Hardware Familiarization

Automation Station
This chapter starts with an introduction to the
hardware configuration for a PCS 7 project
and then carries on to elaborate many aspects
of the hardware configuration using the
Hardware Config Tool.

Hardware configuration first steps

An automation station (AS) at least comprises
of a rack, power supply and a CPU.
Picture 5.1 illustrates an AS. Functions of the
components are given in Table 5.1.

Picture 5.1: An S7-400 AS

 After creating a new project in the SIMATIC Manager, the next

step is to configure an automation station. The main steps
are;

Automation Systems S7-400

The automation systems of PCS 7 are selected S7400 components.
S7-400 controllers are modular, fan-free, robust,
and capable of a high degree of expansion.
S7-400 controllers have comprehensive
communication facilities, integral system
functions, and connections to the central or
distributed I/Os.
Almost any automation task can be implemented
with a suitable choice of S7-400 automation
systems.

S7-400 CPU design

Picture 5.6: CPUs 41x-2 series

Mode selector switch

Using the mode selector switch you can switch
a CPU to RUN, RUN-P, or STOP mode or carry
out a memory reset. Functions of the
positions are listed in Table 5.3.

PROFIBUS
Brief introduction
PROFIBUS is currently the field bus system in most widespread use.
The system exists in the three variants PROFIBUS -DP, -PA, and FMS.
The FMS variant is primarily deployed at the cell level, and will play a
less significant role in the future than the use of TCP/IP at cell levels.
PROFIBUS-DP is the most frequently used communication profile. It is
optimised for speed, efficiency and low connection costs and is
designed especially for communication between automation systems
and distributed peripherals.
DP is suitable as a replacement for conventional, parallel signal
transmission with 24 volts in manufacturing automation and as well as
for analog signal transmission with 4 20 mA or Hart in process
automation.

 The use of PROFIBUS in typical devices and applications in process

automation is defined by the PA profile. The PA profile defines the
parameters and behaviour of typical field devices such as measuring
transducers or positioners independent of manufacturers.
The definitions and options of the PA application profile make
PROFIBUS suitable as a substitute for analog signal transmission
with 4 20 mA or Hart.
Couplers or links are available for the transition between the
various transmission technologies as shown in Picture 5.18. While
couplers transparently implement the protocol taking account of
physical circumstances, links are intrinsically intelligent and thus
offer extended options for the configuration of PROFIBUS networks.

Picture 5.18: PROFIBUS system

In Picture 5.18, a Profibus line is routed from the integrated DP port of a S7400 CPU. An S7-400 CPU could support up to 5 DP subnets using the
interface module CP443-5 ext.

Distributed I/Os
I/Os could be centrally located with a S7 controller. They are central
I/Os.
If there are inputs and outputs at considerable distances from a
controller, there may be long runs of cabling which could cause
electromagnetic interference and reduce reliability.
Distributed I/O devices are an ideal solution in such situation.
The controller CPU is located centrally.
The I/O devices (inputs and outputs) are located remotely from a
controller.
The high-performance of PROFIBUS-DP ensures that the controller
CPU and I/O devices communicate smoothly.

Within the PCS 7 environment distributed I/Os are mounted on

the ET200M station.

Structure and components of ET200M

An ET 200M station is based on a 19 - inch profile rail as
shown in Picture 5.31. The interface module is of IM153
series, which communicates with a DP master. Up to 8 I/O
modules can be mounted on one ET200M station.

Picture 5.31: ET200M structure

Bus Systems
1) Plant bus - Industrial Ethernet: Bus for
communication between the ES/OS and AS
2) Fieldbus - PROFIBUS DP: Bus for
communication between the distributed I/O
and AS