Maintenance / Trouble Shooting

Simatic S7

This document has been prepared for the purpose of training. It is based on the
respective operation and maintenance manuals. Operation and maintenance must be
performed in accordance with the operating and maintenance manuals!

Siemens AG
Sector Industry, I&S IS ICS2 KHC
P.O.Box 3240
D-91050 Erlangen
E-Mail: ics2khc.industry@siemens.com
Guidelines for Handling Electrostatically-Sensitive Devices (ESD)

B.1 What is ESD?

Definition:
All electronic modules are equipped with large-scale integrated ICs or components.
Due to their design, these electronic elements are very sensitive to overvoltages
and thus to any electrostatic discharge.
These Electrostatically-Sensitive Devices are commonly referred to by the
abbreviation ESD.
Electrostatically-sensitive devices are labeled with the following symbol:

Caution
! Electrostatically-sensitive devices are subject to voltages that are far below the
voltage values that can still be perceived by human beings. These voltages are
present if you touch a component or the electrical connections of a module without
previously being electrostatically discharged. In most cases, the damage caused
by an overvoltage is not immediately noticeable and results in total damage only
after a prolonged period of operation.

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Maintenance 7
Chapter Overview

Section Description Page

7.1 Replacing the Backup Battery 7-2
7.2 Replacing a Power Supply Module 7-4
7.3 Replacing CPUs 7-5
7.4 Replacing Digital or Analog Modules 7-7
7.5 Changing the Fuses in the Digital Modules 7-9
7.6 Replacing Interface Modules 7-11
7.7 Replacing the Fuse of the Fan Subassembly 7-13
7.8 Replacing Fans in the Fan Subassembly During Operation 7-14
7.9 Replacing the Filter Frame of the Fan Subassembly During Operation 7-16
7.10 Replacing the Power Supply PCB and Monitoring PCB of the Fan 7-18
Subassembly
7.11 Replacing Interface Submodules 7-19

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Maintenance

7.1 Replacing the Backup Battery

Replacing the Backup Battery

1. Discharge any static charge by touching a grounded metal part of the S7-400.
2. Open the cover of the power supply module.
3. Using the loop(s), pull the backup battery/batteries out of the battery
compartment.

4. Insert the new backup battery/batteries in the battery compartment of the power
supply module.
Ensure correct polarity of the battery/batteries.
5. Switch on battery monitoring with the BATT INDIC slide switch.

If You ... ...Then

have a single-width power supply module, set the BATT INDIC switch to
BATT.
have a double or triple-width power supply module set the BATT INDIC switch to
and want to monitor a backup battery, 1BATT.
have a double or triple-width power supply module set the BATT INDIC switch to
and want to monitor both backup batteries, 2BATT.

6. Press the FMR button.

7. Close the cover of the power supply module.

Note
If you store the batteries for a long period, a passivation layer may form. Please
read Section 6.8, Inserting a Backup Battery.

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 Maintenance

Using Backup Batteries

You should change the backup battery once a year.
Observe the usual regulations/guidelines for disposing of lithium batteries in your
country.
Backup batteries should be stored in a cool, dry place.
Backup batteries can be stored for ten years. If they are stored for a longer period,
however, a passivation layer may form.

Rules for the Care of Backup Batteries

You must observe the following rules to avoid hazards in the care of backup
batteries:

Warning
! Risk of injury, material damage, release of hazardous substances.
Lithium batteries can explode if handled improperly. Their improper disposal may
result in the release of hazardous substances. Strictly adhere to the following in-
structions:
• Do not throw a new or low battery into an open fire and do not perform any sol-
dering work on the cell casing (max. temperature 100 °C). Do not recharge the
battery – risk of explosion! Do not open a battery. Replace a faulty battery onoly
with the same type. Replacement batteries can be ordered from SIEMENS (for
order numbers, refer to the “Module data” reference manual, in appendix C).
This will insure that your are installing a short circuit-proof type.
• Always try to return low batteries to the manufacturer or deliver these to a regi-
stered recycling company.

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Maintenance

7.2 Replacing a Power Supply Module

Slot Numbering
If you have provided the modules in your system with slot numbering, you must
remove the number from the old module when replacing it and apply the number to
the new module.

Removing the Module (Ignore Steps 1 and 2 When Using Redundant Power
Supply Modules)
1. Set the CPU mode switch to STOP.
When you replace the power supply module in an ER, the CR may remain in the
RUN state, depending on CPU programming. You can back up the data in the
ER via the EXT. BATT. socket of the receive IM.
2. If you wish to back up the data in the CPU, you can use the EXT. BATT. socket
of the CPU (see Reference Manual, Chapter 1).
3. Set the standby switch of the power supply module to (0 V output voltages).
4. Set the line disconnector to OFF.
5. Remove the cover.
6. Remove the backup battery/batteries if applicable.
7. Disconnect the power supply connector from the power supply module.
8. Loosen the mounting screws of the module.
9. Swing the module out.

Installing a New Module

1. Check the voltage selector switch.
2. Attach the new module of the same type and swing it downwards.
3. Screw the module on.

4. Check that the power disconnector is set to OFF and the standby switch to .
5. Plug in the power supply connector at the power supply module.
6. Insert the backup battery/batteries, if applicable.
7. Close the cover.
8. Set the power disconnector to ON.
9. Set the standby switch of the power supply module to I (output voltages at rated
value).
10.Set the CPU mode switch to RUN if applicable.

How the S7-400 Behaves after Exchanging Modules

If an error occurs after replacing a module, you can read out the cause of the error
from the diagnostic buffer.

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 Maintenance

7.3 Replacing CPUs

Slot Numbering
If you have provided the modules in your system with slot numbering, you must
remove the number from the old module when replacing it and apply the number to
the new module.

Saving the Data

Save the user program including configuration data.

Removing the Module

1. Set the CPU mode switch to STOP.

2. Set the standby switch of the power supply module to (0 V output voltages).
3. Remove the cover of the CPU.
4. Disconnect the MPI connector, if applicable.
5. Disconnect the connector at the EXT. BATT. socket, if applicable.
6. Remove the memory card.
7. Loosen the mounting screws of the module.
8. Swing the module out.

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Maintenance

Installing a New Module

1. Attach the new module of the same type and swing it downwards.
2. Screw the module on.
3. If applicable, plug the connector for the external battery supply into the socket.
4. Set the CPU mode switch to STOP.
5. Insert the memory card.
6. Set the standby switch of the power supply module to I (output voltages at rated
value).
The remaining procedure depends on whether you use a Flash card and
whether or not you have configured your system for networking.
7. Proceed as follows to operate with a Flash card:
Transfer the user and configuration data.
Set the CPU mode switch to RUN.
Close the cover.
8. If your system is not configured for networking, proceed as follows:
Transfer the user and configuration data by means of the programming device,
via the programming device cable (see Section 6.3).
Set the CPU mode switch to RUN.
Close the cover.
9. If your system is configured for networking, proceed as follows:
Transfer the user and configuration data by means of the programming device,
via the programming device cable (see Section 6.3).
Set up your network by plugging in the MPI connector.
Set the CPU mode switch to RUN.
Close the cover.

How the S7-400 Behaves after Exchanging Modules

If an error occurs after replacing a module, you can read out the cause of the error
from the diagnostic buffer.

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 Maintenance

7.4 Replacing Digital or Analog Modules

Slot Numbering
If you have provided the modules in your system with slot numbering, you must
remove the number from the old module when replacing it and apply the number to
the new module.

Installing a Module
1. You can replace analog and digital modules in RUN mode. You must have taken
the appropriate action in your STEP 7 program to ensure correct responses
from your system.
If you are not sure whether your program will react correctly, set the CPU mode
switch to STOP.

Warning
! Improper handling of the front connectors can result in injury and damage.
If the front connector is removed and inserted during operation, hazardous
voltages of >25 VAC or >60 VDC may be present at the pins of the module.
When such voltages are present at the front connector, modules with power
applied may only be replaced by electrical specialists or trained personnel in such
a way that the pins of the module are not touched.

2. Loosen the mounting screw of the front connector and pull it off.
3. Loosen the mounting screws of the module.
4. Swing the module out.

Note
In order that the removal and insertion of digital or analog modules can be
detected by the CPU, a minimum time of two seconds must elapse between
removal and insertion.

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Maintenance

Removing the Front Connector Coding Key

Before fitting the front connector, you must remove (break off) the front part of the
coding key, because this part is already fitted in the wired front connector.

Caution
! The module can be damaged.
If, for example, you insert a front connector of a digital module in an analog
module, the module may be damaged.
Only operate modules with their complete front connector coding key.

Installing a New Module

1. Attach the new module of the same type at the appropriate slot and swing it
downwards.
2. Screw the module on with both mounting screws.
3. Fit the front connector.
4. If you have set the CPU to STOP, you must now set it to RUN again.
5. After fitting, each programmable module will be reinitialized by the CPU with
parameters.

How the S7-400 Behaves after Exchanging Modules

If an error occurs after replacing a module, you can read out the cause of the error
from the diagnostic buffer.

Exchanging the Front Connector

1. Switch off all load power supplies for the module.
2. Loosen the screw of the front connector and pull it off.
3. Remove the labels from the front connector and insert them into the new front
connector.
4. Wire the new front connector.
5. Insert the front connector in the module.
6. Screw the front connector on.
7. Switch on the load voltage.

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 Maintenance

7.5 Changing the Fuses in the Digital Modules

Modules with Fuses

The following modules have fuses which you can change yourself if they are
defective:
• Digital output module SM 422; DO 16 x DC 20–125 V/1,5A
(6ES7422-5EH10-0AB0)
• Digital output module SM 422; DO 16 x AC 20-120 V/2A
(6ES7422-5EH00-0AB0)
• Digital output module SM 422;DO 8 x AC 120/230 V/5A
(6ES7422-1FF00-0AA0)
• Digital output module SM 422;DO 16 x AC 120/230 V/2A
(6ES7422-1FH00-0AA0)

Check the Plant

Correct the faults which led to the fuses blowing.

Changing the Fuses

To change the fuses in a digital module, you must remove the front connector from
the digital module and remove the module from the rack.

Warning
! Improper handling of the digital modules can result in injury and damage.
Hazardous voltages of >25 VAC or >60 VDC may be present below the covers on
the right-hand side of the module.
Before you open these covers, ensure that either the front connector for the
module is removed or the module is disconnected from the voltage supply.

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Maintenance

Warning
! Improper handling of the front connectors can result in injury and damage.
If the front connector is removed and inserted during operation, hazardous
voltages of >25 VAC or >60 VDC may be present at the pins of the module.
When such voltages are present at the front connector, modules with power
applied may only be replaced by electrical specialists or trained personnel in such
a way that the pins of the module are not touched.

To change the fuses:

1. You must have taken the appropriate action in your STEP 7 program to ensure
correct responses from your system.
If you are not sure whether your program will react correctly, set the CPU mode
switch to STOP.
2. Loosen the mounting screw of the front connector and pull it off.
3. Loosen the mounting screws of the module.
4. Swing the module out.

Note
In order that the removal and insertion of digital modules can be detected by the
CPU, a minimum time of two seconds must elapse between removal and insertion.

5. Remove the covers on the right-hand side of the module by levering them out
with a screwdriver.
6. Replace the defective fuses with new fuses of the same type.
7. Place the guides on the covers into the appropriate cutouts in the module
casing and close the covers until they click into place.
8. Attach the module onto its slot and swing it down.
9. Screw the module on with both mounting screws.
10.Fit the front connector.
11. If you have switched the CPU to STOP, you must now switch it to RUN again.
12.After fitting, each programmable module will be reinitialized by the CPU with
parameters.

How the S7-400 Behaves after Replacing the Fuse

If an error occurs after replacing a fuse, you can read out the cause of the error
from the diagnostic buffer.

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 Maintenance

7.6 Replacing Interface Modules

Slot Numbering
If you have provided the modules in your system with slot numbering, you must
remove the number from the old module when replacing it and apply the number to
the new module.

Hot–swapping Modules
Observe the following warning when fitting and removing the interface modules and
the corresponding connecting cables.

Caution
! Data can be lost or corrupted.
If you remove or insert the interface modules and/or corresponding connecting
cables with power applied, data may be lost or corrupted.
Switch off the power supply modules of the CR and ERs on which you are working
before carrying out any actions.

Removing Modules / Exchanging Cables

1. If you wish to back up your data in the CPU, you can do this with a backup
battery or via an external battery supply at the CPU (see the CPU Data
Reference Manual, Chapter 1).
2. Set the CPU mode switch to STOP.
3. Set the standby switches of both power supply modules (in the CR and the ER)
to (0 V output voltages).
4. Remove the cover.
5. Disconnect the connecting cables.
6. Disconnect the terminator, if applicable.
7. Loosen the mounting screws of the module.
8. Swing the module out.

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Maintenance

Installing a New Module

1. Set the number of the rack at receive IMs.
2. Attach the new module of the same type and swing it downwards.
3. Screw the module on.
4. Fit the connecting cables.
5. Plug in the terminator, if applicable.
6. Secure the cover.
7. First switch on the power supply module in the ER.
8. Then switch on the power supply module in the CR.
9. Set the CPU mode switch to RUN mode.

How the S7-400 Behaves after Exchanging Modules

If an error occurs after replacing a module, you can read out the cause of the error
from the diagnostic buffer.

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 Maintenance

7.7 Replacing the Fuse of the Fan Subassembly

Fuse Type
The fuse of the fan subassembly is a standard 5 x 20 mm cartridge fuse to DIN and
not a spare part.
Use the following fuse:
• 160 mA slow blow if the voltage selector switch is set to 230 V
• 250 mA slow blow if the voltage selector switch is set to 120 V

Replacing the Fuse

To replace the fuse of the module, follow the steps outlined below:
1. Disconnect the power cable of the fan subassembly from the supply.
2. Use a screwdriver to unscrew the fuse cap.

Voltage selector switch

Fuse cap

3. Remove the blown fuse from the fuse cap.

4. Insert the new fuse in the fuse cap and screw the cap into the fan subassembly.
5. Connect the power cable of the fan subassembly to the supply.

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Maintenance

7.8 Replacing Fans in the Fan Subassembly During

Operation

Removing the Fans

1. Use a screwdriver to make a quarter turn counter-clockwise and open the two
quick-release locks on the front of the fan subassembly.

ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ
ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ
Fan 1 Fan 2 Fan 3

Base
Quick-release locks
Reset button

LEDs: F 1 = Fan 1
F 2 = Fan 2
F 3 = Fan 3

2. Grasp the base with both hands, press it down slightly and pull it fully out of the
fan subassembly.
3. Release the fan to be replaced by pressing the fan grip away from the housing
with your thumb.

Fan

Fan grip

Base

4. Pull out the fan to be replaced.

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 Maintenance

5. Slide the new fan in until it engages.

6. Slide the base in again and press it up.
7. Use a screwdriver to make a quarter turn clockwise and close the two
quick-release locks.
8. Use a pointed object to press the RESET button. The fault LED will go off and
the fan will start running.

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Maintenance

7.9 Replacing the Filter Frame of the Fan Subassembly

During Operation

Replacing the Filter Frame

1. Use a screwdriver to make a quarter turn counter-clockwise and open the two
quick-release locks on the front of the fan subassembly.
2. Grasp the base with both hands, press it down slightly, pull it first fully forward
and then up at an angle out of the fan subassembly.

3. The filter frame is secured either in the bottom of the base or at its rear edge
with snap hinges and snap catches. The individual filter mats are joined with the
filter frame.
Remove the filter frame as follows:
– The filter frame is fitted in the bottom of the base:
Near the snap catches, press against the filter frame from below and remove
the filter frame.
– The filter frame is secured at the rear edge of the base:
With the flat of your hand, press the filter frame away from the base of the
fan subassembly. This will release the filter frame from the snap hinges.

Filter mat
Filter frame
Cover

Snap catches

Base with cover and filter

frame (optionally fitted at
bottom or rear)

Snap hinges Quick-release locks

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 Maintenance

4. Fit the new filter frame:

– Fitting the filter frame at the bottom of the base:
Insert the filter frame in the snap hinges at the base cutout and engage it
with the snap catches.
– Fitting the filter frame at the rear edge of the base:
At about a right angle to the base, insert the filter frame in the snap hinges at
the rear edge of the base.
5. Slide the base in again and press it up.
6. Use a screwdriver to make a quarter turn clockwise and close the two
quick-release locks.
7. Replacing the filter frame will not trigger an interrupt. There is therefore no need
to press the RESET button.

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Maintenance

7.10 Replacing the Power Supply PCB and Monitoring PCB

of the Fan Subassembly

Exchanging the Mother Board

1. Disconnect the power cable of the fan subassembly from the supply.
2. Use a screwdriver to make a quarter turn counter-clockwise and open the two
quick-release locks on the front of the fan subassembly.
3. Remove the base of the fan subassembly (see Section 7.9).
Shown in the following figure is a front view of the fan subassembly. You can also
see the locations of the printed-circuit boards (PCBs).

ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ
Fan 1 Fan 2 Fan 3

Quick-release Power supply Monitoring Quick-release

lock PCB PCB lock Reset button

4. Pull the faulty PCB forward and out of the fan subassembly.
5. Slide the new PCB in until it engages.
6. Slide the base in again and press it up.
7. Use a screwdriver to make a quarter turn clockwise and close the two
quick-release locks.
8. Connect the power cable of the fan subassembly to the supply.
9. Use a pointed object to press the RESET button. The fans will start running.

Caution
! Electronic components can be damaged.
If you do not observe the ESD guidelines when handling printed-circuit boards with
electronic components, the components can be damaged by a static discharge.
Observe the ESD guidelines (see Appendix).

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 Maintenance

7.11 Replacing Interface Submodules

Available Interface Submodules

Note
Only use interface submodules that are explicitly released for use in S7-400
devices.

Installing Interface Submodules

Warning
! The modules can be damaged.
When inserting or removing interface submodules with power applied, the CPU
and interface submodules can be damaged (exception: using synchronization
submodules in an H system).
Never insert or remove the interface submodules while power is being supplied
(exception: synchronization submodules). Always switch off the power supply
before inserting or removing interface submodules.

Caution
! Danger of damage to persons and property.
Interface submodules contain electronically-sensitive components that may be
damaged if they are touched.
The surface temperatures on the components can reach up to 70o C and there is a
risk of burning.
For this reason, you should always hold the interface submodules on the longest
sides of the front panel.
Observe the ESD guidelines when installing interface submodules.

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Maintenance

You can replace an interface submodule with another one without having to remove
the associated CPU from the rack. Follow the steps outlined below:
1. Switch the CPU to STOP (not the synchronization module of a redundant
system).
2. Switch off the power supply (not the synchronization module of a redundant
system).
3. Loosen the screws of the sub-D-connector and remove all connectors.
4. Loosen the two captive slot-head screws which secure the front plate of the
interface submodule to the left frame of the card slot so that the screws can be
removed by 6 mm.
5. Carefully remove the interface submodule from the guide support of the card
slot (see figure 7-1). Hold the interface module on the long sides of the front
plate.

Guide
rails

Figure 7-1 Inserting an Interface Submodule in a CPU

Installing Interface Submodules

In order to install an interface submodule, proceed in reverse order. For further
information, see section 6.10 ”Installing Interface Submodules”.

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 Getting Started

3.3 Examples of Fault-Tolerant System Response to Faults

Example 1: Failure of a central processing unit or power supply

Initial situation: The S7-400H is in redundant system mode.
1. Cause CPU0 to fail by turning off the power supply.
Result: The LEDs REDF, IFM1F and IFM2F light on CPU1. CPU1 goes into
solo mode, and the user program continues to run.
2. Turn the power supply back on.
Result:
– CPU0 performs an automatic LINK-UP and UPDATE.
– CPU0 changes to RUN and now operates as the standby CPU.
– The S7-400H is now in redundant system mode.

Example 2: Failure of a fiber-optic cable

Initial situation: The S7-400H is in redundant system mode. The mode selector of
each CPU is at the RUN or RUN-P position.
1. Disconnect one of the fiber-optic cables.
Result: The LEDs REDF and IFM1F or IFM2F (depending on which fiber-optic
cable was disconnected) now light on the two CPUs. The original master CPU
(CPU0) changes to single mode and the user program continues to run.
2. Reconnect the fiber-optic cable that you disconnected earlier.
3. Restart the original standby CPU (CPU1), which is now at STOP, by means of
STEP7 “operating status”, for example.
Result:
– CPU1 performs an automatic LINK-UP and UPDATE.
– The S7-400H reverts to redundant system mode.

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Installation of a CPU 41x-H

4.1 Controls and Indicators of the CPUs

Operation and Display Elements of the CPU 414-4H/417-4H

Module designation, version, abbre-

viated order number and firmware
version
V3.0.0

INTF, EXTF, BUS1F, BUS1F REDF, IFM1F, IFM2F,

BUS2F, FRCE, RUN, STOP
BUS2F
IFM1F
MSTR, RACK0, RACK1
LEDs
IFM2F
LEDs
RACK0

Slot for the memory card RACK1

Mode selector

Under cover Under cover

Memory card slot for

MPI/PROFIBUS DP interface synchronization submodule 1

PROFIBUS DP interface Memory card slot for

synchronization submodule 2

Incoming supply of external backup

voltage
Under the metal lid
on the left-hand side
Interface for memory ex-
pansion*
* Only in CPU 417-4H

Figure 4-1 Layout of the controls and indicators of the CPU 414-4H/417-4H

LEDs
Table 4-1 gives you an overview of the LEDs on the individual CPUs.
Section 4.2 describes the statuses and errors indicated by these LEDs.

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 Installation of a CPU 41x-H

Table 4-1 LEDs of the CPUs

LED Color Meaning

INTF red Internal fault
EXTF red External fault
FRCE yellow Active force request
RUN green RUN mode
STOP yellow STOP mode
BUS1F red Bus fault at MPI/PROFIBUS DP interface 1
BUS2F red Bus fault at PROFIBUS DP interface 2
MSTR yellow CPU leads the process
REDF red Loss of redundancy/redundancy error
RACK0 yellow CPU in rack 0
RACK1 yellow CPU in rack 1
IFM1F red Error at interface submodule 1

IFM2F red Error at interface submodule 2

Operating Mode Selector

You can use the mode selector to select the current operating mode of the CPU.
The mode selector is a key switch with four switching positions. You can use
different protection levels and limit any program changes or startup options (STOP
to RUN transition) to a certain group of people.
Section 4.4 describes the functions of the mode selector and the protection levels
of the CPUs.

Slot for Memory Cards

You can insert a memory card in this slot.
There are two types of memory card:
• RAM cards
You can expand the load memory of a CPU with the RAM card.
• FLASH cards
You can use the FLASH card to store your user program and your data so that
they are failproof (even without a backup battery). You can either program the
FLASH card on the programming device or in the CPU. The FLASH card also
expands the load memory of the CPU.
A detailed description of memory cards is available in Chapter 4.5.1.

Interface for Expanded Memory

CPU 417-4H provides an additional interface for expanded memory. This make it
possible to expand the working memory. (See Chapter 4.5 )

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Installation of a CPU 41x-H

Slot for Interface Modules

The H synchronization module can be inserted into this slot.

MPI/DP Interface
You can connect the following devices to the MPI of the CPU, for example:
• Programming devices
• Operation and monitoring devices
• Additional S7-400 or S7-300 controllers (see Section 4.6).
Use the bus connector with an angular outgoing cable (see the Installation manual,
Chapter 7)
You can also configure the MPI interface as a DP master and use it as a
PROFIBUS DP interface with up to 32 DP slaves.

Profibus-DP Interface
You can connect the distributed I/O, programming devices/OPs and additional
DP master stations to the PROFIBUS DP interface.

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Installation of a CPU 41x-H

4.1 Controls and Indicators of the CPUs

Operation and Display Elements of the CPU 414-4H/417-4H

Module designation, version, abbre-

viated order number and firmware
version
V3.0.0

INTF, EXTF, BUS1F, BUS1F REDF, IFM1F, IFM2F,

BUS2F, FRCE, RUN, STOP
BUS2F
IFM1F
MSTR, RACK0, RACK1
LEDs
IFM2F
LEDs
RACK0

Slot for the memory card RACK1

Mode selector

Under cover Under cover

Memory card slot for

MPI/PROFIBUS DP interface synchronization submodule 1

PROFIBUS DP interface Memory card slot for

synchronization submodule 2

Incoming supply of external backup

voltage
Under the metal lid
on the left-hand side
Interface for memory ex-
pansion*
* Only in CPU 417-4H

Figure 4-1 Layout of the controls and indicators of the CPU 414-4H/417-4H

LEDs
Table 4-1 gives you an overview of the LEDs on the individual CPUs.
Section 4.2 describes the statuses and errors indicated by these LEDs.

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Table 4-1 LEDs of the CPUs

LED Color Meaning

INTF red Internal fault
EXTF red External fault
FRCE yellow Active force request
RUN green RUN mode
STOP yellow STOP mode
BUS1F red Bus fault at MPI/PROFIBUS DP interface 1
BUS2F red Bus fault at PROFIBUS DP interface 2
MSTR yellow CPU leads the process
REDF red Loss of redundancy/redundancy error
RACK0 yellow CPU in rack 0
RACK1 yellow CPU in rack 1
IFM1F red Error at interface submodule 1

IFM2F red Error at interface submodule 2

Operating Mode Selector

You can use the mode selector to select the current operating mode of the CPU.
The mode selector is a key switch with four switching positions. You can use
different protection levels and limit any program changes or startup options (STOP
to RUN transition) to a certain group of people.
Section 4.4 describes the functions of the mode selector and the protection levels
of the CPUs.

Slot for Memory Cards

You can insert a memory card in this slot.
There are two types of memory card:
• RAM cards
You can expand the load memory of a CPU with the RAM card.
• FLASH cards
You can use the FLASH card to store your user program and your data so that
they are failproof (even without a backup battery). You can either program the
FLASH card on the programming device or in the CPU. The FLASH card also
expands the load memory of the CPU.
A detailed description of memory cards is available in Chapter 4.5.1.

Interface for Expanded Memory

CPU 417-4H provides an additional interface for expanded memory. This make it
possible to expand the working memory. (See Chapter 4.5 )

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Slot for Interface Modules

The H synchronization module can be inserted into this slot.

MPI/DP Interface
You can connect the following devices to the MPI of the CPU, for example:
• Programming devices
• Operation and monitoring devices
• Additional S7-400 or S7-300 controllers (see Section 4.6).
Use the bus connector with an angular outgoing cable (see the Installation manual,
Chapter 7)
You can also configure the MPI interface as a DP master and use it as a
PROFIBUS DP interface with up to 32 DP slaves.

Profibus-DP Interface
You can connect the distributed I/O, programming devices/OPs and additional
DP master stations to the PROFIBUS DP interface.

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4.2 Monitoring Functions of the CPU

Monitoring and Error Messages

The CPU hardware and the operating system have monitoring functions that
ensure that the system functions correctly and that there is a defined response to
an error. A number of errors will also produce a response from the user program.
The following table gives you an overview of possible errors, their causes and the
responses of the CPU.
There are also test and information functions available in each CPU that you can
call up with STEP 7.

Type of Cause of Error Response of the Operating

Error LED
Fault/Error System
Clock pulse Monitoring of the failure of the processor Disabling of the digital outputs by
failure clock pulse issuing the “OD” (Output Disable) –
System standstill signal
Access error Module failure (SM, FM, CP) “EXTF” LED lights up until the fault is
acknowledged.
In SMs:
• OB 122 call
• Entry in the diagnostics buffer
• In the case of input modules: EXTF
Entry of null for the date in the
accumulator or the
process image
In the case of other modules:
• OB 122 call
Timing error • The runtime of the user program (OB1 “INTF” LED lights up until the fault is
and all the interrupts and error OBs) acknowledged.
exceeds the specified maximum cycle
time. OB 80 call INTF
• OB request error If the OB is not loaded: The CPU
• Overrun of the start information buffer goes into STOP mode.
• Time error interrupt
Power supply In the central or distributed I/O rack: OB 81 call
module error • At least one backup battery in the If the OB is not loaded: The CPU
(not power power supply module is empty. continues to run.
EXTF
failure) • The backup voltage is missing.
• The 24 V supply to the power supply
module has failed.
Diagnostics An I/O module with interrupt capability OB 82 call
Interrupt reports a diagnostics interrupt. If the OB is not loaded: The CPU EXTF
goes into STOP mode.
Remove/insert Removal or insertion of an SM and OB 83 call
interrupt insertion of an incorrect module type. If the If the OB is not loaded: The CPU
only inserted SM is removed during STOP goes into STOP mode.
mode of the CPU with default parameter EXTF
assignment, the EXTF LED will not light up.
If the SM is inserted again, the LED lights
up briefly.
Priority class • Priority class is called, but the OB 85 call
error corresponding OB is not available. If the OB is not loaded: The CPU INTF
• In the case of an SFB call: The goes into STOP mode.
instance DB is missing or defective.
• Error during the updating of the
EXTF
process image

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Type of Cause of Error Response of the Operating

Error LED
Fault/Error System
Failure of a • Power failure in an expansion rack OB 86 call
rack/station • Failure of a DP line If the OB is not loaded: The CPU
EXTF
• Failure of a coupling line: missing or goes into STOP mode.
defective IM, interrupted line)
Communication • Status information cannot be entered in OB 87 call
error DB If the OB is not loaded: The CPU
• Incorrect frame identifier goes into STOP mode.
INTF
• Frame length error
• Impermissible global identifier number
• DB access error

Cancel The processing of a program block is OB 88 call

processing cancelled. Possible reasons for the If the OB is not loaded: The CPU
cancellation are: goes into STOP mode.
• Too much nesting depth of a
bracket level
• Too much nesting depth of a
master control relay
• Too much nesting depth for
synchronization errors INTF
• Too much nesting depth from
block calls (i stack)
• Too much nesting depth from
block calls (b stack)
• Error allocating local data
• Unknown instruction
• Branch instruction with destination
outside of the block
Programming Error in the machine code or in the user OB 121 call
error program: If the OB is not loaded: The CPU
• BCD conversion error goes into STOP mode.
• Range length error
• Range error
• Alignment error INTF
• Write error
• Timer number error
• Counter number error
• Block number error
• Block not loaded
MC7 code error Error in the compiled user program (e.g. The CPU goes into STOP mode.
impermissible OP code or jump over the Reboot or memory reset required. INTF
end of the block)

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4.3 Status and Error LEDs

LEDs RUN and STOP

The RUN and STOP LEDs provide information about the currently active CPU
operating status.

LED Meaning
RUN STOP
H D CPU is in RUN mode.
D H CPU is in STOP mode. The user program is not processed. Restart and
warm restart/reboot is possible. If the STOP status was triggered by an
error, the error indication (INTF or EXTF) is also set.
B B CPU has the status DEFECT. The INTF, EXTF and FRCE LEDs also
2 Hz 2 Hz flash.

B H HALT status has been triggered by a test function.

0.5 Hz
B H A warm restart/reboot/restart has been triggered. It can take a minute or
2 Hz longer to execute the warm restart/reboot/restart depending on the length
of the OB called. If the CPU still does not go into RUN, there might be an
error in the system configuration.
B B Self–test running for unbuffered POWER ON.
2 Hz 2 Hz
x B Memory reset is requested by the CPU.
0.5 Hz
x B Memory reset is running.
2 Hz

D = LED is dark; H = LED lights up; B = LED flashes with the specified frequency;
x = LED status is irrelevant

LEDs MSTR, RACK0 and RACK1

The three LEDs, MSTR, RACK0 and RACK1, provide information about the
mounting rack number configured in the synchronization module and which CPU
has process control of the switched I/O modules.

LED Meaning
MSTR RACK0 RACK1
H x x CPU has the process control for the switched I/O
x H D CPU on rack number 0
x D H CPU on rack number 1

D = LED is dark; H = LED lights up; x = LED status is irrelevant

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LEDs INTF, EXTF and FRCE

The three LEDs, INTF, EXTF and FRCE, provide information about the errors and
special events during running of the user program.

LED Meaning
INTF EXTF FRCE
H x x An internal error has been detected (programming or parameter
assignment error).
x H x An external error has been detected (in other words, the cause of
the error cannot be traced back to the CPU module).
x x H A force request is active.

H = LED lights up; x = LED status is irrelevant

LEDs BUSF1 and BUSF2

The LEDs BUSF1 and BUSF2 indicate errors in connection with the MPI/DP
interface and the PROFIBUS DP interface.

LED Meaning
BUS1F BUS2F
H x An error has been detected at the MPI/DP interface.
x H An error has been detected at the PROFIBUS DP interface.
B x DP master: One or more slaves at PROFIBUS DP interface 1
are not replying.
DP slave: not addressed by the DP master
x B DP master: One or more slaves at PROFIBUS DP interface 2
are not replying.
DP slave: not addressed by the DP master

H = LED lights up; B = LED flashes; x = LED status is irrelevant

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LEDs IFM1F and IFM2F

The LEDs IFM1F and IFM2F indicate errors that occur in the first and second
module interfaces.

LED Meaning
IFM1F IFM2F
H x An error has been detected at module interface 1.
x H An error has been detected at module interface 2.

H = LED lights up; x = LED status is irrelevant

LED REDF
The LED REDF indicates specific system states and redundancy errors.

REDF LED System Status Boundary Conditions

Flashes at 0.5 Linking –
Hz
Flashes at 2 Hz Update –
Off Redundant (CPUs are No redundancy error
redundant)
Lights Redundant (CPUs are There is an I/O redundancy error:
redundant) • Failure of a DP master or partial or
complete failure of a DP master
system
• Loss of redundancy on the
DP slave
All the system states apart –
from redundant, linking,
updating

Diagnostics Buffer
You can read out the exact cause of an error in STEP 7 (PLC –> Module
Information) from the diagnostics buffer.

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4.4 Mode Selector

Function of the Mode Selector

Using the mode selector, you can put the CPU in RUN/RUN-P or STOP mode or
reset the memory of the CPU. STEP 7 offers further options for changing the
mode.

Positions
The mode selector switch is designed as a keyswitch. Figure 4-2 illustrates the
possible positions of the mode selector.

RUN-P

RUN

STOP

MRES

Figure 4-2 Positions of the mode selector

Table 4-2 explains the positions of the mode selector. In the event of a fault or if
there are startup problems, the CPU will go into or remain in STOP mode
irrespective of the position of the mode selector.

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Table 4-2 Positions of the mode selector

Position Explanation
RUN-P If there are no startup problems or errors and the CPU was able to go into RUN, the CPU
executes the user program or runs with no load. It is possible to access the I/O. The key
cannot be removed in this position.
Programs can:
• Be read out with the programming device from the CPU (CPU programming device)
• Be transferred to the CPU (programming device CPU).
RUN If there are no startup problems or errors and the CPU was able to go into RUN, the CPU
executes the user program or runs with no load. It is possible to access the I/O. The key
can be removed in this position to ensure that the mode cannot be changed without
authorization.
Programs in the CPU can be read out with the programming device (CPU % programming
device).
The program in the CPU cannot be changed when the switch is in the RUN position.
(See STEP 7.) The protection level can be bypassed using a password set in
STEP 7/HWCONFIG (STEP 7 V4.02 and above). In other words, if you use this
password, the program can also be changed when the switch is in the RUN position.
STOP The CPU does not process the user program. The digital signal modules are disabled.
The key can be removed in this position to ensure that the operating mode cannot be
changed without authorization.
Programs can:
• Be read out with the programming device from the CPU (CPU programming device)
• Be transferred to the CPU (programming device CPU).
MRES Momentary-contact position of the key switch for the master reset of the CPU and for cold
(Master restart (see the following pages).
Reset)

Protection Levels
A protection level can be defined in the CPUs of the S7-400 that can be used to
protect the programs in the CPU from unauthorized access. You can determine
with the protection level which programming device functions a user can execute
on the CPU in question without particular authorization (password). You can
execute all the programming device function using a password.

Setting the Protection Levels

You can set the protection levels (1 to 3) for a CPU under STEP 7/Configuring
Hardware.
You can remove the protection level set under STEP 7/Configuring Hardware using
a manual reset with the mode selector.
You can also set protection levels 1 and 2 using the mode selector. Table 4-3 lists
the protection levels of a CPU of the S7-400.

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Table 4-3 Protection levels of a S7-400 CPU

Protection Function Switch Position

Level
1 • All programming device functions are permitted RUN-P/STOP
(default setting).
2 • It is permissible to load objects from the CPU into RUN
programming device. In other words, only read
programming device functions are permitted.
• Functions for process control, process monitoring
and process communication are permitted.
• All information functions are permitted.
3 • Functions for process control, process monitoring –
and process communication are permitted.
• All information functions are permitted.

If different protection levels are set with the mode selector and with STEP 7, the
higher protection level applies (3 before 2, 2 before 1).

Operating Sequence for Memory Reset

Case A: You want to download a complete, new user program to the CPU.
1. Turn the switch to the STOP setting.
Result: The STOP LED lights up.
2. Turn the switch to MRES, and keep it in this position.
Result: The STOP LED is dark for a second, light for a second, dark for a
second and then remains on.
3. Turn the switch back to STOP, and then within the next 3 seconds turn it back
to MRES and then back to STOP.
Result: The STOP LED flashes for at least 3 seconds at 2 Hz (memory reset is
executed) and then lights up continuously
Case B: When the STOP LED flashes slowly at 0.5 Hz, the CPU is requesting
a memory reset (system memory reset request, after a memory card has
been removed or inserted, for example).
Turn the switch to MRES and back to the STOP position.
Result: The STOP LED flashes for at least 3 seconds at 2 Hz (a memory reset
is executed) and then lights up continuously.
You can find the complete description of what happens during a memory reset in
the: S7-400, M7-400 Programmable Controllers Installation Manual, Chapter 6.

Cold Restart
Following a cold restart, the user program starts from the beginning again. All the
data, including the retentive data, are deleted.

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Reboot (Warm Restart)

Following a reboot, the user program is restarted from the beginning. The retentive
data and the contents of the data blocks are retained.

Operation Sequence for Reboot/Warm Start

1. Turn the switch to the STOP setting.
Result: The STOP LED lights up.
2. Turn the switch to the RUN/RUNP position.

Operating Sequence at Cold Restart

1. Turn the switch to the STOP setting.
Result: The STOP LED lights up.
2. Turn the switch to MRES, and keep it in this position.
Result: The STOP LED is dark for a second, light for a second, dark for a
second and then remains on.
3. Turn the switch to the RUN/RUNP position.

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Failure and Replacement of Components During Operation

10.1 Failure and Replacement of Components in Central

Racks and Expansion Racks

Which components can be replaced?

The following components can be replaced during operation:
• central processing units – for example, CPU 417-4H
• power supply modules – for example, PS 405 and PS 407
• signal and function modules
• communication processors
• synchronization submodules and fiber-optic cables
• interface modules – for example, IM 460 and IM 461

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10.1.1 Failure and Replacement of a Central Processing Unit

(Fault-Tolerant CPU)

Complete replacement of the CPU is not always necessary. If the failure affects
only the load memory, all you have to do is replace the memory card concerned.
Both cases are described below.

Starting situation for replacement of the complete CPU

Failure How Does the System React?

The S7-400H is in redundant system mode • Partner CPU switches to single mode.
and a CPU fails. • Partner CPU reports the event in the
diagnostics buffer and via OB 72.

Requirements for a replacement

The module replacement described below is possible only if the “new” central
processing unit
• has the same operating system version as the failed CPU and
• the same main memory and load memory as the failed CPU.

Notice
New CPUs are always delivered with the latest operating system version. To be
able to use this type of CPU as a replacement module, you must create an
operating system update card for the operating system version of the failed CPU
and use it to transfer the operating system to the replacement CPU.

Procedure
To change a central processing unit, perform the following steps:

Step What Has To Be Done? How Does the System React?

1 Turn off the power supply module. • Entire subsystem is turned off
(system operating in single mode).
2 Replace the central processing unit. -
3 Plug in the synchronization -
submodules. Make sure the rack
number is set correctly.
4 Plug in the fiber-optic cable connections -
of the synchronization submodules.

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Failure and Replacement of Components During Operation

Step What Has To Be Done? How Does the System React?

5 Switch the power supply module on • CPU executes the self-tests and
again. goes to STOP.
6 Perform Memory Reset on the replaced -
CPU.
7 Start the replaced CPU (e.g. • CPU performs automatic LINK-UP
STOP³RUN or Start via programming and UPDATE.
device). • CPU changes to RUN and
operates as the standby CPU.

Starting situation for replacement of the load memory

Failure How Does the System React?

The S7-400H is in redundant system mode • Affected CPU switches to STOP and
and an error access to the load memory makes a reset request.
is executed. • Partner CPU switches to single mode.

Procedure
To change the load memory, perform the following steps:

Step What Has To Be Done? How Does the System React?

1 Change the memory card on the -
stopped CPU.
2 Perform a reset on the CPU with the -
replaced memory card.
3 Start the CPU. • CPU performs automatic LINK-UP
and UPDATE.
• CPU changes to RUN and
operates as the standby CPU.

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10.1.2 Failure and Replacement of a Power Supply Module

Initial situation
Both central processing units are at RUN.

Failure How Does the System React?

The S7-400H is in redundant system mode • Partner CPU switches to single mode.
and one power supply module fails. • Partner CPU reports the event in the
diagnostics buffer and via OB 72.

Procedure
To change a power supply module in the central rack, perform the following steps:

Step What Has To Be Done? How Does the System React?

1 Turn off the power supply (24 V DC for • Entire subsystem is turned off
PS 405 or 120/230 V AC for PS 407). (system operating in single mode).
2 Replace the module. -
3 Switch the power supply module on • CPU executes the self-tests.
again. • CPU performs automatic LINK-UP
and UPDATE.
• CPU changes to RUN (Redundant
system mode) and now operates
as the standby CPU.

Note
If you use a redundant power supply (PS 407 10A R), two power supply modules
are assigned to one fault-tolerant CPU. If a part of the redundant PS 407 10A R
power supply module fails, the corresponding CPU keeps on running. The
defective part can be replaced during operation.

Other power supply modules

If the failure concerns a power supply module outside the central rack (e.g. in the
expansion rack or in the I/O device) the failure is reported as a rack failure (central)
or station failure (remote). In this case, simply switch off the power supply to the
power supply module concerned.

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Failure and Replacement of Components During Operation

10.1.3 Failure and Replacement of an Input/Output or Function Module

Initial situation

Failure How Does the System React?

The S7-400H is in redundant system mode • Both CPUs report the event in the
and an input/output or function module fails. diagnostics buffer and via appropriate
OBs.

Procedure
To replace signal and function modules (central or remote), perform the following
steps:

Step What Has To Be Done? How Does the System React?

1 Disconnect the wiring. • Call OB 82 if the module
concerned is
diagnosis-interruptible and
diagnostics interrupts are released
via the configuration.
– Call OB 122 if you are
accessing the module by direct
access
– Call OB 85 if you are accessing
the module by means of the
process image
2 Extract the failed module (in RUN • Both CPUs process the
mode). insert/remove-module interrupt
OB 83 in synchronism.
3 Insert the new module. • Both CPUs process the
insert/remove-module interrupt
OB 83 in synchronism.
• Parameters are assigned
automatically to the module by the
CPU concerned and the module is
addressed again.
4 Connect the wiring. Call OB 82 if the module concerned is
diagnosis-interruptible and diagnostics
interrupts are released via the
configuration.

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10.1.4 Failure and Replacement of a Communication Processor

This section describes the failure and replacement of communication processors

for the PROFIBUS and Industrial Ethernets.
The failure and replacement of communication processors for the PROFIBUS-DP
are described in Section 10.2.1

Initial situation

Failure How Does the System React?

The S7-400H is in redundant system mode • Both CPUs report the event in the
and one communication processor fails. diagnostics buffer and via appropriate
OBs.
• With communications via standard
connections
Connection failed
• With communications via redundant
connections
Communications are maintained without
interruption over an alternative channel.

Procedure
To replace a communication processor for a PROFIBUS or an industrial Ethernet,
perform the following steps:

Step What Has To Be Done? How Does the System React?

1 Extract the module. Both CPUs process the
insert/remove-module interrupt OB 83
in synchronism.
2 Make sure that the new module has no • Both CPUs process the
parameter data in its integrated insert/remove-module interrupt
FLASH EPROM and plug it in. OB 83 in synchronism.
• The module is automatically
configured by the appropriate
CPU.
3 Turn the module back on. The module resumes communications
(system establishes communication
connection automatically).

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Failure and Replacement of Components During Operation

10.1.5 Failure and Replacement of a Synchronization Submodule or

Fiber-Optic Cable

In this section three different error scenarios are to be differentiated:

• Failure of a synchronization submodule or fiber-optic cable
• Successive failure of the two synchronization submodules or fiber-optic cables
• Simultaneous failure of the two synchronization submodules or fiber-optic
cables

Initial situation

Failure How Does the System React?

Failure of a Fiber–Optic or Synchronization • Master CPU reports the event in the
Module: diagnostics buffer and via OB 72.
The S7-400H is in redundant system mode • Master CPU remains in RUN mode;
and a fiber-optic cable or a synchronization standby CPU goes into STOP
submodule fails.

Procedure
To replace a synchronization submodule or fiber-optic cable, perform the following
steps:

Step What Has To Be Done? How Does the System React?

1 Replace the fiber-optic cable first. 1) -
2 Start the standby CPU (e.g. The following reactions are possible:
STOP³RUN or Start via programming 1. CPU goes into RUN mode.
device).
2. CPU goes into STOP mode. In this
case continue with step 3.
3 Unplug the faulty synchronization -
submodule from the standby CPU. To
do so, screw the threaded pin in the
additional front panel of the
synchronization submodule into the
thread of the module.
4 Insert the new synchronization -
submodule in the standby CPU.1) Make
sure the rack number is set correctly.
5 Plug in the fiber-optic cable connections -
of the synchronization submodules.
6 Start the standby CPU (e.g. The following reactions are possible:
STOP³RUN or Start via programming 1. CPU goes into RUN mode.
device).
2. CPU goes into STOP mode. In this
case continue with step 7.

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Step What Has To Be Done? How Does the System React?

7 If in step 6 the standby CPU has gone • Master CPU executes
to STOP: insert/remove-module interrupt
Extract the synchronization submodule OB 83 and redundancy error
from the master CPU. OB 72 (incoming).

8 Plug the new synchronization • Master CPU executes

submodule into the master CPU. Make insert/remove-module interrupt
sure the rack number is set correctly. OB 83 and redundancy error
OB 72 (outgoing).
9 Plug in the fiber-optic cable connections -
of the synchronization submodules.
10 Start the standby CPU (e.g. • CPU performs automatic LINK-UP
STOP³RUN or Start via programming and UPDATE.
device). • CPU changes to RUN (Redundant
system mode) and now operates
as the standby CPU.

1) The CPU displays by means of LEDs and by means of the diagnosis whether the lower or
upper redundant link has failed. After the defective parts (fiber-optic cable or
synchronization submodule) have been replaced, LEDs IFM1F and IFM2F go out. Not until
then can you perform the next step.

Note
If both fiber-optic cables or synchronization submodules are successively
damaged or replaced the system reactions are the same as described above.
The only exception is that the standby CPU does not go to STOP mode but
instead requests a reset.

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Failure and Replacement of Components During Operation

Initial situation

Failure How Does the System React?

Simultaneous Failure of a Fiber–Optic or • Both CPUs report the event in the
Synchronization Module: diagnostics buffer and via OB 72.
The S7-400H is in redundant system mode • Both CPUs become the master CPU and
and both fiber-optic cables or remain in RUN mode.
synchronization submodules fail.

Procedure
The double error described results in loss of redundancy. In this event proceed as
follows:

Step What Has To Be Done? How Does the System React?

1 Switch off a subsystem. -
2 Replace the faulty components. -
3 Turn the subsystem back on. LEDs IFM1F and IFMF2F go out. The
standby LED lights.
4 Start the CPU (e.g. STOP³RUN or • CPU performs automatic LINK-UP
Start via programming device). and UPDATE.
• CPU changes to RUN (Redundant
system mode) and now operates
as the standby CPU.

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10.1.6 Failure and Replacement of an IM 460 and IM 461 Interface

Module

The IM 460 and IM 461 interface modules make it possible to connect expansion
racks.

Initial situation

Failure How Does the System React?

The S7-400H is in redundant system mode • Connected expansion unit is turned off.
and one interface module fails. • Both CPUs report the event in the
diagnostics buffer and via OB 86.

Procedure
To change an interface module, perform the following steps:

Step What Has To Be Done? How Does the System React?

1 Turn off the power supply of the central • The partner CPU switches to
rack. single mode.
2 Turn off the power supply of the -
expansion unit in which you want to
replace the interface module.
3 Extract the interface module. -
4 Insert the new interface module and -
turn the power supply of the expansion
unit back on.
5 Switch the power supply of the central • CPU performs automatic LINK-UP
rack back on and start the CPU. and UPDATE.
• CPU changes to RUN and
operates as the standby CPU.

Automation System S7-400H Fault-tolerant Systems

A5E00068197-08 10-11
Failure and Replacement of Components During Operation

10.2 Failure and Replacement of Components of the

Distributed I/O

Which components can be replaced?

The following components of the distributed I/O can be replaced during operation:
• PROFIBUS-DP master
• PROFIBUS-DP interface module (IM 153-2 or IM 157)
• PROFIBUS-DP slave
• PROFIBUS-DP cable

Note
Replacement of I/O and function modules located in remote stations is described
in Section 10.1.3.

Automation System S7-400H Fault-tolerant Systems

10-12 A5E00068197-08
 Failure and Replacement of Components During Operation

10.2.1 Failure and Replacement of a PROFIBUS-DP Master

Initial situation

Failure How Does the System React?

The S7-400H is in redundant system mode • With single-channel, one-way I/O:
and one DP master module fails. DP master can no longer process
connected DP slaves.
• With switched I/O:
DP slaves are addressed via the DP
master of the partner.

Procedure
To replace a PROFIBUS-DP master, perform the following steps:

Step What Has To Be Done? How Does the System React?

1 Turn off the power supply of the central The fault-tolerant system goes to
rack. single mode.
2 Unplug the DP Profibus cable for the -
affected DP master module.
3 Replace the affected module. -
4 Plug in the DP Profibus cable again. -
5 Turn on the power supply of the • CPU performs automatic LINK-UP
central rack. and UPDATE.
• CPU changes to RUN and
operates as the standby CPU.

Automation System S7-400H Fault-tolerant Systems

A5E00068197-08 10-13
Failure and Replacement of Components During Operation

10.2.2 Failure and Replacement of a Redundant PROFIBUS-DP

Interface Module

Initial situation

Failure How Does the System React?

The S7-400H is in redundant system mode Both CPUs report the event in the
and a PROFIBUS-DP interface module diagnostics buffer and via OB 70.
(IM 153-2, IM 157) fails.

Replacement procedure
To replace PROFIBUS-DP interface module, perform the following steps:

Step What Has To Be Done? How Does the System React?

1 Turn off the supply for the affected DP -
interface module.
2 Unplug the connected bus connector. -
3 Insert the new DP Profibus interface -
module and turn the supply back on.
4 Plug the bus connector back on. • CPUs process the mounting rack
failure OB 70 in synchronism
(outgoing event).
• Redundant access to the station is
again possible for the system.

Automation System S7-400H Fault-tolerant Systems

10-14 A5E00068197-08
 Failure and Replacement of Components During Operation

10.2.3 Failure and Replacement of a PROFIBUS-DP Slave

Initial situation

Failure How Does the System React?

The S7-400H is in redundant system mode Both CPUs report the event in the
and one DP slave fails. diagnostics buffer and via the appropriate
OB.

Procedure
To replace a DP slave, perform the following steps:

Step What Has To Be Done? How Does the System React?

1 Turn off the supply for the DP slave. -
2 Unplug the connected bus connector. -
3 Replace the DP slave. -
4 Plug the bus connector on and turn the • CPUs process the mounting rack
supply back on. failure OB 86 in synchronism
(outgoing event).
• DP slave can be addressed by the
relevant DP master system.

Automation System S7-400H Fault-tolerant Systems

A5E00068197-08 10-15
Failure and Replacement of Components During Operation

10.2.4 Failure and Replacement of PROFIBUS-DP Cables

Initial situation

Failure How Does the System React?

The S7-400H is in redundant system mode • With single-channel, one-way I/O:
and the PROFIBUS-DP cable is defective. Rack failure OB (OB 86) is started
(incoming event). DP master can no
longer process connected DP slaves
(station failure).
• With switched I/O:
I/O redundancy error OB (OB 70) is
started (incoming event). DP slaves are
addressed via the DP master of the
partner.

Replacement procedure
To replace PROFIBUS-DP cables, perform the following steps:

Step What Has To Be Done? How Does the System React?

1 Check the wiring and localize the -
interrupted PROFIBUS-DP cable.
2 Replace the defective cable. -
3 Switch the failed modules to RUN. CPUs process error OBs in synchronism
• With one-way I/O:
Mounting rack failure OB 86 (outgoing
event)
DP slaves can be addressed via the
DP master system.
• With switched I/O:
I/O redundancy error OB70 (outgoing
event).
DP slaves can be addressed via both
DP master systems.

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10-16 A5E00068197-08
 Displays and Mode Selector

7 Displays and Mode Selector

LED Displays
The CP 443-1 has 9 display elements on the front panel to display the CP state
and the communication state:

INT
EXTF
FDX
LINK
TXD
RXD
FAST

RUN
STOP

CP Operating Mode

INTF LED EXTF LED RUN LED STOP LED CP Operating Mode
(red) (red) (green) (yellow)
Starting up (STOP->RUN)

Running (RUN)

Stopping (RUN->STOP)

Stopped (STOP)
In the STOP mode configuring and performing
diagnostics on the CP remain possible.
STOP with internal error or memory reset.
In this state, the CPU or intelligent modules in
the rack remain accessible using PG functions.
STOP with external error

Waiting for firmware update (CP currently has

an incomplete or incorrect firmware version)
Ready for firmware loading (this mode is active
for ten seconds following power up when the
mode selector is set to STOP)
Legend: lit off flashing

S7 CPs for Industrial Ethernet Manual / Part B4 – CP 443-1

C79000-G8976-C152–04 B4–19
Displays and Mode Selector

CP Communication State
In addition to the LEDs that signal the CP state, the front panel also includes LEDs
that provide information about the status of the CP interface to Industrial Ethernet.

Table 7-1

LED Meaning (LED on)

FDX LED (green) Signals an existing full duplex connection
LINK LED (green) Signals an existing connection to ITP/TP
TXD LED (green) Flashing: The CP is transmitting via AUI / ITP
RXD LED (green) Flashing: The CP is receiving via AUI / ITP
FAST LED (green) Signals an existing connection to ITP/TP at 100 Mbps (Fast Ethernet)
Flashing: the CP is in the “Autosensing/Autonegotiation” phase; see
also Section 9.2.

Note
Read the explanations of the operating modes in the NCM S7 for Industrial
Ethernet manual LEERER MERKER.

Controlling the Operating Mode

You can control the mode of the CP 443-1 as follows:
S Mode selector
S NCM S7 configuration software
S SIMATIC Manager in STEP 7
To control the mode from STEP 7 / NCM S7, the mode selector must be set to
RUN.

S7 CPs for Industrial Ethernet Manual / Part B4 – CP 443-1

B4–20 C79000-G8976-C152–04
 Displays and Mode Selector

Mode Selector
With the mode selector, you can set the following modes:
S Switch from STOP to RUN:
The CP reads the configured and/or downloaded data into the work memory
and then changes to the RUN mode.
S Switch from RUN to STOP:
The CP changes to STOP with the following results:
– Established connections (ISO transport, ISO-on-TCP, TCP connections) are
terminated (transitional phase with LED display “STOPPING”);
In the STOP mode:
– all connections are terminated
– configuration and diagnostics are possible
– the time of day is passed on (time-of-day frames are passed on by
Industrial Ethernet to the CPU only via the communication bus).

Note
If you plug in the CP with the mode selector set to STOP or turn on the power
supply, the display “Firmware Download” appears for approximately 10 seconds.
When necessary, this function also allows the current firmware version to be
downloaded. In normal operation, you can ignore this display and switch to RUN
immediately.
For more information on downloading new firmware, refer to Section 10.

Note
Refer to the explanations in the manual LEERER MERKER on the topic of loading
the database on the CP.

S7 CPs for Industrial Ethernet Manual / Part B4 – CP 443-1

C79000-G8976-C152–04 B4–21
Performance Data

8 Performance Data

8.1 General Characteristics

Table 8-1

Characteristic Explanation / Values

Total number of connections on Industrial Ethernet 64 max.

Example
You can operate:
7 x S7 connections
2 x ISO-on-TCP connections
25 x TCP connections
25 x UDP connections
5 x ISO transport connections

8.2 S7 Communication
The functions and characteristics of S7 communication are described in
LEERER MERKER and LEERER MERKER. Note the following restrictions:

Table 8-2

Characteristic Explanation / Values

Number of S7 connections via Industrial Ethernet Maximum 48

LAN interface – data record length per PDU

S sending 480 bytes / PDU
S receiving 480 bytes / PDU

8.3 SEND/RECEIVE Interface

SEND/RECEIVE can be operated via TCP, ISO-on-TCP, ISO transport and via
UDP connections. The following characteristics are important:

S7 CPs for Industrial Ethernet Manual / Part B4 – CP 443-1

B4–22 C79000-G8976-C152–04
Installing and Removing the FM 350-2 3
What Does this This chapter contains information on installing and removing the FM 350-2.
Chapter Describe?
S You will learn what you must look out for when installing. You will get
notes and hints on configuring, arranging, and installing an FM 350-2.
S You will learn step by step how to install and remove an FM 350-2.

Chapter Section Description Page

Overview 3.1 Preparing for Installation 3-2
3.2 How to Install and Remove the FM 350-2 3-3

FM 350-2 Counter Function Module

C79000-G7076-C353-01 3-1
Installing and Removing the FM 350-2

3.1 Preparing for Installation

Defining the Slots The FM 350-2 function module can be inserted in any slot just as any signal
module.

Mechanical Manual /70/ describes the possibilities open to you for mechanical
Configuration installation and how to proceed when configuring. The following paragraphs
give only a few supplementary tips.
1. A maximum of eight signal modules (SM) or function modules (FM) are
permitted per rack.
2. The maximum number is restricted by the width of the modules or the
length of your DIN rail. The FM 350-2 requires an installation width of
80 mm.
3. The maximum number is restricted by the total current consumptions of
all modules to the right of the CPU from the 5-V backplane bus supply.
The current consumption of the FM 350-2 is 100 mA.
4. The maximum number is restricted by the memory required by the CPU
software for communication with the FM 350-2.

Vertical or Horizontal arrangement is preferable. For vertical arrangement, you must

Horizontal observe the restricted ambient temperatures (max. 40° C).
Arrangement

Determining the The start address of the FM 350-2 is required for communications between
Start Address the CPU and the FM 350-2. The start address is entered in the counter DB
(see Chapters 6 and 10). The entry is made either with the help of the
Program Editor or in the parameter assignment dialog boxes.
You can determine the start address of the FM 350-2 in accordance with the
same rules used to determine the start address of an analog module.

Fixed Addressing In the case of fixed addressing, the start address depends on the slot. Refer to
the tables in manual /70/ for the start address of an analog module in the
various slots.
You can also calculate this fixed start address using the following formula:
Address = 256 + (mounting rack no. * 128) + (slot no. – 4) * 16

Free Addressing With free addressing, you specify the start address of the module using
STEP 7.

Important Safety There are important regulations you must observe for integrating an S7-300
Regulations with an FM 350-2 into a plant or a system. These rules and regulations are
explained in manual /70/.

FM 350-2 Counter Function Module

3-2 C79000-G7076-C353-01
 Installing and Removing the FM 350-2

3.2 How to Install and Remove the FM 350-2

Rules No special protection measures (ESD guidelines) are required for installing
an FM 350-2.

Tools Required You require a 4.5 mm screwdriver for installing and removing the FM 350-2.

Installation Below is a description of how to proceed when installing the FM 350-2 on

Procedure the DIN rail. You will find further information on installing modules in
manual /70/.
1. Switch the CPU to STOP.
2. The FM 350-2 is supplied with an expansion bus. Plug this into the bus
connector of the module to the left of the FM 350-2. (The bus connector
is located on the back and you may have to loosen the neighboring
module.)
3. Hook the FM 350-2 onto the rail and swing it down.
4. If further modules are to be installed to the right of the FM 350-2, first
connect the expansion bus of the next module to the right-hand backplane
bus connector of the FM 350-2.
If the FM 350-2 is the last module in the rack, do not connect an
expansion bus.
Tighten the screw on the FM 350-2 (tightening torque approximately 0.8
to 1.1 Nm).
5. Label the FM 350-2 with its slot number. Use the number wheel supplied
with the CPU for this purpose.
Manual /70/ describes the numbering scheme you must use and how to
connect the slot numbers.
6. Install the shield attachment.
You can order the shield attachment under the order number
6ES7 390-5AA00-0AA0.

FM 350-2 Counter Function Module

C79000-G7076-C353-01 3-3
Installing and Removing the FM 350-2

Procedure for Below is a description of how to remove the FM 350-2. You will find further
Removing or information on removing modules in manual /70/.
Exchanging
1. Switch off the auxiliary voltage and the load voltage at the front
Modules
connector.
2. Switch the CPU to STOP.
If you are running the FM 350-2 in an active backplane bus you can also
exchange the module while the CPU is in RUN.
3. Open the front panel. If necessary, remove the labeling strip.
4. Unscrew the fixing screw for the front connector and remove the front
connector.
5. Unscrew the fixing screw on the module.
6. Swing the module out of the DIN rail and unhook it.
7. Install the new module if applicable.

Further Manual /70/ contains further information on installing and removing

Information modules.

FM 350-2 Counter Function Module

3-4 C79000-G7076-C353-01
 Product Overview

Front View of the IM 153-1 and -2

Front door closed Front door open

... with fiber-optic
... with RS 485 interface cable interface
(IM 153-2 FO only)
PROFI- PROFI-
BUS-DP Status and fault BUS-DP
SF SIEMENS SF LEDs SF
BF BF BF
ACT ACT PROFIBUS-DP ACT
ON Door ON interface: ON
9-pin socket
or
fiber-optic cable
connection
SIMATIC Cable pit
ET 200M ON ON
64 64
32 Setting the 32
16 PROFIBUS 16
IM 153-2 8 8
4 address 4
Slot
2 2
1 1
Jumper
(removable)
Version
Terminals for
M M
L
power supply and
L
2 X 2 Order M functional ground M
3 4 + +
153-2AA02-0XB0 Number 24 V DC 24 V DC

LED ACT in IM 153-2 only

Figure 1-3 Front View of the IM 153-1 and IM 153-2

ET 200M Distributed I/O Device

EWA 4NEB 780 6006-02 03 1-9
Product Overview

Front View of the IM 153-3

Front door closed Front door open

PROFIBUS-
SF SIEMENS DP
Door
BF1 SF
DP1 BF1
BF2 DP1 PROFIBUS PROFIBUS
DP2 MODULE MODULE
BF2 Handle
ON DP2
ON

SIMATIC ON
ET 200M 64
32
16 m
8
4
IM 153-3 2
1
m+1
Installa-
tion
location MLFB
PROFIBUS
M module
X 2 L
2 3 4 M
153-3AA00-0XB0
+
24 V DC

Order number Version PROFIBUS module version

Figure 1-4 Front View of the IM 153-3

ET 200M Distributed I/O Device

1-10 EWA 4NEB 780 6006-02 03
Installation

Bending Radius for the Fiber-Optic Cable

Make sure when you wire the fiber-optic duplex cable cores and insert them into
the plug-in adapter, that the permissible bending radius of 30 mm is not exceeded.
See also the installation guidelines on fiber-optic cables in the ET 200M Distributed
I/O Device manual or the SIMATIC NET PROFIBUS Networks manual.

3.5 Setting the PROFIBUS Address

Definition
Each bus node must receive a PROFIBUS address to uniquely identify it on the
PROFIBUS-DP bus system.

Rules
Observe the following rules for the PROFIBUS addresses of the IM 153-x:
S Permissible PROFIBUS address are: 1 to 125.
Are you using the IM 153-3? If so, then you can set the same or different
PROFIBUS addresses for both PROFIBUS modules. In the case of different
PROFIBUS addresses, the PROFIBUS module 2 is given the PROFIBUS
address of the PROFIBUS module +1.
S Each PROFIBUS address can only be assigned once on the bus.

ET 200M Distributed I/O Device

3-20 EWA 4NEB 780 6006-02 03
 Installation

Setting the PROFIBUS Address

Set the PROFIBUS address using a screwdriver and with the door open.
The PROFIBUS address is the addition of the switches that are on the right
(”ON” position).
IM 153-3: If you want to assign different addresses to the PROFIBUS modules, put
switch m+1 into the ON position. PROFIBUS module 1 then has the PROFIBUS
address m, and PROFIBUS module 2 has the PROFIBUS address m+1.

IM 153-1/-2 IM 153-3

Bus
ADDRESS
ON ON
64 64
32 32 Bus
16 16 ADDRESS
8 8 m
Module 1
4 4
2 2
1 1 Bus
m+1 ADDRESS
Module 2

M M
L+ L+
M M
24 V DC 24 V DC

PROFIBUS PROFIBUS PROFIBUS

address = address m = address m+1 =
64 64 64
+ 32 + 32 + 32
+2 +2 +2
+1 +1 +1
+1
= 99 = 99 = 100

Figure 3-9 Setting the PROFIBUS Address

Changing the PROFIBUS Address

You can change the set PROFIBUS address at any time. The IM 153-x will accept
the changed PROFIBUS address once the DC 24 V supply has been turned off
and on again.

ET 200M Distributed I/O Device

EWA 4NEB 780 6006-02 03 3-21
Maintenance 6
Maintenance
The ET 200M is a maintenance-free DP slave.

In This Chapter
In this chapter you will find out how to replace modules or components.

Section Subject Page

6.1 Replacing the Power Supply Module 6-1
6.2 Replacing the IM 153-1 6-3
6.3 Replacing the IM 153-2 or IM 153-2 FO 6-4
6.4 IM 153-3: Replacing the PROFIBUS Module 6-7
6.5 Replacing Modules Without the ”Module Change During Operation” 6-9
Function
6.6 Replacing Modules With the ”Module Change During Operation” 6-11
Function
6.7 Replacing the Bus Module 6-14
6.8 Replacing Fuses in the Case of Digital Output Modules 6-15

6.1 Replacing the Power Supply Module

Initial Situation
The power supply module you want to replace is installed and wired. You want to
install a new power supply module of the same type.

Slot Numbering
If you have given slot numbers to the power supply modules in your system, you
must remove the numbering from the old power supply module when you replace
the module and then use them for the new power supply module.

ET 200M Distributed I/O Device

EWA 4NEB 780 6006-02 03 6-1
Maintenance

Removing the Power Supply Module

To remove the power supply module, proceed as follows:
1. Operate the supply isolating switch in order to deenergize the power supply
module.
2. Remove the cover.
3. Disconnect all the wiring.
4. Undo the fixing screws of the power supply module.
5. Swing the power supply module out.

Installing the New Power Supply Module

To Install the new power supply module, proceed as follows:
1. Check the voltage selector.
2. Hook the new power supply module of the same type onto the rail and swing it
down into place.
3. Screw the power supply module on securely.
4. Wire the power supply module.
5. Connect the power supply module to the line voltage.
6. Close the cover.

Response of the ET 200M After Module Replacement

If there is an error after the power supply modules have been replaced, you can
have the cause displayed in the diagnostic buffer with STEP 5 or with STEP 7.

ET 200M Distributed I/O Device

6-2 EWA 4NEB 780 6006-02 03
 Maintenance

6.2 Replacing the IM 153-1

Initial Situation
The IM 153-1 is installed. You want to install a new IM 153-1 of the same type.

Slot Numbering
If you have given slot numbers to the modules in your system, you must remove
the numbering from the old module when you replace the module and use it on the
new module.

Disconnecting the Bus Connector

With a looped-through interconnecting cable you can unplug the bus connector
from the PROFIBUS-DP interface without interrupting data traffic on the network.

Note
A data communication error may occur on the network.
A network segment must always be terminated at both ends with the terminating
resistor. This is not the case, for example, if the power supply is not activated on
the last slave with a bus connector. The efficacy of the terminating resistor is
impaired because the terminating resistor in the bus connector gets its voltage
from the node.
Please make sure that power is always supplied to nodes on which the terminating
resistor is active. Tip: You can use the PROFIBUS terminator as an active bus
terminating element.

Removing a Module
To remove the module, proceed as follows:

1. Put the on/off switch of the power supply module in the 0 position ( :output
voltage 0 V).
2. Remove the bus connector.
3. Disconnect the wiring.
4. Remove the fixing screws of the IM 153-1.
5. Swing the IM 153-1 out.

ET 200M Distributed I/O Device

EWA 4NEB 780 6006-02 03 6-3
Maintenance

Installing a New Module

Install the new module as follows:
1. Set the same DP address on this IM 153-1 as for the old IM 153-1.
2. Hook the new IM 153-1 onto the rail and swing it down into place.
3. Screw the module on securely.
4. Wire the IM 153-1.
5. Screw the bus connector tight.
6. Put the standby switch of the power supply module into the 1 position (output
voltages to rated value).

Response of the ET 200M After Module Replacement

If there is an error after the modules have been replaced, you can have the cause
displayed in the diagnostic buffer with STEP 5 or STEP 7.

6.3 Replacing the IM 153-2 or IM 153-2 FO

Initial Situation
The IM 153-2/-2 FO is installed. You want to install a new IM 153-2/-2 FO of the
same type.

Slot Numbering
If you have given slot numbers to the modules in your system, you must remove
the numbering from the old module when you replace the module and use it on the
new module.

ET 200M Distributed I/O Device

6-4 EWA 4NEB 780 6006-02 03
 Maintenance

IM 153-2: Removing the Bus Connector

With a looped-through interconnecting cable you can unplug the bus connector
from the PROFIBUS-DP interface without interrupting data traffic on the network.

Note
A data communication error may occur on the network.
A network segment must always be terminated at both ends with the terminating
resistor. This is not the case, for example, if the power supply is not activated on
the last slave with a bus connector. The efficacy of the terminating resistor is
impaired because the terminating resistor in the bus connector gets its voltage
from the node.
Please make sure that power is always supplied to nodes on which the terminating
resistor is active. Tip: You can use the PROFIBUS terminator as an active bus
terminating element.

IM 153-2 FO: Removing the Fiber-Optic Cable

If you remove the fiber-optic cable from the IM 153-2 FO, all the following DP
slaves will also no longer be accessible to the DP master.

Caution
! Do not look directly into the opening of the optical sender diodes.
The light beam could damage your eyes.

In the Case of Redundancy:

If you replace the IM 153-2/-2 FO in a redundant configuration, the following
applies:

“ACT” LED is on: “ACT” LED is off:

The IM 153-2/-2 FO is the active one of the The IM 153-2/-2 FO is the passive one of
two IM 153-2/-2 FO modules. the two IM 153-2/-2 FO modules.
You can replace these IM 153-2/-2 FO
modules without the need for switchover
operations in the ET 200M.

ET 200M Distributed I/O Device

EWA 4NEB 780 6006-02 03 6-5
Maintenance

Removing a Module
To remove the module, proceed as follows:
1. In the case of redundancy: The IM 153-2/-2 FO to be replaced must be
deenergized! Switch off the associated power supply module or disconnect it
from the IM 153-2/-2 FO.
No redundancy:Put the on/off switch of the power supply module into the 0
position ( :output voltage 0 V).
2. Remove the bus connector or fiber-optic cable.
In the case of fiber-optic cables: Flip open the grip of the plug-in adapter and
remove it from the IM 153-2 FO.
3. Disconnect the wiring.
4. Remove the fixing screws of the IM 153-2/-2 FO.
5. Swing the IM 153-2/-2 FO out.

Installing a New Module

Install the new module as follows:
1. Set the same DP address on this IM 153-2/-2 FO as for the old IM 153-2/-2 FO.
2. Hook the new IM 153-1/-2 FO onto the rail and swing it down into place.
3. Screw the module on securely.
4. Wire the IM 153-2/-2 FO.
5. Screw the bus connector on securely.
6. Put the standby switch of the power supply module into the 1 position (output
voltages to rated value).

ET 200M Distributed I/O Device

6-6 EWA 4NEB 780 6006-02 03
 Maintenance

Response of the ET 200M After Module Replacement

If there is an error after the modules have been replaced, you can have the cause
displayed in the diagnostic buffer with STEP 5 or STEP 7.

In the Case of Redundancy:

Have you replaced an active IM 153-2/-2 FO Have you replaced a passive IM 153-2/-2 FO
(”ACT” LED on)? (”ACT” LED off)?
A switchover took place in the ET 200M to the No change in data traffic: It continues between the
other IM 153-2/-2 FO, and data traffic continues active IM 153-2/-2 FO and its DP master.
between it and its DP master.
Has the new IM 153-2/-2 FO got a different version to the one that wasn’t replaced?
If you switch to the new IM 153-2/-2 FO after replacement, and the new IM 153-2/-2 FO takes over the
data traffic to the DP master while the other IM 153-2/-2 FO “goes into ”STOP” mode (all the LEDs flash),
then you must upgrade the IM 153-2/-2 FO that was not replaced to the same version.
Contact your Siemens contact.

6.4 IM 153-3: Replacing the PROFIBUS Module

Initial Situation
It is possible to replace PROFIBUS modules while the ET 200M is in operation.
The IM 153-3 is installed and both PROFIBUS modules are inserted. Data transfer
occurs via at least one of the two PROFIBUS modules to the associated DP
master.

What to Look Out for Beforehand:

Are you replacing a defective PROFIBUS module? If so, then data transfer will
continue via the active PROFIBUS module.
Are you replacing an active PROFIBUS module, and the passive PROFIBUS
module is OK? If so, the IM 153-3 switches from the active PROFIBUS module to
the passive one when the module is replaced.
Are you replacing an active PROFIBUS module, and the passive PROFIBUS
module is defective? If so, you must interrupt data transfer to the DP master!
You can tell whether the PROFIBUS module is active or passive by the status
indicators of the IM 153-3 (see Section 5.2).

ET 200M Distributed I/O Device

EWA 4NEB 780 6006-02 03 6-7
Maintenance

Removing the PROFIBUS Module

To remove one of the two PROFIBUS modules, proceed as follows:
1. Remove the bus connector.
2. Undo the lower fixing screw of the PROFIBUS module.
3. Push the front cover of the PROFIBUS module down using both of the handles.
4. Undo the upper fixing screw of the PROFIBUS module.
5. Remove the PROFIBUS module from the IM 153-3.

Inserting a PROFIBUS Module.

To insert a PROFIBUS module, proceed as follows:
1. Push the PROFIBUS module into the IM 153-3.
2. Tighten the upper fixing screw of the PROFIBUS module (with a torque of
50 Ncm).
3. Push the front cover of the PROFIBUS module upwards.
4. You can now tighten the lower fixing screw of the PROFIBUS module (with a
torque of 50 Ncm).
5. Insert the bus connector and screw it tight.

Response of the IM 153-3 After Replacement of the PROFIBUS Module

After the PROFIBUS module is replaced, the associated DP master resumes data
transfer. The setting of the outputs and reading of the inputs continues via the
other PROFIBUS module.
If there is an error, you can evaluate the error displays of the IM 153-3 and the
diagnosis (see Section 5.2 and 5.3).

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 Maintenance

6.5 Replacing Modules Without the ”Module Change During

Operation” Function

Removing a Module

Table 6-1 Removing Modules Without ”Module Change During Operation”

Step 20-Pin Front Connector 40-Pin Front Connector

1. Switch off the load voltage to the module.
2. Switch off the power supply for the IM 153-x.
3. Remove the labeling strip from the module.
4. Open the front door.
5. Unlock the front connector and pull it off the module.
To do this, depress the locking Remove the fixing screw from the
button (5) with one hand and, with middle of the front connector. Pull
the other hand, grip the front the front connector out while
connector (5a) at the appropriate holding the grips.
point and pull it out.
6. Undo the module fixing screw(s).
7. Swing the module up and off the rail.

3
5

2
4
ET–0055

5a
6

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Maintenance

Removing the Front Connector Coding Key

Prior to installing the new module, you must remove the front connector coding key
from the new module. Reason: This part is already in the wired front connector
(see Figure 6-1).

Figure 6-1 Removing the Front Connector Coding Key

Installing a New Module

Table 6-2 Installing New Modules

Step Installing a Module

1. Hook the new module of the same type onto the rail and swing it down
into place.
2. Screw the module on securely.
3. Push the labeling strip of the old module into place on the new module.

3
1A
ET–0056

1B
2

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 Maintenance

Putting a New Module into Service

Table 6-3 Putting New Modules into Service

Step Putting a Module into Service

1. Open the front door.
2. Bring the front connector back into its operating position.

ET–0057
2

3. Close the front door.

4. Switch on the power supply for the IM 153-x.
5. Switch the load voltage back on.

Response of the ET 200M After Module Replacement

When you have replaced a module and no errors have occurred, the IM 153-x
starts data transfer. If the IM 153-x stays in STOP mode, you can display the
cause of the error with STEP 5 or STEP 7

6.6 Replacing Modules with the ”Module Change During Operation”

Function

Prerequisites
You can replace the modules during operation of the ET 200M once you have done
the following:
S Installed the ET 200M on the rail with active bus modules for the ”module
change during operation” function.
S Configured the ET 200M for the ”module change during operation” function.

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Maintenance

Warning
! When you insert output modules, uncontrolled system states may occur.
This is also the case when you insert input/output modules at an angle to the bus
modules.
When you insert an output module, the outputs set by the user program
immediately become active.
We recommend that you set the outputs in the user program to ”0” when you
remove an output module.
If modules are removed and inserted incorrectly, neighboring modules may be
affected via the backplane bus.

Removing a Module

Table 6-4 Removing Modules With ”Module Change During Operation”

Step 20-Pin Front Connector 40-Pin Front Connector

1. Undo the module fixing screw(s) of the module.
2. Swing the module up and off the rail.
3. Open the front door.
4. Unlock the front connector and pull it off the module (see the figure in
Table 6-1 on page 6-9).
To do this, depress the locking Remove the fixing screw from the
button (4) with one hand and, with middle of the front connector. Pull
the other hand, grip the front the front connector out while
connector (4a) at the appropriate holding the grips.
point and pull it out.
5. Remove the labeling strip from the module.

Removing the Front Connector Coding Key

Prior to installing the new module, you must remove the front connector coding key
from the new module. Reason: This part is already in the wired front connector
(see Figure 6-1, page 6-10).

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 Maintenance

Installing a New Module

Table 6-5 Installing New Modules

Step Installing a Module

1. Insert the front connector into the module and bring it into its operating
position.
2. Hook the new module onto the rail and swing it down into place.
3. Screw the module on securely.
4. Insert the labeling strip of the old module into its place on the new
module.

Response of the ET 200M During Module Replacement

Table 6-6 Response of the ET 200M When Modules Are Removed or Inserted

Remove/ Actual = Response of the ET 200M

Insert Desired
configuration?
Removing a – The IM 153-x reports the removal of a module via the diagnosis. The
module diagnostic event corresponds to the module removal interrupt (see
Section 5.4.9). The IM 153-x also enters the removal of the module in the
module diagnosis (see Chapter 5.4.5).
Inserting a Yes When a configured module is inserted, the IM 153-x deletes the entry in
module the module diagnosis to the effect that the module is no longer addressed
by the IM 153-x. If the ET 200M is in user data mode, the IM 153-x
reports a diagnostic event that corresponds to the module insertion
interrupt (see Section 5.4.9). The inserted module is parameterized in
accordance with the last parameter assignment and is accepted in the
ET 200M.
No The IM 153-x ignores the inserted module.
The IM 153-x reports a diagnostic event corresponding to the module
insertion interrupt (see Section 5.4.9).
The entry concerning the removal of the module remains in the module
diagnosis.

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Maintenance

6.7 Replacing the Bus Module

Removing the Bus Module

Only remove bus modules if they are deenergized!

Table 6-7 Removing the Bus Module

Step Removing a Bus Module

1. Put the on/off switch of the power supply module into the 0 position
( :output voltage 0 V).
2. Remove the modules on the bus module that is be replaced, on all the bus modules on the
right, as well as the module directly to the left.
3. The bus modules are locked together. On the bus module that is to be replaced, press down
the lock of the bus module on the right, and push the bus module(s) on the right to the right.
4. On the bus module on the left, press down the lock of the bus module that is to be replaced
and push this one to the right.
5. Using a screwdriver push the lock down towards the rail.
6. Lift the bus module off the rail. You can also pull the bus module out from the right side of the
rail.

Lock holding the bus Lock holding the

modules together module to the rail

BM IM/PS BM 2 40 BM 1 80

Installing a New Bus Module

Install the new bus module as described in Section 3.2.3.

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 Maintenance

6.8 Changing Fuses in Digital Output Modules

Fuses for Digital Outputs

Fuses are used for the individual channel groups of the digital outputs of the
following digital output modules, to protect these against short circuit:
S SM 322 DO 16 AC120V digital output module
S SM 322 DO 8 AC120/230V digital output module

Replacement Fuses
If you have to change fuses, you can use, for example, the following replacement
fuses:
S Fuse 8 A, 250 V (e. g. Wickmann 19 194-8 A; Schurter SP001.013; Littlefuse
217.008)
S Fuse holder (e. g. Wickmann 19 653)

Position of the Fuses

The digital output modules have 1 fuse per channel group. The fuses are located
at the left side of the digital output module. Figure 6-2 shows you where to find the
fuses on the digital output modules.

Fuses

Figure 6-2 Location of the Fuses on Digital Output Modules

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Maintenance

Changing Fuses
The fuses are located at the left side of the module.
1. Remove the digital output module as described in Section 6.5
2. Remove the fuse holder from the digital output module.
3. Replace the fuse.
4. Screw the fuse holder back into the digital output module.
5. Install the digital output module again (see Section 6.5).

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4.2 Mounting the analog module

Before the actual mounting of the SM331 the module has to be completed
with a front connector and the desired measurement mode of the inputs is
set.
In this section you will learn
• Which components you need
• What are the properties of the analog input module
• What a measuring range module is and how it is set up
• How you mount the already setup module

4.2.1 Components of the SM331

A functional analog module consists of the following components:

• Module SM331 (in our example 6ES7331-7KF02-0AB0)
• 20-pin front connector. There are two different types of front connectors:
▪ With spring contacts (Order number 6ES7392-1BJ00-0AA0)
▪ With screw contacts (Order number 6ES7392-1AJ00-0AA0)

Figure 4-1 Components of the SM331

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 Table 4-2 The scope of delivery of SM331
Components
Module
Labeling strips
Bus connector
2 cable ties (not in the picture) to tie the external wiring

4.2.2 Properties of the analog module

• 8 inputs in 4 channel groups (each group with two inputs of same type)
• Measurement resolution adjustable for each channel group
• User defined measuring mode per channel group:
▪ Voltage
▪ Current
▪ Resistance
▪ Temperature
• Configurable diagnostic interrupt
• Two channels with limit value interrupt (Only channel 0 and channel 2
are configurable)
• Electrically isolated against backplane bus
• Electrically isolated against load voltage (exception: At least one module
is set to position D)
The module is a universal analog module designed for the most commonly
used applications.
The desired measuring mode should be set up directly on the module with
the measuring range modules (see chapter 4.2.3)

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4.2.3 Measuring range modules

The module SM331 has four measuring range modules (one per channel
group). The measuring range modules can be set to 4 different positions
(A, B, C or D). With the set position you determine which transducer can
be connected to the respective channel group.

Measuring mode A-D

Channel group

Position B (voltage) set

for CH6, 7

Measuring range module

Figure 4-2 4 measuring range modules with default setting B (Voltage)

Table 4-3 Positions of the measuring range modules

Position Measurement type
A Thermocouple / Resistance measurement
B Voltage (default setting)
C Current (2-wire transducer)
D Current (4-wire transducer)

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In our example, a sensor with a 4 to 20mA 2-wire transducer is connected
to channel group 1 at input 0.
A 4-wire transducer is connected to channel group 2 at inputs 2 and 3.
Therefore, the first measuring range module should have Position D and
the second should have Position C

Table 4-4 Positioning of the measuring range modules

Graphics Description
With a screwdriver, pull out the two measur-
ing range modules

Turn the measuring range module to the

desired position:

Plug the measuring range module back into

the module

In our example, the module should have the

following positions:

CH0,1: D
CH2,3: C

Note
When you use a 2-wire transducer, the electrical isolation against the load voltage
is lost for all the channels in the module (at least one measuring range module is
set to position D)

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4.2.4 Mounting the SM331 module

After you have prepared the analog module accordingly, mount it to the rail
as well.

Table 4-5 Mounting the SM331 module

Graphics Description
Mounting the SM331:
• Insert the SM331 to the top part of the rail
• Push it all the way left to the CPU
• Push down
• and tighten the screw at the bottom to the rail

Mounting of the front connectors:

• Press the upper release button of the front
terminal block
• Insert the front connector into the module until
it snaps in

Mechanically the sample station is now completely mounted.

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5.2 Wiring the analog module

The wiring of an analog measurement transducer is dependant on its type

and not on the SM331 module.

5.2.1 Current transducer wiring - Principle

Depending on the current transducer you use, you have to modify the wir-
ing of the power supply. We differentiate between the wiring of a 2-wire cur-
rent transducer and a 4-wire current transducer.
Wiring principles of a 2-wire current transducer
This transducer type is supplied with power from the analog input module.

Sensor,
e.g. pressure
L+
sensor
M

2-wire + M+
P transducer
- M-

Lo-
P + M+
ADU gic
2-wire Backpl
transducer - M- ane
bus
M ana

Figure 5-2 Wiring: 2-wire current transducer

Wiring principles of a 4-wire current transducer

Unlike a 2-wire transducer, this transducer has its own power supply.

Sensor,
e.g.pressure
L+
sensor
M

+ M+
P 4-wire
transducer - M-

Lo-
P + M+ ADU gic
- M- Backpla
ne bus

M ana
L+ M

Figure 5-3 Wiring: 4-wire current transducer

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5.2.2 Wiring of the analog module

The wiring of the analog module consists of the following tasks:

• Connection of the power supply (Red cable)
• Connection of the 2-wire current transducer (Green cables)
• Terminate unused channels with a resistor
• Connection of the first 4-wire current transducer (Green cables)
• Connection of the second 4-wire current transducer (Green cables)
• Connection to zero potential and short-circuit the other unused channels
(blue wires)

Figure 5-4 SM331 Front connector wiring

Warning
Possible destruction of the module!
If you connect a defective 4-wire current transducer to an input, which is configured
for a 2-wire transducer, the module might get destroyed.

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 Step by step the tasks necessary for wiring are explained below:

Table 5-2 SM331 Front connector wiring

Graphics Wiring Comments
Open the front flap of the SM331 The connection diagram is printed
on the front flap
Remove 6 mm of the insulation from the
ends of the wires that go into the front con-
nector. Attach cable end sleeves to these
ends.
Wire the front connector as follows: Power supply of the module
Terminal 1: L+

Terminal 2: M+ Sensor 1 Standard wiring for 2-wire current

Terminal 3: M- Sensor 1 transducer

Connect Terminal 4 and 5 with a 1.5 to 3.3 In order to maintain the diagnostic
kΩ resistor capability of channel group 0, the
second unused input must be con-
nected to a resistor
Terminal 6: M+ Sensor 2 Standard wiring for 4-wire current
Terminal 7: M- Sensor 2 transducer
Terminal 8: M+ Sensor 3
Terminal 9: M- Sensor 3
Connect Terminal 10 (Comp) and terminal For measuring current Comp is not
11 (Mana) with M used
Short-circuit terminals 12 to 19 and connect Mandatory for 2-wire current
with Mana transducers
Terminal 20: M Unused channel groups should be
short-circuited with Mana in order to
achieve a maximum interference
resistance

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