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ITER catalogue for I&C products - Slow controllers PLCThis document contains the list of Siemens S7 components to be used within Plant Systems for slow controls and SIL-2 and 3 purposes.

Approval Process Name Action AffiliationAuthor Simelio A. 11 Aug 2017:signed IO/DG/COO/SCOD/CSD/PCICo-Authors Bhamare A.

Evrard B. Wagner R.

11 Aug 2017:signed11 Aug 2017:signed11 Aug 2017:signed

TATA Consultancy Services France SA (EU)IO/DG/COO/SCOD/CSD/PCIIO/DG/COO/SCOD/CSD/PCI

Reviewers Fernandez Robles C. Patel J. Soni J. Wallander A.

11 Aug 2017:recommended11 Aug 2017:recommended11 Aug 2017:recommended11 Aug 2017:recommended

IO/DG/COO/SCOD/CSD/PCIIO/DG/COO/SCOD/CSD/CDCIO/DG/COO/SCOD/CSD/PCIIO/DG/COO/SCOD/CSD

Approver Petitpas P. 11 Aug 2017:approved IO/DG/COO/SCOD/CSD/PCIDocument Security: Internal Use

RO: Simelio AntoniRead Access LG: PLC group, LG: CODAC team, AD: ITER, AD: External Collaborators, AD: IO_Director-General, AD:

EMAB, AD: OBS - Plant Control and Instrumentation Section (PCI), AD: Auditors, AD: ITER Management Assessor, project administrator, RO, AD: OBS - Control System Division (CSD) - EXT, AD: OBS - CODAC Sec...

IDM UID

333J63VERSION CREATED ON / VERSION / STATUS

11 Aug 2017 / 4.1 / Approved

EXTERNAL REFERENCE / VERSION


Change Log

ITER catalogue for I&C products - Slow controllers PLC (333J63)

Version Latest Status Issue Date Description of Change

v1.0 Signed 10 Dec 2009

v1.1 Approved 01 Feb 2010 Updated for version %5.1 of PCDHv1.2 Signed 31 Aug 2010 Update of documentation links, minor syntax changes, change of module

references:Replace 6ES7 317-2EK13-0AB0 by 6ES7 317-2EK14-0AB0 within section 3.1.3Replace 353-1AH01-0AE0 by 6ES7353-1AH01-0AE0 within section 3.2.6Replace 6ES7 75710-8MA11 by 6ES5710-8MA11 within section 3.3.1Replace 6ES7 8GL11-0AA0 by 6ES7 8LG11-0AA0 within section 3.3.3Replace 6ES7 416-3 PN 3ER05-0AB0 by 6ES7 416-3ER05-0AB0 within section 3.4.3Replace 6GK7 443-1EX20-0EX0 by 6GK7 443-1EX20-0XE0 within section 3.4.4Replace 6ES7 414-FH by 6ES7414HM14-0AB0 within section 3.5.3Replace 6ES7 960-1AA04-5BK0 by 6ES7 960-1AA04-0XA0 within section 3.5.5Replace 6ES7153-1BK00-0AB0 by 6ES7153-1BK00-0XB0 within section 3.5.5Replace 6ES7326-1BK01-0AB0 by 6ES7326-1BK02-0AB0 within section 3.6.4Replace 6ES7326-2BF01-0AB0 by 6ES7326-2BF10-0AB0 within section 3.6.4Replace 6ES7650-1KA11-7XX0 by 6ES7650-1AK11-7XX0 within section 3.6.5Replace 6ES7 138-4CF02-0AA0 by 6ES7138-4CF03-0AB0 within section 3.7.2Replace 6ES7 953-8GL11-0AA0 by 6ES7953-8LG11-0AA0 within section 3.7.3

v1.3 Signed 22 Oct 2010 Replace 6ES7390-1BC00-0AA0 by 6ES7390-1AJ30-0AA0 within section 3.1.1Replace 6ES7341-1CH02 by 6ES7341-1CH02-0AE0 within section 3.1.5Replace 6ES7193-4CC20-0AA0 by 6ES7193-4CC30-0AA0 within section 3.3.2

v1.4 Signed 28 Oct 2010 Replace 6ES7307-1EA00-0AA0 by 6ES7307-1EA01-0AA0 within section 3.1.2Add reference S7 PLC ordering process (https://user.iter.org/?uid=3Q6UQ3)

v1.5 Signed 17 Nov 2010 Add 6ES7971-0BA00 within section 3.4.2Add 6ES7952-1AM00-0AA0 within section 3.5.3Add 6ES7960-1AA04-0XA0 within section 3.5.3Add section 3.5.7Add 6ES7922-3BD00-0AS0 within section 3.6.5Add 6ES7922-3BD00-0AN0 within section 3.6.5

v1.6 Signed 06 Jan 2011 New RO: B Evrardv1.7 Approved 09 Feb 2011 Version updated after PCDH review.v2.0 In Work 22 Oct 2012 Catalog organization completely Re-shuffled.

TAble of Content is different.v3.0 Signed 03 Dec 2012 Complete Re-shuffling.

References moved to another living documentAddition of gudielines for architectures

v3.1 Approved 13 Dec 2012 - Update of Satelite Documents picture.- Update Reviewers and Approver


- Addition of Exploded view for s7-400 Rackv3.2 Revision

Required31 Jul 2013 Modification of Chapter 7: Software Packages

v3.3 Approved 04 Jul 2014 Solve problem with cover pagev3.4 In Work 02 Feb 2016 Addition of Network Section

Addition of exploded views.v4.0 Signed 10 Aug 2017 Major modification of the Document:

Reference System :o SIEMENS Reference List is the main document referenced

Systems Selection :o Main reshape of the chapter adapted to the current philosophyo 1500 CPUs addedo Controller, CPU Range subchapters reformulated, CPU and communication performance is taking in accounto Remote IO Selection sub reformulatedo Network selection subchapter reshaped, detailed and enlarged taking in account new needs of the Plant Systemso Cubicle Monitoring system selection addedo Accessing point selection added

System Composition :o Main reshape of the chapter adapted to the current philosophyo Inclusion of 1500 Family devices

Network Composition :o Main reshape of the chapter adapted to the current philosophyo Added devices taking in account the new needs of the Plant Systems

Software :o Reshape of the chaptero TIA Portal Added

v4.1 Approved 11 Aug 2017 Typo mistakes corrected.

Major modification of the document regarding version 3.X:

-Reference System:- SIEMENS Reference List settled as the main reference of the catalogue.

-Systems Selection:- Main reshape of the chapter, adapted to the current philosophy.- 1500 CPUs added.- Controllers and CPU Range subchapters reformulated, CPU and communication performance is taken in account.- Remote IO Selection subchapter reformulated.- Network selection subchapter reshaped, detailed and enlarged taking in account new needs of the Plant Systems.- Cubicle monitoring system selection added.- Accessing point selection added.

-System Composition:- Main reshape of the chapter, adapted to the current philosophy.- Inclusion of 1500 Family devices.- Network Composition :- Main reshape of the chapter, adapted to the current philosophy.


- Added devices taking in account the new needs of the Plant Systems.

-Software:- Reshape of the chapter.- TIA Portal Added.

ITER_D_333J63 v4.1

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Table of Contents

1 PURPOSE ............................................................................................................................4

2 SCOPE .................................................................................................................................5

2.1 PCDH context ..............................................................................................................5

3 DEFINITIONS ....................................................................................................................6

3.1 Acronyms .....................................................................................................................6

3.2 Definitions ....................................................................................................................6

3.3 Reference Documents .................................................................................................7

4 REFERENCE SYSTEM ....................................................................................................8

5 SYSTEM SELECTION ......................................................................................................9

5.1 Controller type selection.............................................................................................9

5.2 CPU Rack Selection ....................................................................................................9 A. Standard System(no designation) ...............................................................................10 B. High Availability System(“H”)...................................................................................10 C. Fail-Safe System(“F”):................................................................................................10

5.3 CPU Range Selection ................................................................................................11 A. Processor Performance and Memory Size ..................................................................11 B. Communication Performance Expected .....................................................................14 C. Sample System (example)...........................................................................................14

5.4 Remote IO Devices Selection....................................................................................15

5.5 Network Selection .....................................................................................................19 A. Technology Selection..................................................................................................20 B. Field Network Architectures .......................................................................................21

5.5.B.1 FieldBus (Profibus) .........................................................................................22 5.5.B.2 Field Net (Profinet) using Central I&C Systems Physical Infrastructure. ......24

5.5.B.3 FieldNet (Profinet) using independent physical infrastructure. ......................26 5.5.B.4 Modbus ...........................................................................................................28

C. Plant System Local (Private) Network Architecture. .................................................29

5.5.C.1 Inter-Controllers communications using the Central I&C Networks. ............29 5.5.C.2 Inter-Controllers communications using independent physical architecture ..31

5.6 Central I&C Network accessing point Selection ....................................................33 A. Analysis of the Arguments..........................................................................................33 B. Outcome of the analysis .............................................................................................35

5.7 Cubicle Monitoring System Selection .....................................................................36 A. Complete Solution for 1 cubicle .................................................................................36 B. Partial Solution for ‘2 to 11’ cubicles .........................................................................37

6 SYSTEMS COMPOSITION ...........................................................................................40

6.1 Slow Controllers Range ............................................................................................40 A. Low (distributed) Range of Slow Controllers .............................................................40

6.1.A.1 Low (Distributed) Range PLCs: [S7-1500] CPU + IO Rack ..........................40 B. Medium Range of Slow Controllers ...........................................................................42

6.1.B.1 Mid-range PLCs: [S7-300 or S7-1500] CPU Rack........................................42 6.1.B.1.1 S7-300: CPU Rack....................................................................................42

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6.1.B.1.2 S7-1500: CPU Rack..................................................................................45

6.1.B.2 Mid-range PLC with local IO: [S7-300 or S7-1500] CPU+IO Rack.............48

6.1.B.2.1 S7-300: CPU+IO Rack .............................................................................48

6.1.B.2.2 S7-1500: CPU+IO Rack ...........................................................................50 6.1.B.3 Mid-range Fail Safe PLCs: [S7-300 or S7-1500] CPU rack...........................52

6.1.B.3.1 S7-300 “F” CPU rack ...............................................................................52 6.1.B.3.2 S7-1500 “F” CPU rack .............................................................................53

C. High Range of Slow Controllers .................................................................................54

6.1.C.1 High range PLCs: S7-400 ...............................................................................54 6.1.C.2 High range Fail Safe PLCs: S7-400 “F” CPU rack ........................................57 6.1.C.3 High Range, High Availability PLCs: S7-400 “H” CPU Rack ......................59

6.2 Remote I/O Modules Range .....................................................................................63 A. Small I/O modules [S7-300 or S7-1500] ...................................................................63

6.2.A.1 S7-300 Family: ET200S .................................................................................63

6.2.A.2 S7-1500 Family: ET200SP .............................................................................65

B. Medium I/O modules [S7-300 or S7-1500] ...............................................................67 6.2.B.1 S7-300 Family: ET200M ................................................................................67 6.2.B.2 S7-1500 Family: ET200MP ............................................................................69

C. Medium I/O Fail-Safe modules [S7-300 or S7-1500] ................................................71

6.2.C.1 S7-300 Family: ET200M –“F” .......................................................................71 6.2.C.2 S7-1500 Family: ET200MP –“F” ...................................................................73

6.3 Accessories .................................................................................................................75

7 NETWORK COMPOSITION .........................................................................................76

7.1 Field Network Architecture equipment ..................................................................76 A. Field Bus (Profibus) components................................................................................76 B. Field Net (Profinet) components .................................................................................77

7.2 Plant System Local (Private) Network Architecture equipment ..........................78

8 SOFTWARE : STEP7 & TIA Portal ..............................................................................79

8.1 STEP7.........................................................................................................................79 A. Dependencies ..............................................................................................................79 B. Versions compatibility ................................................................................................80

8.2 TIA Portal ..................................................................................................................81 A. Dependencies ..............................................................................................................81

B. Versions compatibility ................................................................................................82

8.3 What version to install ? ...........................................................................................83

8.4 Applications portability between versions ..............................................................83

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Table of Figures

Figure 1: PCDH documents ___________________________________________________5 Figure 2: Hardware selection flowchart __________________________________________9 Figure 3: SIMATIC S7-300 CPU 317-2 PN/DP___________________________________11

Figure 4: SIMATIC S7-400, CPU 416-3 PN/DP __________________________________12 Figure 5: SIMATIC S7-1500, CPU 1516-3 PN/DP ________________________________13 Figure 6: ET200M__________________________________________________________15 Figure 7: ET200MP ________________________________________________________15 Figure 8: ET200S __________________________________________________________16

Figure 9: ET200SP _________________________________________________________16 Figure 4: Network Functional Segregation _______________________________________19 Figure 5: FieldBus (Profibus) Network using independent infrastructure _______________23 Figure 6: FieldNet Network (Profinet) using ‘Central I&C Network’ infrastructure _______25

Figure 7: FieldNet Network (Profinet) using independent infrastructure ________________27 Figure 10 : Modbus RTU Network Layout_______________________________________28 Figure 8 : Inter-Controllers (S7 communication) using the ‘Central I&C Network’ _______30

Figure 9: Inter-Controllers (S7 Communication) using independent infrastructure ________32 Figure 30 : Target of the solution for the monitoring of one single cubicle ______________36 Figure 31 : SIEMENS Hardware for CUB MON SYS 1 Single Cubicle _____________37 Figure 32 : Target of the solution for the monitoring of ‘2 to 11’ Cubicles ______________37

Figure 33 : SIEMENS Hardware for CUB MON SYS From ‘2 to 11’ cubicles ________38 Figure 11 : Distributed Rack [S7-1500 + IO] exploded view _________________________41 Figure 12: Rack s7-300 exploded view. _________________________________________43

Figure 13: Rack S7-1500 exploded view ________________________________________46 Figure 14: Rack S7-300 + IO exploded view _____________________________________48

Figure 15 : Rack S7-1500 + IO exploded view ___________________________________50

Figure 16: Fail Safe, High range PLCs S7300F ___________________________________52

Figure 17 : Fail Safe, High range PLCs S71500F _________________________________53 Figure 18: Rack S7-400 exploded view. _________________________________________55

Figure 19: Fail Safe, High range PLCs S7400F ___________________________________57 Figure 20: High availability PLCs architecture ___________________________________59 Figure 21: High availability PLCs S7-400H ______________________________________60

Figure 22: ET200S Modules exploded view _____________________________________63 Figure 23: ET200SP Modules exploded view ____________________________________65 Figure 24: ET200M Modules _________________________________________________67 Figure 25: ET200M Modules to use with s7-400”H” _______________________________68 Figure 26: ET200MP Modules ________________________________________________69 Figure 27: ET200M “F” Modules ______________________________________________71 Figure 28: ET200M “F” Modules for S7-400FH __________________________________72

Figure 29: ET200MP “F” Modules_____________________________________________73 Figure 34: Software and Applications Dependency Tree for STEP7 ___________________79

Figure 35: Software and Applications Dependency Tree for TIA Portal ________________81

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1 PURPOSE

This catalogue has been created and is constantly maintained to help the Plant System

manufacturers and system integrators in their work. The primary objective is to promote the

usage of identical equipment in all Plant Systems so that the integration and interoperability

with the ITER Instrumentation and Control system would be seamless. The secondary

objective is to coordinate site-wide maintenance of the equipment. The third objective is to

provide tools for the obsolescence management.

The objectives will be met by a careful selection of industrial COTS products which will

comply with existing standards, defined by the Plant Control Design Handbook (PCDH,

[RD1]).

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2 SCOPE

This document addresses the needs for Plant Control Systems developed using COTS system

devices, named Slow Controllers in the Plant Control Design Handbook.

This document is applicable to Conventional, Interlock and Occupational Safety I&C systems

based on slow controllers.

Slow controllers used for the nuclear safety I&C systems are out of scope of this document and

are described in [RD9].

‘ITER Catalogue of I&C Products - Slow Controllers PLC’ gives a list of COTS products

recommended by ITER Organization for Slow I/O systems.

‘ITER Catalogue of I&C Products - Slow Controllers PLC’ is a living document, which is

released at regular intervals throughout the lifetime of ITER. Versions of standards and

products are subject to updates and extensions as the ITER project progresses.

2.1 PCDH context

The ‘Plant Control Design Handbook (PCDH)’ [RD1] defines methodology, standards,

specifications and interfaces applicable to ITER Plant Systems Instrumentation & Control

(I&C) system life cycle. I&C standards are essential for ITER in order to:

• Integrate all plant systems into one integrated control system.

• Maintain all plant systems after delivery acceptance.

• Contain cost by economy of scale.

PCDH comprises a core document which presents the plant system I&C life cycle and recaps

the main rules to be applied to the plant system I&Cs for conventional controls, interlocks and

safety controls. Some I&C topics will be explained in greater detail in dedicated documents

associated with PCDH as presented in the picture below. This document is one of them.

Figure 1: PCDH documents

Core PCDH (27LH2V)

Plant system control philosophy

Plant system control Life Cycle

Plant system control specifications

CODAC interface specifications

Interlock I&C specification

Safety I&C specification

PCDH core and satellite documents: v7PS CONTROL DESIGN

Plant system I&C architecture (32GEBH)

Methodology for PS I&C specifications (353AZY)

CODAC Core System Overview (34SDZ5) INTERLOCK CONTROLS

Guidelines for PIS design (3PZ2D2)

Guidelines for PIS integration & config. (7LELG4)

Management of local interlock functions (75ZVTY)

PIS Operation and Maintenance (7L9QXR)

I&C CONVENTIONS

I&C Signal and variable naming (2UT8SH)

ITER CODAC Glossary (34QECT)

ITER CODAC Acronym list (2LT73V)

PS SELF DESCRIPTION DATA

Self description schema documentation (34QXCP)

CATALOGUES for PS CONTROL

Slow controllers products (333J63)

Fast controller products (345X28)

Cubicle products (35LXVZ)

Integration kit for PS I&C (C8X9AE)

PS CONTROL INTEGRATION

The CODAC -PS Interface (34V362)

PS I&C integration plan (3VVU9W)

ITER alarm system management (3WCD7T)

ITER operator user interface (3XLESZ)

Guidelines for PON archiving (B7N2B7)

PS Operating State management (AC2P4J)

Guidelines for Diagnostic data structure (354SJ3)

PS CONTROL DEVELOPMENT

I&C signal interface (3299VT)

PLC software engineering handbook (3QPL4H)

Guidelines for fast controllers (333K4C)

Software engineering and QA for CODAC (2NRS2K)

Guidelines for I&C cubicle configurations (4H5DW6)

CWS case study specifications (35W299)

NUCLEAR PCDH (2YNEFU)

OCCUPATIONAL SAFETY CONTROLS

Guidelines for PSS design (C99J7G)

Available and approved

Legend

This document

(XXXXXX) IDM ref.

Slow controllers products (333J63)

ITER_D_333J63 v4.1

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3 DEFINITIONS

3.1 Acronyms

AI Analogue Input

AO Analogue Output

CIN Central Interlock Network

CIS Central Interlock System

CODAC COntrol Data Access and Communications

COTS Commercial Off the Shelf

CNP CODAC Network Panel

DA Domestic Agency

DC Direct Current

DI Digital Input

DO Digital Output

I&C Instrumentation & Control

I/O Input / Output

IO ITER Organization

IEC International Electro technical Commission

IM Interface Module (Profibus or Profinet)

IP Internet Protocol

LED Light Emitting Diode

NTP Network Time Protocol

PCDH Plant Control Design Handbook

PLC Programmable Logic Controller

PLN Plant System Local Network

PS Plant System

PSH Plant System Host

SIL Safety Integrity Level

TBC To Be Confirmed

TBD To Be Defined

TS Transceiver

UPS Uninterruptible Power Supply

WMC Wall Mounted Cubicle

1oo2 One out Of Two

2oo3 Two out Of Three

3.2 Definitions

Central I&C Systems

Central Control System including the CODAC

(Conventional Control), the CIS (Interlock) and the

CSS (Safety)

Dark Fiber Network-device-free optical fiber link between two

locations

CNP

CODAC Network Panel

Wall mounted cubicle that perform passive patch

cabling between optical fiber patch panels.

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3.3 Reference Documents

IDM Number Title

[RD1] ITER_D_27LH2V Plant Control Design Handbook

[RD2] ITER_D_6M58M9 CODAC DDD [Network Infrastructure Chapter]

[RD2] ITER_D_C8X9AE Integration Kit for PS I&C

[RD3] ITER_D_3QPL4H PLC Software Engineering Handbook

[RD4] ITER_D_AWYQ5G SIEMENS Reference List

[RD6] ITER_D_32GEBH Plant System I&C Architecture

[RD7] ITER_D_4H5DW6 I&C Cubicle Internal Configuration

[RD8] ITER_D_UBZTCW Guide for Development of the Modbus protocol programming

[RD9] ITER_D_JHQLDP ITER catalogue for Nuclear Safety I&C products

[RD10] ITER_D_UVYE98 Benchmark information about the communication

performance between CODAC and the PLCs

[RD11] ITER_D_DZJ4ZT Occupational Safety Cubicle Monitoring System based

on S7-1200

https://user.iter.org/?uid=27LH2V

https://user.iter.org/?uid=6M58M9

https://user.iter.org/?uid=C8X9AE

https://user.iter.org/?uid=C8X9AE&version=v1.0&action=get_document

https://user.iter.org/?uid=3QPL4H

https://user.iter.org/?uid=AWYQ5G

https://user.iter.org/?uid=32GEBH

https://user.iter.org/default.aspx?uid=4H5DW6

https://user.iter.org/default.aspx?uid=UBZTCW&newcontentuid=UBZTCW

https://user.iter.org/default.aspx?uid=UBZTCW&newcontentuid=UBZTCW

https://user.iter.org/?uid=UBZTCW&version=v0.0&action=get_document&index=none

https://user.iter.org/default.aspx?uid=JHQLDP

https://user.iter.org/default.aspx?uid=DZJ4ZT

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4 REFERENCE SYSTEM

In the document, no Manufacture Reference will be mentioned. Every product will be

associated to a Short Designation. All Manufacture references are specified in another

document: [RD4]. The reason is that references may change frequently and would make this

document obsolete almost every 3 months. So the products are designed by a Short

Designation, itself pointing to a Manufacturer reference in the other document.

Example:

Short Designation Description Product Reference Status

CPU317-2 CPU 317-2 PN/DP (2x Eth) 6ES7317-2EK14-0AB0 Active

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5 SYSTEM SELECTION

This chapter provides guidance to aid in the selection of slow controller hardware. CPU, CP,

power supplies, I/O modules and Field Network technology should all be selected in parallel

for homogenous system design.

START

Controller Type Selection (Standard, “H”, “F”)

PLC Range Selection (S7-300, 400, 1500)

I/O Selections

END

Network SelectionPower SupplyCommunication Processor (CP)

Central Processing Unit (CPU)

Figure 2: Hardware selection flowchart

5.1 Controller type selection

Selection between fast and slow control is out of scope of this document. Refer to the PCDH

[RD1] for guidance related to fast or slow control selection and network performance criteria.

This catalogue has been developed to provide guidance in selecting you PLC system hardware.

5.2 CPU Rack Selection

The following information provides guidance for the selection of a conventional CPU. It is

recommended that you consult your ITER Control System Division representative if you

require more information than the given below.

These factors should be considered when selecting a CPU rack:

o Standard System

o High Availability System (“H”)

o Fail-safe System (“F”)

The first step in selecting your CPU is to determine your rack requirements. Select the type of

system in development; Standard, High Availability, Fail-safe, or High Availability Fail-safe.

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A. Standard System(no designation) The following standard CPUs are found in the Siemens Reference List [RD4].

CPU 317-2 PN/DP

CPU 416-3 PN

CPU 1512SP-1 PN for Rail DIN

CPU 1516-3 PN/DP

Standard CPUs will be used in an estimated 90% of all ITER conventional control systems.

Notes:

(1) The CPU 1214C is included in the Siemens Reference List [RD4]. The CPU 1214C must

be used, only, in the cubicle monitoring system and forbidden for use in conventional control

systems.

(2) The ITER Control System Division recommends using the S7-400 for master control

functions.

B. High Availability System(“H”)

The S7-400H is suitable as a controller for high-availability processes, with two H CPUs of the

same type; in the event of a fault, changeover takes place from the master system to the

standby station.

For more information regarding “H” CPUs, see: SIMATIC S7-400H High-availability CPUs

The following “H” high availability CPUs are found in the Siemens Reference List:

CPU 414-5H PN/DP

CPU 416-5H PN/DP

CPU 417-5H PN/DP

In Siemens CPU references, an “H” is integrated in the short description and in the Siemens

reference number: i.e. “CPU414-5H,” and “6ES7414-5HM06-0AB0.”

Notes: (1) An “H” CPU also qualifies as High Availability FailSafe, or “FH”.

(2) The ITER Control System Division recommends using the S7-400H for master control

functions.

C. Fail-Safe System(“F”):

The following “F” Fail-safe CPUs are found in the Siemens Reference List:

CPU 315F-2 PN/DP Fail Safe CPU

CPU 1516F-3 PN/DP Fail Safe CPU

In Siemens CPU references, an “F” is integrated in the short description and in the Siemens

reference number: i.e. “CPU315F-2,” and “6ES7315-2FJ14-0AB0”

Note: (1)“F” CPUs are used in interlock and safety systems only and are not required for use in

conventional control systems. The fail-safe controllers are used to guarantee the functional

safety of machines. For more information regarding “F” CPUs, see: Fail-safe SIMATIC CPUs

See the Siemens Reference List [RD4] for the latest information regarding ITER approved

CPUs.

http://w3.siemens.com/mcms/programmable-logic-controller/en/advanced-controller/s7-400/cpu/fault-tolerant-cpus/pages/default.aspx

http://w3.siemens.com/mcms/programmable-logic-controller/en/advanced-controller/s7-300/cpu/fail-safe-cpus/pages/default.aspx

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5.3 CPU Range Selection

A. Processor Performance and Memory Size

The second step in selecting your CPU is to determine your performance and memory

requirements for the system. The following tables provided for the S7-300, S7-400 and

S7-1500 ranges were extracted from Siemens Online resources.

SIMATIC S7-300 CPU 317-2 PN/DP

CPU Processing Time

for bit operations, typ. 0.025 µs

for word operations, typ. 0.03 µs

for fixed point arithmetic, typ. 0.04 µs

for floating point arithmetic, typ. 0.16 µs

CPU - blocks

Number of blocks (total) 2048 (DBs, FCs, FBs)

Size, max. 64 kbyte

Digital channels

Inputs 65536

Outputs 65536

Inputs, of which central 1024

Outputs, of which central 1024

Analog channels

Inputs 4096

Outputs 4096

Inputs, of which central 256

Outputs, of which central 256

Hardware Configuration

Racks, max. 4

Modules per rack, max. 8

Expansion devices, max. 3

Interfaces

Number of other interfaces 1; Ethernet, 2-port switch, 2*RJ45

PROFINET IO Controller

Transmission rate, max. 100 Mbit/s

number of connectable IO devices, max. 128

PROFIBUS proxy functionality

number of linked PROFIBUS devices 16

Data length per connection, max. 240 byte; slave-dependent

Work memory

integrated 1024 kbyte

expandable No

size of retentive memory for DBs 256 kbyte

Load memory

Pluggable (MMC), max. 8 Mbyte

Software TIA Portal and STEP 7

Figure 3: SIMATIC S7-300 CPU 317-2 PN/DP

https://mall.industry.siemens.com/goos/WelcomePage.aspx?regionUrl=/fr&language=en

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SIMATIC S7-400, CPU 416-3 PN/DP

CPU Processing Time





CPU - blocks

DB number, max. 10,000

FB number, max. 5,000

FC number, max. 5,000

Size, max. 64 kbyte

Digital channels

Inputs 131,072

Outputs 131,072

Inputs, of which central 131,072

Outputs, of which central 131,072

Analog channels

Inputs 8,192

Outputs 8,192

Inputs, of which central 8,192

Outputs, of which central 8,192


Racks, max. 21

connectable Ops 95

multi-computing Yes, 4 CPUs max. (with UR1 and UR2)

Interfaces

Interfaces/bus type 1xMPI/PROFIBUS DP, 1xPROFINET (2 ports), 1xPROFIBUS DP number of RS 485 interfaces 1; combined MPI / PROFIBUS DP

number of other interfaces 1; PROFIBUS DP with IF 964-DP

PROFINET IO Controller


number of connectable IO devices, max. 256

PROFIBUS DP Master


number of linked PROFIBUS devices 32

Work memory

integrated 16 Mbyte

expandable No

Load memory

expandable FEPROM, max. 64 Mbyte

integrated RAM, max. 1 Mbyte

Software TIA Portal & STEP 7

Figure 4: SIMATIC S7-400, CPU 416-3 PN/DP

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SIMATIC S7-1500, CPU 1516-3 PN/DP

CPU Processing Time





CPU - blocks

Number of elements (total) 6,000

Size, max. 5 MB

Address area

number of IO modules 8,192; max. number of modules

Inputs 32 kbyte; All in the process image

Outputs 32 kbyte; All in the process image

Number of distributed IO systems 64


modules per rack, max 32; CPU + 31 modules

number of lines max 1

PtP CM limited only by the number of

available slots

Interfaces

number of PROFINET interfaces 2

number of PROFIBUS interfaces 1

number of other interfaces 1; PROFIBUS DP with IF 964-DP

1st PROFINET IO Controller

Number of connectable IO devices, max.

256; in total, up to 1,000 distributed I/O devices can be connected via AS-I

PROFIBUS or PROFINET

2nd PROFINET IO Controller

Number of connectable IO devices, max.

32; in total, up to 1,000 distributed I/O devices can be connected via AS-I

PROFIBUS or PROFINET

PROFIBUS; RJ 45 (Ethernet), RS 485


number of linked PROFIBUS devices 256, via integrated interfaces of the

CPU and connected CPs / CMs

Work memory

integrated (for program) 1 Mbyte

integrated (for data) 5 Mbyte

Load memory

Plug-in (SIMATIC Memory Card), max 32 Gbyte

Software TIA Portal

Figure 5: SIMATIC S7-1500, CPU 1516-3 PN/DP

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B. Communication Performance Expected

Another important point in order to determine the CPU is the ‘Communication Performance’

expected. This performance is in straight relation with the quantity of data your application is

going to manage (send/receive). Logically bigger quantity of data needs more powerful CPUs

to achieve an acceptable communication rate.

Moreover, ITER standards advice to use the CP as a device connecting to the High Network

and this has also an impact in the ‘communication performance’ towards the ‘Central I&C

System’

Please refer to the document [RD10] to have detailed information about the ‘communication

performances’ of the ‘ITER PLC Configurations’ in relation with the quantity of data ‘sent’

towards the ‘Central I&C System’.

C. Sample System (example)

With the information provided above, a determination can be made for the conventional system

CPU based on rack requirements and performance and memory requirements.

For example, a system has the following requirement:

[CSD1] The PLC shall perform standard process control and monitoring

This requires a standard rack leaving us with the following CPUs to select from:

CPU 317-2 PN/DP CPU 416-3 PN CPU 1512SP-1 PN

for Rail DIN

CPU 1516-3 PN/DP

Next, the system has the following performance requirement:

[CSD2] The PLC shall perform bit operations in less than 0.02 µs.

From the notes above, the CPU 1214C must only be used in the cubicle monitoring system.

The CPU 1512SP-1 PN for ‘Rail DIN’ is a distributed controller. From the tables above the

minimum bit operation time for the CPU 317-2 PN/DP is 0.025 µs. This excludes the CPU

317-2 PN/DP from consideration; it does not meet the [CSD2] performance requirement.

Two CPUs meet the above requirements, the CPU 416-3 PN or the CPU 1516-3 PN/DP.

Selection of CPU can be based on other considerations.

The CPU 416-3 PN is programmed in STEP 7 or TIA Portal while the CPU 1516-3 PN/DP can

be programmed only in TIA Portal. These programming platforms are described in the chapter:

[Software]. Other system requirements can be used to make a final CPU selection. It is

recommended that you consult your ITER Control System Division representative should you

require assistance in selecting your CPU range.

Refer to chapter [Systems Composition] of this document for more information regarding each

of the CPU ranges.

[CSD3] The Application needs to send ‘16K’ of ‘process variables’ with a

‘communication rate’ of ‘150ms’ towards the ‘Central I&C System.

Last point is to confirm that the ‘communication performance’ provided for the selected ‘PLC

Configuration’ matches with what is needed for the application. Refer to the document [RD10]

to verify the ‘PLC Configuration’ chosen (by CSD1 and CSD2) is able to accomplish the

‘communication rate’ desired.

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5.4 Remote IO Devices Selection

When selecting an IO rack you are confronted to the following choices:

o Medium : ET200M or ET200MP

o Small : ET200S or ET200SP

o Standard or Fail-Safe

SIMATIC ET200M – Medium Range Remote IO

The SIMATIC ET200M belongs to the S7-300 family.

The SIMATIC ET200M is a modular I/O station for the control cabinet with high density-

channel applications. Connection to PROFIBUS and PROFINET is achieved using interface

modules.

The ET200M can be used for standard as well as fail-safe applications. Up to 12 multi-channel

signal modules (e.g. 64 digital outputs) and a high range of different modules to use as

interface to process.

ET200M supports modules with expanded user data, e.g. HART modules with HART minor

variables. In addition to proven connection techniques the ET200M offers the insulation

displacement method FAST CONNECT for easy wiring.

Figure 6: ET200M

For more information see Section [Systems Composition] below and: SIMATIC ET200M

SIMATIC ET200MP – Medium Range Remote IO

The ET200MP belongs to the S7-1500 family.

The simple use of SIMATIC ET200MP is exemplified by a modular and scalable station with

the SIMATIC S7-1500 I/O modules in a distributed configuration. The modules have high

channel density and low parts variance. As a result, ordering, logistics and spare-parts

inventory are considerably simplified.

The ET200MP IO system with IP20 degree of protection is scalable and is used not only as a

central IO system for S7-1500, but also in a distributed configuration connected to PROFINET

or PROFIBUS. As many as 30 IO modules can be inserted into each station. The modules use a

limited variety of parts and the front connector is standardized for all 35mm wide modules.

Figure 7: ET200MP

For more information see Section [Systems Composition] below and: SIMATIC ET200MP

http://w3.siemens.com/mcms/distributed-io/en/ip20-systems/et200m/pages/default.aspx

http://w3.siemens.com/mcms/distributed-io/en/ip20-systems/et-200mp/pages/simatic-et200mp.aspx

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SIMATIC ET200S – Small Range Remote IO

The ET200S belongs to the S7-300 family.

The ET200S distributed I/O system is a discretely modular, highly flexible DP slave for

connection to process signals on a central controller or a field bus. ET200S supports field bus

types PROFIBUS DP and PROFINET IO. ET200S has a protection class IP20.

The ET200S is installed on a mounting rail.

Depending on the interface module, each ET200S can consist of up to 63 modules – for

example, power modules, I/O modules and motor starters.

For the solution of technological tasks, high-performance function modules are available that

perform these tasks largely autonomously and relieve the CPU significantly. Used directly

onsite; e.g. for counting, measuring and positioning tasks.

Figure 8: ET200S

For more information see Section [Systems Composition] below and SIMATIC ET200S

SIMATIC ET200SP – Small Range Remote IO

The ET200SP belongs to the S7-1500 family.

The I/O system ET200SP provides maximum usability, compact design, and high performance.

The ET200SP distributed I/O system is used for connecting process signals to a central

controller via PROFINET or PROFIBUS.

The ET200SP is installed on a mounting rail and generally comprises:

o An interface module, which communicates with all of the controllers that behave

according to the PROFINET standard IEC 61158

o Up to 64 I/O modules, which are plugged into passive base units in any combination

o A server module, which completes the structure of the SIMATIC ET200SP

The distributed I/O system is particularly easy to operate, and with its compact design it

achieves maximum economy in the control cabinet.

Figure 9: ET200SP

For more information see Section [Systems Composition] below and: ET200SP

http://w3.siemens.com/mcms/distributed-io/en/ip20-systems/et200s/pages/default.aspx

http://w3.siemens.com/mcms/distributed-io/en/ip20-systems/et-200sp/system-overview/Pages/default.aspx

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ET200M(P) and ET200S(P) essential differences:

o Number of channels available. ET200M is highly integrated. One big module can

integrate up to 64 signals. (this catalogue restricts to 32 signals module)

o ET200S can be expended with compatible Siemens Frequency Converters.

o ET200S has faster analogue modules. So faster Control Loops can be achieved.

o ET200M is adapted to “Fast Connect” wiring solutions. ET200S have to be wired

directly on the module.

o An ET200S module is smaller than an ET200M and can be mounted on a simple DIN

Rail.

Extract of Siemens Catalogue ST70

ET200S ET200M

o Ex approval to Cat. 3 for Zone 2 acc.

to ATEX100 a

o Transmission rates up to 12 Mbit/s

o Ex approval to Cat. 3 for Zone 2 acc.

to ATEX100 a

o Transmission rates up to 12 Mbit/s

o Distributed I/O system to degree of

protection IP20 with minimal wiring

outlay, also for extremely time-critical

tasks such as high-speed closed-loop

controls

o Discretely-modular design for exact

adaptation to the automation task in

hand.

o Interface modules available with

PROFIBUS DP or PROFINET

interfaces

o Can be combined from digital and

analog in/output modules, technology

modules, motor starters and frequency

converters for the control of drives up

to 7.5 or 4 kW.

o Exchange of modules during operation

(hot swapping), permanent wiring with

multi-conductor connection

o Channel-specific diagnostics for high

availability

o Can be supplied with integrated fiber

optic interface if required

o FastConnect using unstripped quick

connection technology, screw or

o Modular I/O system with degree of

protection IP20, particularly suitable

for user-specific and complex

automation tasks

o Can be expanded with S7-300

automation system signal,

communication and function modules.

o Applicable Ex analogue input or

output modules with HART optimize

the ET 200M for use in process

engineering

o Can be used in redundant systems (S7-

400H, S7-400F/FH)

o Consists of a PROFIBUS DP IM 153

connection, up to eight or twelve I/O

modules of the S7-300 automation

system (assembly with bus

connections or active bus modules)

and if required a power supply

o Modules can be replaced during

operation (hot swapping) with the bus

modules active

o Can be supplied with integrated fiber

optic interface if required

o Fail-safe digital in/outputs as well as

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spring-loaded terminals

o Slot reservation with spare modules

o Fail-safe DI modules with safety-

related signal processing according to

PROFIsafe

Option handling – for simples

management of machine options

analogue inputs for safety oriented

signal processing in accordance with

PROFIsafe

o Support of modules with expanded

user data, e.g. HART modules with

HART minor variables

The choice of Fail-Safe products is driven by the outcome of a specific analysis, according to

IEC61508 standard. In some cases you may need Hardware suitable for loops with SIL>=2.

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5.5 Network Selection

First of all, let’s specify what type of communication networks the ITER Project will contain.

Central I&C System

Plant

System

Host

Slow

Controller

Slow

Controller

Slow

Controller

IO Module IO Module IO Module



1

2

3

2

Figure 10: Network Functional Segregation

In Figure 10, the network organization described in [RD6] is specified. The networks are

broken down in 3 communication groups:

- Group(1): The Communication between the Controller and the Central I&C Systems.

- Group(2): The Communication between Slow Controllers and their Field

Inputs/Outputs.

- Group(3): The Communication between the Controllers.

Group (1): is entirely covered by the Central I&C Networks.

Group (2): can be:

1. Field Network, based on Field bus: A Profibus network.

2. Field Network, Ethernet based network: Profinet.

In this cased it can be:

o Covered by the Physical Infrastructure of the Central I&C Networks

The Central Infrastructure is implemented exclusively using single-mode

Fibers.

o Covered by a physically independent network.

Group (3): is based on Ethernet, is using Siemens S7 Specific Protocols and it can be:

- Covered by the Central I&C Networks

- Covered by a physically independent network based on Ethernet called “Plant System

Local (Private) Network”.

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A. Technology Selection

Group (2): To choose between Profibus or Profinet?

The choice between Profibus and Profinet is straightforward. By default the selected protocol

must be Profinet, but if the slaves support only Profibus and/or the requirements or

characteristics of your system make it necessary (i.e: OS safety), then Profibus must be

selected. Avoid heterogeneous architectures mixing Profinet and Profibus with bridges. If you

application has Profibus and Profinet slaves, then deploy both networks with the CPU as a

master.

Group (2) (Profinet case) and Group (3):

To choose between using the ‘Physical Infrastructure’ of the ‘Central I&C Networks’ or

a completely independent network?

It is difficult to give a strict decision tree. The table below just list advantages and

disadvantages of both solutions.

Central I&C Networks Infra Plant System Local (Private) Network

Advantages Nothing to do for the design.

Only give the number of

connections required to ‘Central

I&C Systems’.

No network Management. No

technical responsibility.

In case of failure of the network, the

recovery is instantaneous.

Administration at commissioning,

then nothing to do any more.

Disadvantages In case of failure in the higher

layers of the network, recovery

time might take seconds (4-6).

There is physical common mode

with the other networks.

Modification on other logical

networks might impact the

network.

Impact on the Design, interface with

cable trays, …

Magnetic Field and radiation

impacts to be assessed.

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B. Field Network Architectures

For the FieldBus the protocol to use is PROFIBUS.

PROFIBUS (Process Field Bus) is a standard for fieldbus communication in automation

technology and was first promoted in 1989 by BMBF (German department of education and

research) and then used by Siemens.

For the FieldNet the protocol to use is PROFINET.

PROFINET (pitch acronym for Process Field Net) is an industry technical standard for data

communication over Industrial Ethernet, designed for collecting data from, and controlling,

equipment in industrial systems, with a particular strength in delivering data under tight time

constraints (on the order of 1ms or less).

CSD is advising, through this document, the use of only these two protocols: PROFINET

and PROFIBUS, as the standards to apply for any ‘Field Network Architecture’ of the

ITER project.

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5.5.B.1 FieldBus (Profibus)

The picture below is showing an example of a Plant Control System with 4 Panels (Cubicles or

WMC) with Profibus network between the CPU and the IO modules. It is a Ring Physical

Topology. This is only possible with the usage of Fiber Optic Transceiver Modules. From the

application Layer, the Profibus is still seen as a BUS Topology.

The layout represents almost all the possible scenarios:

In ‘CU-0001’, you have the CPU of the PLC. It is connected by Profibus Copper cable to

the inputs/outputs module located in this same cubicle. Then, as a part of the Integration

KIT, you also have the switch and the PSH.

The Profibus network is extended outside the cubicle using Fiber Optics. The transceivers

modules (TS) are performing the conversion between copper Physical Layer and Optical

fiber physical layer. These modules performs several functions:

o Physical Layer Conversion.

o Repeater: One copper segment supports only 32 stations, while Profibus afford 128

stations. So each module support 32 stations, and the connection between them

allows using the full addressing range.

o Ring Management: Most of the providers of these modules allow a ring connection.

It means that a break in the ring will be managed instantaneously, and is

transparent to the application

In ‘CU-002’, the connection to the next cubicle is made of fiber optic pairs, routed in the

cable trays of the building. The concerned Plant System is fully in charge of the

management of this routing. (Interface with PBS44, etc…).

The copper segment bus can be extended to field devices

In ‘CU-003’, connexion to cubicles in another building could be made using the Central

I&C Systems dark fibers. The concerned Plant System must communicate it previously it

to CSD.

This has to be absolutely managed in the interface documents with PBS 45 (CODAC).

Topology :

The 2 network legs of the ring should preferably use 2 different routes (cable trays)

If field devices are located too far away from the cubicles, the bus can be extended with FO

to a WMC (wall mounted cubicle) embedding a Media Converter ( OLM)

The picture below is showing an example based in ‘Conventional Control’ architecture and it is

not necessarily shared for Interlock and Safety.

Reference PCDH satellite documents for more information regarding interlock or safety

networks.

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Figure 11: FieldBus (Profibus) Network using independent infrastructure

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5.5.B.2 Field Net (Profinet) using Central I&C Systems Physical Infrastructure.

Picture below is showing an example of a Plant Control System with 4 Panels (Cubicles or

Wall Mounted Cubicle) with Profinet Network between the CPU and the IO modules. The

Central I&C Networks are used as a Physical Layer (the Fiber Optic used in the Central I&C

Networks is a single-mode fiber).


Cubicle “CU-0001” is embedding a PLC CPU, One Input/Output Rack, the PSH and the

Network Switch of the Integration Kit see [RD2]. The PLC and the Input/Output modules

are connected to the Network Switch using conventional copper Ethernet cables (CAT5).

The Switch is connected to the Central I&C Systems networks via the CNPs. It is

connected through 2 pairs (RX/TX) of Fiber Optics. This double connection assumes

redundancy in the Central I&C Systems network. See [RD2] for more details.

Panel “CU-0002” is an example of a Panel close to the “CU-0001”. The Remote I/O

modules can be connected to the network switch of “CU-0001”with regular Ethernet

copper cables (CAT5(E))

Panel “CU-0003” is an example of a Panel far away from “CU-0001”. An intermediary

network switch has to be installed. This switch must be chosen, in this same document, in

the chapter [Networks Composition]. The Remote I/O modules have to be connected to

this intermediary network switch. The connection to “CU-0001” is done through the

‘Central I&C Systems’ Networks via the CNP and also 2 pairs of Fiber Optics.


Cubicle “CU-0004” located in another building is exactly in the same conditions as “CU-

0003”. ‘Central I&C Systems’ is managing building interconnection; this is the big

advantage of this configuration.





networks.

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Figure 12: FieldNet Network (Profinet) using ‘Central I&C Network’ infrastructure

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5.5.B.3 FieldNet (Profinet) using independent physical infrastructure.

Figure below is showing an example of a Plant Control System with 4 Panels (Cubicles or

WMC) with Profinet network between the CPU and the IO modules. An independent network

is used as a Physical Layer. It is a Ring Physical Topology. The picture is representing almost

all the possible scenarios:

In “CU-0001”, the Ethernet Interface of the PLC CPU is connected to a DIN Rail

Manageable Switch. The Input /Outputs module is connected to this switch as well.

“CU-0002” is close to “CU-0001”, so the inputs/outputs modules are connected to the

switch of “CU-0001”with a copper cable. The copper cable is routed in the cable trays.

“CU-0003” is located somewhere else in the same building. So there is another

manageable Switch in the cubicle to connect the Inputs/Outputs modules. This switch is

connected to “CU-0003”with fiber optic pairs routed in the cable trays. The concerned

Plant System is fully in charge of the management of this routing. (Interface with

PBS44, etc…)

Profinet Slave devices can be also connected to this DIN Rail Manageable Switch.

“CU-004” is an extreme case, the cubicle is located in another building , so, it is

recommended to perform the connexion to panels in another building through the ‘Central

I&C Systems’ dark fibers (however every Plant System could select another way if the

suitability is improved). So the FO has to be connected to the ‘Central I&C Systems’

CNPs.


Topology :

All the DIN rail switches are connected in a ring configuration. The 2 network legs of the

ring should preferably use 2 different CNPs in order to avoid a common mode in the ring

routing.




networks.

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Figure 13: FieldNet Network (Profinet) using independent infrastructure

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5.5.B.4 Modbus

Modbus RTU and MODBUS TCP

Modbus RTU is an open, serial (RS-232 or RS-485) protocol derived from the Master/Slave

architecture. It is a widely accepted protocol due to its ease of use and reliability. Modbus RTU

is widely used within Building Management Systems (BMS) and Industrial Automation

Systems (IAS).

Modbus TCP/IP (also Modbus-TCP) is simply the Modbus RTU protocol with a TCP

interface that runs on Ethernet. The Modbus messaging structure is the application protocol

that defines the rules for organizing and interpreting the data independent of the data

transmission medium.

CSD, through this document, is advising against the use of MOBUS (as said only

PROFINET and PROFIBUS must be used in ITER Project).

However, exceptionally, if the circumstances of the particular Plant System make the use

of MODBUS absolutely necessary and unavoidable , its use could be allowed after

presenting the necessary justification and under the approval of the engineers in charge.

Two mandatory conditions to follow for the software and for the hardware.

Software:

For the programming of the ‘Modbus Communication’ it is mandatory to follow the document

[RD8].

Hardware:

CSD is providing the necessary HARDWARE to allow this communication. The selection of

other hardware is not allowed. Refer to [RD4].

In the figure below, suitable MODBUS RTU boards are exposed.

Figure 14 : Modbus RTU Network Layout

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C. Plant System Local (Private) Network Architecture.

Two types of ‘inter communication’ between controllers are allowed in the ITER Standards:

- S7 Communication is a Siemens proprietary protocol that runs between programmable

logic controllers (PLCs) of the Siemens standard families.

- TCP Connection is taking advantage of the existing TCP/IP protocol to stablish the

communication link between the PLC devices.

In the ‘S7 Communication’, as well as, in ‘TCP Connection’ the communication has to be

programmed using dedicate blocks in every PLC involved.

5.5.C.1 Inter-Controllers communications using the Central I&C Networks.

In this case you are just using the Central I&C Networks as described in all the PCDH

documents to interconnect your controllers. Figure below is showing how practically to extend

your network.

The layout is showing an example of a Plant Control System with 4 Panels (Cubicles or WMC)

with S7 communications between a “Main” (Master, Server, …) PLC and “subordinated”

(Slaves, Clients,…) PLCs. The Central I&C Networks are supporting the ‘Inter-Controllers

communications’ and, in addition, ‘Central I&C Systems’ communications. . The figure is

representing almost all the possible scenarios:

Panel “CU-0001” is embedding a PLC CPU, the PSH and the Network Switch of the

Integration Kit, [RD2]. The PLC is connected to the Network Switch using conventional

copper Ethernet cables (CAT5 (E)).

The Switch is connected to the ‘Central I&C Systems’ networks via the CNPs. It is

connected through 2 pairs (RX/TX) of Fiber Optics. This double connection assumes

redundancy in the ‘Central I&C Systems’ network. See [RD2] for more details.

Panel “CU-0002” is an example of a Panel close to the “CU-0001”. The subordinated

PLC can be connected to the network switch of “CU-0001”with regular Ethernet copper

cables (CAT5(E))

Panel “CU-0003” is an example of a Panel far away from “CU-0001”. An intermediary

network switch has to be installed. This switch must be chosen in [Networks

Composition]. The subordinated PLCs have to be connected to this intermediary network

switch. The connection to “CU-0001” is done through the ‘Central I&C Systems’

Networks via the CNP and also 2 pairs of Fiber Optics.


Panel “CU-004”, located in another building, is exactly in the same conditions as “CU-003.

‘Central I&C Systems’ are managing building interconnections; this is the big advantage of

this configuration.




networks.

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i

Figure 15 : Inter-Controllers (S7 communication) using the ‘Central I&C Network’

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5.5.C.2 Inter-Controllers communications using independent physical architecture

Figure below is showing an example of a Plant Control System with 4 Panels (Cubicles or

WMC) with S7 Communications between a “Main” (Master, Server, …) Controller and

“subordinated” (Slaves, Clients,…) PLCs. An independent network is used as a Physical

Layer, generally referred at ITER as, Plant System Local Network. It is a Ring Physical

Topology.


In “CU-0001”, the Ethernet Interface of the Communication Processor (“CP”) of the Main

“400-PLC” is connected to a DIN Rail Manageable Switch.

Important note: the CP requires 2 Ethernet connexions, as the first one is already

used by the connection to Central I&C Networks (CP440-1-Adv to be used).

“CU-0002” is close to “CU-0001”, the Ethernet Interface of a Communication Processor

(CP) of the “Subordinated” PLC is connected to the switch of “CU-0001” with a copper

cable. The copper cable is routed in the cable trays.

Important note: As in the figure below, if the PLC is a S7-300, then it will require a

second Communication Processor, as the first one is dedicated to connection to

Central I&C Networks.

“CU-0003” is located somewhere else in the same building. So there is another

manageable Switch in the cubicle to connect the Inputs/Outputs modules. This switch is

connected to “CU-0003” with fiber optic pairs routed in the cable trays. The concerned

Plant System is fully in charge of the management of this routing. (Interface with

PBS44, etc…)

In “CU-0004” it is recommended to perform the connexion to panels in another building

through the ‘Central I&C Systems’ dark fibers (however every Plant System could select

another way if the suitability is improved). So the FO has to be connected to the ‘Central

I&C Systems’ CNPs. This has to be absolutely managed in the interface documents

with PBS 45 (CODAC).

Topology :

All the ‘DIN Rail’ switches are connected in a ring configuration. The 2 network legs of

the ring should preferably use 2 different CNPs in order to avoid a common mode in the

ring routing.

It is recommended to connect all the ‘Slow Controllers’ to the ‘Central I&C Networks’,

however if this is not possible for the requirements or constraints of a particular system, so it is

the case in a ‘Plant System Local Network’, anyway the PLCs in this ‘private network’ must be

‘Time Synchronized’ with the ‘Central System Time Server’. It is strongly advised in this case

to use a ‘Time and Frequency Synchronization Platform’ to work in between two networks, to

get the ‘Time Synchronization’ information from a ‘Central Network’ and deliver it to the

‘‘Plant System Local Network’ in order to synchronize all the devices in there. Refer to

CODAC Department to get the specific data of the device.




networks.

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Figure 16: Inter-Controllers (S7 Communication) using independent infrastructure

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5.6 Central I&C Network accessing point Selection

A. Analysis of the Arguments

In order to get connected to the ‘central I&C Networks’ (in case of the ‘central I&C Systems’

infrastructure) the developer will be confronted to the choice: CP or CPU.

At the same time, in order to get connected to the ‘PROFINET Network’, the developer will be

confronted to the same choice: CP or CPU.

The present chapter summarizes the arguments to take in account in order to the select the

proper device to do such a task: the best point of connection (device/slot) to the ‘central

I&C Network’. This set of criteria is summarized below:

- For the ‘Central I&C Networks’ Communication

o Network Security

o Communication Performance to the ‘Central I&C Network’

o Reset of the communication with the ‘Central I&C Network’.

- For the Profinet Communication

o Number of slaves connected to Profinet Network

o Necessary Functions to implement Profinet Communication

o System Health Monitoring

These criteria are analysed against the three hardware families proposed in this catalogue: 300,

400 and 1500.

Below, the summary table with the capital arguments for every family of devices:

Device to

connect Subject

‘Central I&C Networks’ Communication Network security CP343-1-ADV The CP has the security functions : VPN, Firewall,

CPU317-2 The Ethernet interface of the CPU does not have the security functions.

CP443-1-ADV The CP has the security functions : VPN, Firewall

CPU416-3 The Ethernet interface of the CPU does not have the security functions.

CP1543-1 The CP has the security functions : VPN, Firewall

CPU1516-3 X2 Port X2 of CPU does not have security functions

CPU1516-3 X1 Port X1 of CPU does not have security functions

Communication Performance to the ‘Central I&C Network’

TCP/IP maximum data volume to send in a single command

CP343-1-ADV 32KB Data with Block AG-SEND with a CPU Bit Operation Performance of 25ns

But diminished for the [CP CPU] backplane serial bus of 1MB communication

CPU317-2 32KB Data with Block T-SEND with a CPU Bit Operation Performance of 25ns

CP443-1-ADV 32KB Data with Block AG-SEND with a CPU Bit Operation Performance of 12.5ns

But diminished for the [CP CPU] backplane parallel bus communication

CPU416-3 32KB Data with Block T-SEND with a CPU Bit Operation Performance of 12.5ns

CP1543-1 64KB Data with Block T-SEND with a CPU Bit Operation Performance of 10ns

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Device to

connect Subject

But diminished for the [CP CPU] backplane serial bus communication

CPU1516-3 X2 64KB Data with Block T-SEND with a CPU Bit Operation Performance of 10ns

Reset of the Communication with Central I&C Networks CP343-1-ADV Reset of CP could be done using ‘SIEMENS Console’ connected through CPU

(without restarting CPU, so, not affecting buses attached to CPU interfaces)

CPU317-2

CP443-1-ADV Reset of CP could be done using ‘SIEMENS Console’ connected through CPU

(without restarting CPU, so, not affecting buses attached to CPU interfaces)

CPU416-3

CP1543-1 Reset of CP could be done using ‘Special Functions’: T-Reset

CPU1516-3 X2

Profinet Communication Number of slaves connected to Profinet Network CP343-1-ADV The CP can manage 32 devices

CPU317-2 The CPU (315 or 317) can manage 128 devices

CP443-1-ADV The CP can manage 128 devices

CPU416-3 The CPU (416-3 PN/DP) can manage 256 devices.

CP1543-1 The CP does not have Profinet capabilities

CPU1516-3 X1 CPU X1 can manage 256 devices

Necessary Functions to implement Profinet Communication CP343-1-ADV To communicate with the devices it is needed to add to the program the software

blocks ‘PNIO_SEND’ and ‘PNIO_RECV’

CPU317-2 To communicate with the devices no need to add software blocks

CP443-1-ADV To communicate with the devices no need to add software blocks


CP1543-1 The CP does not have Profinet capabilities


System Health Monitoring CP343-1-ADV CP failed to do this job with the standard program used by ITER. Other methods may

succeed.

CPU317-2 CPU can extract System Health data

CP443-1-ADV CP can extract System Health data


CP1543-1 CP cannot extract System Health data ( no PROFINET)


Every argument stated is corroborated with SIEMENS.

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B. Outcome of the analysis

For the 300 Family:

- It is advised to use a CP to perform the connection to the ‘Central I&C Networks’.

- It is advised to use a CP to perform the connection to the ‘Plant System Local (private)

Network’.

- It is advised to use the CPU to perform the connection to the Field Devices Network.

For the 400 Family:


- It is advised to use a CP to perform the connection to the ‘Plant System Local (private)

Network’.

- It is advised to use the CPU to perform the connection to the Field Devices Network.

For the 1500 Family:


Note: The use of the ‘CPU [Port X2]’ to perform this connection, instead of a CP, could

be accepted if the security and performance of the controller’s configuration is not

endangered.

- It is advised to use CPU Port X1 to perform the connection to the Field Devices

Network

- It is advised to use CP to perform the connection to a Plant System Local (Private)

Network.

Communication Performance Tests between CODAC and the most representative PLC

Configurations are being run at the time this document is released.

This information will be summarized in [RD10].

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5.7 Cubicle Monitoring System Selection

Cubicle Monitoring System is a mandatory requirement stated in the [R157] of the Plant

Control Design Handbook [RD1]:

- The I&C cubicles shall be equipped with a monitoring system for doors, temperature

and cooling monitoring and the monitoring system shall be interfaced to the plant

system I&C.

The detailed specification of the ‘Cubicle Monitoring System’ could be found in the ‘Chapter

7’ of the key document ‘I&C Cubicle Internal Configuration’ [RD7].

The solutions given are targeting the Conventional Control.

*In case the cubicle belongs to a Safety System please refer to the document [RD11].

A. Complete Solution for 1 cubicle

ITER is providing a standard complete solution for the monitoring of 1 single Cubicle.

This solution is already being widely used in the ‘Integration Kit [RD2]’ provided by CODAC

Section.

Target of the Solution:

So, this solution is targeting the monitoring of only 1 Cubicle

Figure 17 : Target of the solution for the monitoring of one single cubicle

Implementation of the solution:

Subject Reference Document

Electrical Diagrams I&C Integration Kit Cubicle Monitoring System(HMU)

Electrical Diagrams

Guide for the configuration

and start-up Guide for the configuration and start-up of the ITER

Standard Cubicle Monitoring System

Software SVN Link referenced in the ‘Guide for the Configuration and

start-up’

https://user.iter.org/?uid=QTD994&version=v1.2&action=get_document

https://user.iter.org/?uid=QTD994&version=v1.2&action=get_document

https://user.iter.org/?uid=RRF3NH&version=v2.2&action=get_document



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SIEMENS equipment involved in the solution:

TS90Ethernet Interface

RA

IL D

IN

CPU1214C

PON

Figure 18 : SIEMENS Hardware for CUB MON SYS 1 Single Cubicle

Short Designation QTY Description and Characteristics

CPU1214C 1

RAIL DIN

CPU 1214C 14DI, 10DO, 2AI

Power Supply 230V

*For the exact reference of every component please refer to [RD4].

*For the datasheet of the every product, use the reference and refer to SIEMENS Website.

B. Partial Solution for ‘2 to 11’ cubicles

ITER is providing a partial solution to monitor ‘from 2 to 11’ cubicles.

So, this solution is targeting the monitoring of a sets of cubicle, up to 11, placed in a row,

close, one after the other, or separated by small distances, less than 15 m.

Figure 19 : Target of the solution for the monitoring of ‘2 to 11’ Cubicles


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Implementation of the solution:

Subject Reference Document

Electrical Diagrams

Current IDM Electrical Diagrams are not applicable

The Electrical Diagrams must be developed for the supplier.

The Electrical Diagrams presented in the ‘Complete solution

for 1 single cubicle’ could be used as a template for the

dedicated electric diagrams to every particular case.

Guide for the configuration

and start-up

Current IDM Guide is applicable.

Guide for the configuration and start-up of the ITER

Standard Cubicle Monitoring System

Software

Software is applicable

( SVN Link referenced in the ‘Guide for the Configuration and

start-up’)

- Hardware Configuration of the Project will need to be

modified. Adding the new IO Boards.

- PLC-Code is applicable ( No modification is necessary)

SIEMENS equipment involved in the solution:

TS90Ethernet Interface

RA

IL D

IN

CPU

1214

C

CPU1214C

PON

SM12

21-1

6DI

SM12

21-1

6DI

SM12

22-8

DO

SM12

31-8

AI

SM12

31-8

AI

SM1221-16DI SM1222-8DO SM1231-8AI

Figure 20 : SIEMENS Hardware for CUB MON SYS From ‘2 to 11’ cubicles




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CPU1214C 1

RAIL DIN

CPU 1214C 14DI, 10DO, 2AI

Power Supply 230V

SM1221-16DI 2 ● 16 Digital Input for S7-1200

SM1222-8DO 1 ● 8 Digital Output for S7-1200

SM1231-8AI 2 ● 8 Analogue Input for S7-1200

SM1231-8AI 2 ● 8 Digital Output for S7-1200




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6 SYSTEMS COMPOSITION

6.1 Slow Controllers Range

A. Low (distributed) Range of Slow Controllers

Low range controllers are the intelligent choice for applications in the low to mid-performance

range. They are modular, small, compact and cost-effective. The objective is to achieve flexible

solutions for simple networking with integrated and optional communications connections.

The decentralization of intelligence helps hugely in making machines and plants more flexible

and is thus becoming a decisive competitive factor. Increasing networking makes possible to

integrate autonomous, intelligent units at the field level into the system-wide communication

system. The remote I/O systems capabilities can be expanded using integral, intelligent

controllers. This gives rise to distributed controllers.

6.1.A.1 Low (Distributed) Range PLCs: [S7-1500] CPU + IO Rack

Exceptionally, if the needs of the process are extremely limited and the segregation of the

functionalities in different controllers a main objective for the particular Control System the

use of the Distributed [CPU + IOs] could be suitable.

However, even in the case stated above the use of the ‘Distributed Remote I/O Modules’ in

their small version is highly recommended.

- The fact of using a PLC, uniquely, as a ‘Data Transmitter’ to a higher control instance

is not wise from a ‘Control System’ point of view. This is precisely the job of a

Distributed I/O Module.

- The fact of placing several controllers dedicated to control different functions of the

same Plant system in the same cubicle or contiguous cubicles is not wise from a

Cubicle configuration point of view.

The ‘Distributed CPU’ is using as a background support the Standard RAIL DIN.

The ‘I/O Modules’ to be attached to the CPU correspond to the ‘S7-1500 Small Range’

subfamily (ET200SP) and their background support is, as well, the standard RAIL DIN.

It is recommended to place the modules in the following order:

- Digital Inputs

- Digital outputs

- Analog Inputs

- Analog outputs.

The concern is not technical. The idea is to have same I/O structures on all racks.

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Figure 21 : Distributed Rack [S7-1500 + IO] exploded view


CPU1512SP-1 1 CPU1512SP-1 characteristics detailed in the datasheet.

TM-P-SP 1 Terminal Module for Power Supply

TM-E-SP (1..n)-1 Terminal Module for Power Supply Bridge

Monitors the supply voltage

Diagnostics support

Rated voltage 24VDC

SM131SP-16DI 1..n 16 DI Module, Module Diagnostic

SM132SP-16DO 1..n 16 DO Module, Module Diagnostic

SM134SP-4AI 1..n 4AI U/I Input Module, Module Diagnostic

SM134SP-4RTD/TC 1..n 4 RTD/TC input Module High Feature. Diagnosis

SM134SP-8AI-U 1..n 8 AI "U" Input Module, Diagnosis

SM134SP-8AI-I 1..n 8 AI "I" 2-/4-WIRE Input Module, Diagnosis

SM135SP-4AO 1..n 4 U/I Output Module, Diagnosis




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B. Medium Range of Slow Controllers

The perfect alternative for the mid-range applications; medium controllers offer the features

and flexibility needed without the overhead of larger systems, but suitable for medium and

complex applications. Medium controllers with modular expansion capability are long-term

compatible, maintenance-free, scalable and include safety certified. They are the ideal solution

for any automation task.

6.1.B.1 Mid-range PLCs: [S7-300 or S7-1500] CPU Rack

6.1.B.1.1 S7-300: CPU Rack

The S7-300 is the modular PLC system for the low and mid-performance ranges. In ITER, a

small plant system which requires medium range of performances could perfectly work using

these mid-range PLCs.

The backplane is the regular one, without Hot Swapping capability.

In the figure below, two possible configurations for the Ethernet Communication Processor

(CP343) are presented:

First configuration ( Standard one ) :

o A connection to a Profinet Network

o A connection to the Central I&C Networks

The connection to Profinet is made through the CPU Ethernet Port. The connection to

the Central I&C Networks through the CP343-1 Ethernet Port (the CP has 2 Ethernet

slots, but it is the same Ethernet connection)

Second configuration ( In case of Plant System Local (private) Network ) :

o A connection to a Profinet Network,

o A connection to a Plant System Local (Private) Network.

o A connection to the Central I&C Networks

The connection to Profinet is made through the CPU Ethernet Port. The connection to

the Plant System Local (Private) Net through the “X1” Interface of the CP343-1-Adv

and the connection to the Central I&C Networks through the “X2” Interface. Another

possibility is to add a new CP343-1 for the Plant System Local (private) Network.

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Figure 22: Rack s7-300 exploded view.

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PLC Software Engineering Handbook Page 44 of 83


RAIL-19IN 1 Rail 19"

PS300-5A 1 PS 300 5A (1 Slot)

MMC-2M-EEPROM 1 Micro Memory Card 2MB (Upto 8 MB Max)

CPU317-2 1 CPU 317-2 PN/DP (2x Eth) Central Unit.

Detailed information in [System Selection].

Detailed characteristics in datasheet.

CP343-1 1 Communication Processor Ethernet

16 Connections maximum

Profinet

1 x Ethernet Port

SEND/RECEIVE:

ISO-on-TCP: 8Kb

TCP/IP: 8Kb

UDP : 2Kb

S7 communications

Web based diagnostic

DHCP Client

NTP Client

SNMP v1

CP343-1-Adv 1 Communication Processor Ethernet


Profinet

2 x Ethernet Port

SEND/RECEIVE:

ISO-on-TCP: 8Kb

TCP/IP: 8Kb

UDP : 2Kb

S7 communications

Web based diagnostic

DHCP Client

NTP Client

SNMP v1




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6.1.B.1.2 S7-1500: CPU Rack

The S7-1500 is the modular PLC system for the mid-performance ranges. In ITER a small or

medium plant system which requires medium range of performances could perfectly work with

these Mid-range PLCs.

The backplane is the regular one for the 1500 family, without hot Swapping capability.

In the below, it is presented the basic configuration proposed for the ‘1500 family’.

Connection to Central I&C Networks

The connection to Central I&C Networks will be made through the Ethernet Port of the

CP 1543-1, installed in the second slot.

Connection to the FIELD (Remote IO) : FieldBus or FieldNet

The connection to Profinet will be made through the CPU Ethernet Port X1.

The connection to Profibus will be made through the CPU Profibus Port.

In case of Plant System Local (Private) Net

Connection to Plant System Local (Private) Network (S7 Comm. between PLCs).

Another CP will be installed (CP1543-1) in the third slot.

The connection to the ‘Plant System Local Network’ will be made through the Ethernet

Port of CP1543.

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Figure 23: Rack S7-1500 exploded view

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RAIL-1500-19IN 1 1500 MOUNTING RAIL 482 MM

PS1500-3A 1 PS 1507 24 V/3 A STABILIZED POWER SUPPLY

MMC-24M-EEPROM 1 SIMATIC S7, MEMORY CARD FOR S7-1X00

CPU/SINAMICS, 3,3 V FLASH, 24 MBYTE

CPU1516-3 1 CPU 1516-3 PN/DP Central Unit.


Detailed characteristics in the datasheet.

CP1543-1 1 Communication Processor Ethernet CP1543-1. Detailed

characteristics in datasheets.

Interfaces 1 Ethernet Interface

Performance

Data

118 Connections maximum (S7 and

Open Communication)

ISO-on-TCP by means of T Blocks:

64Kb

Protocols

Supported

S7/Open Communication

DCP

NTP

SNMP v1

Product

Function

Web Based Diagnostic




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6.1.B.2 Mid-range PLC with local IO: [S7-300 or S7-1500] CPU+IO Rack

6.1.B.2.1 S7-300: CPU+IO Rack

If the needs are very limited, a single rack with CPU+IOs may be sufficient. The first part is

identical to the CPU rack described in chapter [S7-300 CPU Rack]. The following boards are

Inputs/Outputs modules, of all the kind, detailed in the table below. Up to 7 modules can be

added after the Communication Processor CP343-1. If no communication modules appear in

the configuration, then, up to 8 modules can be added.


Special modules (RS232/RS485,…)

Digital Inputs

Digital outputs

Analog Inputs

Analog outputs.


Figure 24: Rack S7-300 + IO exploded view

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CP341-1 1 Communication Processor RS232,RS422,RS485

SM321-32DI n Digital Input Module, 32 DI, 24V, 500 V DC isolated

SM321-16DI n Digital Input Module, 16 DI Module with Channel

Diagnostics

SM322-32DO n Digital Input Module, 32 DO, 24V, 500 V DC isolated

SM322-8DO n Digital Input Module, 8 DO, 24V, 500 V DC isolated with

Channel Diagnostics

SM331-8AI n Analog Input Module, 8 AI, 500 V DC isolated, 15 bits,

Diagnostic Status

SM332-8AO n Analog Input Module, 8 AO, 500 V DC isolated, 12 bits,

Diagnostic Status




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6.1.B.2.2 S7-1500: CPU+IO Rack

If the needs are very limited, a single rack with CPU+IOs may be sufficient. The first part is

identical to the CPU rack described in the chapter [S7-1500: CPU Rack]. The following

boards are Inputs/Outputs modules, of all the kind, described in the following table. Up to 31

modules can be added after the CPU1516.

So, the Communication Processor will take the place right after the CPU1516, then 30 modules

more could be added.


Special modules (CM-PTP,…)

Digital Inputs

Digital outputs

Analog Inputs

Analog outputs.


Figure 25 : Rack S7-1500 + IO exploded view

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CM-PTP 1 Communication Module CM 1541-1 for Serial RS422,

RS485

SM521-32DI n 32 DI module with Diagnostics

SM522-32DO n 32 DO Module with Diagnostics

SM531-8AI n 8 Analog Inputs Module U/I/RTD/TC with Diagnosis

SM532-8AO n 8 Analog Outputs Module U/I with Diagnosis




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6.1.B.3 Mid-range Fail Safe PLCs: [S7-300 or S7-1500] CPU rack

Safety Configurations are used to control processes and adopt or remain in a safe state as soon

as an error occurs. They provide a consistent and efficient safety concept in plants with

increased safety requirements.

Safety Configurations will be used by Safety an Interlock systems. Specific information about

systems composition and network connectivity could be found, for these two ‘Control System’

vertical tiers, in their dedicated documentation; refer to [RD1].

However, an important detail to remember is that S7-300F for the OS can only be used for

local functions; central functions require a S7-400.

6.1.B.3.1 S7-300 “F” CPU rack

S7-300 “F” systems are medium range Fail safe systems provided by Siemens.

PS300-5A

CP343-1

RAIL-19IN

CPU Profibus DP Interface

CPU Ethernet Interface

CP343-1 Ethernet Interface

MMC-2MB-EEPROM

CPU 315F-2 PN/DP

Figure 26: Fail Safe, High range PLCs S7300F


RAIL-19IN 1 Rail 19"

PS300-5A 1 PS 300 5A (1 Slot)

CPU315F 1

CPU 315F-2 PN/DP (detailed information in datasheet).

Software STEP 7 V 5.5 or higher,

Distributed Safety V 5.4 SP4

MMC-2M-EEPROM 1 Micro Memory Card 2MB





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6.1.B.3.2 S7-1500 “F” CPU rack

S7-1500 “F” systems are medium range Fail safe systems provided by Siemens.

It is important to remember that at the time of the release of this document the ‘CSD-PCI-

Safety’ department guidelines do not cover yet this PLC. Please refer to the ‘CSD-PCI-Safety’

department to get the last update if you are willing to use this PLC for a Safety application.

Figure 27 : Fail Safe, High range PLCs S71500F


RAIL-1500-19IN 1 1500 MOUNTING RAIL 482 MM

PS1500-3A 1 PS 1507 24 V/3 A STABILIZED POWER SUPPLY

CPU1516F-3 1

CPU 1516-3 PN/DP Fail Safe CPU (detailed info in datasheet)

Software TIA Portal V14 SP1 or higher

Safety Advanced v14

CP1543-1

1

Communication Processor Ethernet CP1543-1.




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C. High Range of Slow Controllers

High Range Slow Controllers are suitable for the most demanding application needs. They

offer modular architectures and a wide spectrum of I/O and network options. These powerful

control solutions deliver world-class capabilities from process to safety to motion. Designed

for distributed or supervisory control applications, high range programmable automation

controllers provide multi-computing skills, modularity, exceptional reliability, performance

and diagnostic abilities.

6.1.C.1 High range PLCs: S7-400

The Figure 28 represents two kinds of configurations for the Ethernet Communication

Processor (CP443-1).

First configuration (standard configuration):


o A connection to the Central I&C Networks.

The connection to Profinet is made through the CPU Ethernet Port.

The connection to the ‘Central I&C Networks’ is made through the CP 443-1 Ethernet

Port. The CP has 2 Ethernet ports, but it is the same Ethernet connection.

Second configuration (in case of Plant System Local (Private) Net):


o A connection to a Plant System Local (Private) Network

o A connection to the Central I&C Networks.

The connection to Profinet is made through the CPU Ethernet Port.

The connection to the Plant System Local (Private) Network is made through the “X1”

Interface of the CP 443-1-Adv and the connection to the Central I&C Networks through

the “X2” Interface of the CP 443-1-Adv.

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Figure 28: Rack S7-400 exploded view.

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UR2 1 Chassis 400 UR2 9 Slots

PS400-10A 1 PS 400 10A

BAT-400 2 Back Up Battery 400

PCCARD-4MB-RAM 1 Memory PC Card 4MB RAM



CPU416-3 1 CPU 416-3 PN/DP Central Unit.


Detailed characteristics listed in datasheet.



Profinet

SEND/RECEIVE:

ISO-on-TCP: 8Kb

TCP/IP: 8Kb

UDP : 2Kb

Open IE (“T” Blocks)

ISO-on-TCP: 1452 Bytes

S7 communications

http server

DHCP Client

NTP Client

SNMP v1

CP443-1-ADV 1 Communication Processor Ethernet “Advanced”.

This CP has 2 interfaces, and supports some more protocols.

For each Interface:


Profinet

IRT

SEND/RECEIVE:

ISO-on-TCP: 8Kb

TCP/IP: 8Kb

UDP : 2Kb

Open IE (“T” Blocks)

ISO-on-TCP: 1452 Bytes

S7 communications

http server

DHCP Client

NTP Client

SNMP v1

FTP




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6.1.C.2 High range Fail Safe PLCs: S7-400 “F” CPU rack

Safety systems are used to control processes and adopt or remain in a safe state as soon as an

error occurs. They provide a consistent, efficient safety concept in plants with increased safety

requirements. S7-400 “F” systems are high range Fail safe systems provided by Siemens.

The hardware is exactly the same at what is shown in the redundant configuration, but in a

Single Configuration (either CP443-1 or CP443-1-ADV can be used depending of the needs of

the system)

These systems will be used by Safety an Interlock systems. More information regarding

network connectivity can be found in the documentation of these systems.

Figure 29: Fail Safe, High range PLCs S7400F



PS400-10A 1 PS 400 10A


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PCCARD-4MB-RAM

(or FLASH)

1 Memory PC Card 4MB RAM

CPU414-H 1 CPU 414-5H PN/DP. Detailed characteristics listed in

datasheets.

Memory Work memory

Integrated 4 Mbyte

Integrated (for program) 2 Mbyte

Integrated (for data) 2 Mbyte

Load memory

Expandable FEPROM, max. 64

Mbyte

Integrated RAM, max. 512 Kbyte

Expandable RAM, max. 64

Mbyte

Address Area I/O address area

Inputs 8 Kbytes

Outputs 8 Kbytes

Process Images

Inputs 8 Kbytes

Outputs 8 Kbytes

Profibus DP

Interface First Interface:

RS 485 / PROFIBUS + MPI ,

MPI + DP Master,

32 Max DP Slaves

Second Interface:

RS 485 / PROFIBUS,

DP Master,

96 Max DP Slaves

Ethernet

Interface 64 connections maximum

Profinet

open ie,

o TCP : 32Kb

o ISO-on-TCP : 32Kb

o UDP : 1452 Bytes

S7 communications

Integrated Switch

Software STEP 7 v5.5 SP2 with HF1

(or CPU416-H)

(or CPU417-H)


CP443-1-ADV 1 Communication Processor Ethernet Advanced


*For the datasheet of the every product, use the reference and refer to SIEMENS Website


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6.1.C.3 High Range, High Availability PLCs: S7-400 “H” CPU Rack

In addition to the Failsafe feature, this PLC configuration presents High Availability: it is

redundant.

These devices will be used for Safety an Interlock control systems. More information

regarding network connectivity can be found in the documentation of these systems.

A highly availability controller minimizes the probability of production failures and thus

decisively contributes to maximum productivity and safety.

Picture below represents the complete architecture of a S7-400FH. Three noticeable facts:

Connection to ‘Remote I/Os’ is made through Profibus or Profinet, using the interfaces that

the CPU provides. And preferably stablishing rings ‘Profinet Redundant Ring’ or ‘Profibus

Redundant Ring’ in order to make the ‘IO Network’ more reliable.

The connection to the Central I&C Networks is still established through a CP while there is

an Ethernet connection on the CPU.

o Previously the CPU414-4H itself didn’t have an Ethernet connexion, so the CP was

required. Now the systems CPU416-H and CPU417-H already have Ethernet Port

included in the CPU, but the recommendation remains the same : use CP.

Configuration of the two redundant backplane shall be exactly the same. They are twins.

Figure 30: High availability PLCs architecture

*At the moment of the release of this document, the connexion to the Central I&C Networks

for Conventional Control, through on-board Ethernet Connexion of a Redundant PLC is being

tested. Please refer to ‘Control System Division’ to know the last update of the tests if you are

willing to use it.

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Here below the advantages of using high availability PLC Configuration:

Highest system availability with early fault detection and integrated diagnostic

capabilities

Efficient solutions with scalable performance and redundancy

Simple programming and configuration

Performance-oriented solution for time-critical processes

Synchronized hardware solution without information loss

Highly available communication via Industrial Ethernet

Integrated diagnostic functions

Exchange of all components during operation ( hot swapping)

The figure below shows a S7-400H Configuration in detail:

UR2-2x9

CPU4146-H

PS400-1

0A-KR

PS400-1

0A-KR

CP443-1

PS400-10A-KR

CP443-1

SYNC-10KM-5H

PCCARD-4MB-FLASH

PCCARD-4MB-RAM

SYNC-10M-5H

2 x UR2

CPU414-H

PS400-1

0A-KR

PS400-1

0A-KR

CP443-1EX20

RACK “A” RACK “B”

Sync

Sync

F0-10M

F0-2M

PON

CPU416-H

4xBAT400

CP443-1-ADV Ethernet Interface

“X1”

CP443-1-ADV Ethernet Interface

“X2”

PON

Private Net(S7)

CP443-1-ADV

Replace CP443-1 of every

RACK for

In case of PS Local (private) Network

PON

Figure 31: High availability PLCs S7-400H

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Both stations are connected to each other with Synchro modules and fiber cables.

o Be careful with references, the older references for previous CPU414H are still

available for spare parts, they are not compatible with the new generation “5H”.

There are 2 types of Synchro Modules:

o For a distance of up to 10 m,

o For a distance up to 10Km.

Siemens provides 10m and 2m cables. For longer distances, cables shall be bought to

specific providers.

2 different backplanes of 9 slots must be used if each S7-400 CPU is installed in different

cubicles. Otherwise, in the same cubicle, a 2x9 backplane has to be used. Be careful it is

not a regular 18 slots backplane!

Plant System Local (private) Net is optional, depending of the needs of the Plant System. In

case this is necessary, a supplementary CP443-1 must be installed or the current CP443-1

(appearing in the drawing above) must be replaced for a CP443-1-Adv.


UR2-2x9 1 Chassis 400 UR2H 18 Slots (2x9)


PS400-10A-KR 4 PS 400 10A For Redundant Rack


PCCARD-4MB-RAM

(or FLASH)

2 Memory PC Card 4MB RAM

CPU416-H

(or CPU414-H)

(or CPU416-H)

2 CPU 416-5H PN/DP Central Unit. Detailed characteristics

listed in datasheets.

Memory Work memory

Integrated 16 Mbyte

Integrated (for program) 6 Mbyte

Integrated (for data) 10 Mbyte

Load memory

Expandable FEPROM, max. 64

Mbyte

Integrated RAM, max. 1Mbyte

Expandable RAM, max. 64

Mbyte

Address Area I/O address area

Inputs 16 Kbytes

Outputs 16 Kbytes

Process Images

Inputs 16 Kbytes

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Outputs 16 Kbytes

Profibus DP

Interface First Interface:

RS 485 / PROFIBUS + MPI ,

MPI + DP Master,

32 Max DP Slaves

Second Interface:

RS 485 / PROFIBUS,

DP Master,

125 Max DP Slaves

Ethernet

Interface 96 connections maximum

Profinet

open ie,

o TCP : 32Kb

o ISO-on-TCP : 32Kb

o UDP : 1452 Bytes

S7 communications

Integrated Switch

Software STEP 7 v5.5 SP2 with HF1

FO-2M 2 Synchro Cable FO 2m

FO-10M 2 Synchro Cable FO 10m

SYNC-10M-5H 2 Synchro Module FO 10m compliant 414-5H

SYNC-10KM-5H 2 Synchro Module FO 10km compliant 414-5H





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6.2 Remote I/O Modules Range

A. Small I/O modules [S7-300 or S7-1500]

Distributed I/O systems are particularly easy to operate, and with its compact design it achieves

maximum economy in the control cabinet. Their high speed and transmission rate ensure

significantly greater performance than conventional systems. Several modules have been

identified in ITER.

The CPUs 300/400/1500 work with these modules remotely.

Two types of ‘Distributed I/O’ are presented in the catalogue:

- ET200S for the S7-300 Family

- ET200SP for the S7-1500 Family

6.2.A.1 S7-300 Family: ET200S

Figure 32 is showing how to build the system.

The configuration can have up to 63 signal modules in an ET200S. A Power Module (PM-E)

is placed in front of a bank of signals modules. The maximum number of signal modules for a

bank depends on the current consumption. A Terminal Module (TM-E) can drive up to 8A.

ET200S modules have hot swapping capability.

PM-E module requires a TM-P base. SMs modules require TM-E bases.

Figure 32: ET200S Modules exploded view

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IM151-1 HF 1 Interface Module for linking ET200S to Profibus DP.

Supports DP V0 and DP V1

Connection type RS485

IM151-3 1 IM151-3 PN Interface module for ET200S IO modules

Interface module for linking the ET 200S to PROFINET

Integrated 2-port switch

MMC-128K-EEPROM Micro Memory Card 128 KB

TM-P 1 TM-P Terminal Module for Power Supply

PM-E 1 Power Module for PM-E electronic Module

TM-E (1..n) -1 Terminal Module for Power Supply Bridge


Diagnostics support

Rated voltage 24VDC

Electrical isolation

SM131-8DI 1..n Digital Input Module, 8 DI, 24V, 500 V DC isolated

SM131-8DO 1..n Digital output Module, 8 DO, 24V, 500 V DC isolated

SM134-2AI 1..n Analog Input Module, 2 AI, 500 V DC isolated, 14 bits,

Diagnostic Status

SM134-2TC 1..n Thermocouple Module, 2 AI, 500 V DC isolated, 16 bits,

Diagnostic Status

SM134-2AO 1..n Analog Output Module, 2 AO, 13 bits, 500 V DC isolated,

Diagnostic Status

SM134-2RTD 1..n RTD Module, 2 AI, 16 bits, 500 V DC isolated, Diagnostic

Status




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6.2.A.2 S7-1500 Family: ET200SP

Figure below is showing how to build the system.

The configuration can have up to 32 signal modules. The first ‘I/O board’ will need a Terminal

Power Module (TM-P-SP), so, this is placed in the first position, top left (this is necessary to

feed the whole process downstream of the ET200SP). Right after, every ‘I/O board’ will need

one Terminal Follower Module (TM-E-SP).

The maximum number of signals for a bank depends on the current consumption. A TM-P-SP

can drive up to 10A.

ET200SP modules have hot swapping capability.

Figure 33: ET200SP Modules exploded view

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IM155DP-6DP-HF 1 Interface Module to link ET200SP to Profibus DP.

Supports DP V0 and DP V1

Connection type RS485

IM155PN-6DP-ST 1 Interface Module to Link ET200SP to PROFINET

Integrated 2 port Switch

TM-P-SP 1 Terminal Module for Power Supply

TM-E-SP (1..n)-1 Terminal Module for Power Supply Bridge


Diagnostics support

Rated voltage 24VDC

SM131SP-16DI 1..n 16 DI Module, Module Diagnostic

SM132SP-16DO 1..n 16 DO Module, Module Diagnostic

SM134SP-4AI 1..n 4AI U/I Input Module, Module Diagnostic

SM134SP-4RTD/TC 1..n 4 RTD/TC input Module High Feature. Diagnosis

SM134SP-8AI-U 1..n 8 AI "U" Input Module, Diagnosis

SM134SP-8AI-I 1..n 8 AI "I" 2-/4-WIRE Input Module, Diagnosis

SM135SP-4AO 1..n 4 U/I Output Module, Diagnosis




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B. Medium I/O modules [S7-300 or S7-1500]

6.2.B.1 S7-300 Family: ET200M

ET200M is a modular I/O system used for user-specific and complex automation tasks:

o Used with S7 SIEMENS automation system to expand signals , communication and

function modules :

o In CPUs S7-300 in both local and Remote

o In CPUs S7-400 & S7-400H in Remote

o In CPUs S7-1500 in remote

o Supports PROFIBUS DP and PROFINET interface module

o Modules can be replaced during operation (hot swapping) with the bus modules active.

Attention must be paid to the type of base module:

o PS300-5A and IM must be place on a “BM-PS-IM153” base module.

o SM modules must be placed on “BM-sx40 base” modules.

o If the architecture is redundant, the IM153-2 modules must by placed on “BM-IM153-

IM153” base modules

If the configuration uses Profibus, you can set up to 8 SM modules.

If the configuration uses Profinet, you can set up to 12 SM modules.

RAIL-19IN-HS

PS300-5

A

SM321-3

2DI

IM153-4

SM322-3

2DO

SM332-8

AI

SM331-8

TC

PS300-5A

IM153-4 IM153-2OR

IM Profibus DP Interface

IM ProfiNet Interface

RAIL-19IN-HS

BM-PS-IM153

BM-2x40 BM-2x40 BM-2x40

MMC-128K-EEPROM

Figure 34: ET200M Modules

See Table below

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Figure 35: ET200M Modules to use with s7-400”H”


RAIL-19IN-HS 1 Mounting Rail Hot SWAP length: 19 Inches, up to 5 bus

modules

PS300-5A 1 PS 300 5A (1 Slot)

IM153-4 1 IM153-4 High Feature (ProfiSafe Compliant)


PN IO Transmission protocol

IM153-2 1 IM153-2 Standard Feature

Profibus Transmission Protocol

MMC-128K-EEPROM 1 Micro Memory Card 128 KB

BM-PS-IM153 1 Backplane Module PS/IM153. Hot swap capability

SM321-32DI 1 Digital Input Module, 32 DI, 24V, 500 V DC isolated

SM322-32DO 1 Digital Input Module, 32 DO, 24V, 500 V DC isolated

SM331-8AI 1 Analog Input Module, 8 AI, 500 V DC isolated, 15 bits,

Diagnostic Status

SM332-8AO 1 Analog Input Module, 8 AO, 500 V DC isolated, 12 bits,

Diagnostic Status

BM-2x40 n/2 Backplane Module 2x40. Hot swap capability




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6.2.B.2 S7-1500 Family: ET200MP

ET200MP is a module I/O system used for user-specific and complex automation tasks:

o Used with S7 SIEMENS automation system to expand signals , communication and

function modules :

o In CPUs S7-1500 in both local and Remote

o In CPUs S7-400 in Remote

o In CPUs S7-300 in Remote

o Supports PROFIBUS DP or PROFINET interface module

o Modules cannot be replaced during operation with the bus module active. Without hot

swapping capability.

If the configuration uses Profibus, you can set up to 12 SM modules.

If the configuration uses Profinet, you can set up to 12 SM modules.

Figure 36: ET200MP Modules

See Table below

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RAIL-1500-19IN-HS 1 1500 Mounting Rail 482 MM. Including grounding

element

PS1500-8A 1 PS 1507 24V/8A Stabilized Power Supply

IM155-5PN-HF 1 IM153-5PN High Feature



Profisafe Compliant

IM155-5DP-ST 1 IM155-5DP Standard Feature

Profibus Transmission protocol

Profisafe Compliant

U-TYPE-CONNECTOR N Spare Part, U-Type-Connector for Connection IO Module

SM521-32DI 1 32 DI module with Diagnosis

SM522-32DO 1 32 DO Module with Diagnosis

SM531-8AI 1 8 Analog Inputs Module U/I/RTD/TC with Diagnosis

SM532-8AO 1 8 Analog Outputs Module U/I with Diagnosis




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C. Medium I/O Fail-Safe modules [S7-300 or S7-1500]

6.2.C.1 S7-300 Family: ET200M –“F”

ET200M-F is a modular I/O system used for Fail-Safe automation tasks:

o Used in S7 SIEMENS automation system to expand signals, communication and function

modules :

o In CPUs S7-300F in both local and Remote

o In CPUs S7-400F and S7-400FH in Remote

o In CPUs S7-1500F in remote

o Supports PROFISAFE over Profibus DP

o Modules can be replaced during operation (hot swapping) with the bus modules active.

Attention must be paid to the type of base module:

o PS300-5A and IM must be place on a “BM-PS-IM153” base module.

o SM modules of 1 slot width must be placed on “BM-2x40” base modules.

o SM modules of 2 slots width must be placed on “BM-80” base modules

o If the architecture is redundant, the IM153-2 modules must by placed on “BM-IM153-

IM153” base modules

You can set up to 8 SM modules on the same rack.

Figure 37: ET200M “F” Modules

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Figure 38: ET200M “F” Modules for S7-400FH


RAIL-19IN-HS 1 Mounting Rail Hot SWAP length: 19 Inches

PS300-5A 1 PS 300 5A (1 Slot)

IM153-2 1-2 IM 153-2 Profibus Coupler

BM-PS-IM153 0..n Backplane Module PS + IM153

BM-IM153-IM153 0..n Backplane Module IM153+ IM153

BM-80 0..n Backplane Module for 80mm modules

BM-2x40 0..n Backplane Module for 2x 40mm modules.

SM326-24DI 0..n 24 F-DI Module

SM326-10DO 0..n 10 F-DO Module

SM336-6AI 0..n 6 F-AI Module




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6.2.C.2 S7-1500 Family: ET200MP –“F”

ET200MP-F is a modular I/O system used for Fail-Safe automation tasks:

o Used in S7 SIEMENS automation system to expand signals, communication and function

modules :

o In CPUs S7-1500F in both local and Remote

o In CPUs S7-400F in Remote

o In CPUs S7-300F in remote

o Supports PROFISAFE over Profibus DP and PROFINET

o Modules cannot be replaced during operation with the bus modules active.

You can set up to 12 SM modules on the same rack using the PROFIBUS header

You can set up to 30 SM modules on the same rack using the PROFINET header.

OR

IM Profibus DP Interface

IM ProfiNet Interface

PS1500-8A IM155-5DP-STIM155-5PN-HF

RAIL-1500-19IN

SM526-16DI SM526-8DO

SM526-1

6DI

SM526-8

DO

Figure 39: ET200MP “F” Modules

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RAIL-1500-19IN-HS 1 1500 Mounting Rail 482 MM. Including grounding

element

PS1500-8A 1 PS 1507 24V/8A Stabilized Power Supply

IM155-5PN-HF 1 IM153-5PN High Feature



Profisafe Compliant

IM155-5DP-ST 1 IM155-5DP Standard Feature

Profibus Transmission protocol

Profisafe Compliant

U-TYPE-CONNECTOR n Spare Part, U-Type-Connector for Connection IO Module

SM326-16DI 1 16 F-DI Module

SM326-8DO 1 8 F-DO Module




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6.3 Accessories


SITOP-10A 1 PS SITOP 10A

SITOP-20A 1 SITOP power supply Modular 230Vac/24Vdc 20A

SITOP-DIODES 1 SITOP redundancy module 24Vdc/40A

PC-USB 1 PC Adapter (USB)




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7 NETWORK COMPOSITION

The network is an integral part of the Control System infrastructure based on slow controllers.

In this chapter, a set of equipment is presented to ease and drive the job of development of such

infrastructure.

- Field Network Architecture equipment

To implement the immediate layer below the ‘Slow Controllers’; to connect them to

their slaves, using either Profinet or Profibus.

- Plant System Local (Private) Network Architecture equipment

To implement the immediate layer above the ‘Slow Controllers’, to interconnect them,

using Ethernet.

7.1 Field Network Architecture equipment

A. Field Bus (Profibus) components

The ‘FieldBus (Profibus) components’ are the ‘Media Converters and Connectivity devices’.

This equipment will be used to deploy the ‘Profibus Network Architecture’.

A Key device is the OLM (Optical Link Module or Profibus transceiver module (TS)),

normally called Media Converter, represented several times in the chapter: [Network

Selection].


PB-CABLE

- Profibus Cable (20m)

PB-CON

- Profibus Connector

OLM

-

Profibus Optical Link Module

1 RS485 and 1 Glass-Focinterface (2 Bfoc-Sockets)

Single mode fiber. Support Ring Redundancy

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B. Field Net (Profinet) components

The ‘FieldNet (Profinet) components are the ‘Field Switches’.

This equipment will be used to deploy an ‘independent Profinet Network Architecture’ stated

in the chapter: [Network Selection].

Two references are stated, both of them suitable to implement properly this task.


RS20-08 (Hirschman)

0..n

DIN Mounting

8 ports: 6 RJ45/2 FO

10/100Mbits

FO: Monomode, SC connectors

24VDC Power Supply

Manageable

Redundancy Management: Hyper-Ring

X308-2LD (Siemens)

0..n

DIN Mounting

10 ports : 7 RJ45/2FO

10/100/1000Mbits

FO: Monomode, SC connectors

24VDC Power Supply

Manageable

Redundancy Management




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7.2 Plant System Local (Private) Network Architecture equipment

The ‘Plant System Local Network components’ are the ‘Network Switches’.

This equipment will be used to deploy an ‘independent Plant System Local (Private) Network’

stated in the chapter: [Network Selection].

Two references are stated, both of them suitable to implement properly this task.


MACH102 (Hirschman)

0..n

19” RACK Mounting

24 Ports Fast Ethernet

2 Ports Combo Ethernet Gigabit

10/100/1000Mbits

230 VAC Power Supply

Manageable

Redundancy Management: Hyper-Ring

XR324-12M (Siemens)

0..n

19” RACK Mounting

24 ports (ST, SC, LC)

100/1000Mbits

230 VAC Power Supply

Manageable

Redundancy Management

*This is the network equipment to be used, also, when the PLC must be connected to the

‘Central I&C Networks’. This equipment should be provided, by default, with the Interface Kit

[RD3].




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8 SOFTWARE : STEP7 & TIA Portal

8.1 STEP7 STEP7 is an engineering software for the configuration and programming of SIMATIC-S7

PLCs of SIEMENS. Targeting the families: S7-300 and S7-400.

A. Dependencies

The graph below shows the software packages required, depending on the type of applications.

The blue coloured rectangles boxes represents installable packages,

The container rectangles represent inseparable packages, for commercial and/or technical

reasons.

The ellipses represent in which domain of activity the software package is used in ITER (in

the current state of development), linked to the device able to develop such task :

o S7-300,S7-400,S7-300F, S7-400FH

The arrows represent the dependencies. Between applications and software packages, and

between software packages.

Distributed Safety

Step 7 Professional Bundle

F Systems

STEP7(LAD,FBD,LST)

SCL CFCPLCSIM S7-Graph

Distributed Safety

(Programming)

S7 F Configuration Pack (Library)

F Systems (Programming)

F Systems (Library)

ConventionalControl Applications

S7-300,S7-400

Safety ApplicationsS7-300F

Interlock & Safety Applications

S7-400FH

Opt

iona

l

Figure 40: Software and Applications Dependency Tree for STEP7

For safety applications, there are 2 ways. The reason is that ‘Distributed Safety (F)’ and F-

Systems (FH) are two different product lines in Siemens. Their life cycles are completely

dissociated. F-Systems can be user for any application whereas distributed safety is only

allowed for systems implementing local functions.

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Important: if you deploy a S7-400FH without the redundancy feature, you will finally

have something more or less functionally equivalent to a S7-400 F. But it will not be a

genuine S7-400F, at least from the Siemens perspective.

The “Distributed Safety” Package is in 2 parts:

“Distributed Safety: ” programming part

“S7 F Configuration Pack”: Library part

Both packages are provided together and require to be installed.

The “F Systems” Package is in 2 parts:

“F Systems ” programming part

“F Systems Library”: Library part

Both packages are provided together and require to be installed.

B. Versions compatibility

The versions compatibility is a complex topic. Siemens is regularly issuing new major or

minor versions, service packs and updates. They also are keeping up with their supporting OS

Microsoft Windows roadmap. A versions compatibility matrix is maintained at the following

location:

http://support.automation.siemens.com/WW/llisapi.dll?func=cslib.csinfo&lang=en&objid=187

34363&caller=view

In the table underneath, there is an example of a “coherent” suite that can be installed under

Windows 7 64 Bits + SP1 Ultimate, Enterprise or Pro.

It is including the latest packages at the time of writing this document.

Short Designation Description

Bundle Package

Step 7 Professional

Bundle

Step 7 Basic LAD,FDB,LST editors

PLCSIM Hardware Simulator

SCL Structured Text Editor

S7-Graph Graphset Editor

CFC CFC Continuous Flow Chart editor.

Distributed Safety Distributed Safety “Programming” Part

S7-F Configuration Pack “Library” Part

“F” Systems “F” Systems “Programming” Part

“F” Systems Library “Library” Part

http://support.automation.siemens.com/WW/llisapi.dll?func=cslib.csinfo&lang=en&objid=18734363&caller=view

http://support.automation.siemens.com/WW/llisapi.dll?func=cslib.csinfo&lang=en&objid=18734363&caller=view

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8.2 TIA Portal

TIA PORTAL is an engineering software for the configuration and programming of SIMATIC-

S7 PLCs of SIEMENS. Targeting the families: S7-1200, S7-1500, S7-300 and S7-400.

A. Dependencies

The figure below shows the software packages required, depending on the type of applications.

The blue coloured rectangles boxes represents installable packages,

The container rectangles represent inseparable packages, for commercial and/or technical

reasons.

Safety Advanced

Step 7 Professional Bundle

PLCSIM

TIA Portal(LAD,FBD,STL,S7-Graph)

SCL PLCSIM S7-Graph

Safety Advanced

(Programming)

Safety Advanced (Library)

ConventionalControl Applications

S7-1200,S7-1500S7-300,S7-400

Interlock ApplicationsS7-1500F

PLCSIMAdvanced

Figure 41: Software and Applications Dependency Tree for TIA Portal

About the Software Packages:

Safety Advanced V14 SP1:

STEP 7 Safety Advanced is the add-on package for all fail-safe TIA SIMATIC controller

classes (S7-1500, S7-1200, S7-1500 Software Controller, S7-300, S7-400, WinAC).

This add-on package combines updated engineering features and supports the extended

portfolio of S7-1500F and S7-1200F.

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With ‘Safety Advanced’ package, configuration control (option handling) for SIMATIC F-I/O

is supported in the following configurations:

o Distributed on a F-CPU S7-300/400/1200/1500

o Central on a F-CPU S7-1500 (including fail-safe ET200SP CPUs)

Simatic PLCSIM Advanced

SIMATIC PLCSIM Advanced enables you to create virtual controllers for simulating S7-1500

and ET 200SP controllers and provides extensive simulation of functions. Compared to the

standard S7-PLCSIM, PLCSIM Advanced offers the following additional functions:

o API for connection to co-simulations

o Multiple, distributed instances possible

o Web server and OPC UA access.

B. Versions compatibility

To be able to install TIA Portal, you need one of the following operating system versions:

• Windows 7 Professional/Enterprise/Ultimate in 32/64Bit

• Windows 8 Professional/Enterprise

• Windows Server 2008 R2 Standard SP1

• Windows Server 2012

Siemens is regularly issuing new major or minor versions, service packs and updates for TIA

portal. Below table provide the list of packages

Short Designation Description

Bundle Package

Step 7 Professional

bundle

TIA Portal LAD,FDB,STL,SCL and

S7-GRAPH editors

PLCSIM Hardware Simulator

Safety Advanced Safety Advanced “Programming” Part

Safety Advanced “Library” Part

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8.3 What version to install ?

In fact one doesn’t really have the choice. Siemens is selling only the latest Software release.

SIEMENS will also give support on the compatibility between the installed packages, and the

new ones. If some packages, already installed, are incompatible with the new one installed, the

only solution is to upgrade the obsolete ones, and eventually pay for the upgrade.

If the software packages installed in the ‘Siemens Console’ are not updated to the latest

version, there is no need to upgrade unless:

The application is facing a technical issue, solved in a newer version.

The application need to configure a new hardware, not supported by the current

version.

Siemens will assume support on any “coherent” package, according to their compatibility table,

no matter how old it is.

The version of the software to use is stated in [RD4].

8.4 Applications portability between versions

The ascendant compatibility is complete, and assumed by Siemens. In other words any

application created in version “n” is compatible with the “n+i” version. There are just a few

possible problems, because sometimes some freedom possible in version “n” is restricted in

version “n+i”. But Siemens always supports these cases and provides the solution.

The reverse way is not advised but remains possible, in some conditions:

If the application didn’t add a hardware not supported in “n-i” version

If the application didn’t add a feature (ie a System Block) not available in “n-i” version.

For minor code modification, they should remain compatible.

This information is critical and must be taken into account for the transfer of responsibility

between the supplier and ITER.

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