what is needed for the application. Refer to the document [RD10] to verify the PLC Configuration chosen (by CSD1 and CSD2) is able to accomplish the communication rate desired. Page 14 of 83

19 5.4 Remote IO Devices Selection When selecting an IO rack you are confronted to the following choices: o Medium : ET200M or ET200MP o Small : ET200S or ET200SP o Standard or Fail-Safe SIMATIC ET200M Medium Range Remote IO The SIMATIC ET200M belongs to the S7-300 family. The SIMATIC ET200M is a modular I/O station for the control cabinet with high densitychannel applications. Connection to PROFIBUS and PROFINET is achieved using interface modules. The ET200M can be used for standard as well as fail-safe applications. Up to 12 multi-channel signal modules (e.g. 64 digital outputs) and a high range of different modules to use as interface to process. ET200M supports modules with expanded user data, e.g. HART modules with HART minor variables. In addition to proven connection techniques the ET200M offers the insulation displacement method FAST CONNECT for easy wiring. Figure 6: ET200M For more information see Section [Systems Composition] below and: SIMATIC ET200M SIMATIC ET200MP Medium Range Remote IO The ET200MP belongs to the S family. The simple use of SIMATIC ET200MP is exemplified by a modular and scalable station with the SIMATIC S I/O modules in a distributed configuration. The modules have high channel density and low parts variance. As a result, ordering, logistics and spare-parts inventory are considerably simplified. The ET200MP IO system with IP20 degree of protection is scalable and is used not only as a central IO system for S7-1500, but also in a distributed configuration connected to PROFINET or PROFIBUS. As many as 30 IO modules can be inserted into each station. The modules use a limited variety of parts and the front connector is standardized for all 35mm wide modules. Figure 7: ET200MP For more information see Section [Systems Composition] below and: SIMATIC ET200MP Page 15 of 83

20 SIMATIC ET200S Small Range Remote IO The ET200S belongs to the S7-300 family. The ET200S distributed I/O system is a discretely modular, highly flexible DP slave for connection to process signals on a central controller or a field bus. ET200S supports field bus types PROFIBUS DP and PROFINET IO. ET200S has a protection class IP20. The ET200S is installed on a mounting rail. Depending on the interface module, each ET200S can consist of up to 63 modules for example, power modules, I/O modules and motor starters. For the solution of technological tasks, high-performance function modules are available that perform these tasks largely autonomously and relieve the CPU significantly. Used directly onsite; e.g. for counting, measuring and positioning tasks. Figure 8: ET200S For more information see Section [Systems Composition] below and SIMATIC ET200S SIMATIC ET200SP Small Range Remote IO The ET200SP belongs to the S family. The I/O system ET200SP provides maximum usability, compact design, and high performance. The ET200SP distributed I/O system is used for connecting process signals to a central controller via PROFINET or PROFIBUS. The ET200SP is installed on a mounting rail and generally comprises: o An interface module, which communicates with all of the controllers that behave according to the PROFINET standard IEC o Up to 64 I/O modules, which are plugged into passive base units in any combination o A server module, which completes the structure of the SIMATIC ET200SP The distributed I/O system is particularly easy to operate, and with its compact design it achieves maximum economy in the control cabinet. Figure 9: ET200SP For more information see Section [Systems Composition] below and: ET200SP Page 16 of 83

21 ET200M(P) and ET200S(P) essential differences: o Number of channels available. ET200M is highly integrated. One big module can integrate up to 64 signals. (this catalogue restricts to 32 signals module) o ET200S can be expended with compatible Siemens Frequency Converters. o ET200S has faster analogue modules. So faster Control Loops can be achieved. o ET200M is adapted to Fast Connect wiring solutions. ET200S have to be wired directly on the module. o An ET200S module is smaller than an ET200M and can be mounted on a simple DIN Rail. Extract of Siemens Catalogue ST70 ET200S o Ex approval to Cat. 3 for Zone 2 acc. to ATEX100 a o Transmission rates up to 12 Mbit/s o Distributed I/O system to degree of protection IP20 with minimal wiring outlay, also for extremely time-critical tasks such as high-speed closed-loop controls o Discretely-modular design for exact adaptation to the automation task in hand. o Interface modules available with PROFIBUS DP or PROFINET interfaces o Can be combined from digital and analog in/output modules, technology modules, motor starters and frequency converters for the control of drives up to 7.5 or 4 kw. o Exchange of modules during operation (hot swapping), permanent wiring with multi-conductor connection o Channel-specific diagnostics for high availability o Can be supplied with integrated fiber optic interface if required o FastConnect using unstripped quick connection technology, screw or ET200M o Ex approval to Cat. 3 for Zone 2 acc. to ATEX100 a o Transmission rates up to 12 Mbit/s o Modular I/O system with degree of protection IP20, particularly suitable for user-specific and complex automation tasks o Can be expanded with S7-300 automation system signal, communication and function modules. o Applicable Ex analogue input or output modules with HART optimize the ET 200M for use in process engineering o Can be used in redundant systems (S7-400H, S7-400F/FH) o Consists of a PROFIBUS DP IM 153 connection, up to eight or twelve I/O modules of the S7-300 automation system (assembly with bus connections or active bus modules) and if required a power supply o Modules can be replaced during operation (hot swapping) with the bus modules active o Can be supplied with integrated fiber optic interface if required o Fail-safe digital in/outputs as well as Page 17 of 83

22 spring-loaded terminals o Slot reservation with spare modules o Fail-safe DI modules with safetyrelated signal processing according to PROFIsafe Option handling for simples management of machine options analogue inputs for safety oriented signal processing in accordance with PROFIsafe o Support of modules with expanded user data, e.g. HART modules with HART minor variables The choice of Fail-Safe products is driven by the outcome of a specific analysis, according to IEC61508 standard. In some cases you may need Hardware suitable for loops with SIL>=2. Page 18 of 83

23 5.5 Network Selection First of all, let s specify what type of communication networks the ITER Project will contain. Central I&C System 1 3 Plant System Host Slow Controller Slow Controller Slow Controller 2 2 IO Module IO Module IO Module IO Module IO Module IO Module IO Module IO Module IO Module Figure 10: Network Functional Segregation In Figure 10, the network organization described in [RD6] is specified. The networks are broken down in 3 communication groups: - Group(1): The Communication between the Controller and the Central I&C Systems. - Group(2): The Communication between Slow Controllers and their Field Inputs/Outputs. - Group(3): The Communication between the Controllers. Group (1): is entirely covered by the Central I&C Networks. Group (2): can be: 1. Field Network, based on Field bus: A Profibus network. 2. Field Network, Ethernet based network: Profinet. In this cased it can be: o Covered by the Physical Infrastructure of the Central I&C Networks The Central Infrastructure is implemented exclusively using single-mode Fibers. o Covered by a physically independent network. Group (3): is based on Ethernet, is using Siemens S7 Specific Protocols and it can be: - Covered by the Central I&C Networks - Covered by a physically independent network based on Ethernet called Plant System Local (Private) Network. Page 19 of 83

24 A. Technology Selection Group (2): To choose between Profibus or Profinet? The choice between Profibus and Profinet is straightforward. By default the selected protocol must be Profinet, but if the slaves support only Profibus and/or the requirements or characteristics of your system make it necessary (i.e: OS safety), then Profibus must be selected. Avoid heterogeneous architectures mixing Profinet and Profibus with bridges. If you application has Profibus and Profinet slaves, then deploy both networks with the CPU as a master. Group (2) (Profinet case) and Group (3): To choose between using the Physical Infrastructure of the Central I&C Networks or a completely independent network? It is difficult to give a strict decision tree. disadvantages of both solutions. The table below just list advantages and Central I&C Networks Infra Advantages Nothing to do for the design. Only give the number of connections required to Central I&C Systems. No network Management. No technical responsibility. Disadvantages In case of failure in the higher layers of the network, recovery time might take seconds (4-6). There is physical common mode with the other networks. Modification on other logical networks might impact the network. Plant System Local (Private) Network In case of failure of the network, the recovery is instantaneous. Administration at commissioning, then nothing to do any more. Impact on the Design, interface with cable trays, Magnetic Field and radiation impacts to be assessed. Page 20 of 83

25 B. Field Network Architectures For the FieldBus the protocol to use is PROFIBUS. PROFIBUS (Process Field Bus) is a standard for fieldbus communication in automation technology and was first promoted in 1989 by BMBF (German department of education and research) and then used by Siemens. For the FieldNet the protocol to use is PROFINET. PROFINET (pitch acronym for Process Field Net) is an industry technical standard for data communication over Industrial Ethernet, designed for collecting data from, and controlling, equipment in industrial systems, with a particular strength in delivering data under tight time constraints (on the order of 1ms or less). CSD is advising, through this document, the use of only these two protocols: PROFINET and PROFIBUS, as the standards to apply for any Field Network Architecture of the ITER project. Page 21 of 83

26 5.5.B.1 FieldBus (Profibus) The picture below is showing an example of a Plant Control System with 4 Panels (Cubicles or WMC) with Profibus network between the CPU and the IO modules. It is a Ring Physical Topology. This is only possible with the usage of Fiber Optic Transceiver Modules. From the application Layer, the Profibus is still seen as a BUS Topology. The layout represents almost all the possible scenarios: In CU-0001, you have the CPU of the PLC. It is connected by Profibus Copper cable to the inputs/outputs module located in this same cubicle. Then, as a part of the Integration KIT, you also have the switch and the PSH. The Profibus network is extended outside the cubicle using Fiber Optics. The transceivers modules (TS) are performing the conversion between copper Physical Layer and Optical fiber physical layer. These modules performs several functions: o Physical Layer Conversion. o Repeater: One copper segment supports only 32 stations, while Profibus afford 128 stations. So each module support 32 stations, and the connection between them allows using the full addressing range. o Ring Management: Most of the providers of these modules allow a ring connection. It means that a break in the ring will be managed instantaneously, and is transparent to the application In CU-002, the connection to the next cubicle is made of fiber optic pairs, routed in the cable trays of the building. The concerned Plant System is fully in charge of the management of this routing. (Interface with PBS44, etc ). The copper segment bus can be extended to field devices In CU-003, connexion to cubicles in another building could be made using the Central I&C Systems dark fibers. The concerned Plant System must communicate it previously it to CSD. This has to be absolutely managed in the interface documents with PBS 45 (CODAC). Topology : The 2 network legs of the ring should preferably use 2 different routes (cable trays) If field devices are located too far away from the cubicles, the bus can be extended with FO to a WMC (wall mounted cubicle) embedding a Media Converter ( OLM) The picture below is showing an example based in Conventional Control architecture and it is not necessarily shared for Interlock and Safety. Reference PCDH satellite documents for more information regarding interlock or safety networks. Page 22 of 83

27 Figure 11: FieldBus (Profibus) Network using independent infrastructure Page 23 of 83

28 5.5.B.2 Field Net (Profinet) using Central I&C Systems Physical Infrastructure. Picture below is showing an example of a Plant Control System with 4 Panels (Cubicles or Wall Mounted Cubicle) with Profinet Network between the CPU and the IO modules. The Central I&C Networks are used as a Physical Layer (the Fiber Optic used in the Central I&C Networks is a single-mode fiber). The layout represents almost all the possible scenarios: Cubicle CU-0001 is embedding a PLC CPU, One Input/Output Rack, the PSH and the Network Switch of the Integration Kit see [RD2]. The PLC and the Input/Output modules are connected to the Network Switch using conventional copper Ethernet cables (CAT5). The Switch is connected to the Central I&C Systems networks via the CNPs. It is connected through 2 pairs (RX/TX) of Fiber Optics. This double connection assumes redundancy in the Central I&C Systems network. See [RD2] for more details. Panel CU-0002 is an example of a Panel close to the CU The Remote I/O modules can be connected to the network switch of CU-0001 with regular Ethernet copper cables (CAT5(E)) Panel CU-0003 is an example of a Panel far away from CU An intermediary network switch has to be installed. This switch must be chosen, in this same document, in the chapter [Networks Composition]. The Remote I/O modules have to be connected to this intermediary network switch. The connection to CU-0001 is done through the Central I&C Systems Networks via the CNP and also 2 pairs of Fiber Optics. This has to be absolutely managed in the interface documents with PBS 45 (CODAC). Cubicle CU-0004 located in another building is exactly in the same conditions as CU Central I&C Systems is managing building interconnection; this is the big advantage of this configuration. This has to be absolutely managed in the interface documents with PBS 45 (CODAC). The picture below is showing an example based in Conventional Control architecture and it is not necessarily shared for Interlock and Safety. Reference PCDH satellite documents for more information regarding interlock or safety networks. Page 24 of 83

29 Figure 12: FieldNet Network (Profinet) using Central I&C Network infrastructure Page 25 of 83

30 5.5.B.3 FieldNet (Profinet) using independent physical infrastructure. Figure below is showing an example of a Plant Control System with 4 Panels (Cubicles or WMC) with Profinet network between the CPU and the IO modules. An independent network is used as a Physical Layer. It is a Ring Physical Topology. The picture is representing almost all the possible scenarios: In CU-0001, the Ethernet Interface of the PLC CPU is connected to a DIN Rail Manageable Switch. The Input /Outputs module is connected to this switch as well. CU-0002 is close to CU-0001, so the inputs/outputs modules are connected to the switch of CU-0001 with a copper cable. The copper cable is routed in the cable trays. CU-0003 is located somewhere else in the same building. So there is another manageable Switch in the cubicle to connect the Inputs/Outputs modules. This switch is connected to CU-0003 with fiber optic pairs routed in the cable trays. The concerned Plant System is fully in charge of the management of this routing. (Interface with PBS44, etc ) Profinet Slave devices can be also connected to this DIN Rail Manageable Switch. CU-004 is an extreme case, the cubicle is located in another building, so, it is recommended to perform the connexion to panels in another building through the Central I&C Systems dark fibers (however every Plant System could select another way if the suitability is improved). So the FO has to be connected to the Central I&C Systems CNPs. This has to be absolutely managed in the interface documents with PBS 45 (CODAC). Topology : All the DIN rail switches are connected in a ring configuration. The 2 network legs of the ring should preferably use 2 different CNPs in order to avoid a common mode in the ring routing. The picture below is showing an example based in Conventional Control architecture and it is not necessarily shared for Interlock and Safety. Reference PCDH satellite documents for more information regarding interlock or safety networks. Page 26 of 83

31 Figure 13: FieldNet Network (Profinet) using independent infrastructure Page 27 of 83

32 5.5.B.4 Modbus Modbus RTU and MODBUS TCP Modbus RTU is an open, serial (RS-232 or RS-485) protocol derived from the Master/Slave architecture. It is a widely accepted protocol due to its ease of use and reliability. Modbus RTU is widely used within Building Management Systems (BMS) and Industrial Automation Systems (IAS). Modbus TCP/IP (also Modbus-TCP) is simply the Modbus RTU protocol with a TCP interface that runs on Ethernet. The Modbus messaging structure is the application protocol that defines the rules for organizing and interpreting the data independent of the data transmission medium. CSD, through this document, is advising against the use of MOBUS (as said only PROFINET and PROFIBUS must be used in ITER Project). However, exceptionally, if the circumstances of the particular Plant System make the use of MODBUS absolutely necessary and unavoidable, its use could be allowed after presenting the necessary justification and under the approval of the engineers in charge. Two mandatory conditions to follow for the software and for the hardware. Software: For the programming of the Modbus Communication it is mandatory to follow the document [RD8]. Hardware: CSD is providing the necessary HARDWARE to allow this communication. The selection of other hardware is not allowed. Refer to [RD4]. In the figure below, suitable MODBUS RTU boards are exposed. Figure 14 : Modbus RTU Network Layout Page 28 of 83

33 C. Plant System Local (Private) Network Architecture. Two types of inter communication between controllers are allowed in the ITER Standards: - S7 Communication is a Siemens proprietary protocol that runs between programmable logic controllers (PLCs) of the Siemens standard families. - TCP Connection is taking advantage of the existing TCP/IP protocol to stablish the communication link between the PLC devices. In the S7 Communication, as well as, in TCP Connection the communication has to be programmed using dedicate blocks in every PLC involved. 5.5.C.1 Inter-Controllers communications using the Central I&C Networks. In this case you are just using the Central I&C Networks as described in all the PCDH documents to interconnect your controllers. Figure below is showing how practically to extend your network. The layout is showing an example of a Plant Control System with 4 Panels (Cubicles or WMC) with S7 communications between a Main (Master, Server, ) PLC and subordinated (Slaves, Clients, ) PLCs. The Central I&C Networks are supporting the Inter-Controllers communications and, in addition, Central I&C Systems communications.. The figure is representing almost all the possible scenarios: Panel CU-0001 is embedding a PLC CPU, the PSH and the Network Switch of the Integration Kit, [RD2]. The PLC is connected to the Network Switch using conventional copper Ethernet cables (CAT5 (E)). The Switch is connected to the Central I&C Systems networks via the CNPs. It is connected through 2 pairs (RX/TX) of Fiber Optics. This double connection assumes redundancy in the Central I&C Systems network. See [RD2] for more details. Panel CU-0002 is an example of a Panel close to the CU The subordinated PLC can be connected to the network switch of CU-0001 with regular Ethernet copper cables (CAT5(E)) Panel CU-0003 is an example of a Panel far away from CU An intermediary network switch has to be installed. This switch must be chosen in [Networks Composition]. The subordinated PLCs have to be connected to this intermediary network switch. The connection to CU-0001 is done through the Central I&C Systems Networks via the CNP and also 2 pairs of Fiber Optics. This has to be absolutely managed in the interface documents with PBS 45 (CODAC). Panel CU-004, located in another building, is exactly in the same conditions as CU-003. Central I&C Systems are managing building interconnections; this is the big advantage of this configuration. The picture below is showing an example based in Conventional Control architecture and it is not necessarily shared for Interlock and Safety. Reference PCDH satellite documents for more information regarding interlock or safety networks. Page 29 of 83

34 i Figure 15 : Inter-Controllers (S7 communication) using the Central I&C Network Page 30 of 83

35 5.5.C.2 Inter-Controllers communications using independent physical architecture Figure below is showing an example of a Plant Control System with 4 Panels (Cubicles or WMC) with S7 Communications between a Main (Master, Server, ) Controller and subordinated (Slaves, Clients, ) PLCs. An independent network is used as a Physical Layer, generally referred at ITER as, Plant System Local Network. It is a Ring Physical Topology. The layout represents almost all the possible scenarios: In CU-0001, the Ethernet Interface of the Communication Processor ( CP ) of the Main 400-PLC is connected to a DIN Rail Manageable Switch. Important note: the CP requires 2 Ethernet connexions, as the first one is already used by the connection to Central I&C Networks (CP440-1-Adv to be used). CU-0002 is close to CU-0001, the Ethernet Interface of a Communication Processor (CP) of the Subordinated PLC is connected to the switch of CU-0001 with a copper cable. The copper cable is routed in the cable trays. Important note: As in the figure below, if the PLC is a S7-300, then it will require a second Communication Processor, as the first one is dedicated to connection to Central I&C Networks. CU-0003 is located somewhere else in the same building. So there is another manageable Switch in the cubicle to connect the Inputs/Outputs modules. This switch is connected to CU-0003 with fiber optic pairs routed in the cable trays. The concerned Plant System is fully in charge of the management of this routing. (Interface with PBS44, etc ) In CU-0004 it is recommended to perform the connexion to panels in another building through the Central I&C Systems dark fibers (however every Plant System could select another way if the suitability is improved). So the FO has to be connected to the Central I&C Systems CNPs. This has to be absolutely managed in the interface documents with PBS 45 (CODAC). Topology : All the DIN Rail switches are connected in a ring configuration. The 2 network legs of the ring should preferably use 2 different CNPs in order to avoid a common mode in the ring routing. It is recommended to connect all the Slow Controllers to the Central I&C Networks, however if this is not possible for the requirements or constraints of a particular system, so it is the case in a Plant System Local Network, anyway the PLCs in this private network must be Time Synchronized with the Central System Time Server. It is strongly advised in this case to use a Time and Frequency Synchronization Platform to work in between two networks, to get the Time Synchronization information from a Central Network and deliver it to the Plant System Local Network in order to synchronize all the devices in there. Refer to CODAC Department to get the specific data of the device. The picture below is showing an example based in Conventional Control architecture and it is not necessarily shared for Interlock and Safety. Reference PCDH satellite documents for more information regarding interlock or safety networks. Page 31 of 83

36 Figure 16: Inter-Controllers (S7 Communication) using independent infrastructure Page 32 of 83

37 5.6 Central I&C Network accessing point Selection A. Analysis of the Arguments In order to get connected to the central I&C Networks (in case of the central I&C Systems infrastructure) the developer will be confronted to the choice: CP or CPU. At the same time, in order to get connected to the PROFINET Network, the developer will be confronted to the same choice: CP or CPU. The present chapter summarizes the arguments to take in account in order to the select the proper device to do such a task: the best point of connection (device/slot) to the central I&C Network. This set of criteria is summarized below: - For the Central I&C Networks Communication o Network Security o Communication Performance to the Central I&C Network o Reset of the communication with the Central I&C Network. - For the Profinet Communication o Number of slaves connected to Profinet Network o Necessary Functions to implement Profinet Communication o System Health Monitoring These criteria are analysed against the three hardware families proposed in this catalogue: 300, 400 and Below, the summary table with the capital arguments for every family of devices: Device to connect CP343-1-ADV CPU317-2 CP443-1-ADV CPU416-3 CP CPU X2 CPU X1 CP343-1-ADV CPU317-2 CP443-1-ADV CPU416-3 CP Subject Central I&C Networks Communication Network security The CP has the security functions : VPN, Firewall, The Ethernet interface of the CPU does not have the security functions. The CP has the security functions : VPN, Firewall The Ethernet interface of the CPU does not have the security functions. The CP has the security functions : VPN, Firewall Port X2 of CPU does not have security functions Port X1 of CPU does not have security functions Communication Performance to the Central I&C Network TCP/IP maximum data volume to send in a single command 32KB Data with Block AG-SEND with a CPU Bit Operation Performance of 25ns But diminished for the [CP CPU] backplane serial bus of 1MB communication 32KB Data with Block T-SEND with a CPU Bit Operation Performance of 25ns 32KB Data with Block AG-SEND with a CPU Bit Operation Performance of 12.5ns But diminished for the [CP CPU] backplane parallel bus communication 32KB Data with Block T-SEND with a CPU Bit Operation Performance of 12.5ns 64KB Data with Block T-SEND with a CPU Bit Operation Performance of 10ns Page 33 of 83

38 Device to connect CPU X2 CP343-1-ADV CPU317-2 CP443-1-ADV CPU416-3 CP CPU X2 CP343-1-ADV CPU317-2 CP443-1-ADV CPU416-3 CP CPU X1 CP343-1-ADV CPU317-2 CP443-1-ADV CPU416-3 CP CPU CP343-1-ADV CPU317-2 CP443-1-ADV CPU416-3 CP CPU Subject But diminished for the [CP CPU] backplane serial bus communication 64KB Data with Block T-SEND with a CPU Bit Operation Performance of 10ns Reset of the Communication with Central I&C Networks Reset of CP could be done using SIEMENS Console connected through CPU (without restarting CPU, so, not affecting buses attached to CPU interfaces) Reset of CP could be done using SIEMENS Console connected through CPU (without restarting CPU, so, not affecting buses attached to CPU interfaces) Reset of CP could be done using Special Functions : T-Reset Profinet Communication Number of slaves connected to Profinet Network The CP can manage 32 devices The CPU (315 or 317) can manage 128 devices The CP can manage 128 devices The CPU (416-3 PN/DP) can manage 256 devices. The CP does not have Profinet capabilities CPU X1 can manage 256 devices Necessary Functions to implement Profinet Communication To communicate with the devices it is needed to add to the program the software blocks PNIO_SEND and PNIO_RECV To communicate with the devices no need to add software blocks To communicate with the devices no need to add software blocks To communicate with the devices no need to add software blocks The CP does not have Profinet capabilities To communicate with the devices no need to add software blocks System Health Monitoring CP failed to do this job with the standard program used by ITER. Other methods may succeed. CPU can extract System Health data CP can extract System Health data CPU can extract System Health data CP cannot extract System Health data ( no PROFINET) CPU can extract System Health data Every argument stated is corroborated with SIEMENS. Page 34 of 83

39 B. Outcome of the analysis For the 300 Family: - It is advised to use a CP to perform the connection to the Central I&C Networks. - It is advised to use a CP to perform the connection to the Plant System Local (private) Network. - It is advised to use the CPU to perform the connection to the Field Devices Network. For the 400 Family: - It is advised to use a CP to perform the connection to the Central I&C Networks. - It is advised to use a CP to perform the connection to the Plant System Local (private) Network. - It is advised to use the CPU to perform the connection to the Field Devices Network. For the 1500 Family: - It is advised to use a CP to perform the connection to the Central I&C Networks. Note: The use of the CPU [Port X2] to perform this connection, instead of a CP, could be accepted if the security and performance of the controller s configuration is not endangered. - It is advised to use CPU Port X1 to perform the connection to the Field Devices Network - It is advised to use CP to perform the connection to a Plant System Local (Private) Network. Communication Performance Tests between CODAC and the most representative PLC Configurations are being run at the time this document is released. This information will be summarized in [RD10]. Page 35 of 83

40 5.7 Cubicle Monitoring System Selection Cubicle Monitoring System is a mandatory requirement stated in the [R157] of the Plant Control Design Handbook [RD1]: - The I&C cubicles shall be equipped with a monitoring system for doors, temperature and cooling monitoring and the monitoring system shall be interfaced to the plant system I&C. The detailed specification of the Cubicle Monitoring System could be found in the Chapter 7 of the key document I&C Cubicle Internal Configuration [RD7]. The solutions given are targeting the Conventional Control. *In case the cubicle belongs to a Safety System please refer to the document [RD11]. A. Complete Solution for 1 cubicle ITER is providing a standard complete solution for the monitoring of 1 single Cubicle. This solution is already being widely used in the Integration Kit [RD2] provided by CODAC Section. Target of the Solution: So, this solution is targeting the monitoring of only 1 Cubicle Figure 17 : Target of the solution for the monitoring of one single cubicle Implementation of the solution: Subject Electrical Diagrams Guide for the configuration and start-up Software Reference Document I&C Integration Kit Cubicle Monitoring System(HMU) Electrical Diagrams Guide for the configuration and start-up of the ITER Standard Cubicle Monitoring System SVN Link referenced in the Guide for the Configuration and start-up Page 36 of 83

41 SIEMENS equipment involved in the solution: CPU1214C RAIL DIN PON TS90 Ethernet Interface Figure 18 : SIEMENS Hardware for CUB MON SYS 1 Single Cubicle Short Designation QTY Description and Characteristics RAIL DIN CPU1214C 1 CPU 1214C 14DI, 10DO, 2AI Power Supply 230V *For the exact reference of every component please refer to [RD4]. *For the datasheet of the every product, use the reference and refer to SIEMENS Website. B. Partial Solution for 2 to 11 cubicles ITER is providing a partial solution to monitor from 2 to 11 cubicles. So, this solution is targeting the monitoring of a sets of cubicle, up to 11, placed in a row, close, one after the other, or separated by small distances, less than 15 m. Figure 19 : Target of the solution for the monitoring of 2 to 11 Cubicles Page 37 of 83

42 Implementation of the solution: Subject Electrical Diagrams Guide for the configuration and start-up Reference Document Current IDM Electrical Diagrams are not applicable The Electrical Diagrams must be developed for the supplier. The Electrical Diagrams presented in the Complete solution for 1 single cubicle could be used as a template for the dedicated electric diagrams to every particular case. Current IDM Guide is applicable. Guide for the configuration and start-up of the ITER Standard Cubicle Monitoring System Software is applicable Software ( SVN Link referenced in the Guide for the Configuration and start-up ) - Hardware Configuration of the Project will need to be modified. Adding the new IO Boards. - PLC-Code is applicable ( No modification is necessary) SIEMENS equipment involved in the solution: SM DI SM1222-8DO SM1231-8AI CPU1214C SM DI SM DI SM1222-8DO SM1231-8AI SM1231-8AI CPU1214C RAIL DIN PON TS90 Ethernet Interface Figure 20 : SIEMENS Hardware for CUB MON SYS From 2 to 11 cubicles Page 38 of 83

43 Short Designation QTY Description and Characteristics RAIL DIN CPU1214C 1 CPU 1214C 14DI, 10DO, 2AI Power Supply 230V SM DI 2 16 Digital Input for S SM1222-8DO 1 8 Digital Output for S SM1231-8AI 2 8 Analogue Input for S SM1231-8AI 2 8 Digital Output for S *For the exact reference of every component please refer to [RD4]. *For the datasheet of the every product, use the reference and refer to SIEMENS Website. Page 39 of 83

44 6 SYSTEMS COMPOSITION 6.1 Slow Controllers Range A. Low (distributed) Range of Slow Controllers Low range controllers are the intelligent choice for applications in the low to mid-performance range. They are modular, small, compact and cost-effective. The objective is to achieve flexible solutions for simple networking with integrated and optional communications connections. The decentralization of intelligence helps hugely in making machines and plants more flexible and is thus becoming a decisive competitive factor. Increasing networking makes possible to integrate autonomous, intelligent units at the field level into the system-wide communication system. The remote I/O systems capabilities can be expanded using integral, intelligent controllers. This gives rise to distributed controllers. 6.1.A.1 Low (Distributed) Range PLCs: [S7-1500] CPU + IO Rack Exceptionally, if the needs of the process are extremely limited and the segregation of the functionalities in different controllers a main objective for the particular Control System the use of the Distributed [CPU + IOs] could be suitable. However, even in the case stated above the use of the Distributed Remote I/O Modules in their small version is highly recommended. - The fact of using a PLC, uniquely, as a Data Transmitter to a higher control instance is not wise from a Control System point of view. This is precisely the job of a Distributed I/O Module. - The fact of placing several controllers dedicated to control different functions of the same Plant system in the same cubicle or contiguous cubicles is not wise from a Cubicle configuration point of view. The Distributed CPU is using as a background support the Standard RAIL DIN. The I/O Modules to be attached to the CPU correspond to the S Small Range subfamily (ET200SP) and their background support is, as well, the standard RAIL DIN. It is recommended to place the modules in the following order: - Digital Inputs - Digital outputs - Analog Inputs - Analog outputs. The concern is not technical. The idea is to have same I/O structures on all racks. Page 40 of 83

45 Figure 21 : Distributed Rack [S IO] exploded view Short Designation QTY Description and Characteristics CPU1512SP-1 1 CPU1512SP-1 characteristics detailed in the datasheet. TM-P-SP 1 Terminal Module for Power Supply TM-E-SP (1..n)-1 Terminal Module for Power Supply Bridge Monitors the supply voltage Diagnostics support Rated voltage 24VDC SM131SP-16DI 1..n 16 DI Module, Module Diagnostic SM132SP-16DO 1..n 16 DO Module, Module Diagnostic SM134SP-4AI 1..n 4AI U/I Input Module, Module Diagnostic SM134SP-4RTD/TC 1..n 4 RTD/TC input Module High Feature. Diagnosis SM134SP-8AI-U 1..n 8 AI "U" Input Module, Diagnosis SM134SP-8AI-I 1..n 8 AI "I" 2-/4-WIRE Input Module, Diagnosis SM135SP-4AO 1..n 4 U/I Output Module, Diagnosis *For the exact reference of every component please refer to [RD4]. *For the datasheet of the every product, use the reference and refer to SIEMENS Website. Page 41 of 83

46 B. Medium Range of Slow Controllers The perfect alternative for the mid-range applications; medium controllers offer the features and flexibility needed without the overhead of larger systems, but suitable for medium and complex applications. Medium controllers with modular expansion capability are long-term compatible, maintenance-free, scalable and include safety certified. They are the ideal solution for any automation task. 6.1.B.1 Mid-range PLCs: [S7-300 or S7-1500] CPU Rack 6.1.B.1.1 S7-300: CPU Rack The S7-300 is the modular PLC system for the low and mid-performance ranges. In ITER, a small plant system which requires medium range of performances could perfectly work using these mid-range PLCs. The backplane is the regular one, without Hot Swapping capability. In the figure below, two possible configurations for the Ethernet Communication Processor (CP343) are presented: First configuration ( Standard one ) : o A connection to a Profinet Network o A connection to the Central I&C Networks The connection to Profinet is made through the CPU Ethernet Port. The connection to the Central I&C Networks through the CP343-1 Ethernet Port (the CP has 2 Ethernet slots, but it is the same Ethernet connection) Second configuration ( In case of Plant System Local (private) Network ) : o A connection to a Profinet Network, o A connection to a Plant System Local (Private) Network. o A connection to the Central I&C Networks The connection to Profinet is made through the CPU Ethernet Port. The connection to the Plant System Local (Private) Net through the X1 Interface of the CP343-1-Adv and the connection to the Central I&C Networks through the X2 Interface. Another possibility is to add a new CP343-1 for the Plant System Local (private) Network. Page 42 of 83

47 Figure 22: Rack s7-300 exploded view. Page 43 of 83

48 Short Designation QTY Description and Characteristics RAIL-19IN 1 Rail 19" PS300-5A 1 PS 300 5A (1 Slot) MMC-2M-EEPROM 1 Micro Memory Card 2MB (Upto 8 MB Max) CPU CPU PN/DP (2x Eth) Central Unit. Detailed information in [System Selection]. Detailed characteristics in datasheet. CP Communication Processor Ethernet 16 Connections maximum Profinet 1 x Ethernet Port SEND/RECEIVE: ISO-on-TCP: 8Kb TCP/IP: 8Kb UDP : 2Kb S7 communications Web based diagnostic DHCP Client NTP Client SNMP v1 CP343-1-Adv 1 Communication Processor Ethernet 16 Connections maximum Profinet 2 x Ethernet Port SEND/RECEIVE: ISO-on-TCP: 8Kb TCP/IP: 8Kb UDP : 2Kb S7 communications Web based diagnostic DHCP Client NTP Client SNMP v1 *For the exact reference of every component please refer to [RD4]. *For the datasheet of the every product, use the reference and refer to SIEMENS Website. PLC Software Engineering Handbook Page 44 of 83

49 6.1.B.1.2 S7-1500: CPU Rack The S is the modular PLC system for the mid-performance ranges. In ITER a small or medium plant system which requires medium range of performances could perfectly work with these Mid-range PLCs. The backplane is the regular one for the 1500 family, without hot Swapping capability. In the below, it is presented the basic configuration proposed for the 1500 family. Connection to Central I&C Networks The connection to Central I&C Networks will be made through the Ethernet Port of the CP , installed in the second slot. Connection to the FIELD (Remote IO) : FieldBus or FieldNet The connection to Profinet will be made through the CPU Ethernet Port X1. The connection to Profibus will be made through the CPU Profibus Port. In case of Plant System Local (Private) Net Connection to Plant System Local (Private) Network (S7 Comm. between PLCs). Another CP will be installed (CP1543-1) in the third slot. The connection to the Plant System Local Network will be made through the Ethernet Port of CP1543. Page 45 of 83

50 Figure 23: Rack S exploded view Page 46 of 83

51 Short Designation QTY Description and Characteristics RAIL IN MOUNTING RAIL 482 MM PS1500-3A 1 PS V/3 A STABILIZED POWER SUPPLY MMC-24M-EEPROM 1 SIMATIC S7, MEMORY CARD FOR S7-1X00 CPU/SINAMICS, 3,3 V FLASH, 24 MBYTE CPU CPU PN/DP Central Unit. Detailed information in [System Selection]. Detailed characteristics in the datasheet. CP Communication Processor Ethernet CP Detailed characteristics in datasheets. Interfaces 1 Ethernet Interface Performance Data Protocols Supported 118 Connections maximum (S7 and Open Communication) ISO-on-TCP by means of T Blocks: 64Kb S7/Open Communication DCP NTP Product Function SNMP v1 Web Based Diagnostic *For the exact reference of every component please refer to [RD4]. *For the datasheet of the every product, use the reference and refer to SIEMENS Website. Page 47 of 83

52 6.1.B.2 Mid-range PLC with local IO: [S7-300 or S7-1500] CPU+IO Rack 6.1.B.2.1 S7-300: CPU+IO Rack If the needs are very limited, a single rack with CPU+IOs may be sufficient. The first part is identical to the CPU rack described in chapter [S7-300 CPU Rack]. The following boards are Inputs/Outputs modules, of all the kind, detailed in the table below. Up to 7 modules can be added after the Communication Processor CP If no communication modules appear in the configuration, then, up to 8 modules can be added. It is recommended to place the modules in the following order: Special modules (RS232/RS485, ) Digital Inputs Digital outputs Analog Inputs Analog outputs. The concern is not technical. The idea is to have same I/O structures on all racks. Figure 24: Rack S IO exploded view Page 48 of 83

53 Short Designation QTY Description and Characteristics CP Communication Processor RS232,RS422,RS485 SM321-32DI n Digital Input Module, 32 DI, 24V, 500 V DC isolated SM321-16DI n Digital Input Module, 16 DI Module with Channel Diagnostics SM322-32DO n Digital Input Module, 32 DO, 24V, 500 V DC isolated SM322-8DO n Digital Input Module, 8 DO, 24V, 500 V DC isolated with Channel Diagnostics SM331-8AI n Analog Input Module, 8 AI, 500 V DC isolated, 15 bits, Diagnostic Status SM332-8AO n Analog Input Module, 8 AO, 500 V DC isolated, 12 bits, Diagnostic Status *For the exact reference of every component please refer to [RD4]. *For the datasheet of the every product, use the reference and refer to SIEMENS Website. Page 49 of 83

54 6.1.B.2.2 S7-1500: CPU+IO Rack If the needs are very limited, a single rack with CPU+IOs may be sufficient. The first part is identical to the CPU rack described in the chapter [S7-1500: CPU Rack]. The following boards are Inputs/Outputs modules, of all the kind, described in the following table. Up to 31 modules can be added after the CPU1516. So, the Communication Processor will take the place right after the CPU1516, then 30 modules more could be added. It is recommended to place the modules in the following order: Special modules (CM-PTP, ) Digital Inputs Digital outputs Analog Inputs Analog outputs. The concern is not technical. The idea is to have same I/O structures on all racks. Figure 25 : Rack S IO exploded view Page 50 of 83

55 Short Designation QTY Description and Characteristics CM-PTP 1 Communication Module CM for Serial RS422, RS485 SM521-32DI n 32 DI module with Diagnostics SM522-32DO n 32 DO Module with Diagnostics SM531-8AI n 8 Analog Inputs Module U/I/RTD/TC with Diagnosis SM532-8AO n 8 Analog Outputs Module U/I with Diagnosis *For the exact reference of every component please refer to [RD4]. *For the datasheet of the every product, use the reference and refer to SIEMENS Website. Page 51 of 83

56 6.1.B.3 Mid-range Fail Safe PLCs: [S7-300 or S7-1500] CPU rack Safety Configurations are used to control processes and adopt or remain in a safe state as soon as an error occurs. They provide a consistent and efficient safety concept in plants with increased safety requirements. Safety Configurations will be used by Safety an Interlock systems. Specific information about systems composition and network connectivity could be found, for these two Control System vertical tiers, in their dedicated documentation; refer to [RD1]. However, an important detail to remember is that S7-300F for the OS can only be used for local functions; central functions require a S B.3.1 S7-300 F CPU rack S7-300 F systems are medium range Fail safe systems provided by Siemens. PS300-5A CPU 315F-2 PN/DP MMC-2MB-EEPROM CP343-1 Ethernet Interface CP343-1 CPU Profibus DP Interface CPU Ethernet Interface RAIL-19IN Figure 26: Fail Safe, High range PLCs S7300F Short Designation QTY Description and Characteristics RAIL-19IN 1 Rail 19" PS300-5A 1 PS 300 5A (1 Slot) CPU 315F-2 PN/DP (detailed information in datasheet). CPU315F 1 Software STEP 7 V 5.5 or higher, Distributed Safety V 5.4 SP4 MMC-2M-EEPROM 1 Micro Memory Card 2MB CP Communication Processor Ethernet *For the exact reference of every component please refer to [RD4]. *For the datasheet of the every product, use the reference and refer to SIEMENS Website. Page 52 of 83

57 6.1.B.3.2 S F CPU rack S F systems are medium range Fail safe systems provided by Siemens. It is important to remember that at the time of the release of this document the CSD-PCI- Safety department guidelines do not cover yet this PLC. Please refer to the CSD-PCI-Safety department to get the last update if you are willing to use this PLC for a Safety application. Figure 27 : Fail Safe, High range PLCs S71500F Short Designation QTY Description and Characteristics RAIL IN MOUNTING RAIL 482 MM PS1500-3A 1 PS V/3 A STABILIZED POWER SUPPLY CPU PN/DP Fail Safe CPU (detailed info in datasheet) CPU1516F-3 1 Software TIA Portal V14 SP1 or higher Safety Advanced v14 CP Communication Processor Ethernet CP *For the exact reference of every component please refer to [RD4]. *For the datasheet of the every product, use the reference and refer to SIEMENS Website. Page 53 of 83

58 C. High Range of Slow Controllers High Range Slow Controllers are suitable for the most demanding application needs. They offer modular architectures and a wide spectrum of I/O and network options. These powerful control solutions deliver world-class capabilities from process to safety to motion. Designed for distributed or supervisory control applications, high range programmable automation controllers provide multi-computing skills, modularity, exceptional reliability, performance and diagnostic abilities. 6.1.C.1 High range PLCs: S7-400 The Figure 28 represents two kinds of configurations for the Ethernet Communication Processor (CP443-1). First configuration (standard configuration): o A connection to a Profinet Network, o A connection to the Central I&C Networks. The connection to Profinet is made through the CPU Ethernet Port. The connection to the Central I&C Networks is made through the CP Ethernet Port. The CP has 2 Ethernet ports, but it is the same Ethernet connection. Second configuration (in case of Plant System Local (Private) Net): o A connection to a Profinet Network, o A connection to a Plant System Local (Private) Network o A connection to the Central I&C Networks. The connection to Profinet is made through the CPU Ethernet Port. The connection to the Plant System Local (Private) Network is made through the X1 Interface of the CP Adv and the connection to the Central I&C Networks through the X2 Interface of the CP Adv. Page 54 of 83

59 Figure 28: Rack S7-400 exploded view. Page 55 of 83

60 Short Designation QTY Description and Characteristics UR2 1 Chassis 400 UR2 9 Slots PS400-10A 1 PS A BAT Back Up Battery 400 PCCARD-4MB-RAM 1 Memory PC Card 4MB RAM PCCARD-8MB-RAM 1 Memory PC Card 8MB RAM PCCARD-16MB-RAM 1 Memory PC Card 16MB RAM CPU CPU PN/DP Central Unit. Detailed information in [System Selection]. Detailed characteristics listed in datasheet. CP Communication Processor Ethernet 96 Connections maximum Profinet SEND/RECEIVE: ISO-on-TCP: 8Kb TCP/IP: 8Kb UDP : 2Kb Open IE ( T Blocks) ISO-on-TCP: 1452 Bytes S7 communications http server DHCP Client NTP Client SNMP v1 CP443-1-ADV 1 Communication Processor Ethernet Advanced. This CP has 2 interfaces, and supports some more protocols. For each Interface: 96 Connections maximum Profinet IRT SEND/RECEIVE: ISO-on-TCP: 8Kb TCP/IP: 8Kb UDP : 2Kb Open IE ( T Blocks) ISO-on-TCP: 1452 Bytes S7 communications http server DHCP Client NTP Client SNMP v1 FTP *For the exact reference of every component please refer to [RD4]. *For the datasheet of the every product, use the reference and refer to SIEMENS Website. Page 56 of 83

61 6.1.C.2 High range Fail Safe PLCs: S7-400 F CPU rack Safety systems are used to control processes and adopt or remain in a safe state as soon as an error occurs. They provide a consistent, efficient safety concept in plants with increased safety requirements. S7-400 F systems are high range Fail safe systems provided by Siemens. The hardware is exactly the same at what is shown in the redundant configuration, but in a Single Configuration (either CP443-1 or CP443-1-ADV can be used depending of the needs of the system) These systems will be used by Safety an Interlock systems. More information regarding network connectivity can be found in the documentation of these systems. Figure 29: Fail Safe, High range PLCs S7400F Short Designation QTY Description and Characteristics UR2 1 Chassis 400 UR2 9 Slots PS400-10A 1 PS A BAT Back Up Battery 400 Page 57 of 83

62 PCCARD-4MB-RAM 1 Memory PC Card 4MB RAM (or FLASH) CPU414-H (or CPU416-H) 1 CPU 414-5H PN/DP. Detailed characteristics listed in datasheets. (or CPU417-H) Memory Work memory Integrated 4 Mbyte Integrated (for program) 2 Mbyte Integrated (for data) 2 Mbyte Load memory Expandable FEPROM, max. 64 Mbyte Integrated RAM, max. 512 Kbyte Expandable RAM, max. 64 Mbyte Address Area I/O address area Inputs 8 Kbytes Outputs 8 Kbytes Process Images Inputs 8 Kbytes Outputs 8 Kbytes Profibus DP Interface Ethernet Interface First Interface: RS 485 / PROFIBUS + MPI, MPI + DP Master, 32 Max DP Slaves Second Interface: RS 485 / PROFIBUS, DP Master, 96 Max DP Slaves 64 connections maximum Profinet open ie, o TCP : 32Kb o ISO-on-TCP : 32Kb o UDP : 1452 Bytes S7 communications Integrated Switch Software STEP 7 v5.5 SP2 with HF1 CP Communication Processor Ethernet CP443-1-ADV 1 Communication Processor Ethernet Advanced *For the exact reference of every component please refer to [RD4]. *For the datasheet of the every product, use the reference and refer to SIEMENS Website Page 58 of 83

63 6.1.C.3 High Range, High Availability PLCs: S7-400 H CPU Rack In addition to the Failsafe feature, this PLC configuration presents High Availability: it is redundant. These devices will be used for Safety an Interlock control systems. More information regarding network connectivity can be found in the documentation of these systems. A highly availability controller minimizes the probability of production failures and thus decisively contributes to maximum productivity and safety. Picture below represents the complete architecture of a S7-400FH. Three noticeable facts: Connection to Remote I/Os is made through Profibus or Profinet, using the interfaces that the CPU provides. And preferably stablishing rings Profinet Redundant Ring or Profibus Redundant Ring in order to make the IO Network more reliable. The connection to the Central I&C Networks is still established through a CP while there is an Ethernet connection on the CPU. o Previously the CPU414-4H itself didn t have an Ethernet connexion, so the CP was required. Now the systems CPU416-H and CPU417-H already have Ethernet Port included in the CPU, but the recommendation remains the same : use CP. Configuration of the two redundant backplane shall be exactly the same. They are twins. Figure 30: High availability PLCs architecture *At the moment of the release of this document, the connexion to the Central I&C Networks for Conventional Control, through on-board Ethernet Connexion of a Redundant PLC is being tested. Please refer to Control System Division to know the last update of the tests if you are willing to use it. Page 59 of 83

64 Here below the advantages of using high availability PLC Configuration: Highest system availability with early fault detection and integrated diagnostic capabilities Efficient solutions with scalable performance and redundancy Simple programming and configuration Performance-oriented solution for time-critical processes Synchronized hardware solution without information loss Highly available communication via Industrial Ethernet Integrated diagnostic functions Exchange of all components during operation ( hot swapping) The figure below shows a S7-400H Configuration in detail: In case of PS Local (private) Network Replace CP443-1 of every RACK for PON CP443-1-ADV Ethernet Interface X1 CPU416-H CP443-1 Private Net (S7) CP443-1-ADV CP443-1-ADV Ethernet Interface X2 PS400-10A-KR PS400-10A-KR CPU4146-H CP443-1 PCCARD-4MB-FLASH PS400-10A-KR PS400-10A-KR CPU414-H CP443-1EX20 PCCARD-4MB-RAM PON PON 4xBAT400 PS400-10A-KR SYNC-10M-5H RACK A RACK B F0-10M SYNC-10KM-5H Sync Sync F0-2M 2 x UR2 UR2-2x9 Figure 31: High availability PLCs S7-400H Page 60 of 83

65 Both stations are connected to each other with Synchro modules and fiber cables. o Be careful with references, the older references for previous CPU414H are still available for spare parts, they are not compatible with the new generation 5H. There are 2 types of Synchro Modules: o For a distance of up to 10 m, o For a distance up to 10Km. Siemens provides 10m and 2m cables. For longer distances, cables shall be bought to specific providers. 2 different backplanes of 9 slots must be used if each S7-400 CPU is installed in different cubicles. Otherwise, in the same cubicle, a 2x9 backplane has to be used. Be careful it is not a regular 18 slots backplane! Plant System Local (private) Net is optional, depending of the needs of the Plant System. In case this is necessary, a supplementary CP443-1 must be installed or the current CP443-1 (appearing in the drawing above) must be replaced for a CP443-1-Adv. Short Designation QTY Description and Characteristics UR2-2x9 1 Chassis 400 UR2H 18 Slots (2x9) UR2 2 Chassis 400 UR2 9 Slots PS400-10A-KR 4 PS A For Redundant Rack BAT Back Up Battery 400 PCCARD-4MB-RAM 2 Memory PC Card 4MB RAM (or FLASH) CPU416-H (or CPU414-H) (or CPU416-H) 2 CPU 416-5H PN/DP Central Unit. Detailed characteristics listed in datasheets. Memory Work memory Integrated 16 Mbyte Integrated (for program) 6 Mbyte Integrated (for data) 10 Mbyte Load memory Expandable FEPROM, max. 64 Mbyte Integrated RAM, max. 1Mbyte Expandable RAM, max. 64 Mbyte Address Area I/O address area Inputs 16 Kbytes Outputs 16 Kbytes Process Images Inputs 16 Kbytes Page 61 of 83

66 Profibus DP Interface Ethernet Interface Outputs 16 Kbytes First Interface: RS 485 / PROFIBUS + MPI, MPI + DP Master, 32 Max DP Slaves Second Interface: RS 485 / PROFIBUS, DP Master, 125 Max DP Slaves 96 connections maximum Profinet open ie, o TCP : 32Kb o ISO-on-TCP : 32Kb o UDP : 1452 Bytes S7 communications Integrated Switch Software STEP 7 v5.5 SP2 with HF1 FO-2M 2 Synchro Cable FO 2m FO-10M 2 Synchro Cable FO 10m SYNC-10M-5H 2 Synchro Module FO 10m compliant 414-5H SYNC-10KM-5H 2 Synchro Module FO 10km compliant 414-5H CP Communication Processor Ethernet *For the exact reference of every component please refer to [RD4]. *For the datasheet of the every product, use the reference and refer to SIEMENS Website Page 62 of 83

67 6.2 Remote I/O Modules Range A. Small I/O modules [S7-300 or S7-1500] Distributed I/O systems are particularly easy to operate, and with its compact design it achieves maximum economy in the control cabinet. Their high speed and transmission rate ensure significantly greater performance than conventional systems. Several modules have been identified in ITER. The CPUs 300/400/1500 work with these modules remotely. Two types of Distributed I/O are presented in the catalogue: - ET200S for the S7-300 Family - ET200SP for the S Family 6.2.A.1 S7-300 Family: ET200S Figure 32 is showing how to build the system. The configuration can have up to 63 signal modules in an ET200S. A Power Module (PM-E) is placed in front of a bank of signals modules. The maximum number of signal modules for a bank depends on the current consumption. A Terminal Module (TM-E) can drive up to 8A. ET200S modules have hot swapping capability. PM-E module requires a TM-P base. SMs modules require TM-E bases. Figure 32: ET200S Modules exploded view Page 63 of 83

68 Short Designation QTY Description and Characteristics IM151-1 HF 1 Interface Module for linking ET200S to Profibus DP. Supports DP V0 and DP V1 Connection type RS485 IM IM151-3 PN Interface module for ET200S IO modules Interface module for linking the ET 200S to PROFINET Integrated 2-port switch MMC-128K-EEPROM Micro Memory Card 128 KB TM-P 1 TM-P Terminal Module for Power Supply PM-E 1 Power Module for PM-E electronic Module TM-E (1..n) -1 Terminal Module for Power Supply Bridge Monitors the supply voltage Diagnostics support Rated voltage 24VDC Electrical isolation SM131-8DI 1..n Digital Input Module, 8 DI, 24V, 500 V DC isolated SM131-8DO 1..n Digital output Module, 8 DO, 24V, 500 V DC isolated SM134-2AI 1..n Analog Input Module, 2 AI, 500 V DC isolated, 14 bits, Diagnostic Status SM134-2TC 1..n Thermocouple Module, 2 AI, 500 V DC isolated, 16 bits, Diagnostic Status SM134-2AO 1..n Analog Output Module, 2 AO, 13 bits, 500 V DC isolated, Diagnostic Status SM134-2RTD 1..n RTD Module, 2 AI, 16 bits, 500 V DC isolated, Diagnostic Status *For the exact reference of every component please refer to [RD4]. *For the datasheet of the every product, use the reference and refer to SIEMENS Website Page 64 of 83

69 6.2.A.2 S Family: ET200SP Figure below is showing how to build the system. The configuration can have up to 32 signal modules. The first I/O board will need a Terminal Power Module (TM-P-SP), so, this is placed in the first position, top left (this is necessary to feed the whole process downstream of the ET200SP). Right after, every I/O board will need one Terminal Follower Module (TM-E-SP). The maximum number of signals for a bank depends on the current consumption. A TM-P-SP can drive up to 10A. ET200SP modules have hot swapping capability. Figure 33: ET200SP Modules exploded view Page 65 of 83

70 Short Designation QTY Description and Characteristics IM155DP-6DP-HF 1 Interface Module to link ET200SP to Profibus DP. Supports DP V0 and DP V1 Connection type RS485 IM155PN-6DP-ST 1 Interface Module to Link ET200SP to PROFINET Integrated 2 port Switch TM-P-SP 1 Terminal Module for Power Supply TM-E-SP (1..n)-1 Terminal Module for Power Supply Bridge Monitors the supply voltage Diagnostics support Rated voltage 24VDC SM131SP-16DI 1..n 16 DI Module, Module Diagnostic SM132SP-16DO 1..n 16 DO Module, Module Diagnostic SM134SP-4AI 1..n 4AI U/I Input Module, Module Diagnostic SM134SP-4RTD/TC 1..n 4 RTD/TC input Module High Feature. Diagnosis SM134SP-8AI-U 1..n 8 AI "U" Input Module, Diagnosis SM134SP-8AI-I 1..n 8 AI "I" 2-/4-WIRE Input Module, Diagnosis SM135SP-4AO 1..n 4 U/I Output Module, Diagnosis *For the exact reference of every component please refer to [RD4]. *For the datasheet of the every product, use the reference and refer to SIEMENS Website Page 66 of 83

71 B. Medium I/O modules [S7-300 or S7-1500] 6.2.B.1 S7-300 Family: ET200M ET200M is a modular I/O system used for user-specific and complex automation tasks: o Used with S7 SIEMENS automation system to expand signals, communication and function modules : o In CPUs S7-300 in both local and Remote o In CPUs S7-400 & S7-400H in Remote o In CPUs S in remote o Supports PROFIBUS DP and PROFINET interface module o Modules can be replaced during operation (hot swapping) with the bus modules active. Attention must be paid to the type of base module: o PS300-5A and IM must be place on a BM-PS-IM153 base module. o SM modules must be placed on BM-sx40 base modules. o If the architecture is redundant, the IM153-2 modules must by placed on BM-IM153- IM153 base modules If the configuration uses Profibus, you can set up to 8 SM modules. If the configuration uses Profinet, you can set up to 12 SM modules. IM Profibus DP Interface See Table below PS300-5A IM153-4 OR IM153-2 PS300-5A IM153-4 SM321-32DI SM322-32DO SM332-8AI SM331-8TC MMC-128K-EEPROM RAIL-19IN-HS RAIL-19IN-HS IM ProfiNet Interface BM-PS-IM153 BM-2x40 BM-2x40 BM-2x40 Figure 34: ET200M Modules Page 67 of 83

72 Figure 35: ET200M Modules to use with s7-400 H Short Designation QTY Description and Characteristics RAIL-19IN-HS 1 Mounting Rail Hot SWAP length: 19 Inches, up to 5 bus modules PS300-5A 1 PS 300 5A (1 Slot) IM IM153-4 High Feature (ProfiSafe Compliant) Integrated 2-port switch PN IO Transmission protocol IM IM153-2 Standard Feature Profibus Transmission Protocol MMC-128K-EEPROM 1 Micro Memory Card 128 KB BM-PS-IM153 1 Backplane Module PS/IM153. Hot swap capability SM321-32DI 1 Digital Input Module, 32 DI, 24V, 500 V DC isolated SM322-32DO 1 Digital Input Module, 32 DO, 24V, 500 V DC isolated SM331-8AI 1 Analog Input Module, 8 AI, 500 V DC isolated, 15 bits, Diagnostic Status SM332-8AO 1 Analog Input Module, 8 AO, 500 V DC isolated, 12 bits, Diagnostic Status BM-2x40 n/2 Backplane Module 2x40. Hot swap capability *For the exact reference of every component please refer to [RD4]. *For the datasheet of the every product, use the reference and refer to SIEMENS Website Page 68 of 83

73 6.2.B.2 S Family: ET200MP ET200MP is a module I/O system used for user-specific and complex automation tasks: o Used with S7 SIEMENS automation system to expand signals, communication and function modules : o In CPUs S in both local and Remote o In CPUs S7-400 in Remote o In CPUs S7-300 in Remote o Supports PROFIBUS DP or PROFINET interface module o Modules cannot be replaced during operation with the bus module active. Without hot swapping capability. If the configuration uses Profibus, you can set up to 12 SM modules. If the configuration uses Profinet, you can set up to 12 SM modules. See Table below Figure 36: ET200MP Modules Page 69 of 83

74 Short Designation QTY Description and Characteristics RAIL IN-HS Mounting Rail 482 MM. Including grounding element PS1500-8A 1 PS V/8A Stabilized Power Supply IM155-5PN-HF 1 IM153-5PN High Feature Integrated 2-port switch PN IO Transmission protocol Profisafe Compliant IM155-5DP-ST 1 IM155-5DP Standard Feature Profibus Transmission protocol Profisafe Compliant U-TYPE-CONNECTOR N Spare Part, U-Type-Connector for Connection IO Module SM521-32DI 1 32 DI module with Diagnosis SM522-32DO 1 32 DO Module with Diagnosis SM531-8AI 1 8 Analog Inputs Module U/I/RTD/TC with Diagnosis SM532-8AO 1 8 Analog Outputs Module U/I with Diagnosis *For the exact reference of every component please refer to [RD4]. *For the datasheet of the every product, use the reference and refer to SIEMENS Website Page 70 of 83

75 C. Medium I/O Fail-Safe modules [S7-300 or S7-1500] 6.2.C.1 S7-300 Family: ET200M F ET200M-F is a modular I/O system used for Fail-Safe automation tasks: o Used in S7 SIEMENS automation system to expand signals, communication and function modules : o In CPUs S7-300F in both local and Remote o In CPUs S7-400F and S7-400FH in Remote o In CPUs S7-1500F in remote o Supports PROFISAFE over Profibus DP o Modules can be replaced during operation (hot swapping) with the bus modules active. Attention must be paid to the type of base module: o PS300-5A and IM must be place on a BM-PS-IM153 base module. o SM modules of 1 slot width must be placed on BM-2x40 base modules. o SM modules of 2 slots width must be placed on BM-80 base modules o If the architecture is redundant, the IM153-2 modules must by placed on BM-IM153- IM153 base modules You can set up to 8 SM modules on the same rack. Figure 37: ET200M F Modules Page 71 of 83

76 Figure 38: ET200M F Modules for S7-400FH Short Designation QTY Description and Characteristics RAIL-19IN-HS 1 Mounting Rail Hot SWAP length: 19 Inches PS300-5A 1 PS 300 5A (1 Slot) IM IM Profibus Coupler BM-PS-IM n Backplane Module PS + IM153 BM-IM153-IM n Backplane Module IM153+ IM153 BM n Backplane Module for 80mm modules BM-2x40 0..n Backplane Module for 2x 40mm modules. SM326-24DI 0..n 24 F-DI Module SM326-10DO 0..n 10 F-DO Module SM336-6AI 0..n 6 F-AI Module *For the exact reference of every component please refer to [RD4]. *For the datasheet of the every product, use the reference and refer to SIEMENS Website Page 72 of 83

77 6.2.C.2 S Family: ET200MP F ET200MP-F is a modular I/O system used for Fail-Safe automation tasks: o Used in S7 SIEMENS automation system to expand signals, communication and function modules : o In CPUs S7-1500F in both local and Remote o In CPUs S7-400F in Remote o In CPUs S7-300F in remote o Supports PROFISAFE over Profibus DP and PROFINET o Modules cannot be replaced during operation with the bus modules active. You can set up to 12 SM modules on the same rack using the PROFIBUS header You can set up to 30 SM modules on the same rack using the PROFINET header. IM Profibus DP Interface PS1500-8A IM155-5PN-HF OR IM155-5DP-ST SM526-16DI SM526-8DO SM526-16DI SM526-8DO RAIL IN IM ProfiNet Interface Figure 39: ET200MP F Modules Page 73 of 83

78 Short Designation QTY Description and Characteristics RAIL IN-HS Mounting Rail 482 MM. Including grounding element PS1500-8A 1 PS V/8A Stabilized Power Supply IM155-5PN-HF 1 IM153-5PN High Feature Integrated 2-port switch PN IO Transmission protocol Profisafe Compliant IM155-5DP-ST 1 IM155-5DP Standard Feature Profibus Transmission protocol Profisafe Compliant U-TYPE-CONNECTOR n Spare Part, U-Type-Connector for Connection IO Module SM326-16DI 1 16 F-DI Module SM326-8DO 1 8 F-DO Module *For the exact reference of every component please refer to [RD4]. *For the datasheet of the every product, use the reference and refer to SIEMENS Website Page 74 of 83

79 6.3 Accessories Short Designation QTY Description and Characteristics SITOP-10A 1 PS SITOP 10A SITOP-20A 1 SITOP power supply Modular 230Vac/24Vdc 20A SITOP-DIODES 1 SITOP redundancy module 24Vdc/40A PC-USB 1 PC Adapter (USB) *For the exact reference of every component please refer to [RD4]. *For the datasheet of the every product, use the reference and refer to SIEMENS Website Page 75 of 83

80 7 NETWORK COMPOSITION The network is an integral part of the Control System infrastructure based on slow controllers. In this chapter, a set of equipment is presented to ease and drive the job of development of such infrastructure. - Field Network Architecture equipment To implement the immediate layer below the Slow Controllers ; to connect them to their slaves, using either Profinet or Profibus. - Plant System Local (Private) Network Architecture equipment To implement the immediate layer above the Slow Controllers, to interconnect them, using Ethernet. 7.1 Field Network Architecture equipment A. Field Bus (Profibus) components The FieldBus (Profibus) components are the Media Converters and Connectivity devices. This equipment will be used to deploy the Profibus Network Architecture. A Key device is the OLM (Optical Link Module or Profibus transceiver module (TS)), normally called Media Converter, represented several times in the chapter: [Network Selection]. Short Designation QTY Description and Characteristics PB-CABLE - Profibus Cable (20m) PB-CON - Profibus Connector OLM Profibus Optical Link Module - 1 RS485 and 1 Glass-Focinterface (2 Bfoc-Sockets) Single mode fiber. Support Ring Redundancy Page 76 of 83

81 B. Field Net (Profinet) components The FieldNet (Profinet) components are the Field Switches. This equipment will be used to deploy an independent Profinet Network Architecture stated in the chapter: [Network Selection]. Two references are stated, both of them suitable to implement properly this task. Short Designation QTY Description and Characteristics RS20-08 (Hirschman) 0..n DIN Mounting 8 ports: 6 RJ45/2 FO 10/100Mbits FO: Monomode, SC connectors 24VDC Power Supply Manageable Redundancy Management: Hyper-Ring X308-2LD (Siemens) 0..n DIN Mounting 10 ports : 7 RJ45/2FO 10/100/1000Mbits FO: Monomode, SC connectors 24VDC Power Supply Manageable Redundancy Management *For the exact reference of every component please refer to [RD4]. *For the datasheet of the every product, use the reference and refer to SIEMENS Website Page 77 of 83

82 7.2 Plant System Local (Private) Network Architecture equipment The Plant System Local Network components are the Network Switches. This equipment will be used to deploy an independent Plant System Local (Private) Network stated in the chapter: [Network Selection]. Two references are stated, both of them suitable to implement properly this task. Short Designation QTY Description and Characteristics MACH102 (Hirschman) 19 RACK Mounting 24 Ports Fast Ethernet 2 Ports Combo Ethernet Gigabit 0..n 10/100/1000Mbits 230 VAC Power Supply Manageable Redundancy Management: Hyper-Ring XR324-12M (Siemens) 0..n 19 RACK Mounting 24 ports (ST, SC, LC) 100/1000Mbits 230 VAC Power Supply Manageable Redundancy Management *This is the network equipment to be used, also, when the PLC must be connected to the Central I&C Networks. This equipment should be provided, by default, with the Interface Kit [RD3]. *For the exact reference of every component please refer to [RD4]. *For the datasheet of the every product, use the reference and refer to SIEMENS Website Page 78 of 83