SIMATIC. Distributed I/O Device ET 200iSP. Preface, Contents. Product Overview Getting Started with Commissioning. Configuration Options.

Transcription

1 SIMATIC Distributed I/O Device ET 200iSP Manual This documentation is available under order number 6ES7152-1AA00-8BA0 Preface, Contents Product Overview Getting Started with Commissioning Configuration Options Installation Wiring Commissioning and Diagnostics Maintenance General Technical Data Terminal Modules Power Supply PS Interface Module Digital Electronic Modules Analog Electronic Modules Reserve Module Appendices Glossary, Index Edition 02/2005 A5E

2 Safety Guidelines This manual contains notices you have to observe in order to ensure your personal safety, as well as to prevent damage to property. The notices referring to your personal safety are highlighted in the manual by a safety alert symbol, notices referring to property damage only have no safety alert symbol. The notices shown below are graded according to the degree of danger.!!! Danger indicates that death or severe personal injury will result if proper precautions are not taken. Warning indicates that death or severe personal injury may result if proper precautions are not taken. Caution with a safety alert symbol indicates that minor personal injury can result if proper precautions are not taken. Caution without a safety alert symbol indicates that property damage can result if proper precautions are not taken. Attention indicates that an unintended result or situation can occur if the corresponding notice is not taken into account. If more than one degree of danger is present, the warning notice representing the highest degree of danger will be used. A notice warning of injury to persons with a safety alert symbol may also include a warning relating to property damage. Qualified Personnel The device/system may only be set up and used in conjunction with this documentation. Commissioning and operation of a device/system may only be performed by qualified personnel. Within the context of the safety notices in this documentation qualified persons are defined as persons who are authorized to commission, ground and label devices, systems and circuits in accordance with established safety practices and standards. Prescribed Usage Note the following:! Warning This device and its components may only be used for the applications described in the catalog or the technical description, and only in connection with devices or components from other manufacturers which have been approved or recommended by Siemens. Correct, reliable operation of the product requires proper transport, storage, positioning and assembly as well as careful operation and maintenance. Trademarks All names identified by are registered trademarks of the Siemens AG. The remaining trademarks in this publication may be trademarks whose use by third parties for their own purposes could violate the rights of the owner. Copyright Siemens AG 2004 All rights reserved The distribution and duplication of this document or the utilization and transmission of its contents are not permitted without express written permission. Offenders will be liable for damages. All rights, including rights created by patent grant or registration of a utility model or design, are reserved Siemens AG Automation and Drives Postfach 4848, D Nuernberg Siemens Aktiengesellschaft Disclaim of Liability We have reviewed the contents of this publication to ensure consistency with the hardware and software described. Since variance cannot be precluded entirely, we cannot guarantee full consistency. However, the information in this publication is reviewed regularly and any necessary corrections are included in subsequent editions. Siemens AG 2005 Technical data subject to change.

3 Preface Purpose of this manual The information in this manual enables you to operate the ET 200iSP distributed I/O device as a DP slave via an RS 485 IS coupler on the PROFIBUS-DP RS 485 IS. Basic knowledge required To understand the manual, you require general experience in the field of automation engineering. In particular when operating a PLC in safety-relevant areas, observe the information on the safety of electronic control systems in the S7-300, CPU 31xC, and CPU 31x operating instructions: Installation. The following qualifications are also required: Table 1-1 Qualified Personnel Activities Qualifications Installation of ET 200iSP Basic technical training Knowledge of safety regulations regarding the workplace Wiring the ET 200iSP Basic practical training in electrical engineering Knowledge of the relevant safety regulations for electrical engineering Knowledge of methods of installing explosion-proof electrical equipment Knowledge of safety regulations regarding the workplace Commissioning the ET 200iSP Knowledge of all electrical and functional parameters and properties of ET 200iSP Knowledge of the functions and commissioning of PROFIBUS-DP Knowledge of the connected encoders, actuators, and HART field devices Knowledge of the safety regulations regarding the workplace, and in particular of procedures in potentially explosive areas iii

4 Preface Scope of the manual This manual applies to the distributed I/O station ET 200iSP. Approbation for information on standards and certifications, refer to chapter 8-2. CE certification for information on standards and certifications, refer to chapter 8-2. Identification for Australia (C tick mark) for information on standards and certifications, refer to chapter 8-2. Standards for information on standards and certifications, refer to chapter 8-2. Where this documentation fits in In addition to this manual, you also need the manuals supplied with the DP master and RS 485 IS coupler you are using (see the Order numbers in the appendix). The Order numbers appendix provides a list of further sources of information on SIMATIC S7 and on the ET 200 distributed I/O system. A description of the parameter assignment and configuration frame is not included in this manual. The description is available on the Internet URL Guide to the manual This manual describes the hardware of the ET 200iSP distributed I/O station. It consists of introductory chapters and reference chapters (technical data). Installing and wiring the ET 200iSP distributed I/O station Commissioning and diagnostics of the ET 200iSP distributed I/O station Components of the ET 200iSP distributed I/O station Order numbers Recycling and disposal The ET 200iSP distributed I/O station can be recycled due to its low-pollutant equipment. For environment-friendly recycling and disposal of your electronic waste, please contact a company certified for the disposal of electronic waste. iv

5 Preface Further Support If you have any technical questions, please get in touch with your Siemens representative or agent responsible. You will find your contact person at: You will find a guide to the technical documentation offered for the individual SIMATIC Products and Systems here at: The online catalog and order system is found under: Training Centers Siemens offers a number of training courses to familiarize you with the SIMATIC S7 automation system. Please contact your regional training center or our central training center in D Nuremberg, Germany for details: Telephone: +49 (911) Internet: v

6 Preface Technical Support You can reach the Technical Suport for all A&D products Via the Web formula for the Support Request Phone: Fax: Additional information about our Technical Support can be found on the Internet pages: Service & Support on the Internet In addition to our documentation, we offer our Know-how online on the internet at: where you will find the following: The newsletter, which constantly provides you with up-to-date information on your products. The right documents via our Search function in Service & Support. A forum, where users and experts from all over the world exchange their experiences. Your local representative for Automation & Drives. Information on field service, repairs, spare parts and more under Services. vi

7 Contents 1 Product Overview What are Distributed I/O Stations? What is the ET 200iSP Distributed I/O Station? ET 200iSP in Potentially Explosive Environments Integration into the Control System Getting Started with Commissioning Introduction Requirements Materials and Tools Required for the Sample Configuration Configuration Overview Installation of the Sample Configuration Installation of the ET 200iSP Mounting the S Installing the RS 485-IS Coupler Wiring the Sample Configuration Insert the Interface Module and the Electronic Modules Setting the PROFIBUS Address Configuring the Example Configuring the S Configuring and Assigning Parameters to ET 200iSP Programming the Example Putting the Example into Operation Analysis of Diagnostics Data Removing and Inserting Modules Wire Break of the NAMUR Encoder Connected to the Digital Input Module vii

8 Contents 3 Configuration Options Modular System Electronics Modules to Suit Your Application Electronic Modules Matching the Terminal Modules Power Supply of ET 200iSP Configuration Options in Zones Limitation of the Number of Connectable Electronic Modules Maximum Configuration of ET 200iSP Direct Data Exchange Time Stamping Time Stamping at an Accuracy of 20 ms Time Synchronization with Flexible Time Interval Counting Features Function Principle Configuring Counters Configuring Counters Frequency Measurement Features Function Principle Configuring Frequency Counters Assigning Frequency Counter Parameters Identification Data I&M Redundancy with IM Redundancy with S7 DP Masters Software redundancy Redundancy of the Power Supply Configuration Changes in RUN Operating the ET200iSP with Older CPUs Date of Production of the Module Installation Rules for Installation Installing the Mounting Rail Installing the Terminal Module for Power Supply PS Installing Terminal Modules for the Interface Module and Electronic Modules Installing the Bus Termination Module and the Slot Cover Installing the Slot Number Labels viii

9 Contents 5 Wiring General Rules and Regulations for Wiring ET 200iSP Operation with Equipotential Bonding PA Electrical Installation of the ET 200iSP Lightning and Overvoltage Protection Overview The Lightning Protection Zone Concept Rules for the Interface Between Lightning Protection Zones 0 to Rules for the Interfaces between Lightning Protection Zones and higher Example of Protection from Overvoltage for Networked ET 200iSP Stations Wiring the ET 200iSP Rules for Wiring the ET 200iSP Wiring a Terminal Module with Screw Terminals Wiring a Terminal Module with Spring Terminals Grounding the Mounting Rail Wiring Terminal Module TM-PS-A Wiring Terminal Modules TM-IM/EM and TM-IM/IM Wiring Terminal Modules TM-EM/EM Terminating the Cable Shielding Connecting a TC Sensor Module Inserting and Labeling the Power Supply, Interface Module, and Electronic Modules Setting the PROFIBUS address Inserting and Changing the SIMATIC Micro Memory Card (MMC) Commissioning and Diagnostics Configuring in STEP Configuring with GSD File and SIMATIC PDM Commissioning and Startup of ET 200iSP Requirements for Commissioning Commissioning the ET 200iSP Startup of ET 200iSP Startup of ET 200iSP with IM 152 redundancy Start up for time synchronization / time stamping of signal changes Assigning Parameters for the ET 200iSP during Operation using SIMATIC PDM Diagnostics by Means of the Process Input Image Status and Error LEDs on the ET 200iSP Diagnostics in STEP Introduction Reading Diagnostics Data Diagnostic Messages of the Electronics Modules Evaluating Interrupts of the ET 200iSP (S7 DP Slave/ DPV1 Slave) Structure of the Slave Diagnostics Station Status 1 to Master PROFIBUS address ix

10 Contents Manufacturer s ID ID-related Diagnostics Module Status Channel-Specific Diagnostics H-Status (Only with the S7-400H and Standard Redundancy) Interrupts Diagnostics for Incorrect Module Configuration States of the ET 200iSP Maintenance Actions in Run Removing and Inserting Electronic Modules During Operation (Hot Swapping) Exchanging the Interface Module Maintenance during Operation Cleaning IM 152 Firmware Update General Technical Data General Technical Data Standards and Certifications Electromagnetic Compatibility and Shipping and Storage Conditions Mechanical and Climatic Ambient Conditions Information on Dielectric Tests, Class of Protection, Degree of Protection, and Rated Voltage of the ET 200iSP Terminal Modules Overview of Contents Terminal Modules TM-PS-A and TM-PS-B Terminal modules TM-IM/EM 60S and TM-IM/EM 60C Terminal module TM-IM/IM Terminal modules TM-EM/EM 60S and TM-EM/EM 60C Power Supply PS Interface Module Interface module IM Parameters for IM Description of the Parameters for IM Operation if Preset-<> Actual configuration Self-diagnostics Redundant Power Supply diagnostics Diagnostics Interrupts Process Alarms Time Stamping / Edge Evaluation Data Format Interference Frequency Suppression Unit of temperature Slot Reference Junction / Reference Junction Input Identification and Message Functions (I&M) x

11 Contents 12 Digital Electronic Modules Digital Electronic Module 8 DI NAMUR Digital Electronic Module 4 DO Parameters of the Digital Electronics Modules Digital Electronic Module 8 DI NAMUR Digital electronic module 4 DO Parameters of the Digital Electronics Modules Time Stamping Pulse Stretching Flutter Monitoring Counting Parameters Frequency Counting Parameters Identification and Message Functions (I&M) Analog Electronic Modules Analog Value Visualization Analog Value Representation for Measuring Ranges with SIMATIC S Measuring Ranges of the Analog Input Modules in S7 Format Output Ranges of the Analog Output Modules in S7 Format Basics of Analog Value Processing Connecting Thermocouples Basics of HART HART Features Function Principle of HART Integration of HART Field Devices with ET 200iSP Use of HART IEEE Tags HART Data Records Response of the Analog Modules during Operation and if Faults Occur Analog Electronic Module 4 AI I 2WIRE HART Analog Electronic Module 4 AI I 2WIRE HART Analog Electronic Module 4 AI RTD Analog Electronic Module 4 AI TC Analog Electronic Module 4AO I HART Parameters of the Analog Electronic Modules Parameters of the Analog Electronic Modules 4 AI I 2WIRE HART, 4 AI I 4WIRE HART Parameters of the Analog Electronic Modules 4 AI RTD and 4 AI TC Parameters of the Analog Electronic Module 4AO I HART Description of the Parameters of the Analog Electronic Modules Reference Junction / Reference Junction Number Smoothing Channel and IEEE Tag HART Warning HART Diagnostics Identification and Message Functions (I&M) xi

12 Contents 14 Reserve Module A Order Numbers A-1 A.1 Order numbers A-1 B Dimensional Drawings B-1 C Reaction Times C-1 C.1 Response times at the DP master C-1 C.2 Reaction Times on the ET 200iSP C-2 C.3 Reaction Times with Digital Input Modules C-2 C.4 Reaction Times with Digital Output Modules C-2 C.5 Reaction Times of Analog Input Modules C-2 C.6 Reaction Times of Analog Output Modules C-4 D Address Space of the Inputs and Outputs D-1 D.1 Digital Input Module D-1 D.2 Digital Output Module D-3 D.3 Analog Input Modules D-4 D.4 Analog Output Modules D-4 D.5 Analog Input Modules with HART (4 AI I 2WIRE HART, 4 AI I 4WIRE HART) D-5 D.6 Analog Output Module with HART (4 AO I HART) D-6 E Certifications E-1 E.1 EC Prototype Certificates E-1 E.2 EC Declarations of Conformity E-51 Glossary Index Glossary-1 Index-1 xii

13 Contents Figures 1-1 Typical PROFIBUS DP network structure View of the ET 200iSP Distributed I/O Station Identifiers of ET 200iSP Integration into the Control System Overview of the Sample Configuration Wiring TM-PS-A Wiring the RS 485-IS Coupler Wiring the ET 200iSP Module Setting the PROFIBUS-address Configuring the S Configuring and Assigning Parameters to ET 200iSP Deactivating ET 200iSP Channels Example of an ET 200iSP Configuration Power Supply PS Configuration Options for the ET 200iSP in Zone Example of Direct Data Exchange Example of Time Stamping and Edge Evaluation Example configuration with 2 IM 152s for redundancy in an H-system Principle of Operation of the 16-bit Up Counter Principle of Operation of the 16-bit Down Counter PIO with 2 Count/ 6 DI NAMUR Configuration PIO with 2 Count/ 6 DI NAMUR Configuration PII with 2 Trace/ 6 DI NAMUR Configuration Redundancy with 2 x IM 152 in an H-system Redundancy of the Power Supply Year of production Enclosure for ET200iSP in Zone Enclosure for ET200iSP in Zone Enclosure for ET 200iSP in Zone Enclosure for ET200iSP in Zone Minimum Clearances to the Enclosure Mounting Terminal Module TM-PS-A Mounting Terminal Module TM-PS-B Installing Terminal Modules TM-IM/EM and TM-EM/EM Removing Terminal Module TM-EM/EM, Starting from the Right Side Installing the bus termination module Installing the Slot Cover Installing the Slot Cover Installing the Slot Number Labels ET 200iSP Operation with Equipotential Bonding PA Potentials in the ET 200iSP System Lightning Protection Zones of a Building Example of the Wiring of Networked ET 200iSP Stations Wiring with Spring Terminals Grounding the Mounting Rail Connecting the Power Supply and Grounding Conductor PA to the TM-PS-A Wiring Terminal Module TM-IM/EM (PROFIBUS RS 485-IS) Wiring Terminal Module TM-IM/IM (PROFIBUS RS 485-IS) Wiring the Terminal module TM-EM/EM Terminating the Cable Shielding TC-Sensor Module Installing the Power Supply PS Installing and Labeling Interface Modules and Electronic Modules xiii

14 Contents 5-15 Removing Interface and Electronic Modules Changing the Type of an Electronic Module Setting the PROFIBUS DP Address Position of the MMC Slot on the IM Function Principle of Configuring Startup of ET 200iSP Startup of the ET 200iSP with IM 152 redundancy Starting Up Time Synchronization / Time Stamping LED Display on IM 152 Interface Module LED Displays on the Digital Electronic Modules LED Displays on the Analog Electronic Modules Interrupts from Analog Input Modules Structure of Slave Diagnostics Evaluation of the Slave Diagnostics Structure of the ID-Related Diagnostic Information for ET 200iSP Module Status Structure of Channel-Specific D iagnostics Structure of the H-Status of the IM 152 (for S7-400H only) Structure of the Interrupt Status of the Interrupt Section Structure of bytes x+4 to x+7 for Diagnostic Interrupts Structure Starting at Byte x+8 for Diagnostics Interrupt from Interface Module Structure Starting at Byte x+8 for Diagnostic Interrupt (Input / Output Modules without HART) Structure Starting at Byte x+8 for Diagnostic Interrupt (Input or Output Module with HART) Example of a Diagnostic Interrupt Example of a Diagnostic Interrupt (Continued) Structure Starting at Byte x+4 for Hardware Interrupts (Analog Input) Structure Starting at Byte x+4 for Process Alarms (Time Stamping) Structure Starting at Byte x+4 for Remove/Insert Interrupts Structure Starting at Byte x+4 for Update Interrupt Automatic Parameter Assignment after Replacing a Module Block Diagram of Terminal Modules TM-P-A and TM-PS-B Block diagram of Terminal Module TM-IM/EM Block diagram of Terminal Module TM-IM/IM Block Diagram of Terminal Module TM-EM/EM Block Diagram of the Power Supply PS Block Diagram Interface Module IM Block Diagram of 8 DI NAMUR Block Diagram 4 DO Output Characteristics 4 DO DC23.1V/20mA Output Characteristics 4 DO DC17.4V/27mA Output Characteristics 4 DO DC17.4V/40mA Actuator Shutdown by Means of Intrinsically Safe Switching Signal (Safety Barrier) Principle of Pulse Stretching Principle of Flutter Monitoring xiv

15 Contents 13-1 Compensation by 4 AI RTD Example of the Configuration of Reference Junctions The HART Signal Location of the HART Analog Modules in the Distributed System System Environment for HART Applications IEEE Tag IEEE754 Format Status Byte Block Diagram of 4 AI I 2WIRE HART Block Diagram of 4 AI I 4WIRE HART Block Diagram of 4 AI RTD Block Diagram of 4 AI TC Block Diagram of 4AO I HART Example of the Influence of Smoothing on the Step Response Assigning the IEEE Tags B-1 Terminal Module TM-PS-A with Inserted Power Supply PS B-1 B-2 Terminal Module TM-IM/EM with Inserted Interface Module and Electronic Module B-2 B-3 Terminal Module TM-EM/EM with Inserted Electronic Modules B-2 B-4 Terminating module B-3 C-1 Response times between the DP master and the ET 200iSP C-1 C-2 Cycle Time of the Analog Input Module C-3 C-3 Cycle Time of the Analog Output Module C-4 C-4 Response Time of an Analog Output Channel C-5 D-1 PII with 8 DI NAMUR Configuration D-1 D-2 PII with 2 Counter/ 6 DI NAMUR Configuration D-2 D-3 PII with 2 Counter/ 6 DI NAMUR Configuration D-2 D-4 PII with 2 Trace/ 6 DI NAMUR Configuration D-3 D-5 PIO with Digital Output Module D-3 D-6 PII with Analog Input Modules D-4 D-7 PIO with Analog Output Modules D-4 D-8 PIO with Analog Input Modules with HART D-5 D-9 PIO/PII with Analog Output Module with HART D-6 xv

16 Contents Tables 1-1 ET 200iSP Components Features and Benefits Zone Classes Intrinsic Safety of the Types of Protection Required Material and Tools Changes Sample program Electronics Modules to Suit Your Application Modules and Terminal Modules Rules for Configuration Current Consumption Calculation Table Current consumption calculation table Assignment of Digital Inputs of 2 Count / 6 DI NAMUR Assignment of Digital Inputs of 2 Count / 6 Control Parameters for the Counters Assignment of digital inputs of 2 Trace / 6 DI NAMUR Parameters for the Frequency Counters Identification data I&M Parameters for Redundancy of the Power Supply PS Reaction of the I/O Operating the ET200iSP with Older CPUs Installation Dimensions Rail Mounting Diagram Fixing Screws System Startup after Certain Events Mains Power in the Safe Area VDC Supply in the Safe Area Protection from External Electrical Influences V DC Supply in the Safe Area Lightning Protection Zones Protection of Cables with Overvoltage Protection Components Example of a Lightning-Protected Configuration Rules for Wiring the ET 200iSP Available MMCs Comparison of DPV1, S7 DP and DPV Software requirements Requirements for Commissioning Commissioning the ET 200iSP Status and Error LEDs on the IM Status and Error LEDs on the Digital Electronic Modules Status and Error LEDs on the Analog Electronic Modules Reading Diagnostics Data Using STEP Digital Input Modules Digital Output Modules Analog Input Modules Analog Output Modules Structure of Station Status 1 (byte 0) Structure of Station Status 2 (byte 1) Structure of Station Status 3 (byte 2) Structure of the Vendor ID Types of error of the electronic modules SKF Identifiers (STEP 7) Diagnostics of Faulty Configuration of the ET 200iSP xvi

17 Contents 7-1 Permitted actions / tasks in the potentially explosive areas Requirements Modules and Terminal Modules Pinout on Terminal Modules TM-PS-A and TM-PS-B Pinout on the TM-IM/EM Pinout on the TM-IM/IM Pinout of Terminal Module TM-EM/EM Parameters for Interface Module IM Pinout for NAMUR Encoders or Encoders According to DIN Pinout for NAMUR Changeover Contacts or Encoders According to DIN Changeover Contacts Terminal Assignment of Single Contact with 10 k Load Resistance (Mechanical NO Contact) Terminal Assignment of Changeover Contact with 10 k Load Resistance (Mechanical Changeover Contact) Terminal Assignment of a Single Contact without Load Resistance (Mechanical NO Contact with Single Contact ) Terminal Assignment of a Changeover Contact without Load Resistance (Mechanical Changeover Contact) Changeover Contact Diagnostics DO Terminal Assignment DI NAMUR parameters Parameters for 2 Count/ 6 DI NAMUR and 2 Count/ 6 Control Count/ 6 Control Parameters Parameters for 2 Trace/ 6 DI NAMUR Parameters for 4 DO Measured Values in the Event of Wire Break Dependent on Enabled Diagnostics (Format S7) Analog Value Representation (SIMATIC S7 Format) Examples Measured Value Resolution of the Analog Values (SIMATIC S7 Format) SIMATIC S7 Format: Measuring Range 80 mv SIMATIC S7 Format: Measuring Ranges 0 to 20 ma, 4 to 20 ma SIMATIC S7 Format: Measuring Ranges 600 Absolute SIMATIC S7 Format: Measuring Ranges Pt 100 Standard in C and F SIMATIC S7 Format: Measuring Ranges Pt 100 Climatic in in C and F SIMATIC S7 Format: Measuring Ranges Ni 100 Standard in C and F SIMATIC S7 Format: Measuring Ranges Ni 100 Climate in C and F SIMATIC S7 Format: Measuring Range Type B in C and F SIMATIC S7 Format: Measuring Range Type E in C and F SIMATIC S7 Format: Measuring Range Type J in C and F SIMATIC S7 Format: Measuring range Type K in C and F SIMATIC S7 Format: Measuring Range Type L in C and F SIMATIC S7 Format: Measuring Range Type N in C and F SIMATIC S7 Format: Measuring Range Type R, S in C and F SIMATIC S7 Format: Measuring Range Type T in C and F SIMATIC S7 Format: Measuring Range Type U in C and F SIMATIC S7 Format: Output Ranges 0 to 20 ma, 4 to 20 ma Compensation of the Reference Junction Temperature Reference Junction Parameters Examples of HART Parameters Properties of the ET 200iSP HART Analog Modules HART Data Records Dependencies of the Input and Output Values on the Operating State of the PLC (CPU of the DP Master) and the Supply Voltage L xvii

18 Contents Response of the Analog Modules, Depending on the Location of the Analog Input Value in the Range of Values Response of the Analog Modules, Depending on the Location of the Analog Output Value in the Range of Values Terminal Assignment of 4 AI I 2WIRE HART Terminal Assignment of 4 AI I 4WIRE HART Terminal Assignment of 4 AI RTD Terminal Assignment of 4 AI TC Parameters of the 4 AI I 2WIRE HART and 4 AI I 4WIRE HART Configurations Parameters of the...w+x Configuration AI RTD and 4 AI TC Parameters Parameters of the 4AO I HART Configuration Parameters of the...i +x Configuration A-1 Interface module A-1 A-2 Terminal Modules A-1 A-3 Power Supply A-2 A-4 Digital Electronic Modules A-2 A-5 Analog electronic modules A-2 A-6 Reserve module A-2 A-7 ET 200iSP Accessories A-3 A-8 Network Components for ET 200iSP A-5 A-9 STEP 7 and SIMATIC S7 Manuals A-6 A-10 Reference for PROFIBUS DP with SIMATIC S7 and STEP A-8 xviii

19 Product Overview What are Distributed I/O Stations? Distributed I/O stations Fields of Application When a system is set up, the inputs and outputs from and to the process are often located centrally in the programmable logic controller. If there are inputs and outputs at considerable distances from the programmable logic controller, there may be long runs of cabling which are not immediately comprehensible, and electromagnetic interference may impair reliability. In such systems, it is often advisable to use distributed I/O stations: The control CPU is located centrally. The I/O devices (inputs and outputs) operate locally on a distributed basis. the high-performance PROFIBUS DP system provides high-speed data transmission rates for reliable communication between the control CPU and the I/O devices. low installation effort by reduced wiring. What is PROFIBUS DP? PROFIBUS DP is an open bus system based on IEC :2002 Ed1 CP 3/1 with the DP transmission protocol (DP stands for distributed I/O). PROFIBUS DP is implemented either as an electrical network based on shielded twisted-pair cables, or as an optical network based on fiber optic cable. The DP transmission protocol allows a rapid, cyclic exchange of data between the control CPU and the distributed I/O devices. What is PROFIBUS RS 485-IS In contrast to PROFIBUS DP, PROFIBUS DP RS 485-IS is intrinsically safe (intrinsically safe i type of protection). The RS 485-IS coupler ensures intrinsic safety and acts as a safety barrier. For further information on PROFIBUS RS 485-IS, refer to the PROFIBUS RS 485-IS User and Installation Guideline ( 1-1

20 Product Overview What are DP-masters and DP-slaves? The DP master links the control CPU with the distributed I/O devices. It exchanges data with the distributed I/O devices via PROFIBUS DP and monitors PROFIBUS DP. The distributed I/O devices (= DP slaves) prepare the data of the sensors and actuators locally so that they can be transmitted to the control CPU by PROFIBUS DP. Which devices can be connected to the PROFIBUS-DP? An extremely wide range of devices can be connected to the PROFIBUS DP as DP-masters or DP-slaves, provided their behavior complies with IEC :2002 Ed1 CP 3/1. These include devices of the following product families: SIMATIC S7/M7/C7 SIMATIC PG/PC SIMATIC human-machine interface, or HMI (operator panel, OP; operator station, OS; and text display, TD) Distributed I/O devices Devices from other vendors Structure of a PROFIBUS DP network The figure below illustrates the typical layout of a PROFIBUS DP network. The DP master is integrated in the relevant device. For example, the S7-400 is equipped with a PROFIBUS DP interface. The ET 200iSP distributed I/O devices are interconnected with the DP masters via PROFIBUS DP and PROFIBUS RS 485-IS. S7-400 ET 200M PG/PC PROFIBUS DP RS 485-IS coupler PROFIBUS RS 485-IS ET 200iSP ET 200iSP Potentially explosive area: Zone 1 Potentially explosive area: Zone 2 Figure 1-1 Typical PROFIBUS DP network structure 1-2

21 Product Overview 1.2 What is the ET 200iSP Distributed I/O Station? Definition The ET 200iSP distributed I/O device is a highly modular and intrinsically safe DP slave with degree of protection IP 30. Fields of application The ET 200iSP distributed I/O device can be operated in potentially explosive environments characterized by gas and dust atmospheres: Certification ET 200iSP Station* Inputs and outputs CENELEC Zone 1 and Zone 21 up to Zone 0, Zone 20 Zone 2 and Zone 22 up to Zone 0, Zone 20 * with installation in a corresponding enclosure The ET 200iSP distributed I/O device is also suitable for operation in safety areas, of course. You can insert almost any combination of ET 200iSP I/O modules directly next to the interface module that transfers the data to the DP master. This allows you to tailor the system to meet local requirements. Each ET 200iSP consists of a power supply module, an interface module, and up to 32 electronic modules (for example, digital electronic modules.) Note the maximum current consumption (see the chapter 3.6.) Terminal and Electronic Modules An ET 200iSP distributed I/O station basically consists of various passive terminal modules you can use to connect the power supply and electronic modules. The ET 200iSP is connected to PROFIBUS RS 485-IS by means of a connector on terminal module TM-IM/EM. Each ET 200iSP represents a DP slave on PROFIBUS RS 485-IS. 1-3

22 Product Overview View The figure below shows an example of an ET 200iSP configuration. Power Supply PS Interface module IM 152 Electronic module Bus termination module Terminal module TM-PS-A Terminal module TM-IM/EM Terminal modules TM-EM/EM Figure 1-2 View of the ET 200iSP Distributed I/O Station ET 200iSP Components The table below provides an overview of the most important components of the ET 200iSP. Table 1-1 ET 200iSP Components Component Function View Enclosure DIN rail...is an additional measure to increase safety, in order to avoid the development of high temperatures, sparks and electric arcs....rack of the ET 200iSP. Install the ET 200iSP on this DIN rail. 1-4

23 Product Overview Table 1-1 ET 200iSP Components, continued Component Function View Terminal module...carries the wiring and accommodates the power supply module, interface module, and the electronic modules. Terminal modules versions available: for power supply TM-PS-A for redundant power supply TM-PS-B for interface module TM-IM/EM for redundant interface module TM-IM/IM for electronic modules TM-EM/EM TM-PS-A TM-IM/EM TM-PS-B TM-IM/IM TM-EM/EM Power Supply PS...is plugged into terminal module TM-PS-A or TM-PS-B. The power supply module supplies power to the electronic circuits and encoders. 1-5

24 Product Overview Table 1-1 ET 200iSP Components, continued Component Function View Interface module...is plugged into the terminal module. The interface module interconnects the ET 200iSP with the DP master and prepares the data for the inserted electronic modules. Electronic module...is plugged onto the terminal module and decides the function: Digital electronic modules for NAMUR sensors, digital output Analog electronic modules with current and resistance measurement circuit, thermoresistor and thermocouples, analog output Reserve module Bus terminating module...completes the ET 200iSP RS 485-IS coupler...couples PROFIBUS DP to PROFIBUS RS 485-IS. Label sheet (DIN A4, perforated, foil)...for machine labeling or printing 80 strips per label sheet Slot number labels...used to identify the slots of the terminal module PROFIBUS- cable with bus connector...interconnects the PROFIBUS RS 485-IS nodes or the RS 485-IS Coupler with ET 200iSP. PROFIBUS connector RS 485-IS, including switched terminating resistor 1-6

25 Product Overview Features of ET 200iSP and its benefits Table 1-2 Features and Benefits Features Modular structure based on 4- or 8-channel electronic modules Wide range of electronic modules Permanent wiring by separating mechanical and electronic components Integrated Powerbus Screw terminals or spring terminals I/Os intrinsically safe to EEx ia IIC Automatic coding of the I/O modules Large label Shutdown of the digital outputs of a module by means of intrinsically safe control signal Regarding design Benefits Cost-effective station design Reduced engineering and documentation costs Space-saving with user-specific in-line installation of the modules Wide field of application Prewiring possible Hot swapping of modules while the ET 200iSP is in operation, if at least two electronic modules are present. Reduced wiring effort Regarding terminating technique Use of most suitable terminating technique Intrinsically safe encoders, actuators and HART field devices up to Zone 0/20 can be connected Fast and safe module replacement Adequate space for clear labeling Control of outputs independent of process image 1-7

26 Product Overview Table 1-2 Features and Benefits, continued Reconfiguration and expansion in runtime Time stamp, flutter monitoring, pulse stretching Counting and frequency measurements Identification data I&M Analog value display in S7-format IEEE tags Regarding functionality No restart of the ET 200iSP necessary Efficient monitoring of the inputs Technological fields of application Unique identification / assignment of modules (for example, for validation, quality assurance) Analog modules with HART support up to four IEEE tags in IEEE754 format Redundancy of IM 152 (V2.0 and higher) on S7-DP masters (e.g. S7-400H) with software redundancy Redundancy of the Power Supply PS with TM-PS-B DP master All ET 200iSP modules support communication with DP masters that are compliant with IEC :2002 Ed1 CP 3/1 and operate with DP transmission protocol (DP = Distributed I/O). 1-8

27 Product Overview 1.3 ET 200iSP in Potentially Explosive Environments Properties of the zones Potentially explosive areas are divided into zones. The zones are distinguished based on the probability of the existence of an explosive atmosphere. The ET 200iSP can be operated in the potentially explosive areas Zone 1/21 and Zone 2/22, and in the safe area. ET 200iSP supports the connection of intrinsically safe sensors, actuators and HART field devices located in Zone 0/20 and in the safe area. The sensors, actuators, and HART field devices must be certified for operation in the relevant potentially explosive areas. The table below shows the zone classes: Table 1-3 Zone Classes Potentially explosive areas Zone 0/20 Zone 1/21 Zone 2/22 Risk of explosion Long-term, frequent or permanent presence of explosive gas or dust atmosphere Infrequent presence of potentially explosive gas or dust atmosphere Rare or short-term presence of potentially explosive gas or dust atmosphere Example Within containers. In the region of openings for filling and draining. Areas bordering on zone 1/21 For further information, refer to the Principles of Intrinsically-Safe Design manual. Types of protection of ET 200iSP The types of protection include design and electrical measures relating to the equipment in order to achieve Ex protection in potentially explosive areas. 1-9

28 Product Overview Table 1-4 Intrinsic Safety of the Types of Protection Type of protection Intrinsic safety i Meaning All voltage, current, inductive and capacitive loads are limited by electrical measures (intrinsically safe). Sparking or thermal effects capable of causing ignition are thus excluded. View Pressure-proof encapsulation d The power supply module is installed in a stable (pressure-proof) enclosure. If the explosive atmosphere within the enclosure ignites, the enclosure will withstand the explosion and contain the explosion within the power supply module. Increased safety e In zone 1 of the hazardous area, the ET 200iSP must be installed in an additional enclosure. The enclosure must have the increased safety e type of protection. This type of protection is an additional measure to avoid the development of high temperatures, sparking and electrical arcs by increasing the degree of safety This type of protection is not required in the potentially explosive zone 2. Here, the ET 200iSP must simply be installed in an enclosure suitable for zone 2 with at least degree of protection IP

29 Product Overview Identification of the ET 200iSP Equipment for operation in potentially explosive areas is marked with an identifier indicating the Ex environments in which the equipment can be used. Identifiers of ET 200iSP: Enclosure: EEx e Basic ET 200iSP structure: EEx d e ia/ib IIC T4 Power Supply EEx de [ib] IIC T4 IM 152 and EMs: EEx ib IIC T4 Inputs and outputs: EEx ia IIC T4 PROFIBUS RS 485-IS Potentially explosive area: Zone 1 ma Meaning: EEx: Identifier of explosion protection ia : Type of protection intrinsic safety (up to Zone 0) ib : Type of protection intrinsic safety (up to Zone 1) d : Type of protection pressure-proof encapsulation e : Type of protection increased safety IIC : Explosion group for hydrogen T4 : Temperature class: Highest permitted surface temperature 135 C Figure 1-3 Identifiers of ET 200iSP 1-11

30 Product Overview 1.4 Integration into the Control System PCS7 PCS 7 is a high-performance process control system. PCS 7 integrates ET 200iSP directly into the process control system. PCS 7 components PC/ PCS 7-OS Operating and monitoring with WinCC Industrial Ethernet S7-400 PC/ PCS 7-ES Configuring and parameter assignment using STEP 7 Configuring using GSD file Configuring with SIMATIC PDM higher-ranking layer PROFIBUS DP RS 485-IS Coupler PROFIBUS RS 485-IS ET 200iSP in enclosure lowest layer: Actuators, encoders, field devices Figure 1-4 Potentially explosive area: Zone 1 Zone 0 Integration into the Control System m A 1-12

31 Getting Started with Commissioning Introduction Introduction This manual guides you step-by-step through a practical example until you have created a functioning application. You will become familiar with the basic hardware and software functions of your ET 200iSP. 2.2 Requirements The following requirements must be met: You must be familiar with the basics of electrical and electronic engineering and the procedures relating to Ex areas as well as experience of working with computers and Microsoft(R) Windows(TM) 2000/XP. STEP 7 (version 5.3, Service pack 1 or higher and the current HW update) or PCS 7 (version 6.1 or higher) is installed on your PG and you have a basic knowledge of STEP 7. You may also use older STEP 7 versions. See 6 Commissioning and Diagnostics. If you implement this example in a potentially explosive area, you must adhere to all the rules and regulations explained and listed in this manual. Note When checking the functions, always observe the guidelines to EN This standard also contains the directives of the International Standard IEC ! Danger When laying cables and wiring in potentially explosive areas, make sure that you adhere to the installation regulations in EN and local regulations. When operating the ET 200iSP in combustible atmospheres developing as a result of dust, you need to observe EN as well. 2-1

32 Getting Started with Commissioning! Warning When used in systems, the ET 200iSP is subject to special rules and regulations depending on the area of application. Please note and adhere to the valid safety and accident prevention regulations, for example IEC 204 (EMERGENCY STOP devices). If you do not adhere to these regulations, this can result in serious injury and damage to machines and facilities. 2.3 Materials and Tools Required for the Sample Configuration Table 2-1 Required Material and Tools Number Article Order number (Siemens) 1 SIMATIC S7-300, DIN rail L=160 mm 6ES AB60-0AA0 2 SIMATIC S7-300, DIN rail L=480 mm 6ES AE80-0AA0 1 Enclosure for ET 200iSP, type of protection EEx e (for using ET 200iSP in the potentially explosive area Zone 1) Contact your Siemens representative 1 Terminal module TM-PS-A 6ES DA00-0AA0 1 Terminal module TM-IM/EM with bus termination module 6ES AA00-0AA0 2 Terminal module TM-EM/EM 6ES CA00-0AA0 1 Interface module IM 152 6ES AA00-0AB0 1 Power Supply PS 6ES EA00-0AA0 2 8 DI NAMUR 6ES RF00-0AB0 3 4 DO DC17.4/27mA 6ES RD10-0AB0 1 RS 485-IS Coupler 6ES AC80-0XA0 2 PROFIBUS connector (for master and RS 485-IS coupler) 6ES BB50-0XA0 1 PROFIBUS connector RS 485-IS, up to 1.5 Mbps, incl. terminating resistor 6ES DA60-0XA0 1 PROFIBUS-DP cable e.g. 6XV EH10 2 NAMUR sensor e.g. BERO 3RG NA00 1 Single-pole make action pushbutton commonly available 3 LEDs with series resistor commonly available 1 Power supply module PS S ES EA00-0AA0 1 Central processing unit CPU S DP 6ES AG10-0AB0 1 Programming device (PG) with PROFIBUS DP interface, installed STEP 7 software (Version 5.3, Service pack 1 or higher and the current HW update), communications processor CP 5611 and PG cable various 1 Screwdrivers with 3 mm blade commonly available 2-2

33 Getting Started with Commissioning Table 2-1 Required Material and Tools, continued Number Article Order number (Siemens) 1 Screwdrivers with 4.5 mm blade commonly available 1 Cutting tool for the DIN rails commonly available 1 Side cutters and wire stripping tools commonly available 1 Tool for crimping wire-end ferrules commonly available 1 Cable for grounding DIN rails, 10 mm cross-section with M6 cable lug, length to suit local situation commonly available 1 M6 cable lug commonly available 1 Flexible lead, 1 mm 2 cross-section, with suitable wire-end ferrules, design A, length 6 mm commonly available 2-3

34 Getting Started with Commissioning 2.4 Configuration Overview Overview of the sample configuration (wiring and power sources not shown) PG with CP 5611 S DI NAMUR 4 DO RS 485-IS Coupler Equipotential busbar PA Figure 2-1 Overview of the Sample Configuration 2.5 Installation of the Sample Configuration Installation of the ET 200iSP 1. Install the DIN rail (480 mm) in the EEx e enclosure which is mounted on a firm base. See chapter 4 Installation. 2. Mount the various modules onto the rail, starting from the left. Begin with terminal module TM-PS-A (suspend swivel in). Continue with the remaining modules (suspend swivel on slide to left.) Note the following sequence: Terminal Module TM-PS-A Terminal module TM-IM/EM 2 x terminal module TM-EM/EM Bus terminating module 2-4

35 Getting Started with Commissioning Mounting the S Install the rack on a stable base. See the S7-300, CPU 31xC and CPU 31x operating instructions: Installation. 2. Install the various modules in the rack, starting from the left (fit to the rail push in secure the screws.) Observe the sequence shown below: Power supply PS Central processing unit CPU DP Installing the RS 485-IS Coupler 1. Install the DIN rail (160 mm) on a stable base. 2. Hang the RS 485-IS coupler onto the rail and then swivel it in. Note Install the RS 485-IS coupler in an enclosure outside of the Ex area. 2-5

36 Getting Started with Commissioning 2.6 Wiring the Sample Configuration PA M L+ Figure 2-2 Wiring TM-PS-A to ET 200iSP PROFIBUS RS 485-IS LEDs Strain relief and shielding terminal PROFIBUS RS 485-IS connection PROFIBUS RS 485-IS bus termination switch 24 V power supply PROFIBUS-DP connection (X1 DP) AC DC DC 24 V PROFIBUS-DP from CPU DP Figure 2-3 Wiring the RS 485-IS Coupler 2-6

37 Getting Started with Commissioning Connect the following: 1. The programming device (PG) and the CPU DP (interface: X1 MPI) with a PG cable. 2. The DIN rail of the S7-300, including the grounding conductor 3. The DIN rail of ET 200iSP, the Power Supply PS and the equipotential busbar PA. Use the grounding bolt to fasten the components onto the DIN rail. 4. The CPU DP (interface: X2 DP) with the RS 485-IS Coupler, as shown in Figure 2-3. Use a PROFIBUS DP cable (PROFIBUS connector 6ES BB50-0XA0.) 5. The interface IM 152 with the RS-485-IS coupler, as shown earlier. Use a PROFIBUS DP cable (PROFIBUS connector 6ES BB50-0XA0.) 6. The TM PS-A, the RS 485-IS Coupler and the power supply module PS S7-300 to the power supply. Wire the ET 200iSP as shown below: 2 x 8 DI NAMUR 3 x 4 DO DC 17.4/27 ma Terminals NAMUR sensor LEDs Figure 2-4 Wiring the ET 200iSP Module 2-7

38 Getting Started with Commissioning 2.7 Insert the Interface Module and the Electronic Modules Insert the modules For further information, refer to chapter 4.4 Installing the Terminal Module for the interface and electronic modules. Observe the sequence shown below: Power Supply PS Interface module IM x 8 DI NAMUR 3 x 4 DO DC17.4V/27mA 2.8 Setting the PROFIBUS Address Set PROFIBUS address 3 on the interface module IM 152. See also 5.7. Interface module OFF * ON Example: DP address = = 3 * reserved Figure 2-5 Setting the PROFIBUS-address 3 2-8

39 Getting Started with Commissioning 2.9 Configuring the Example Configuring the S7-300 Step 1 Open STEP 7. Step 2 If the New Project Wizard opens, close it with Cancel. Step 3 In SIMATIC Manager, select File > New. A dialog box opens in which you enter ET 200iSP as the name and then close the dialog with OK. Step 4 Select Insert > Station, then click SIMATIC 300 station on the list. An icon with the name SIMATIC 300(1) is created in the right-hand pane of the project window. Step 5 Double-click the icon of the SIMATIC 300 station in SIMATIC Manager. An icon labeled Hardware now appears in the right-hand pane of the window. Double-click this icon. HW Config opens. Step 6 If the component catalog is not shown in the right section of the window, you can activate it by selecting View > Catalog. Expand the SIMATIC 300 folder and RACK-300 folder until you can see UR. Double-click this entry. Step 7 Select slot 1 (appears on blue background), return to the catalog and open the folders SIMATIC 300, PS 300 and Standard PS 300 until you can see PS 407 5A. Double-click this icon. The power supply module now occupies slots 1 and

40 Getting Started with Commissioning Step 8 Next, select slot 3, then go to SIMATIC 300, CPU 300, CPU DP and 6ES AG10-0AB0. A double-click opens a window titled Properties-PROFIBUS interface DP). Acknowledge this with OK. The CPU is assigned to slot 2. Step 9 In the lower left-hand window, locate the row labeled DP and select it. Right-click on the row and select Object Properties. The Properties DP dialog opens. Click the Properties button, and in the next dialog, click New. The system now creates a new DP subnet operating at 1.5 Mbps. Now confirm by clicking OK three times in succession. Step 10 From the main menu, select Station > Save and Compile to save your changes. Figure 2-6 Configuring the S

41 Getting Started with Commissioning Configuring and Assigning Parameters to ET 200iSP Step 1 In the upper left-hand window of HW Config, click the stylized PROFIBUS to select it. Next, go to the catalog and open PROFIBUS DP and ET 200iSP so that you can see IM 152. Double-click this icon to insert an ET 200iSP station. In the dialog box that opens, change the address to 3 and confirm with OK. At the bottom left, you can now see the new slots with an IM 152 in slot 2. Step 2 Since slot 3 must remain free, select slot 4 and starting from there insert three NAMUR 4DI modules and three 4 DO DC17.4V27mA modules. Figure 2-7 Configuring and Assigning Parameters to ET 200iSP 2-11

42 Getting Started with Commissioning Step 3 Double-click the first module in the configuration table (slot 4: 8 DI NAMUR). Select the Parameters tab. At channels 0 and 1 change the encoder type to NAMUR encoder. Deactivate all other channels. Figure 2-8 Deactivating ET 200iSP Channels Step 4 Follow the same procedure as described in item 3 for each of the ET 200iSP modules, and make the changes as outlined in the table below. Table 2-2 Changes Module Slot Type Channel 0 Channel 1 Channels x DI NAMUR NAMUR sensor NAMUR sensor Encoder type: disabled x DI NAMUR NAMUR sensor Encoder type: Channel disabled x DO No change No change x DO No change No change x DO No change No change --- Encoder type: disabled 2-12