Automation System S7-1500

8/16/2019 Automation System S7-1500

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Solution Partner Certification Workshop S7-1500

Solution Partner Certification Workshop S7-1500Training Document V13 - Chapter 01 1-1

Contents 1

1. System Overview .................................................................................................... 1-2

1.1. Positioning of the Modular S7 Controllers ..........................................................................1-3 1.1.1. Positioning of the S7-1500.................................................................................................1-4 1.1.2. Highlights of the SIMATIC S7-1500 System .......................................................................1-4 1.1.3. Overview of Available Central Modules ..............................................................................1-5 1.1.4. Overview of Available Signal Modules (Central) .................................................................1-5

1.2. SIMATIC S7-1500: Modular Controller for the Mid to Upper Performance Range ...............1-6 1.2.1. SIMATIC S7-1500: Modules ..............................................................................................1-7

1.2.1.1.

SIMATIC S7-1500: Installation and Mounting Positions......................................................1-9 1.2.1.2. SIMATIC S7-1500: Module Assembly .............................................................................. 1-10

1.2.1.3. SIMATIC S7-1500: Connection Technology/Front Connector ........................................... 1-10

1.2.2. SIMATIC S7-1500: CPU Display Overview .................................................................. 1-12 1.2.2.1. SIMATIC S7-1500: CPU Display Menu and Colors .......................................................... 1-13 1.2.2.2. SIMATIC S7-1500: CPU Display Operations.................................................................... 1-14 1.2.2.3. SIMATIC S7-1500: CPU-Display Access and Anti-theft Protection ................................... 1-14

1.3. SIMATIC S7-1200/1500: Technology Functions............................................................... 1-15

1.4. SIMATIC S7-1200/1500: Memory Card(s) Overview ........................................................ 1-16 1.4.1. SIMATIC S7-1200/1500: Memory Card Properties ........................................................... 1-17 1.4.2. SIMATIC S7-1200/1500: Memory Model.......................................................................... 1-18 1.4.3. SIMATIC S7-1200/1500: Memory Concept with CPU Memory Reset ............................... 1-18

1.4.4.

SIMATIC S7-1200/1500: Memory Concept with CPU Reset to Factory Settings ............... 1-19

1.5. Distributed I/O ................................................................................................................. 1-21 1.5.1. Positioning of the Distributed Signal Modules .................................................................. 1-21 1.5.2. Overview of Available Signal Modules (Distributed) ......................................................... 1-21 1.5.3. ET 200SP: Size-optimized Modular Distributed I/O System.............................................. 1-22 1.5.4. ET 200SP: Configuration and Maximum Number of Modules ........................................... 1-23 1.5.5. ET 200MP: Modular Distributed I/O System ..................................................................... 1-24 1.5.6. ET 200MP: Configuration and Maximum Number of Modules .......................................... 1-25

1.6. Tips and Tricks ................................................................................................................ 1-26 1.6.1. Power Budgeting for System Power Supply of S7-1500 and ET200MP ............................ 1-26

1.7. Exercises: Preparing the Training Area for HW Commissioning ....................................... 1-27

1.7.1.

Exercise 1: Resetting the CPU to Factory Settings using the Display ............................... 1-27

1.7.2. Exercise 2: Determining the Modules of the Training Area ............................................... 1-28

1.8. Additional Information...................................................................................................... 1-29

1.9. Firmware Update ............................................................................................................. 1-30

1.9.1. Firmware Update Offline using SIMATIC Memory Card with the Windows Explorer ..... 1-30 1.9.2. Firmware Update: Offline using STEP7 by means of Card Creation in the TIA Portal ...... 1-31 1.9.3. Firmware Update: Online using STEP 7 in the TIA Portal ................................................. 1-32

1.9.4. Firmware Update Important Facts ............................................................................... 1-33


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Solution Partner Certification Workshop S7-15001-2 Training Document V13 - Chapter 01

1. System Overview

This chapter provides an overview of the S7 system family.

Participants will become familiar with the new Controller S7-1500. They will gain an overview ofmodules and submodules.


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1.1. Positioning of the Modular S7 Controllers

SIMATIC S7

The programmable logic controllers can be divided into the micro PLC (S7-1200) and themid/upper (S7-1500) performance ranges.

The existing lower/mid performance range (S7-300) and the mid/upper performance range (S7-400) will be covered in future by an S7-1500 system.


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1.1.1. Positioning of the S7-1500

At the start of the introduction of the new S7-1500 CPU system, modular CPUs are only availableup to the mid performance range.

1.1.2. Highlights of the SIMATIC S7-1500 System


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1.1.3. Overview of Available Central Modules

The S7-1200 and S7-1500 product range will be expanded in the next years such that the S7-300and even the S7-400 can be completely replaced.

1.1.4. Overview of Available Signal Modules (Central)

The S7-1200 and S7-1500 signal module product range will be expanded in the next years suchthat the S7-300 and even the S7-400.


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1.2. SIMATIC S7-1500: Modular Controllerfor t he Mid to Upper Performance Range

Features

Modular control system for the mid to upper performance range

Scaled CPU range

Display for basic CPU settings (system time, interfaces...) and for calling diagnostic andstatus information (diagnostic buffer, message display, CPU state...)

Extensive range of modules

High performance I/O bus for efficient process interfacing via central I/O

Can be expanded up to 32 modules in one tier

Currently only single-tier assembly possible. Multi-tier assembly using distributedET200MP.

Can be networked with PROFIBUS or PROFINET

Slot rules

left of the CPU:1x power supply (PM or PS)

right of the CPU:signal modules (digital, analog), technology modules, communication modules and furtherpower supplies

No slot rules for modules to the right of the CPU


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1.2.1. SIMATIC S7-1500: Modules

Slot Rules

1x PS/PM Slot 0

1x CPU in Slot 1

As of Slot 2 any

Signal Modules

Digital input modules: 24VDC, 230VAC

Digital output modules: 24VDC, 230VAC

Analog input modules: voltage, current, resistance, thermocouple

Analog output modules: voltage, current

Communication Modules (CP - Communication Processor, CM - Communication Module)

Point-to-point connection

PROFIBUS

PROFINET

CPs and CMs are both communication modules.CPs have, as a rule, somewhat more functionality than CMs (e.g. own web server,firewall, or the like).

Technology Modules (TM - Technology Module)

Counting

Position sensing


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Power Supply

I/O modules in the central rack of the S7-1500 require a system power supply via the backplanebus (communication connection to the CPU) and a load power supply (input or output circuits forsensors/encoders and actuators).

PM - Power Module Load Power Supplysupplies modules with 24VDC for input and output circuits as well as sensors/encoders andactuators

If the CPU is supplied 24V via a load power supply (PM), it supplies the system powersupply of 12W for the first inserted I/O modules.

PS - Power System System Power Supplysupplies S7-1500 modules in the central rack via the backplane bus

Each CPU offers a system power supply of 12W for the first inserted I/O modules.Depending on the I/O modules used, further power segments have to be set up, asrequired.

A system power supply (PS) can also supply the load circuit for 24VDC modules in

addition to the CPU.

Power Supply and Power Segments of the I/O Modules

It is necessary to set up power segments in the central rack for larger configurations orconfigurations with greater I/O module power requirements (as a rule, when using CP, CM, TM).

A maximum of 3 power segments can be set up per rack (1xCPU segment plus 2 more).

If the configuration includes additional power segments, additional system power supply modules(PS) are inserted to the right next to the CPU. The CPU continues to control all modules of therack. Only the system power supply of the I/O modules is subdivided here.

Example of a Small S7-1500 Configuration

Example of an S7-1500 Configuration with a 2nd Power Segment

Interface Modules for Expansion Rack

A central multi-tier assembly is not planned. An expansion can be realized using the distributedET200MP I/O system.


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1.2.1.1. SIMATIC S7-1500: Installation and Mounting Posi tions

Installation

The modules are mounted on an S7-1500 profile rail.

Bus Connector

If the installation is made on the profile rail, the modules are then connected with the U-connector.

The U-connector establishes the mechanical and electrical connection between the modules andis included with every I/O module.

Mounting Positions

A horizontal or vertical mounting is possible.

Caution!With a vertical mounting, the maximum allowed ambient temperature is 20 °C lower(ambient temperature 0 to 40 °C).

Integrated Mounting Rail

For the S7-1500 CPU, there is a profile rail on which components can also be mounted accordingto EN 60715. With that, even terminals, miniature circuit breakers, small contactors or similarcomponents can be mounted in addition to the S7-1500.


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Two Front Door Latching Positions

At the bottom of the front cover there are 2 different latching positions for different spacerequirements of the conductor bundle.

Cable storage space that grows with the need (AWG cabling)

American Wire Gauge (AWG) is an American standard measure for copper wires which definesthe wire strength and the allowed damping, whereby a lower AWG value represents a thickerwire.

1.2.2. SIMATIC S7-1500: CPU Display Overview


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1.2.2.1. SIMATIC S7-1500: CPU Display Menu and Colors

Depending on the current CPU state, the color on the Display varies.

Available languages are the available user interface languages of STEP7.

Addi tional Symbols in the Status Info rmation

Password is configured but not entered

Password is configured and entered

An Alarm exists

A Force job is active on the CPU


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1.2.2.2. SIMATIC S7-1500: CPU Disp lay Operations

In the bottom Display line, "ESC" appears on the left or "OK" on the right when one or bothbuttons can be operated to execute a function.

1.2.2.3. SIMATIC S7-1500: CPU-Display Access and Ant i-theft Protection

The settings for Standby mode and Energy-saving mode can be defined via the Display as wellas via the device configuration of the CPU.


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1.3. SIMATIC S7-1200/1500: Technology Functions

High-speed Counters

Up to 6 high-speed counters, 3 at 100 kHz and 3 at 30 kHz are available for precise monitoring ofincremental encoders, frequency counting or counting of highly frequent process events.

Motion

To control rotary speed, position or pulse duty factor, a total of 2 PWM outputs (pulse widthmodulation) are available. Application examples are, for example, controlling the speed of amotor, position of a valve, or the mark-to-space ratio for a heating element. For rotary speed andposition controls, a total of 2 PTO outputs at 100 kHz (pulse train output) are available.

It supplies a pulse train for controlling speed and position of stepper or servo motors.

PID

For simple closed-loop control tasks, up to 16 PID control circuits with automatic PID adjustmentand tuning control panel are available.


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1.4. SIMATIC S7-1200/1500: Memory Card(s) Overview

Memory Card Binding – Copy Protection

The executability of the program can be bound to the serial number of the card.

Load Memory

S7-1500This has no integrated load memory and therefore it is imperative that a card is inserted.

S7-1200This has an integrated load memory. Here, an inserted memory card can replace (expand)the integrated load memory or the card can be used for program updates (distribution ofprograms).

Distri bution of Programs only S7-1200

The use as Transfer card (card mode = "Transfer") is only supported by the S7-1200. Here, aprogram can be downloaded into the CPU without a PG if a card is inserted.

Archiving of Data only S7-1500

It is possible to archive process values on the card.

The use of this functionality influences the operating life of the Memory Card


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1.4.1. SIMATIC S7-1200/1500: Memory Card Properties

Insertion of SD Cards or MMC Cards

Contacts must face upwards!

Number of Delete/Write Operations

With an ambient temperature of up to 60 °C, at least 500,000 delete/write operations are possibleon the SIMATIC Memory Card.


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1.4.2. SIMATIC S7-1200/1500: Memory Model

1.4.3. SIMATIC S7-1200/1500: Memory Concept with CPU Memory Reset

Initiation of Functions

STEP7 online function Memory Reset in Task Card "Test"

Display (only S7-1500)

Main menu "Settings", submenu "Reset"

Function Execution wi th Inserted SIMATIC Card

CPU is reset to the loading state of the user program.


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Function Execution without or w ith Deleted SIMATIC Card

CPU has no user program

1st. interface (X1) has retained parameters (e.g. X1=PN has retained its IP address)

All other interfaces are deactivated, that is, without parameters

1.4.4. SIMATIC S7-1200/1500: Memory Concept with CPU Reset to FactorySettings

Initiation of Functions

STEP7 online function Reset to factory settings in "Online & diagnostics"

Display (only S7-1500) Main menu "Settings", submenu "Reset"

Function Execution wi th Inserted SIMATIC Card

CPU is reset to the loading state of the user program

Diagnostic buffer, Operating hours counter and CPU Time-of-day are deleted

Function Execution withou t o r w ith Deleted SIMATIC Card

Factory reset using STEP7 online function

CPU has no user program

Selection for X1 interface

All other interfaces are deactivated, that is, without parameters


Factory reset using Display (only S7-1500) CPU has no user program

All interfaces are deactivated, that is, without parameters



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1.5. Distr ibuted I/O

1.5.1. Posit ioning of the Distributed Signal Modules

1.5.2. Overview of Available Signal Modules (Distr ibuted)

The ET200SP and ET200MP product range will be expanded in the next years such that these

two product lines completely cover the applications of the ET200S and ET200M.

The ET200pro (interface modules for connection to PROFINET or PROFIBUS) in the degree ofprotection IP65/67for use directly at the machine will continue to be offered.


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1.5.3. ET 200SP: Size-optimized Modular Dist ributed I/O System

For STEP7 V11 there is an HSP and for STEP7 V5.5 or third-party systems there is a GSDMLfile.

To expand the module spectrum, CMs (AS-i master, AS-i F-modules, IO-link master), a TM (1POS input) and a motor starter are in the planning stage.

2d Matrix Code

This code is used for identifying modules and can be photographed or decoded by SmartPhones,PDAs, iPhones and the like.

With the ET200SP modules, the code contains an Internet link to the product page of theassociated module.

Color Coding o f the Module Class

Each module class is marked with a colored square to make it easier to recognize the modulefunctionality.


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1.5.4. ET 200SP: Configuration and Maximum Number of Modules


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1.5.5. ET 200MP: Modular Dist ributed I/O System

The ET200MP enables the distributed connection of S7-1500 series central I/O modules.

Connection is made using an interface module.

In the first delivery stage, only one PROFINET interface module is offered.

For STEP7 V11, STEP7 V5.5 or third-party systems there is a GSDML file.


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1.5.6. ET 200MP: Configuration and Maximum Number of Modules

If a suitable 24VDC supply is available, it can supply the IM from the front even without a PSmodule in the 1st. slot.

If only a few I/O modules or low-performance I/O modules are used on the IM155, they are"supplied by the system" by the IM155 through the backplane bus.

Otherwise, power segments are also to be set up just like the configuration of a central S7-1500rack.

PS module and front-side 24VDC supply to IM155:

System power supply of PS+ System power supply of integrated PS of IM155 _= Feed-in power of system power supply in Power Segment 1


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1.6. Tips and Tricks

1.6.1. Power Budgeting for System Power Supply of S7-1500 and ET200MP

If only a few I/O modules or low-performance I/O modules are used in the central rack of the CPUor on the IM155, they are "supplied by the system" by the CPU or IM through the backplane bus.

It is necessary to set up power segments for larger configurations or configurations with greaterI/O module power requirements (as a rule, when using CP, CM, TM). A maximum of 3 power segments can be set up per rack

central CPU rack: 1xCPU segment plus 2 more segments

ET200MP rack: 1x IM155 segment plus 2 more segments

If the configuration includes additional power segments, additional system power supply modules(PS) are inserted to the right next to the CPU or IM155. The CPU or the IM155 continues tocontrol all modules of the rack. Only the system power supply of the I/O modules is subdividedhere.

Power Budget

The power requirement of each module is specified in the technical data. From it, the power

budget can be calculated and the need for further system power supplies can be determined.

Once the hardware is configured, a power budget of the device configuration can be taken fromthe properties of the CPU or the ET200MP interface module (IM155).


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1.7. Exercises: Preparing the Training Area for HW Commissioning

1.7.1. Exercise 1: Resetting the CPU to Factory Sett ings using the Display

Task

The training area is to be prepared for the next exercises.

What to Do

1. Remove the SIMATIC Memory Card from the CPU

Lift up the CPU Display and remove the card from the CPU

pressing the centre of the card releases the card

2. Carry out a Reset to Facto ry Settings using the CPU Display

Using the cursor keys, select the menu item and choose the relevant function.

3. Checking the function execution

Using the cursor keys, select the menu item or and check that the reset wassuccessful.


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1.7.2. Exercise 2: Determining the Modules of the Training Area

Task

You will make some notes and get an overview of the components of the training area. In the nextexercises, it is necessary to know detailed information about the modules.

Type designation and order number can be found on the module housing.The CPU device version can be accessed using the Display. Device versions (firmware,operating system) of the other modules are determined later using online functions. Addresses are given later.

Enter the type designation and order number for the above-mentioned modules in the overviewon the next page.

Device typeYou will find the type designation on the module nameplate or imprinted at the top of thehousing front.

CPU device versionThe CPU version can be accessed using the Display.

Order NumberYou will find this on the module nameplate or imprinted at the top or bottom of the housingfront.


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1.8. Addi tional Information


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1.9. Firmware Update

Procuring the new firmware is always the first step.

The next steps depend on the selected update possibility.

1.9.1. Firmware Update Offline using SIMATIC Memory Card with the WindowsExplorer


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When the CPU or the Display is updated, Step is necessary in any case. However, this isalso recommended at the end of every module update.

Status of the Update in the Disp lay (only S7-1500)

Only the S7-1500 has a Display.

Status of the Update with LEDs

If the middle LED (red, error ) lights up, the update was not successfully completed or it couldnot be carried out.

Necessary Firmware Update Files

Directory with FW files (FWUPDATE.S7S) and data ID file (S7_JOB.S7S)

Empty Card (Windows Explorer)

1.9.2. Firmware Update: Offline using STEP7 by means of Card Creation in theTIA Portal

7

Do NOT delete

hidden files!!!


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Necessary Fi rmware Update File e.g.

FW file (MLFB_ausgabe.upd)

Card Contents

The SD card for the update does not necessarily have to be deleted first. During creation you areprompted:

YesCard is deleted and update card is created

NoThe update is only added to the card contents and the card type is set to "Update firmware".This can only be done for updating the Display since the program is active and CPU + I/Omodules cannot be updated in this state.

For updating the CPU or the Display, an empty card is necessary in order to conclude

the update (see Step ).

For that reason, it is generally recommended to delete the "Program" card or to use aseparate card for updates.

1.9.3. Firmware Update: Online using STEP 7 in the TIA Portal


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Before running the update, the appropriate *.upd must be selected.

Before running an update of I/O modules, the CPU should be switched to STOP, if theactive user program uses this module.

Wait until update is completed...

CPU Update

Advantage: The current "Program" card is not changed. Attention !The retentiveness is however deleted, that is, the program is then reset to the loadingstate.

1.9.4. Firmware Update Important Facts

During an update, the supply voltage must not fail or be removed.

Distributed I/O without memory card is exclusively update-able online using STEP7.

After updating the CPU or the Display (only S7-1500), the CPU should be switched off, an empty

memory card inserted in the CPU and the CPU switched back on.It is possible to do a simultaneous update of several modules offline using the memory card.

Respective firmware update files are stored in the folder for Firmware update

The Sequence is Relevant if Several Module Types are Updated

1. Update of the Display firmware (only S7-1500)

2. Update of the central I/O modules

3. Update of the distributed I/O modules

4. Update of the Boot loader of the CPU

5. Update of the CPU

Documents

Automation System S7-1500