2. System family High-performance and medium range
The power PLC for manufacturing and process engineering
Overwiev
S7-400
Low-end and medium range
S7-300
Micro PLC
S7-200
+ Programming devices
+ STEP 7 software
+ Communications
+ Human-machine interface

3. Fields of application of SIMATIC S7-400
Irrespective of your sector ...
Overwiev
Process
Discrete
Food & Beverages
Pulp & Paper
Cement & Glass
Metal / Mining
Pharmaceuticals
Oil & Gas
Automotive
Chemicals
Electronics
Refinery
Energy
Water
Siemens offers on the automation market as sole manufacturer a platform with which factory automation tasks as well as batch and continuous process applications can be implemented using PCS 7. The S7-400 is the controller that is used successfully in both of these important fields. Sectors with a substantial share of both such as the pharmaceuticals industry profit in particular from this characteristic of the S These hybrid industries can utilize one and the same system or even the same CPU type across the entire production workflow. This enables spare part costs to be saved, maintenance engineers only need to be trained for one system and the system is characterized by integrated horizontal communication.
The S7-400 has proved that you can match the challenge of both major automation applications. A large number of references exist starting with power plants, refineries such as Shell, chemical plants, breweries such as Anheuser Bush, many further applications in the food and beverage industry and of course in the large automobile manufacturers throughout the world. There is hardly an industry in which the S7 is not represented.
The´S7-400 is thus the only automation system for the manufacturing and process industries!
SIMATIC S the automation system
for production and process engineering

4. Totall Integrated Automation
... from inbound logistics via discrete and process automated production to outbound logistics – with S reduced complexity and optimized interoperation of all components.
Overwiev
Supplier
Inbound Logistics
Outbound Logistics
Process
Discrete
Customer
Production Workflow
Reduce your engineering & training cost by reducing the required number of different software and hardware platforms.
Integrate your production and business systems using open industry standards.
Improve the efficiency and capability of your existing systems using application specific technologies.
Migrate to modern technology incrementally as you need to upgrade and modernize your processes.
Production workflow within the supply chain, from supplier to customer
Within the production workflow, special emphasis is placed on the production stages within the company:
It starts with inbound logistics where preprocessing and feeding into the next processing stage take place e.g. in beer production hops, malt, bottles, labels, bottle caps,...
Then comes the process part of the cycle. In beer production this would be the actual brewing procedure which includes the brew house, fermenting and storage cellar and filtration phases.
Next comes the classical manufacturing stage (discrete). In beer production this entails bottling and packing.
Finally comes outbound logistics with warehousing and dispatch.

5. S7-400 overview S7-400 S7-400 H system S7-400 FH system
Overwiev
S7-400
S7-400 H system
S7-400 FH system
Process and production engineering
Data-intensive tasks
Coordination of complete plants
High repeatability
Flexible, reaction-free expansion
Hot swapping of modules as well as expansions
Primarily process engineering
Avoidance of high restart costs
Avoidance of down times
Unmanned operation
Switchover time less than 100 ms
Maximum safety for man, machine, environment
Also complies with EN 954 (up to category 4) and IEC (up to SIL 3)
Coexistence of standard and fail-safe programs on one CPU (also fault-tolerant)
The S7-400 is normally used to perform high-speed or data-intensive tasks.
It's reproducibiity is excellent, i.e. there is little fluctuation. Irregular communication or test routines are executed without a measurable effect on the PLC cycle. In situations involving extremely complex applications, as many as four CPUs can be operated in parallel in the same subrack.
The number of I/O channels is often in the thousands. As higher-order coordinating control unit and interface to the master computer, the S7-400 is normally equipped with one or more Ethernet cards.
A high level of availability is guaranteed by even the standard system, in part through module replacement during operation (hot swapping).
Based on standard controllers
The S7-400H, as a high-availability (redundant) member of the S7-400 family, is a PLC which drastically reduces the risk of production downtimes.
Thanks to its high-availability structure, the S7-400H is perfect for applications in which failures and downtimes must be largely avoided.
High availability is achieved thanks to two parallel CPUs, redundant PROFIBUS DP lines, redundant I/O and redundant communication. In the event of a failure, switching is bumpless, i.e. the standby CPU takes over the control of the process at the point of interruption and without any loss of information. The CPU 414H and 417H CPUs are available for use in high-availability systems.
Fail-safe SIMATIC S7-400F controllers assume or remain in a safe state the moment a fault occurs, thereby ensuring the highest level of safety for human, machine, environment and process. The safety functions are executed by the safety program in the CPU in conjunction with fail-safe I/O modules. Standard I/O and fail-safe I/O may be present in the same system.
High-availability CPUs 414H/FH and 417H/FH are available for use in process automation, CPU 416F for use in production engineering.

6. Highlights - Engineering
Efficient configuration and programming based on STEP 7 global standard
IEC
Highlights
Highlights
Higher availability due to powerful integrated diagnostics
Availability
Cost effective use of ingineering tools (CFC, S7- Graph,...)
Graphic
programming

7. Hot swapping Decentral Peripherie Highlights - Design
Modular design without slot assignment rules
Configuration run
Highlights
Rugged operation
Pulling and pushing under the strain
0-60C operating temperatur
Hot swapping
Central expansion options and simple design of distributed structures with wide range of modules
Decentral Peripherie

8. Highlights - Performance
High processing speeds and deterministic response times for short machine cycle times
30ns / Binary
instruction
Highlights
Highlights
Scalable performance
Graded range of CPUs
Multicomputing
Large quantity frameworks
Communication included
Standard interfaces integrated
Connection to the IT world via Ethernet
4-port switch @

9. Graduated Performance Spectrum
New
since July 04!
CPUs
Type
Memory
Instr. processing
Communicat. interfaces
I/O
Counters/timers
PLC
144KB KB
from 100ns
MPI/DP PROFIBUS-DP
PLC
512KB MB
from 60ns
MPI/DP PROFIBUS-DP
PLC
2.8MB MB
from 40ns
MPI/DP PROFIBUS-DP
PLC
417-4
20MB
from 30ns
MPI/DP PROFIBUS-DP
The slide shows the new line of CPUs. The new CPUs will have the exact same list prices as the old CPUs, greatly improving the price-performance ratio.
Sufficient digital and analog inputs/outputs possible
2048 / 2048
2048 / 2048
2048 / 2048
2048 / 2048
Technical Slides

10. System diagnostics Detailed fault reporting Optimum plan operation
Faults in the automation
system
Programming fault
Memory fault
Module failure
Channel fault...
Detailed fault reporting
CPUs
System diagnostics in S7-400
Fault diagnostics from the CPU to the I/Os
Internal CPU services (e.g. error messages with time stamp)
Automatic signaling from CPU to HMI device or STEP 7
Optimum plan
operation
Technical Slides

11. Process diagnostics Fast faul identification Increased productivity
Faults in the plant
Interlocking not fulfilled
Actuator timeout
Motor protection
triggered
Limit switch
fault...
Fast faul identification
CPUs
Increased productivity
Process diagnostics functions in S7-400
Monitoring of critical process signals using program
Convenient CPU configuring using S7-PDIAG and ProAgent
Automatic signaling from CPU to HMI device
Operators do not have
to be engineer to
perform maintenance
Technical Slides

12. Communications integrated
MPI/DP Interface (12 Mbit/s)
Integrated into every CPU
Can be re-parameterized
as DP master
HMI services for connection
of OP/OS
No additional programming
Minimum CPU cycle load
All S7 components can
be connected
S7-400
(Master)
CPUs
PG (Master)
OP (Master)
S7-400 (Slave)
S7-300
Programming from any location in the network (routing)
Economical communication without additional hardware
Technical Slides

13. Multicomputing Segmented Rack / Multicomputing Scaling Subdivision
So that you can easily increase performance by plugging in additional CPUs
Subdivision
So that you can spread complex task over up to 4 CPUs
Decoupling
So that you can separate time-critical from non critical processes
Segmenting
So that you can assign I/O segments to specific CPUs with common communication
CPUs
Segmented Rack / Multicomputing
Technical Slides

14. Latest functions Emphasis on process engineering
Configuration in RUN
Reaction-free modifications to configuration during operation with distributed I/O
Applications
Process engineering plants which must not be switched off
Production plants with high restart costs
Customer benefits
Time-saving, low-cost plant modifications
No restart procedure required
High flexibility to modified process engineering
requirements
CPUs
Prerequisites: S7-400 FW V3.1, STEP7 V5.2
Applications for CiR – Configuration in Run – are industrial plants with non-stop requirements, continuous processes which must not be halted or interrupted, and production plants with high restart costs.
CiR enables non-reacting expansion and optimization of plants with distributed I/O while the plant is in operation. Plant modifications can thus be completed quickly and cost-effectively.
Modifications in RUN mode permit an extremely flexible response to changes in and optimization of industrial processes.
Even plants which have no non-stop requirements can shorten the time otherwise needed for modification and reconfiguration, since plants modified in RUN mode need not be reinitialized or resynchronized because of changes in the hardware configuration.
The following changes can be made to a plant's hardware configuration during operation:
Addition or removal of PROFIBUS DP-/PA slaves.
Addition, removal, reparameterization or I/O modules in the ET200M I/O system.
CiR is possible only for distributed I/O. All S7-400 standard CPUs as well as standalone high-availability S7-400H CPUs can be used. H-CiR is available for redundant H systems.
CiR is possible using the following DP masters:
CPU via integrated interfaces, CP443-5 ext (beginning version V5.0), module IF964-DP.
Shortened start-up times
Plant and process optimization
Technical Slides

15. Latest functions Emphasis on production engineering
Isochrone mode
Linking of a SIMATIC automation solution to the equidistant PROFIBUS
Synchronization of user program with I/O processing
Equidistant and synchronous signal processing with distributed I/O
Consistent transmission of input and data; all data of the process image have a logical and time relationship
CPUs
Prerequisites: S7-400 FW V3.1, STEP7 V5.2
Because they entail lower costs – less cabling, easier installation - distributed automation solutions are assuming increasing significance. Production processes and machining processes are getting faster and faster, and demands for precision are growing.
Applications for isochrone mode: motion control, synchronous operation, closed-loop control, software-based cam control, multipoint measurement, rotational speed and flow measurement
The user program is synchronized with the I/O, i.e. all procedures are chronologically coordinated. All input data are acquired at a defined point in time, and output data become effective at a defined point in time as well.
The processing of all input and output data is equidistant, i.e. input data are always read in at specific intervals, and output data are always output at specific intervals.
All input and output data are transferred in consistent form, i.e. all data in the process image belong together both logically and chronologically.
High-speed time-based procedures in which reproducibility plays a decisive role can also be automated with distributed I/O.
Safe control of fast processes
Repeatable and defined process response times with distributed I/O
Increased accuracy for controls, positioning, machines with continuous operation
Increase in productivity
Technical Slides

16. Signal modules (SM) - The right module for all common signals
Signal modules for all common signals/ the most different technology
 So you can connect up anywhere
Signal modules with interrupts and diagnostics
 So you can respond more quickly
Connection techniques that simplify installation / maintenance
 Säcrew-type/spring-loaded/crimp terminals
Simple and fast module replacement
 So you can replace the modules even during operation
Highest packing density
 To save you space
Modules
Modular design
Hot swapping

17. Digital signal modules - For all applications
Voltage range
Current range
Channels
Sensors
Reaction time
Diagnostics
Ex(i)*
Digital inputs
V AC/DC V DC V AC
------
16, 32
Switches 2-wire BEROs etc.
from 100 µs
Type A Type B No Yes
NAMUR/Ex(i)
Digitalausgaben
V DC V AC
0,5/1/2A
8, 16, 32
elektronisch/Relais
from 100 µs Typ A Typ B Nein Ja
Namur/Ex(i)
Modules
(* via ET 200M)
Technical Slides

18. Analog signal modules - For all applications
Voltage range
Current range
Channels Sensors
Resolution
Conversion time
Diagnostics*
Ex(i)`*
Analog inputs
+/- 80 mV ... +/- 10 V
+/- 20 mA, mA, and others
8, 16 Pt 100, Pt 1000, Ni 100, thermocouples
bit incl. sign ms
Type A Type B No Yes NAMUR/Ex(i)
Analog outputs
V, ... +/- 10 V
+/- 20 mA, mA, and others
bit incl. sign
ms Type A Type B No Yes
NAMUR/Ex(i)
Modules
(* via ET 200M)
Technical Slides

19. Point-to-point CPs - For special interfaces
Scanner,
Barcodeleser,
Identsysteme
PG, PC,
Rechner
Roboter-
steuerungen
Opto-Elektronik
Drucker
S7-400
1 or 2 interfaces, up to 76 kbit/s
Different physical transmission environment
Standard or customer-specific protocols
Modules
Wägesysteme,
Regler
SIMATIC S5 und Automatisierungs-
geräte auch vieler anderer Hersteller
Simple and flexible
PtP Communication

20. The scope of SIMATIC Technology
„With our scope we offer SIMATIC customers smart solutions for all their technological tasks,
i.e. multiple designs for simple machine component functions up to complex applications and complete machines."
Modules
SIMATIC Technology
Reliable hardware
Flexible software
Proven systems
Secure-investment solutions
for industrial automation
SIMATIC based technology
Easy Motion Control V2.0 with gearbox synchronism; conforming with PLCopen Price: 400 € with / 270 € without data medium, only copy license certificate Start of delivery 03/03
FM high-speed Boolean processor: with current-sourcing digital outputs and a cycle time of 1 µs Price: 930 € Start of delivery 03/03
FM with period/frequency/speed measurement, isochronous mode Price 352 € Start of delivery 03/03
Technology CPU 317T (see S7-300)FM DP isochronous mode, routing for e.g. diagnostics, Teleservice via interface Module price: 3850 € Start of delivery 04/03 EUR Special offer with SW: 4395 € (price advantage 2003 €)

21. Function modules for all technologies - The right choice when...
Good choice when...
... very fast tasks have to be carried out
... great accuracy and reproducibility are necessary
… special sensors or actuators have to be connected
...configuration of technological tasks must be as practice-oriented as possible
Modules
Counting/measuring, cam controlling,
positioning, closed- loop control
Technologies

22. FM 458-1DP application module
For all types of highly dynamic closed-loop control tasks
Freely-configurable using STEP 7 and CFC, optionally with SFC
Comprehensive block library for technological tasks and motion control
Expansion module for I/O and Communications
Modules
Particularly suitable for machine and plant construction

23. Maintenance - Just as simple as everything else
Extremely simple replacement of application program without PG
Memory card
Update device
Download using teleservice
Modules
Simple, reliable replacement of modules without PG
Central data storage in the CPU
CPU sets parameters of newly inserted modules
Also allows you to replace modules during operation
Reduced service
times
High availability
Hot swap increase the availability of the plant

24. Installation - Nice and easy
Simple swivel mounting on
the rack
Robust, enclosed modules
Self-coding front connectors
TOP Connect
Simple and polarity-reversal proof connection of actuators and sensors
Via prefabricated cables
All parameters are set via software - no DIP/DIL switches
Insertion and removal of modules
under process conditions
Front connector with screw, Crimp or spring terminals
Design flexibility
Faster installation

25. TOP Connect - Prefabricated cables
Direct connection of sensors and actuators using 2, 3 and 4-wire techniques
Simple and polarity-reversal-
proof thanks to the prefabricated cables
Saves the intermediate terminal
Terminal blocks on S7-400 standard I/O modules can be connected via front connectors
Using spring-loaded or
Screw-type terminals
Distance
max. 30m
Design flexibility
TOP Connect: terminal blocs
Reduction of the expenditive wiring work
TOP Connect: Terminal blocks
Technical Slides

26. Unlimited expansion Migration
Uniform use of multi-channel I/O modules (central and distributed)  Fewer modules required
No additional power supply required for racks which are not too far away  Reduction in required modules
Immediate reading is possible at any time using direct I/O access  System response times almost as short as when using I/Os only in central rack
S5 expansion rack can be used further with S7-400
Design flexibility
Migration

27. Expansion facilities with the S7-400
Central cabinet CR ER ER
Max. 6 IM per CR
Central expansion , line length 5 m, max. 4 ER per line ER
Design flexibility ER ER
Central expansion ,
line length 1,5m 1st ER without PS
Distributed expansion , line length 102 m/ 605 m, max. 4 ER per line
ER S5
ER S5
Expandable
Distributed expansion, line length 605 m, max. 4 ER per line
Technical Slides

28. Data communication with SIMATIC NET PROFIBUS and Industrial Ethernet
IT communication
Data Kommunikation/cell level
Design flexibility
Field communication
Integrated

29. Data communication – also Internet access
Management computer
PG/PC
Industrial Ethernet
PG/PC
PG/PC
S5-115U S5-135U S5-155U
S7-400
PROFIBUS
Design flexibility
S7-400
S7-400
S5-115U
PROFIBUS DP, MPI, Ethernet @
S7-300
IT integration
PG/OP

30. CP 443-1 Advanced More power and flexibility
New Functions
IP-Access list
SNMP
IP-Configuration
More Communication Performance
More connections
At plant floor and IT communication
Integrated 4-Port Switch
Better Usability
New IP-Address configuration
Double IP-address indication
Diagnostic buffer via WEB
PROFINET
PROFINET IO Controller
PROFINET CBA
Design flexibility

31. The window to your plant/process/machine SIMATIC HMI
SIMATIC Panels:
Push button panels, text displays, operator panels, touch panels or multi- panels via MPI or PROFIBUS-DP
Multiple panels for an
S7-400
One panel for several automation systems
WinCC flexible- for simple PC-based visualization tasks
WinCC V6- The powerful process visualization system
Panel PC oder OS
WinCC
Design flexibility
Multi Panels
Push Button Panels
Text Displays,
Operator Panels, Touch Panels
Easy parametization

32. Parameterization made easy
Software parameterization of the complete S7-400
including the signal modules with STEP 7
Uniform No jumpers / switches to set
Checking the parameter assignment data
for plausibility
Additional parameterization for individual values,
e.g. conversion time parameterization saves valuable time
All S7-400 parameterization data are stored in the CPU
Parameterization is not necessary when replacing modules
CPU checks the S7-400 configuration and the module settings
Incorrect module signaled by diagnostics function
 Efficient for user, from commissioning to maintenance
Configuration and Programming
Easy parameterization

33. Simulation-based engineering with SIMIT
Early detection and clearance of configuration errors
Simulation of the system
Simulation of the units
Simulation of the I/O signals
Testing of the complete scope of automation
Easy-to-use thanks to standardized coupling
“The S7-400 simulation module connected to the PC replaces the central and distributed I/O”
Training
Training of commissioning and service personnel
Configuration and Programming

34. S7-400 solves more complex tasks using the STEP 7 engineering tools
S7-SCL
(Structured control language) - The PLC high-level language
S7-PDIAG/Pro Agent The double pack for process diagnostics
S7-PLCSIM Program testing without hardware
S7-GRAPH Definition using
sequence controls
Configuration and Programming
CFC (Continues function chart) Graphical sequencing of complex functions
S7-HiGraph Definition using status
diagrams

35. S7-400 - The optimum target system
Uses a common database
Integrated and consistent
The powerful S7-400 target system and the engineering tools
work perfectly together as user-friendly, task-oriented configuring tools
The perfect team
Configuration and Programming
S7-400 +
E-Tools =
Optimized for great applications

36. Shaoxin Sewage Treatment
References
Automobile
Food & Beverage
Parma / Chemical
industry
Semiconductor/
Textile industry
References
Glass/ Cement
Legend Inc.
Shaoxin Sewage Treatment
Icoma FSB
Miscellaneous
References

37. SIMATIC S7-400
Totally Integrated Automation