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SIMATIC S7-1200 PLC System
The SIMATIC S7-1200 is a versatile and efficient programmable logic controller (PLC) designed to
handle various industrial automation tasks. At its core, the Central Processing Unit (CPU) serves as the
decision-making unit. The CPU is a microprocessor-based system that monitors inputs, outputs, and other
variables, making decisions based on user program instructions stored in its memory. Some S7-1200
CPUs feature integrated input and output points within the same enclosure, streamlining system design.
For instance, the S7-1200 model includes 14 digital inputs, 10 digital outputs, 2 analog inputs, and 2
analog outputs.
Key Features of S7-1200 CPUs
The SIMATIC S7-1200 PLC CPUs are versatile and compact controllers designed to handle
small to medium-sized industrial automation tasks. These CPUs integrate control,
communication, and monitoring capabilities, making them ideal for various applications. They
are available in three versions:
Standard CPUs for general automation.
Failsafe CPUs for safety-critical applications.
SIPLUS CPUs are designed for extreme environments like high temperatures, humidity, or
corrosive conditions.
The S7-1200 CPUs have built-in memory to store user programs, configuration data, and
diagnostics. Additionally, a SIMATIC Memory Card allows external storage for program
backups, easy transfers, and portability. These CPUs feature PROFINET ports, supporting
industrial Ethernet communication for seamless integration with other devices like PLCs, HMIs,
and sensors. Depending on the model, one or two PROFINET ports are provided for diagnostics
and configuration through the TIA Portal.
The hardware includes a compact enclosure that houses a limited number of digital and/or
analog inputs and outputs (I/O). These I/O are easily accessible via removable connectors
under hinged doors, simplifying wiring and maintenance. LED indicators on the front panel
display the status of the CPU and I/O points for easy troubleshooting.
To enhance functionality, the S7-1200 CPUs support expansion options:
• Signal Boards: Increase the number of digital or analog I/O channels.
• Battery Board: Ensures long-term backup of the real-time clock for time-sensitive
operations.
• Communication Boards: Add serial communication capabilities like RS-232 or RS-485.
The CPUs are equipped with a real-time processor for fast and accurate execution of
automation tasks, including complex logic and PID control. They also feature an integrated web
server, enabling remote system diagnostics, variable monitoring, and maintenance. The modular
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design ensures scalability, with options like CPU 1211C, 1212C, or 1214C tailored to various
application needs.
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S7-1200 Standard CPU Models
The S7-1200 Standard CPUs are designed to provide a compact yet powerful solution for
industrial automation. These CPUs are characterized by their small size, with a uniform height of
100 mm and depth of 75 mm, while the width varies between 90 mm and 150 mm, depending
on the model. This compact design makes them ideal for installations where space is limited.
The S7-1200 Standard CPUs are available in different power configurations, such as
DC/DC/DC, DC/DC/RLY, and AC/DC/RLY, catering to diverse application requirements.
Here's a breakdown of these configurations:
• DC/DC/DC: Accepts a 24 VDC power input and features 24 VDC digital inputs and
outputs.
• DC/DC/RLY: Accepts a 24 VDC power input, includes 24 VDC digital inputs, and
provides relay outputs.
• AC/DC/RLY: Accepts 120/230 VAC power input, includes 24 VDC digital inputs, and
provides relay outputs.
The designations reflect the type of power input and the nature of the onboard digital inputs and
outputs.
• DC (Direct Current): Represents 24 VDC power inputs and outputs.
• RLY (Relay Outputs): Indicates the presence of relay outputs, which offer the flexibility
to work with both AC and DC loads, making them suitable for various control tasks.
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Signal Modules
The S7-1200 PLC system supports a range of Signal Modules, which expand the PLC's
capabilities by providing additional digital and analog input/output channels. These modules
are designed for flexibility, reliability, and ease of use, making them ideal for industrial
applications requiring precise data acquisition and control.
Key Features of Signal Modules:
• Removable Terminal Strips: Allow for easy replacement of modules while keeping the
field wiring intact, minimizing downtime during maintenance.
• Status LEDs: Indicate the on/off state of individual input and output channels, enabling
quick troubleshooting.
• Diagnostic LED: Each module includes a diagnostic LED that turns green when the
module is operational and red when a fault occurs, providing real-time module status.
Types of Signal Modules:
1. Analog Input Modules:
• Used to interface with sensors or transducers providing analog signals, such as
voltage (e.g., 0-10 V) or current (e.g., 4-20 mA).
• Ideal for monitoring variables like temperature, pressure, flow rate, or any
continuous signal.
2. Analog Output Modules:
• Enable the PLC to control analog actuators or devices by outputting analog
signals (e.g., 0-10 V or 4-20 mA).
• Commonly used to control devices such as variable speed drives, proportional
valves, or other process control equipment.
3. RTD Modules:
• Specifically designed for Resistance Temperature Detectors (RTDs), which
measure temperature with high accuracy.
• Support various RTD types like PT100, PT1000, and others, making them ideal
for temperature monitoring and control applications.
4. Thermocouple Modules:
• Support thermocouples for temperature measurement over a wide range.
• Provide cold junction compensation and support for different thermocouple types
(e.g., Type K, Type J).
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5. Digital Input/Output Modules:
• Expand the number of digital input and output points, supporting a wide range of
sensors and actuators.
• Available in both 24 VDC and 120/230 VAC configurations, catering to diverse field
devices.
Applications of Signal Modules:
• Analog Input Modules: Monitoring real-time process variables like flow, temperature,
and pressure.
• Analog Output Modules: Controlling variable devices such as pumps and motors.
• RTD Modules: Accurate temperature measurement for HVAC systems, industrial
furnaces, or chemical processes.
• Digital Modules: Managing on/off devices like relays, switches, and contactors.
These Signal Modules enhance the flexibility and scalability of the S7-1200 PLC, ensuring it
can be tailored to meet the specific needs of complex automation tasks. Their robust design,
coupled with diagnostic capabilities, makes them a reliable choice for modern industrial
environments.
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Energy Meter Module
The SM 1238 Energy Meter Module is a specialized module designed to meet the energy
management needs of enterprises, providing a compact, reliable, and efficient solution for
monitoring energy consumption. It integrates seamlessly with the S7-1200 PLC system, making
it a valuable addition for applications focused on energy optimization and cost savings.
Key Features:
• Compact Design:
• Measures only 45 mm in width, saving space in control panels.
• Easily integrates into the S7-1200 system without significant footprint.
• Comprehensive Energy Monitoring:
• Capable of recording up to 200 energy-related parameters, including voltage,
current, power, and energy usage.
• Suitable for monitoring both single-phase and three-phase electrical networks.
• Wide Voltage Range:
• Supports network voltages of up to 480 VAC, covering a broad spectrum of
industrial applications.
• External Current Transformers:
• Uses external current transformers for accurate current measurement, ensuring
precision in energy monitoring.
• Accommodates different load ranges by selecting appropriate transformers.
Integration with PLC and HMI:
• Data Processing:
• The energy data collected by the module is sent to the S7-1200 CPU, where it
can be processed and analyzed for insights.
• Ideal for advanced energy-saving strategies and efficiency optimization.
• Visualization:
• Energy parameters can be displayed on a SIMATIC HMI Basic or Comfort
Panel, providing real-time visibility.
• Customizable displays enable operators to track energy trends, detect
anomalies, and identify areas for improvement.
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Applications:
1. Industrial Energy Monitoring:
• Tracks energy usage across machines or processes to optimize power
consumption.
2. Building Management Systems (BMS):
• Provides detailed energy data for lighting, HVAC, and other utilities.
3. Cost Allocation:
• Monitors energy usage per production line or department for accurate cost
analysis.
4. Energy Efficiency Projects:
• Enables compliance with energy-saving regulations and standards by identifying
inefficiencies.
The SM 1238 Energy Meter Module is an essential tool for enterprises aiming to improve
energy management, reduce costs, and enhance sustainability. Its compact design, precise
measurement capabilities, and integration with SIMATIC automation systems make it an
indispensable component for modern energy management systems.
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IO-Link Master Module: SM 1278 4 x IO-Link Master
The SM 1278 IO-Link Master Module is a versatile and cost-effective solution for integrating
intelligent sensors and actuators into the S7-1200 PLC system. By supporting the IO-Link
communication standard, this module enables efficient data exchange and enhanced
functionality for automation applications.
Key Features:
• IO-Link Communication Standard:
• Ensures compatibility with a wide range of IO-Link-enabled sensors and
actuators.
• Provides a standardized communication interface for point-to-point
connections.
• Dual Functionality:
• Operates as both a signal module and a communication module, making it a
highly flexible component in automation setups.
• Supports digital I/O functionality, enabling the ports to act as standard
input/output points if needed.
• Compact Design with Multiple Ports:
• Features four IO-Link ports that can connect to IO-Link devices such as
sensors and actuators.
• Each port can also be configured as a standard digital input or output.
• Simplified Wiring:
• Uses 24 VDC power supply and unshielded three-wire cables, reducing
installation costs and complexity.
• Minimizes the need for additional cabling and connectors, streamlining
control panel design.
Benefits of IO-Link Integration:
1. Enhanced Data Exchange:
• Provides real-time communication between the PLC and connected devices.
• Facilitates advanced diagnostics, parameterization, and monitoring of field
devices.
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2. Flexibility and Scalability:
• Supports the addition of new devices or functions without major hardware
changes.
• Allows seamless integration of smart devices into existing automation
systems.
3. Improved Maintenance:
• Enables remote diagnostics to identify and address issues without manual
inspection.
• Reduces downtime by quickly pinpointing device faults or performance
issues.
4. Cost Efficiency:
• Eliminates the need for shielded cables or complex wiring setups.
• Simplifies control panel layouts, reducing overall installation and maintenance
costs.
The SM 1278 IO-Link Master Module offers a robust and efficient way to enhance the intelligence and
connectivity of automation systems, ensuring smoother operations, improved diagnostics, and lower
costs. It is a critical component for modern Industry 4.0 applications.
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Communication Board and Modules
The S7-1200 PLC system is designed with robust communication capabilities to ensure
seamless integration across various automation networks. While every S7-1200 CPU includes
one or two built-in PROFINET ports for Ethernet-based communication, the system also
supports a range of additional communication boards and modules to enhance connectivity
options.
Built-in PROFINET Ports
Standard Feature:
• Every S7-1200 CPU includes PROFINET ports, which support high-speed
communication with industrial devices like HMIs, SCADA systems, and distributed I/O
modules.
Applications:
• Data exchange between the CPU and other PLCs or controllers.
• Remote monitoring and control of industrial processes.
Communication Boards (CB)
CB 1241 (RS-485 Serial Communication):
• Adds serial communication functionality to the PLC.
• Supports RS-485 protocol, ideal for connecting serial devices like barcode scanners,
printers, and older instrumentation.
• Widely used in legacy systems requiring serial connections.
Communication Modules (CM)
CM 1243-5 (PROFIBUS DP Master):
• Enables the CPU to function as a master in a PROFIBUS DP network.
• Used to control and communicate with multiple PROFIBUS-compatible devices such as
remote I/O, drives, and field instruments.
CM 1242-5 (PROFIBUS DP Slave):
• Configures the CPU as a slave in a PROFIBUS DP network.
• Allows the S7-1200 PLC to be controlled by higher-level controllers or systems.
AS-Interface Communication Modules:
• Facilitates connectivity to an AS-Interface (AS-i) network, a simple and cost-effective
Fieldbus standard for integrating sensors and actuators.
• Eliminates complex wiring by allowing multiple devices to connect to a single two-wire
cable.
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Other Communication Options
Serial Communication Protocols:
• Modules like CB 1241 support additional serial protocols, providing flexibility for
connecting with third-party devices.
Wireless Communication:
• Some modules and gateways offer wireless integration, enabling remote control and
monitoring of devices in hard-to-reach locations.
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Tele Control
Tele Control is a crucial feature of the S7-1200 PLC system for enabling remote control and
monitoring of industrial processes. It connects remote control stations to a central control system,
ensuring real-time data exchange and control even over long distances. This functionality is
made possible through the use of specialized communication processors (CP), which facilitate
secure and reliable data transmission.
Communication Processors (CP)
1. CP 1242-7 (GPRS Communication):
• This processor supports GPRS (General Packet Radio Service), a mobile
communication standard that allows the S7-1200 to connect to remote control
stations over cellular networks.
• Ideal for applications where remote locations do not have fixed-line connections,
providing flexibility and mobility in remote industrial environments.
• Application: Suitable for industries like oil and gas, utilities, and remote
monitoring sites.
2. CP 1243-1 (Ethernet/Internet Communication):
• The CP 1243-1 processor enables communication over Ethernet or Internet,
providing robust connectivity for remote control and monitoring through wired or
wireless networks.
• Offers high-speed, reliable communication for industries that require consistent
and secure remote access to PLC systems.
• Application: Used in applications such as remote factory monitoring, distributed
automation systems, and cloud-connected devices.
Supported Protocols
DNP3:
• DNP3 (Distributed Network Protocol) is commonly used in utility and
infrastructure systems, especially for remote monitoring and control in SCADA
systems. It provides a standardized and efficient way of transmitting data over
large distances.
IEC:
• The IEC (International Electrotechnical Commission) protocols, such as IEC
60870-5-104, are widely used in telecontrol applications, particularly in the
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electrical power industry, for real-time monitoring and control of substations and
other remote equipment.
The S7-1200 PLC system is designed to offer a comprehensive and flexible solution for
industrial automation, including the critical functionality of telecontrol. With the support of
communication processors like CP 1242-7 and CP 1243-1, the system ensures secure and reliable
remote monitoring and control, even in challenging environments. By supporting multiple
communication protocols such as GPRS, Ethernet, DNP3, and IEC, the S7-1200 provides
compatibility with a wide range of industrial applications, ensuring its adaptability for diverse
use cases in automation, remote control, and monitoring.
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