Siemens SIMATIC S7, SIMATIC S7-200 SMART System Manual

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SIMATIC

S7 S7-200 SMART

System Manual

V2.3, 07/2017

A5E03822230

Preface

Product overview

Getting started

Installation

PLC concepts

Programming concepts

PLC device configuration

Program instructions

Communication

Libraries

Debugging and troubleshooting

PID loops and tuning

Open loop motion control

Technical specifications

Calculating a power budget

Error codes

Special memory (SM) and system symbol names

References

Ordering information

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A5E03822230-AF

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Legal information

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WARNING

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CAUTION

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NOTICE

indicates that property damage can result if proper precautions are not taken.

Qualified Personnel

personnel qualified

Proper use of Siemens products

WARNING

Siemens products may only be used for the applications described in the catalog and in the relevant technical

maintenance are required to ensure that the products operate safely and without any problems. The permissible ambient conditions must be complied with. The information in the relevant documentation must be observed.

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Disclaimer of Liability

This manual contains notices you have to observe in order to ensure your personal safety, as well as to prevent damage to property. The notices referring to your personal safety are highlighted in the manual by a safety alert symbol, notices referring only to property damage have no safety alert symbol. These notices shown below are graded according to the degree of danger.

If more than one degree of danger is present, the warning notice representing the highest degree of danger will be used. A notice warning of injury to persons with a safety alert symbol may also include a warning relating to property damage.

The product/system described in this documentation may be operated only by task in accordance with the relevant documentation, in particular its warning notices and safety instructions. Qualified personnel are those who, based on their training and experience, are capable of identifying risks and avoiding potential hazards when working with these products/systems.

Note the following:

documentation. If products and components from other manufacturers are used, these must be recommended or approved by Siemens. Proper transport, storage, installation, assembly, commissioning, operation and

All names identified by ® are registered trademarks of Siemens AG. The remaining trademarks in this publication may be trademarks whose use by third parties for their own purposes could violate the rights of the owner.

We have reviewed the contents of this publication to ensure consistency with the hardware and software described. Since variance cannot be precluded entirely, we cannot guarantee full consistency. However, the information in this publication is reviewed regularly and any necessary corrections are included in subsequent editions.

for the specific

06/2017 Subject to change

Preface

Purpose of the manual

Required basic knowledge

Scope of the manual

Certification, CE label and other standards

Service and support

The S7-200 SMART series is a line of micro-programmable logic controllers (Micro PLCs) that can control a variety of automation applications. Compact design, low cost, and a powerful instruction set make the S7-200 SMART a perfect solution for controlling small applications. The wide variety of S7-200 SMART models and the Windows-based programming tool give you the flexibility you need to solve your automation problems.

This manual provides information about installing and programming the S7-200 SMART CPUs and is designed for engineers, programmers, installers, and electricians who have a general knowledge of programmable logic controllers.

To understand this manual, it is necessary to have a general knowledge of automation and programmable logic controllers.

This manual describes the following products:

● STEP 7-Micro/WIN SMART V2.3

● S7-200 SMART CPU firmware release V2.3

For a complete list of the S7-200 SMART products and article numbers described in this manual, see Technical Specifications (Page 679).

Refer to the technical specifications for more information.

In addition to our documentation, we offer our technical expertise on the Internet on the customer support web site (http://www.siemens.com/automation/).

Contact your Siemens distributor or sales office for assistance in answering any technical questions, for training, or for ordering S7 products. Because your sales representatives are technically trained and have the most specific knowledge about your operations, process and industry, as well as about the individual Siemens products that you are using, they can provide the fastest and most efficient answers to any problems you might encounter.

S7-200 SMART System Manual, V2.3, 07/2017, A5E03822230-AF

Preface

Security information

Siemens provides products and solutions with industrial security functions that support the secure operation of plants, systems, machines and networks.

In order to protect plants, systems, machines and networks against cyber threats, it is necessary to implement – and continuously maintain – a holistic, state-of-the-art industrial security concept. Siemens’ products and solutions only form one element of such a concept.

Customer is responsible to prevent unauthorized access to its plants, systems, machines and networks. Systems, machines and components should only be connected to the enterprise network or the internet if and to the extent necessary and with appropriate security measures (e.g. use of firewalls and network segmentation) in place.

Additionally, Siemens’ guidance on appropriate security measures should be taken into account. For more information about industrial security, please visit (http://www.siemens.com/industrialsecurity).

Siemens’ products and solutions undergo continuous development to make them more secure. Siemens strongly recommends to apply product updates as soon as available and to always use the latest product versions. Use of product versions that are no longer supported, and failure to apply latest updates may increase customer’s exposure to cyber threats.

To stay informed about product updates, subscribe to the Siemens Industrial Security RSS Feed under (http://www.siemens.com/industrialsecurity).

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Preface ................................................................................................................................................... 3

1 Product overview .................................................................................................................................. 17

2 Getting started ...................................................................................................................................... 31

3 Installation ............................................................................................................................................ 47

1.1 S7-200 SMART CPU .............................................................................................................. 18

1.2 New features ........................................................................................................................... 21

1.3 CPU feature differences.......................................................................................................... 23

1.4 S7-200 SMART expansion modules ....................................................................................... 26

1.5 HMI devices for S7-200 SMART ............................................................................................. 27

1.6 Communications options ........................................................................................................ 28

1.7 Programming software ............................................................................................................ 29

2.1 Connecting to the CPU ........................................................................................................... 31

2.1.1 Configuring the CPU for communication ................................................................................ 32

2.1.1.1 Overview ................................................................................................................................. 32

2.1.1.2 Establishing the Ethernet hardware communication connection ............................................ 33

2.1.1.3 Setting up Ethernet communication with the CPU .................................................................. 34

2.1.1.4 Establishing the RS485 hardware communication connection............................................... 36

2.1.1.5 Setting up RS485 communication with the CPU .................................................................... 37

2.2 Creating the sample program ................................................................................................. 39

2.2.1 Network 1: Starting the timer .................................................................................................. 40

2.2.2 Network 2: Turning the output on ........................................................................................... 41

2.2.3 Network 3: Resetting the timer ............................................................................................... 42

2.2.4 Setting the CPU type and version for your project ................................................................. 43

2.2.5 Saving the sample project ...................................................................................................... 44

2.3 Downloading the sample program .......................................................................................... 45

2.4 Changing the operating mode of the CPU .............................................................................. 46

3.1 Guidelines for installing S7-200 SMART devices ................................................................... 47

3.2 Power budget .......................................................................................................................... 49

3.3 Installation and removal procedures ....................................................................................... 51

3.3.1 Mounting dimensions for the S7-200 SMART devices ........................................................... 51

3.3.2 Installing and removing the CPU ............................................................................................ 52

3.3.3 Installing and removing a signal board or battery board ......................................................... 55

3.3.4 Removing and reinstalling the terminal block connector ........................................................ 57

3.3.5 Installing and removing an expansion module ....................................................................... 58

3.3.6 Installing and removing the expansion cable .......................................................................... 60

3.4 Wiring guidelines ..................................................................................................................... 62

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Table of contents

4 PLC concepts ....................................................................................................................................... 69

5 Programming concepts ........................................................................................................................ 103

4.1 Execution of the control logic ................................................................................................. 69

4.1.1 Reading the inputs and writing to the outputs ........................................................................ 71

4.1.2 Immediately reading or writing the I/O ................................................................................... 71

4.1.3 Executing the user program ................................................................................................... 72

4.2 Accessing data ....................................................................................................................... 74

4.2.1 Accessing memory areas ....................................................................................................... 75

4.2.2 Format for Real numbers ....................................................................................................... 82

4.2.3 Format for strings ................................................................................................................... 82

4.2.4 Assigning a constant value for instructions ............................................................................ 83

4.2.5 Addressing the local and expansion I/O ................................................................................ 83

4.2.6 Using pointers for indirect addressing.................................................................................... 84

4.2.7 Pointer examples ................................................................................................................... 87

4.3 Saving and restoring data ...................................................................................................... 89

4.3.1 Downloading project components .......................................................................................... 89

4.3.2 Uploading project components .............................................................................................. 92

4.3.3 Types of storage .................................................................................................................... 93

4.3.4 Using a memory card ............................................................................................................. 94

4.3.5 Inserting a memory card in a standard CPU .......................................................................... 96

4.3.6 Transferring your program with a memory card ..................................................................... 97

4.3.7 Restoring data after power on ................................................................................................ 99

4.4 Changing the operating mode of the CPU ........................................................................... 100

4.5 Status LEDs ......................................................................................................................... 101

5.1 Guidelines for designing a PLC system ............................................................................... 103

5.2 Elements of the user program .............................................................................................. 105

5.3 Creating your user program ................................................................................................. 108

5.3.1 Earlier versions of STEP 7-Micro/WIN projects ................................................................... 108

5.3.2 Using STEP 7-Micro/WIN SMART user interface ................................................................ 110

5.3.3 Using STEP 7-Micro/WIN SMART to create your programs ............................................... 111

5.3.4 Using wizards to help you create your control program....................................................... 112

5.3.5 Features of the LAD editor ................................................................................................... 113

5.3.6 Features of the FBD editor ................................................................................................... 114

5.3.7 Features of the STL editor ................................................................................................... 114

5.4 Data block (DB) editor .......................................................................................................... 115

5.5 Symbol table ........................................................................................................................ 118

5.6 Variable table ....................................................................................................................... 121

5.7 PLC error reaction ................................................................................................................ 127

5.7.1 Non-fatal errors and I/O errors ............................................................................................. 128

5.7.2 Fatal errors ........................................................................................................................... 129

5.8 Program edit in RUN mode .................................................................................................. 130

5.9 Features for debugging your program ................................................................................. 132

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6 PLC device configuration .................................................................................................................... 133

7 Program instructions ........................................................................................................................... 169

6.1 Configuring the operation of the PLC system ....................................................................... 133

6.1.1 System block ......................................................................................................................... 133

6.1.2 Configuring communication .................................................................................................. 135

6.1.3 Configuring the digital inputs ................................................................................................ 138

6.1.4 Configuring the digital outputs .............................................................................................. 140

6.1.5 Configuring the retentive ranges ........................................................................................... 141

6.1.6 Configuring system security .................................................................................................. 143

6.1.7 Configuring the startup options ............................................................................................. 147

6.1.8 Configuring the analog inputs ............................................................................................... 148

6.1.9 Reference to the analog inputs technical specifications ....................................................... 150

6.1.10 Configuring the analog outputs ............................................................................................. 151

6.1.11 Reference to the analog outputs technical specifications..................................................... 152

6.1.12 Configuring the RTD analog inputs ....................................................................................... 153

6.1.13 Configuring the TC analog inputs ......................................................................................... 158

6.1.14 Configuring the RS485/RS232 CM01 communications signal board ................................... 162

6.1.15 Configuring the BA01 battery signal board ........................................................................... 163

6.1.16 Clearing PLC memory........................................................................................................... 164

6.1.17 Creating a reset-to-factory-defaults memory card ................................................................ 167

6.2 High-speed I/O ...................................................................................................................... 168

7.1 Bit logic ................................................................................................................................. 169

7.1.1 Standard inputs ..................................................................................................................... 169

7.1.2 Immediate inputs ................................................................................................................... 171

7.1.3 Logic stack overview ............................................................................................................. 172

7.1.4 STL logic stack instructions .................................................................................................. 174

7.1.5 NOT....................................................................................................................................... 176

7.1.6 Positive and negative transition detectors ............................................................................ 177

7.1.7 Coils: output and output immediate instructions ................................................................... 178

7.1.8 Set, reset, set immediate, and reset immediate functions .................................................... 179

7.1.9 Set and reset dominant bistable ........................................................................................... 180

7.1.10 NOP (No operation) instruction ............................................................................................. 181

7.1.11 Bit logic input examples ........................................................................................................ 182

7.1.12 Bit logic output examples ...................................................................................................... 183

7.2 Clock ..................................................................................................................................... 185

7.2.1 Read and set real-time clock ................................................................................................ 185

7.2.2 Read and set real-time clock extended ................................................................................ 187

7.3 Communication ..................................................................................................................... 191

7.3.1 GET and PUT (Ethernet) ...................................................................................................... 191

7.3.2 Transmit and receive (Freeport on RS485/RS232) .............................................................. 199

7.3.3 Get port address and set port address (PPI protocol on RS485/RS232) ............................. 213

7.3.4 Get IP address and set IP address (Ethernet) ...................................................................... 214

7.3.5 Open user communication .................................................................................................... 217

7.3.5.1 OUC instructions ................................................................................................................... 217

7.3.5.2 OUC instruction error codes ................................................................................................. 228

7.4 Compare ............................................................................................................................... 230

7.4.1 Compare number values ...................................................................................................... 230

7.4.2 Compare character strings ................................................................................................... 234

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7.5 Convert ................................................................................................................................. 236

7.5.1 Standard conversion instructions ......................................................................................... 236

7.5.2 ASCII character array conversion ........................................................................................ 240

7.5.3 Number value to ASCII string conversion ............................................................................ 245

7.5.4 ASCII sub-string to number value conversion ..................................................................... 249

7.5.5 Encode and decode ............................................................................................................. 252

7.6 Counters ............................................................................................................................... 253

7.6.1 Counter instructions ............................................................................................................. 253

7.6.2 High-speed counter instructions .......................................................................................... 257

7.6.3 High-speed counter summary .............................................................................................. 260

7.6.4 Noise reduction for high-speed inputs ................................................................................. 261

7.6.5 High-speed counter programming ....................................................................................... 264

7.6.6 Example initialization sequences for high-speed counters .................................................. 277

7.7 Pulse output ......................................................................................................................... 285

7.7.1 Pulse output instruction (PLS) ............................................................................................. 285

7.7.2 Pulse train output (PTO) ...................................................................................................... 287

7.7.3 Pulse width modulation (PWM) ............................................................................................ 289

7.7.4 Using SM locations to configure and control the PTO/PWM operation ............................... 290

7.7.5 Calculating the profile table values ...................................................................................... 294

7.8 Math ..................................................................................................................................... 297

7.8.1 Add, subtract, multiply, and divide ....................................................................................... 297

7.8.2 Multiply integer to double integer and divide integer with remainder................................... 300

7.8.3 Trigonometry, natural logarithm/exponential, and square root ............................................ 302

7.8.4 Increment and decrement .................................................................................................... 305

7.9 PID ....................................................................................................................................... 307

7.9.1 Using the PID wizard ........................................................................................................... 308

7.9.2 PID algorithm ....................................................................................................................... 313

7.9.3 Converting and normalizing the loop inputs ......................................................................... 317

7.9.4 Converting the loop output to a scaled integer value........................................................... 318

7.9.5 Forward- or reverse-acting loops ......................................................................................... 319

7.10 Interrupt ................................................................................................................................ 322

7.10.1 Interrupt instructions ............................................................................................................ 322

7.10.2 Interrupt routine overview and CPU model event support ................................................... 324

7.10.3 Interrupt programming guidelines ........................................................................................ 326

7.10.4 Types of interrupt events that the S7-200 SMART CPU supports ...................................... 328

7.10.5

Interrupt priority, queuing, and example program ................................................................ 330

7.11 Logical operations ................................................................................................................ 335

7.11.1 Invert .................................................................................................................................... 335

7.11.2 AND, OR, and exclusive OR ................................................................................................ 336

7.12 Move .................................................................................................................................... 338

7.12.1 Move byte, word, double word, or real ................................................................................. 338

7.12.2 Block move ........................................................................................................................... 339

7.12.3 Swap bytes ........................................................................................................................... 340

7.12.4 Move byte immediate (read and write) ................................................................................ 341

7.13 Program control.................................................................................................................... 342

7.13.1 FOR-NEXT loop ................................................................................................................... 342

7.13.2 JMP (jump to label) .............................................................................................................. 344

7.13.3 SCR (sequence control relay) .............................................................................................. 345

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8 Communication ................................................................................................................................... 395

7.13.4 END, STOP, and WDR (watchdog timer reset) .................................................................... 354

7.13.5 GET_ERROR (Get non-fatal error code) .............................................................................. 356

7.14 Shift and rotate ...................................................................................................................... 357

7.14.1 Shift and rotate ...................................................................................................................... 357

7.14.2 Shift register bit ..................................................................................................................... 360

7.15 String ..................................................................................................................................... 362

7.15.1 String (Get length, copy, and concatenate) .......................................................................... 362

7.15.2 Copy substring from string .................................................................................................... 364

7.15.3 Find string and first character within string ........................................................................... 365

7.16 Table ..................................................................................................................................... 368

7.16.1 Add to table ........................................................................................................................... 368

7.16.2 First-in-first-out and last-in-first-out ....................................................................................... 370

7.16.3 Memory fill ............................................................................................................................. 372

7.16.4 Table find .............................................................................................................................. 373

7.17 Timer ..................................................................................................................................... 377

7.17.1 Timer instructions .................................................................................................................. 377

7.17.2 Timer programming tips and examples ................................................................................ 380

7.17.3 Interval timers ....................................................................................................................... 386

7.18 Subroutine ............................................................................................................................. 388

7.18.1 CALL (subroutine) and RET (conditional return) .................................................................. 388

8.1 CPU communication connections ......................................................................................... 396

8.2 CPU communication ports .................................................................................................... 397

8.3 HMIs and communication drivers ......................................................................................... 398

8.4 Ethernet ................................................................................................................................ 400

8.4.1 Overview ............................................................................................................................... 400

8.4.2 Local/partner connection ...................................................................................................... 400

8.4.3 Sample Ethernet network configurations .............................................................................. 401

8.4.4 Assigning Internet Protocol (IP) addresses .......................................................................... 402

8.4.4.1 Assigning IP addresses to programming and network devices ............................................ 402

8.4.4.2 Configuring or changing an IP address for a CPU or device in your project ........................ 404

8.4.4.3 Searching for CPUs and devices on your Ethernet network ................................................ 412

8.4.5 Locating the Ethernet (MAC) address on the CPU ............................................................... 413

8.4.6 HMI-to-CPU communication ................................................................................................. 415

8.4.7 Open user communication .................................................................................................... 417

8.4.7.1 Protocols ............................................................................................................................... 417

8.4.7.2 Connections .......................................................................................................................... 418

8.4.7.3 Ports and TSAPs .................................................................................................................. 419

8.5 PROFIBUS ............................................................................................................................ 421

8.5.1 EM DP01 PROFIBUS DP module ........................................................................................ 423

8.5.1.1 Distributed Peripheral (DP) standard communications ......................................................... 423

8.5.1.2 Using the EM DP01 to connect an S7-200 SMART as a DP device .................................... 424

8.5.1.3 Configuring the EM DP01 ..................................................................................................... 426

8.5.1.4 Data consistency ................................................................................................................... 427

8.5.1.5 Supported configurations ...................................................................................................... 428

8.5.1.6 Installing the EM DP01 GSD file ........................................................................................... 429

8.5.1.7 Configuring the EM DP01 I/O ............................................................................................... 431

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Table of contents

9 Libraries ............................................................................................................................................... 471

8.5.1.8 Example of V memory and I/O address area ....................................................................... 433

8.5.1.9 User program considerations ............................................................................................... 435

8.5.1.10 LED status indicators for the EM DP01 PROFIBUS DP ...................................................... 437

8.5.1.11 Using HMIs and S7-CPUs with the EM DP01 ..................................................................... 439

8.5.1.12 Device database file: GSD ................................................................................................... 440

8.5.1.13 PROFIBUS DP communications to a CPU example program ............................................. 444

8.5.1.14 Reference to the EM DP01 PROFIBUS DP module technical specifications ..................... 446

8.6 RS485 .................................................................................................................................. 446

8.6.1 PPI protocol .......................................................................................................................... 447

8.6.2 Baud rate and network address ........................................................................................... 448

8.6.2.1 Definition of baud rate and network address ....................................................................... 448

8.6.2.2 Setting the baud rate and network address for the S7-200 SMART CPU ........................... 449

8.6.3 Sample RS485 network configurations ................................................................................ 451

8.6.3.1 Single-master PPI networks ................................................................................................. 451

8.6.3.2 Multi-master and multi-slave PPI networks .......................................................................... 451

8.6.4 Assigning RS485 addresses ................................................................................................ 452

8.6.4.1 Configuring or changing an RS485 address for a CPU or device in your project ............... 452

8.6.4.2 Searching for CPUs and devices on your RS485 network .................................................. 457

8.6.5 Building your network ........................................................................................................... 458

8.6.5.1 General guidelines ............................................................................................................... 458

8.6.5.2 Determining the distances, transmission rates, and cable lengths for your network ........... 459

8.6.5.3 Repeaters on the network .................................................................................................... 459

8.6.5.4 Specifications for RS485 cable ............................................................................................ 460

8.6.5.5 Connector pin assignments ................................................................................................. 460

8.6.5.6 Biasing and terminating the network cable .......................................................................... 462

8.6.5.7 Biasing and terminating the CM01 signal board .................................................................. 463

8.6.5.8 Using HMI devices on your RS485 network ........................................................................ 464

8.6.6 Freeport mode...................................................................................................................... 465

8.6.6.1 Creating user-defined protocols with Freeport mode........................................................... 465

8.6.6.2 Using the RS232/PPI Multi-Master cable and Freeport mode with RS232 devices ............ 468

8.7 RS232 .................................................................................................................................. 470

9.1 Library types (Siemens and user-defined) ........................................................................... 471

9.2 Overview of Modbus communication ................................................................................... 473

9.2.1 Modbus addressing .............................................................................................................. 473

9.2.2 Modbus read and write functions ......................................................................................... 475

9.3 Modbus RTU library ............................................................................................................. 476

9.3.1 Modbus communication overview ........................................................................................ 476

9.3.1.1 Modbus RTU library features ............................................................................................... 476

9.3.1.2 Requirements for using Modbus instructions ....................................................................... 477

9.3.1.3 Initialization and execution time for Modbus protocol .......................................................... 478

9.3.2 Modbus RTU master ............................................................................................................ 479

9.3.2.1 Using the Modbus RTU master instructions ........................................................................ 479

9.3.2.2 MBUS_CTRL / MB_CTRL2 instruction (initialize master) .................................................... 481

9.3.2.3 MBUS_MSG / MB_MSG2 instruction ................................................................................... 483

9.3.2.4 Modbus RTU master execution error codes ........................................................................ 487

9.3.3 Modbus RTU slave .............................................................................................................. 489

9.3.3.1 Using the Modbus RTU slave instructions ........................................................................... 489

9.3.3.2 MBUS_INIT instruction (initialize slave) ............................................................................... 491

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10 Debugging and troubleshooting ........................................................................................................... 565

9.3.3.3 MBUS_SLAVE instruction ..................................................................................................... 492

9.3.3.4 Modbus RTU slave execution error codes............................................................................ 493

9.3.4 Modbus RTU master example program................................................................................ 494

9.3.5 Modbus RTU advanced user information ............................................................................. 496

9.4 Open user communication library ......................................................................................... 498

9.4.1 Parameters common to the OUC library instructions ........................................................... 499

9.4.2 Open user communication library instructions ...................................................................... 501

9.4.2.1 TCP_CONNECT instruction .................................................................................................. 501

9.4.2.2 ISO_CONNECT instruction ................................................................................................... 504

9.4.2.3 UDP_CONNECT instruction ................................................................................................. 508

9.4.2.4 TCP_SEND instruction.......................................................................................................... 510

9.4.2.5 TCP_RECV instruction.......................................................................................................... 513

9.4.2.6 UDP_SEND instruction ......................................................................................................... 516

9.4.2.7 UDP_RECV instruction ......................................................................................................... 519

9.4.2.8 DISCONNECT instruction ..................................................................................................... 522

9.4.3 Open user communication library instruction error codes .................................................... 524

9.4.4 Open user communication library example .......................................................................... 525

9.4.4.1 Active partner (client) ............................................................................................................ 526

9.4.4.2 CheckErrors subroutine ........................................................................................................ 535

9.4.4.3 Active partner symbol table .................................................................................................. 536

9.4.4.4 Passive partner (server)........................................................................................................ 537

9.4.4.5 CheckErrors subroutine ........................................................................................................ 543

9.4.4.6 Passive partner symbol table ................................................................................................ 544

9.5 USS library ............................................................................................................................ 545

9.5.1 USS communication overview .............................................................................................. 545

9.5.1.1 USS protocol overview.......................................................................................................... 545

9.5.1.2 Requirements for using the USS protocol ............................................................................ 546

9.5.1.3 Calculating the time required for communicating with the drive ........................................... 547

9.5.2 USS program instructions ..................................................................................................... 548

9.5.2.1 Using the USS protocol instructions ..................................................................................... 548

9.5.2.2 USS_INIT instruction ............................................................................................................. 549

9.5.2.3 USS_CTRL instruction .......................................................................................................... 551

9.5.2.4 USS_RPM_x instruction ........................................................................................................ 554

9.5.2.5 USS_WPM_x instruction ....................................................................................................... 557

9.5.2.6 USS protocol execution error codes ..................................................................................... 560

9.5.2.7 USS protocol example program ............................................................................................ 561

9.6 Creating a user-defined library of instructions ................................................................

...... 563

10.1 Debugging your program ...................................................................................................... 565

10.1.1 Bookmark functions .............................................................................................................. 565

10.1.2 Cross reference table............................................................................................................ 566

10.2 Displaying program status .................................................................................................... 568

10.2.1 Displaying status in the program editor ................................................................................ 568

10.2.2 Configuring the STL status options ....................................................................................... 571

10.3 Using a status chart to monitor your program ...................................................................... 572

10.4 Forcing specific values.......................................................................................................... 574

10.5 Writing and forcing outputs in STOP mode .......................................................................... 575

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11 PID loops and tuning ............................................................................................................................ 581

12 Open loop motion control ..................................................................................................................... 595

10.6 How to execute a limited number of scans .......................................................................... 576

10.7 Hardware troubleshooting guide .......................................................................................... 578

11.1 PID loop definition table ....................................................................................................... 582

11.2 Prerequisites ........................................................................................................................ 586

11.3 Auto-hysteresis and auto-deviation...................................................................................... 586

11.4 Auto-tune sequence ............................................................................................................. 587

11.5 Exception conditions ............................................................................................................ 589

11.6 Notes concerning PV out-of-range (result code 3) .............................................................. 590

11.7 PID Tune control panel ........................................................................................................ 590

12.1 Using the PWM output ......................................................................................................... 596

12.1.1 Configuring the PWM output ................................................................................................ 596

12.1.2 PWMx_RUN subroutine ....................................................................................................... 598

12.2 Using motion control ............................................................................................................ 599

12.2.1 Maximum and start/stop speeds .......................................................................................... 599

12.2.2 Entering the acceleration and deceleration times ................................................................ 600

12.2.3 Configuring the motion profiles ............................................................................................ 601

12.3 Features of motion control ................................................................................................... 604

12.4 Programming an Axis of Motion ........................................................................................... 606

12.5 Configuring an Axis of Motion .............................................................................................. 607

12.6 Subroutines created by the Motion wizard for the Axis of Motion ........................................ 620

12.6.1 Guidelines for using the Motion subroutines ........................................................................ 621

12.6.2 AXISx_CTRL subroutine ...................................................................................................... 622

12.6.3 AXISx_MAN subroutine ....................................................................................................... 623

12.6.4 AXISx_GOTO subroutine ..................................................................................................... 625

12.6.5 AXISx_RUN subroutine ........................................................................................................ 626

12.6.6 AXISx_RSEEK subroutine ................................................................................................... 627

12.6.7 AXISx_LDOFF subroutine .................................................................................................... 628

12.6.8 AXISx_LDPOS subroutine ................................................................................................... 629

12.6.9 AXISx_SRATE subroutine ................................................................................................... 630

12.6.10 AXISx_DIS subroutine ......................................................................................................... 631

12.6.11 AXISx_CFG subroutine ........................................................................................................ 632

12.6.12 AXISx_CACHE subroutine ................................................................................................... 633

12.6.13 AXISx_RDPOS subroutine ................................................................................................... 634

12.6.14 AXISx_ABSPOS subroutine ................................................................................................. 635

12.7 Using the AXISx_ABSPOS subroutine to read the absolute position from a SINAMICS

servo drive ............................................................................................................................ 637

12.7.1 AXISx_ABSPOS and AXISx_LDPOS subroutines usage examples ................................... 637

12.7.2 Interconnections ................................................................................................................... 638

12.7.3 Commissioning..................................................................................................................... 639

12.7.3.1 Control mode ........................................................................................................................ 639

12.7.3.2 Setpoint pulse input channel ................................................................................................ 639

12.7.3.3 Setpoint pulse train input format .......................................................................................... 639

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Table of contents

A Technical specifications ...................................................................................................................... 679

12.7.3.4 Common engineering units basis ......................................................................................... 639

12.7.4 Important facts to know ......................................................................................................... 642

12.8 Axis of Motion example programs ........................................................................................ 643

12.8.1 Axis of Motion simple relative move (cut-to-length application) example ............................. 643

12.8.2 Axis of Motion AXISx_CTRL, AXISx_RUN, AXISx_SEEK, and AXISx_MAN example ........ 645

12.9 Monitoring the Axis of Motion ............................................................................................... 649

12.9.1 Displaying and controlling the operation of the Axis of Motion ............................................. 651

12.9.2 Displaying and modifying the configuration of the Axis of Motion ........................................ 656

12.9.3 Displaying the profile configuration for the Axis of Motion .................................................... 656

12.9.4 Error codes for the Axis of Motion (WORD at SMW620, SMW670, or SMW720)................ 658

12.9.5 Error codes for the Motion instruction (seven LS bits of SMB634, SMB684, or

SMB734) ............................................................................................................................... 659

12.10 Advanced topics .................................................................................................................... 661

12.10.1 Understanding the configuration/profile table for the Axis of Motion .................................... 661

12.10.2 Special memory (SM) locations for the Axis of Motion ......................................................... 670

12.11 Understanding the RP Seek modes of the Axis of Motion .................................................... 673

12.11.1 Selecting the work zone location to eliminate backlash ....................................................... 678

A.1 General specifications........................................................................................................... 679

A.1.1 General technical specifications ........................................................................................... 679

A.2 S7-200 SMART CPUs .......................................................................................................... 685

A.2.1 CPU ST20, CPU SR20, and CPU CR20s ............................................................................ 685

A.2.1.1 General specifications and features ..................................................................................... 685

A.2.1.2 Digital inputs and outputs ..................................................................................................... 689

A.2.1.3 Wiring diagrams .................................................................................................................... 692

A.2.2 CPU ST30, CPU SR30, and CPU CR30s ............................................................................ 695

A.2.2.1 General specifications and features ..................................................................................... 695

A.2.2.2 Digital inputs and outputs ..................................................................................................... 698

A.2.2.3 Wiring diagrams .................................................................................................................... 701

A.2.3 CPU ST40, CPU SR40, and CPU CR40s ............................................................................ 704

A.2.3.1 General specifications and features ..................................................................................... 704

A.2.3.2 Digital inputs and outputs ..................................................................................................... 708

A.2.3.3 Wiring diagrams .................................................................................................................... 711

A.2.4 CPU ST60, CPU SR60, and CPU CR60s ............................................................................ 714

A.2.4.1 General specifications and features ..................................................................................... 714

A.2.4.2 Digital inputs and outputs ..................................................................................................... 718

A.2.4.3 Wiring diagrams .................................................................................................................... 721

A.2.5 Wiring diagrams for sink and source input, and relay output................................................ 724

A.3 Digital inputs and outputs expansion modules (EMs) ........................................................... 725

A.3.1 EM DE08 and EM DE16 digital input specifications ............................................................. 725

A.3.2 EM DT08, EM DR08, EM QR16, and EM QT16 digital output specifications ...................... 727

A.3.3 EM DT16, EM DR16, EM DT32, and EM DR32 digital input/output specifications .............. 732

A.4 Analog inputs and outputs expansion modules (EMs) ......................................................... 738

A.4.1 EM AE04 and EM AE08 analog input specifications ............................................................ 738

A.4.2 EM AQ02 and EM AQ04 analog output module specifications ............................................ 741

A.4.3 EM AM03 and EM AM06 analog input/output module specifications ................................... 744

A.4.4 Step response of the analog inputs ...................................................................................... 748

A.4.5 Sample time and update times for the analog inputs ........................................................... 749

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B Calculating a power budget .................................................................................................................. 787

C Error codes .......................................................................................................................................... 791

A.4.6 Measurement ranges of the analog inputs for voltage and current (SB and EM) ............... 749

A.4.7 Measurement ranges of the analog outputs for voltage and current (SB and EM) ............. 750

A.5 Thermocouple and RTD expansion modules (EMs) ............................................................ 752

A.5.1 Thermocouple expansion modules (EMs) ........................................................................... 752

A.5.1.1 EM AT04 thermocouple specifications ................................................................................ 752

A.5.2 RTD expansion modules (EMs) ........................................................................................... 758

A.6 Digital signal boards ............................................................................................................. 763

A.6.1 SB DT04 digital input/output specifications ......................................................................... 763

A.7 Analog signal boards ........................................................................................................... 767

A.7.1 SB AE01 analog input specifications ................................................................................... 767

A.7.2 SB AQ01 analog output specifications ................................................................................ 769

A.8 RS485/RS232 signal boards ................................................................................................ 771

A.8.1 SB RS485/RS232 specifications.......................................................................................... 771

A.9 Battery board signal boards (SBs) ....................................................................................... 773

A.9.1 SB BA01 Battery board ........................................................................................................ 773

A.10 EM DP01 PROFIBUS DP module ....................................................................................... 775

A.10.1 S7-200 SMART CPUs that support the EM DP01 PROFIBUS DP module ........................ 776

A.10.2 Connector pin assignments for EM DP01 ............................................................................ 777

A.10.3 EM DP01 PROFIBUS DP module wiring diagram ............................................................... 778

A.11 S7-200 SMART cables ........................................................................................................ 779

A.11.1 S7-200 SMART I/O expansion cable ................................................................................... 779

A.11.2 RS-232/PPI Multi-Master Cable and USB/PPI Multi-Master Cable ..................................... 780

A.11.2.1 Overview .............................................................................................................................. 780

A.11.2.2 RS-232/PPI Multi-Master Cable ........................................................................................... 781

A.11.2.3 USB/PPI Multi-Master Cable ................................................................................................ 784

B.1 Power budget ....................................................................................................................... 787

B.2 Calculating a sample power requirement ............................................................................ 789

B.3 Calculating your power requirement .................................................................................... 790

C.1 Timestamp mismatch ........................................................................................................... 791

C.2 PLC non-fatal error codes .................................................................................................... 792

C.3 PLC non-fatal error SM flags ............................................................................................... 795

C.4 PLC fatal error codes ........................................................................................................... 796

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Table of contents

D Special memory (SM) and system symbol names................................................................................ 799

D.1 SM (Special Memory) overview ............................................................................................ 799

D.2 SMB0: System status............................................................................................................ 802

D.3 SMB1: Instruction execution status ...................................................................................... 803

D.4 SMB2: Freeport receive character ........................................................................................ 804

D.5 SMB3: Freeport character error ............................................................................................ 804

D.6 SMB4: Interrupt queue overflow, run-time program error, interrupts enabled, freeport

transmitter idle, and value forced .......................................................................................... 805

D.7 SMB5: I/O error status .......................................................................................................... 805

D.8 SMB6-SMB7: CPU ID, error status, and digital I/O points.................................................... 806

D.9 SMB8-SMB19: I/O module ID and errors ............................................................................. 807

D.10 SMW22-SMW26: Scan times ............................................................................................... 808

D.11 SMB28-SMB29: Signal board ID and errors ......................................................................... 808

D.12 SMB30: (Port 0) and SMB130: (Port 1) ................................................................................ 809

D.13 SMB34-SMB35: Time intervals for timed interrupts ............................................................. 809

D.14 SMB36-SMB45 (HSC0), SMB46-SMB55 (HSC1), SMB56-SM65 (HSC2), SMB136-

SMB145 (HSC3), SMB146-SMB155 (HSC4), SMB156-SMB165 (HSC5): high-speed

counters ................................................................................................................................ 810

D.15 SMB66-SMB85 (PTO0/PWM0, PTO1/PWM1), SMB166-SMB169 (PTO0), SMB176-

SMB179 (PTO1), and SMB566-SMB579 (PTO2/PWM2): high-speed outputs .................... 816

D.16 SMB86-SMB94 and SMB186-SMB194: Receive message control ..................................... 819

D.17 SMW98: Expansion I/O bus communication errors .............................................................. 821

D.18 SMW100-SMW114 System alarms ...................................................................................... 822

D.19 SMB130: Freeport control for port 1 (See SMB30) .............................................................. 823

D.20 SMB146-SMB155 (HSC4) and SMB156-SMB165 (HSC5) .................................................. 823

D.21 SMB186-SMB194: Receive message control (See SMB86-SMB94) ................................... 823

D.22 SMB480-SMB515: Data log status ....................................................................................... 823

D.23 SMB600-SMB749: Axis (0, 1, and 2) open loop motion control ........................................... 824

D.24 SMB650-SMB699: Axis 1 open loop motion control (See SMB600-SMB740) ..................... 825

D.25 SMB700-SMB749: Axis 2 open loop motion control (See SMB600-SMB740) ..................... 825

D.26 SMB1000-SMB1049: CPU hardware/firmware ID ................................................................ 826

D.27 SMB1050-SMB1099: SB (signal board) hardware/firmware ID ........................................... 826

D.28 SMB1100-SMB1399: EM (expansion module) hardware/firmware ID ................................. 827

D.29 SMB1400-SMB1699: EM (expansion module) module-specific data ................................... 830

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E References .......................................................................................................................................... 831

F Ordering information ............................................................................................................................ 843

Index ................................................................................................................................................... 849

E.1 Often-used special memory bits .......................................................................................... 831

E.2 Interrupt events in priority order ........................................................................................... 832

E.3 High-speed counter summary .............................................................................................. 833

E.4 STL instructions ................................................................................................................... 834

E.5 Memory ranges and features ............................................................................................... 841

F.1 CPU modules ....................................................................................................................... 843

F.2 Expansion modules (EMs) and signal boards (SBs) ........................................................... 844

F.3 Programming software ......................................................................................................... 844

F.4 Communication .................................................................................................................... 845

F.5 Spare parts and other hardware .......................................................................................... 845

F.6 Human Machine Interface devices....................................................................................... 847

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The S7-200 SMART series of micro-programmable logic controllers (Micro PLCs) can control a wide variety of devices to support your automation needs.

The CPU monitors inputs and changes outputs as controlled by the user program, which can include Boolean logic, counting, timing, complex math operations, and communications with other intelligent devices. The compact design, flexible configuration, and powerful instruction set combine to make the S7-200 SMART a perfect solution for controlling a wide variety of applications.

S7-200 SMART System Manual, V2.3, 07/2017, A5E03822230-AF

Product overview

1.1

S7-200 SMART CPU

①

LEDs for the I/O

②

Terminal connectors

③

Ethernet

④

Clip for installation on a standard (DIN) rail

⑤

Ethernet status LEDs (under door): LINK, Rx/Tx

⑥

Status LEDs: RUN, STOP and ERROR

⑦

RS485 Communication port

⑧

Optional signal board (Standard models only)

⑨

Memory card r door) (Standard models only)

Note CPU CR40 and CPU CR60

S7 CR60 models.

1.1 S7-200 SMART CPU

The CPU combines a microprocessor, an integrated power supply, input circuits, and output circuits in a compact housing to create a powerful Micro PLC. After you have downloaded your program, the CPU contains the logic required to monitor and control the input and output devices in your application.

The CPU provides different models with a diversity of features and capabilities that help you create effective solutions for your varied applications. The different models of CPUs are shown below. For detailed information about a specific CPU, see the technical specifications (Page 685).

communication port

eader (under

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-200 SMART CPU firmware release V2.3 does not apply to the CPU CR40 and CPU

Product overview

SR20

ST20

CR20s

SR30

ST30

CR30s

SR40

ST40

CR40s

SR60

ST60

CR60s

expandable

Relay output

X X X X X X X

I/O points (built-in)

Features

CPU CR20s

CPU CR30s

CPU CR40s

CPU CR60s

Dimensions: W x H x D (mm)

90 x 100 x 81

110 x 100 x 81

125 x 100 x 81

175 x 100 x 81

Program

12 Kbytes

User data

8 Kbytes

Retentive

2 Kbytes max.1

Expansion modules

None

Signal board

None

phase

A/B phase

2 at 50 kHz

PID loops

8 8 8

back-up

ues on retentive timers) to be retentive, up to the specified maximum amount.

1.1 S7-200 SMART CPU

Table 1- 1 S7-200 SMART CPUs

Compact serial, non-

X X X X

Standard, expandable X X X X X X X X

Transistor output (DC) X X X X

Table 1- 2 Compact serial, non-expandable CPUs

User memory

On-board digital I/O

High-speed

• Inputs

• Outputs

Single

• 12 DI

• 8 DQ Relay

• 18 DI

• 12 DQ Relay

• 24 DI

• 16 DQ Relay

4 at 100 kHz 4 at 100 kHz 4 at 100 kHz 4 at 100 kHz

36 DI 24 DQ Relay

counters (4 total)

Real-time clock with 7-day

No No No No

You can configure areas of V memory, M memory, C memory (current values), and portions of T memory (current val-

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Product overview

Features

CPU SR20, CPU ST20

CPU SR30, CPU ST30

CPU SR40, CPU ST40

CPU SR60, CPU ST60

Dimensions: W x H x D (mm)

90 x 100 x 81

110 x 100 x 81

125 x 100 x 81

175 x 100 x 81

User data

8 Kbytes

12 Kbytes

16 Kbytes

20 Kbytes

Retentive

10 Kbytes max.1

Signal board

1 1 1

2 at 30 kHz

1 at 30 kHz

2 at 30 kHz

2 at 20 kHz

1 at 20 kHz

2 at 20 kHz

Pulse outputs 2

2 at 100 kHz

3 at 100 kHz

PID loops

8 8 8

Real-time clock with 7-day back-up

Yes

The specified maximum pulse frequency is possible only for CPU models with transistor outputs. Pulse output operation is not recommended for CPU models with relay outputs.

1.1 S7-200 SMART CPU

Table 1- 3 Standard expandable CPUs

User memory Program 12 Kbytes 18 Kbytes 24 Kbytes 30 Kbytes

On-board digital I/O

• Inputs

• Outputs

• 12 DI

• 8 DQ

• 18 DI

• 12 DQ

• 24 DI

• 16 DQ

• 36 DI

• 24 DQ

Expansion modules 6 max. 6 max. 6 max. 6 max.

High-speed

Single phase 4 at 200 kHz

5 at 200 kHz

4 at 200 kHz

4 at 200 kHz counters (6 total)

A/B phase 2 at 100 kHz

3 at 100 kHz

2 at 100 kHz

You can configure areas of V memory, M memory, C memory (current values), and portions of T memory (current val-

ues on retentive timers) to be retentive, up to the specified maximum amount.

Refer to the technical specifications (Page 679) for the power requirements of the CPU and the expansion modules. Use the worksheets in Appendix B, Calculating a power budget (Page 790) to calculate your power budget.

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Product overview

1.2

New features

New CPU models

Note CPU CR40 and CPU CR60

S7 CR60 models.

Status LED states

High Speed Counters (HSC)

USB/PPI serial interface support by STEP 7-Micro/WIN SMART

1.2 New features

STEP 7-Micro/WIN SMART V2.3 and the S7-200 SMART V2.3 CPUs introduce the following new features:

S7-200 SMART has four new compact serial CPU models:

● CPU CR20s AC/DC/Relay (6ES7288-1CR20-0AA1)

● CPU CR30s AC/DC/Relay (6ES7288-1CR30-0AA1)

● CPU CR40s AC/DC/Relay (6ES7288-1CR40-0AA1)

● CPU CR60s AC/DC/Relay (6ES7288-1CR60-0AA1)

-200 SMART CPU firmware release V2.3 does not apply to the CPU CR40 and CPU

All CPU models now blink the STOP LED at 1 Hz if a value is forced (in RUN or STOP mode).

New HSC capabilities are as follows:

● The number of HSCs increased from four to six on the SR and ST CPU models. The new

CRs CPUs have four HSCs.

● The SR/ST30 CPUs now utilize the high speed inputs I0.6 and I0.7 for HSC4. This means

that the SR/ST30 CPU has one more 200 kHz counter than the other SR/ST models.

You can now use a USB/PPI Multi-Master cable to program all CPU models through any of the following serial ports:

● RS485 port

● Signal board port

● DP01 PROFIBUS port

S7-200 SMART System Manual, V2.3, 07/2017, A5E03822230-AF

Product overview

Firmware update with STEP 7-Micro/WIN SMART

See also

1.2 New features

You can now download firmware updates on all CPU models through any of the following serial ports:

● RS485 port

● Signal board port

● DP01 PROFIBUS port

Creating a user-defined library of instructions (Page 563) EM DE08 and EM DE16 digital input specifications (Page 725) EM DT08, EM DR08, EM QR16, and EM QT16 digital output specifications (Page 727) S7-200 SMART I/O expansion cable (Page 779) Using STEP 7-Micro/WIN SMART to create your programs (Page 111) Modbus RTU library (Page 476) Open user communication library (Page 498) Open user communication (Page 217)

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Product overview

1.3

CPU feature differences

CRs models

No Ethernet port

1.3 CPU feature differences

The S7-200 SMART V2.3 CPU family includes twelve CPU models, separated into two lines: the Compact Line and the Standard Line. The first letter of the CPU designator indicates a line, either Compact (C) or Standard (S). The second letter of the designator indicates AC power supply / relay outputs (R) or DC power supply / DC transistor (T). The number in the designator indicates the total onboard digital I/O count. The new compact models are designated by a lower case "s" character (serial port only) following the I/O count.

The CPU CR20s, CPU CR30s, CPU CR40s, and CPU CR60s models have the following differences from the standard CPUs:

● No Ethernet port: The RS485 port is now the programming port.

● STEP 7-Micro/WIN SMART uses a USB-PPI cable to program the CPU through the

RS485 port.

● The CPUs reserve one connection for the STEP 7-Micro/WIN SMART programmer

connection.

● No CPU instructions that require an Ethernet port

● No support for data logs

● No real-time clock

● No microSD card reader

● No signal board support

● No signal module support

● No 24 V DC sensor supply

● No motion control

● Support for only PROFIBUS/RS485-capable HMIs

● 12 KB of ladder memory and 8 KB of V memory

● Retentive memory limited to 2 KB

Because the CRs models have no Ethernet port, the RS485 port is the programming port. STEP 7-Micro/WIN SMART uses the USB-PPI cable to program the CPU. You can now program any CPU over all serial ports, including the PROFIBUS DP01 modules.

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Product overview

USB-PPI cable

Communication connections

No CPU instructions that require an Ethernet port

LAD instruction

STL instruction

Description

GET

Get data through the Ethernet

GIP_ADDR

GIP

Get Ethernet IP address

SIP_ADDR

SIP

Set Ethernet IP address

TCON

Open an OUC Ethernet connection

TSEND

Send OUC data through the Ethernet

net

tion

No real-time clock

No microSD card reader or any functions related to the use of a microSD card

1.3 CPU feature differences

The CRs models provide the RS485 port as the only programming port for the CPU. Using STEP 7-Micro/WIN SMART and a USB-PPI cable, you can perform the following tasks:

● Upload and download your program

● Monitor program functions

● Perform firmware updates

If you use Freeport (Page 465) in your program, attaching a USB-PPI cable forces the CPU to exit Freeport mode and enables PPI mode. PPI mode allows STEP 7-Micro/WIN SMART to regain control of the CPU.

Since the CRs CPU models support only an RS485 programming port, the CPU always reserves one connection for the STEP 7-Micro/WIN SMART programmer connection. The CRs model CPUs still support four connections on the RS485 port for HMIs.

You cannot use the CPU instructions that utilize the Ethernet port on the CRs models. The instructions that are not available in the CRs models are as follows:

SET SET Write data through the Ethernet

TRECV TRECV Receive OUC data through the Ether-

TDCON TDCON Disconnect an OUC Ethernet connec-

The CRs models do not have a real-time clock; however, the CRs models still support time instructions. The time resets to the default time (January 1, 2000) on every power cycle. The CPU maintains time with limited accuracy without the real-time clock.

Because the CRs models do not support a microSD card, you use the Reset to factory defaults command (Page 164) using the RS485 port in case you forget your password.

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Product overview

HMIs limited to those accessible from PROFIBUS/RS485 networks

1.3 CPU feature differences

The new CRs models only support the following PROFIBUS/RS485-capable HMIs:

● COMFORT HMIs:

– SIMATIC HMI TP700 COMFORT – SIMATIC HMI TP900 COMFORT – SIMATIC HMI TP1200 COMFORT – SIMATIC HMI KP400 COMFORT – SIMATIC HMI KP700 COMFORT – SIMATIC HMI KP900 COMFORT – SIMATIC HMI KP1200 COMFORT – SIMATIC HMI KTP400 COMFORT

● SMART HMIs:

– SMART 700 IE – SMART 1000 IE

● BASIC HMIs:

– SIMATIC HMI KTP600 BASIC COLOR DP – SIMATIC HMI KTP1000 BASIC COLOR DP

● Micro HMIs:

– TD 400C TEXT DISPLAY, 4 LINES

S7-200 SMART System Manual, V2.3, 07/2017, A5E03822230-AF

Product overview

1.4

S7-200 SMART expansion modules

Type

Input only

Output only

Combination In/Out

Other

Module

Type

Description

1.4 S7-200 SMART expansion modules

To better solve your application requirements, the S7-200 SMART family includes a wide variety of expansion modules, signal boards, and a communications module. You can use these expansion modules with the standard CPU models (SR20, ST20, SR30, ST30, SR40, ST40, SR60 or ST60) to add additional functionality to the CPU. The following table provides a list of the expansion modules that are currently available. For detailed information about a specific module, see the technical specifications (Page 679).

Table 1- 4 Expansion modules and signal boards

Digital expansion module

Analog expansion modules

Signal boards

• 8 x DC In

• 16 x DC In

• 4 x Analog In

• 8 x Analog In

• 2 x RTD In

• 4 x RTD In

• 4 x TC In

• 1 x Analog In • 1 x Analog Out • 2 x DC In x 2 x DC Out • RS485/RS232

• 8 x DC Out

• 8 x Relay Out

• 16 x Relay Out

• 16 x DC Out

• 2 x Analog Out

• 4 x Analog Out

Table 1- 5 Communication expansion modules

Communication expansion module (EM)

PROFIBUS DP SMART module EM DP01 PROFIBUS DP

• 8 x DC In / 8 x DC Out

• 8 x DC In / 8 x Relay Out

• 16 x DC In / 16 x DC Out

• 16 x DC In / 16 x Relay Out

• 4 x Analog In / 2 x Analog Out

• 2 x Analog In / 1 x Analog Out

• Battery Board

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Product overview

1.5

HMI devices for S7-200 SMART

Text Display unit:

to your application.

SMART HMIs:

1.5 HMI devices for S7-200 SMART

The S7-200 SMART supports Comfort HMIs, SMART HMIs, Basic HMIs and Micro HMIs. The TD400C and the SMART LINE Touch Panel are shown below. Refer to "HMIs and communication drivers" (Page 398) for a list of supported devices.

Table 1- 6 HMI devices

The TD400C is an RS485-only display device that can be connected to the CPU. Using the Text Display wizard, you can easily program your CPU to display text messages and other data pertaining to your application.

The TD400C device provides a low-cost interface to your application by allowing you to view, monitor, and change the process variables pertaining

The SMART LINE Touch Panel provides operating and monitoring functions for small-scale machines and plants. Short configuration and commissioning times, their configuration in WinCC flexible (ASIA version), and a double-port Ethernet/RS485 interface form the highlights of these HMIs.

The Text Display wizard in STEP 7-Micro/WIN SMART helps you configure Text Display messages quickly and easily for the TD400C. To start the Text Display wizard, select the "Text Display" command from the "Tools" menu.

The SIMATIC Text Display (TD) User Manual can be downloaded from the Siemens customer support web site (http://www.siemens.com/automation/).

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Product overview

1.6

Communications options

Note The CPU models CPU CR20s, CPU CR30s, CPU CR40s, and CPU CR60s have no

Ethernet port and do not support any functions related to the use of Ethernet communica

1.6 Communications options

The S7-200 SMART offers several types of communication between CPUs, programming devices, and HMIs:

● Ethernet:

– Exchange of data from the programming device to the CPU – Exchange of data between HMIs and the CPU – S7 peer-to-peer communication with other S7-200 SMART CPUs – Open User Communication (OUC) with other Ethernet-capable devices

tions.

● PROFIBUS:

– High speed communications for distributed I/O (up to 12 Mbps) – One bus master connects to many I/O devices (supports 126 addressable devices). – Exchange of data between the master and I/O devices – EM DP01 module is a PROFIBUS I/O device.

● RS485:

– Provides a STEP 7-Micro/WIN SMART connection for programming when using a

USB-PPI cable – Supports a total of 126 addressable devices (32 devices per network segment) – Supports PPI (point-to-point interface) protocol – Exchange of data between HMIs and the CPU – Exchange of data between devices and the CPU using Freeport (XMT/RCV

instructions)

● RS232:

– Supports a point-to-point connection to one device – Supports PPI protocol – Exchange of data between HMIs and the CPU – Exchange of data between devices and the CPU using Freeport (XMT/RCV

instructions)

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Product overview

1.7

Programming software

STEP7 user edit, and monitor the logic needed to control your application.

At the top is a quick access toolbar for frequent tasks, followed by menus for all common functions. At the left is the project tre easy access to components and i structions. The program editor and other components that you open o cupy the remainder of the user inte face.

STEP7 three program editors (LAD, FBD, and STL) for convenience and efficiency in developing the control program for your application.

Computer requirements

Installing STEP 7-Micro/WIN SMART

Note To instal

SMART on a Windows XP or Windows 7 operating system, you

must log in with Administrator privileges.

1.7 Programming software

-Micro/WIN SMART provides a

-friendly environment to develop,

e and navigation bar for

-Micro/WIN SMART provides

To help you find the information you need, STEP7-Micro/WIN SMART provides an extensive online help system.

STEP 7-Micro/WIN SMART runs on a personal computer. Your computer should meet the following minimum requirements:

● Operating system: Windows 7 or Windows 10 (both 32 bit and 64 bit versions)

● At least 350M bytes of free hard disk space

● Mouse (recommended)

Insert the STEP 7-Micro/WIN SMART CD into the CD-ROM drive of your computer or contact your Siemens distributor or sales office to download STEP7-Micro/WIN SMART from

S7-200 SMART System Manual, V2.3, 07/2017, A5E03822230-AF

the customer support web site (Page 3). Installation starts automatically and prompts you through the installation process. Refer to the Readme file for more information about installing STEP 7-Micro/WIN SMART.

l STEP 7-Micro/WIN

Product overview

1.7 Programming software

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2.1

Connecting to the CPU

Note The CPU

Ethernet port and no functions related to the use of Ethernet communications.

Connecting power to the CPU

WARNING

Ensure power is off prior to installing, wiring or removing devices

STEP 7-Micro/WIN SMART makes it easy for you to program your CPU. In just a few short steps using a simple example, you can learn how to create a user program that you can download and run on your CPU.

All you need for this example is an Ethernet or USB-PPI communication cable, a CPU, and a programming device running the STEP 7-Micro/WIN SMART programming software.

Connecting your CPU is easy. For this example, you only need to connect power to your CPU and then connect the Ethernet or USB-PPI communication cable between your programming device and the CPU.

models CPU CR20s, CPU CR30s, CPU CR40s, and CPU CR60s have no

Before you install or remove any electrical device, ensure that the power to that equipment has been turned off.

Attempts to install or connect the wiring for the CPU or related equipment with power applied could cause electric shock or faulty operation of equipment. Failure to disable all power to the CPU and related equipment during installation or removal procedures could result in death or serious injury to personnel, and/or damage to equipment.

Always follow appropriate safety precautions and ensure that power to the CPU is disabled before attempting to install or remove the CPU or related equipment.

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Getting started

DC installation

AC installation

2.1.1

Configuring the CPU for communication

2.1.1.1

Overview

A CPU can communicate with a STEP vice on an Ethernet network.

A CPU can co STEP vice on an RS485 network.

2.1 Connecting to the CPU

Connect the CPU to a power source. The following figure shows the wiring connections for either a DC or an AC model of the CPU.

A CPU can communicate with a STEP 7-Micro/WIN SMART programming device on two types of communications networks:

7-Micro/WIN SMART programming de-

mmunicate with a

7-Micro/WIN SMART programming de-

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Getting started

Note The CPU models CPU CR20s, CPU CR30s, CPU CR40s, and CPU CR60s have no

Ethernet port and do not support any functions related to the use of Ethernet communications.

2.1.1.2

Establishing the Ethernet hardware communication connection

①

Ethernet port

2.1 Connecting to the CPU

Consider the following when setting up Ethernet communications between a CPU and a programming device:

● Configuration/Setup: No hardware configuration is required for a single CPU. If you want

multiple CPU's on the same network, then you must change the default IP addresses to

new, unique IP addresses.

● No Ethernet switch is required for one-to-one communications; an Ethernet switch is

required for more than two devices in a network.

The Ethernet interfaces establish the physical connections between a programming device and a CPU. Since Auto-Cross-Over functionality is built into the CPU, either a standard or crossover Ethernet cable can be used for the interface. An Ethernet switch is not required to connect a programming device directly to a CPU.

Follow the steps below to create the hardware connection between a programming device and a CPU:

1. Install the CPU.

2. Remove the RJ45 connection cover from the Ethernet port. Retain the cover for reuse.

3. Plug the Ethernet cable into the Ethernet port on the top left of the CPU as shown below.

4. Connect the Ethernet cable to the programming device.

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Getting started

2.1.1.3

Setting up Ethernet communication with the CPU

2.1 Connecting to the CPU

From STEP 7-Micro/WIN SMART, use one of the following methods to display the Ethernet "Communications" dialog for configuring communication to the CPU.

● From the project tree, double-click the "Communications" node.

● Click the "Communications" button

● Select "Communications" from the "Component" drop-down list in the Windows area of

the "View" menu ribbon strip.

The "Communications" dialog provides two methods of selecting the CPU to be accessed:

● Click the "Find CPUs" button to have STEP 7-Micro/WIN SMART search your local

network for CPUs. The IP address of each CPU found on the network is listed under "Found CPUs".

● Click the "Add CPU" button to manually enter the access information (IP address and so

forth) for a CPU that you wish to access. The IP address for each CPU, manually added with this method, is listed under "Added CPUs" and is retained.

from the navigation bar.

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Getting started

Download button from the Transfer area of the File

parameters and repeat these steps.

2.1 Connecting to the CPU

For "Found CPUs" (CPUs located on your local network), use the "Communications" dialog to connect with your CPU:

• Select TCP/IP for your Communication Inter- face.

• Click the "Find CPUs" button to display all operational CPUs ("Found CPUs") on the local Ethernet network. All CPUs have a default IP address. See the Note below.

• Highlight a CPU, and then click "OK".

For "Added CPUs" (CPUs on the local or remote networks), use the "Communications" dialog to connect with your CPU:

• Select TCP/IP for your Communication Inter- face.

• Click the "Add CPU" button to do one of the following:

– Enter the IP address of a CPU that is ac-

cessible from the programming device, but is not on the local network.

– Enter the IP address of a CPU directly that

is on the local network.

All CPUs have a default IP address. See the Note below.

• Highlight a CPU, and then click "OK".

After you have established communication with the CPU, you are ready to create and download the example program.

To download all project components, click the

or PLC menu ribbon strip, or alternatively press the shortcut key combination CTRL+D.

If STEP 7-Micro/WIN SMART does not find your CPU, check the settings for the communications

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Getting started

Note The CPU list will show all of the CPUs regardless of Ethernet network class and subnet. To make a connection to your CPU, your Communication Interface (for Ethernet, a network

interface card (NIC)) and the CPU must be on the same class of network and on the same subnet. You can either set up your network interface card to match the default IP address of the CPU, or you can change the IP address of the CPU to match the network c subnet of your network interface card.

See the "Configuring or changing an IP address for a CPU or device in your project" for information about how to accomplish this.

2.1.1.4

Establishing the RS485 hardware communication connection

①

RS485 port

2.1 Connecting to the CPU

lass and

The RS485 interfaces establish the physical connections between a programming device and a CPU.

Follow the steps below to create the hardware connection between a programming device and a CPU:

1. Install the CPU.

2. Plug the USB/PPI cable into the RS485 port on the bottom left of the CPU as shown below.

3. Connect the USB/PPI cable to the programming device.

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Getting started

2.1.1.5

Setting up RS485 communication with the CPU

Download button from the Transfer area of the File

parameters and repeat these steps.

2.1 Connecting to the CPU

RS485 network information configuration or changes done in the system block are part of the project and do not become active until you download your project to the CPU.

To access this dialog, perform one of the following:

● In the "Navigation" bar, click the "System Block" button.

● In the Project tree, select the "System Block" node, then press Enter; or double-click the

"System Block" node.

Enter or change the following access information:

• RS485 port address

• RS485 port baud rate

All CPUs and devices that have valid RS485 port addresses are displayed in the "Communications" dialog.

In STEP 7-Micro/WIN SMART, you can access CPUs in one of two ways:

● From the project tree, double-click the "Communications" node.

● Click the "Communications" button

● Select "Communications" from the "Component" drop-down list in the Windows area of

the "View" menu ribbon strip.

After you have established communication with the CPU, you are ready to create and download the example program.

To download all project components, click the

or PLC menu ribbon strip, or alternatively press the shortcut key combination CTRL+D.

If STEP 7-Micro/WIN SMART does not find your CPU, check the settings for the communications

from the navigation bar.

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Getting started

ed.

2.1 Connecting to the CPU

The "Communications" dialog provides two methods of selecting the CPU to be accessed:

● Click the "Find CPUs" button to have STEP 7-Micro/WIN SMART search your local network for CPUs. The RS485 network address of each CPU found on the network is listed under "Found CPUs".

● Click the "Add CPU" button to manually enter the access information (RS485 network address and baud rate) for a CPU that you wish to access. The RS485 network address for each CPU, manually added with this method, is listed under "Added CPUs" and is retained.

For "Found CPUs" (CPUs located on the RS485 network), use the "Communications" dialog to connect with your CPU:

• Select "PC/PPI cable.PPI.1" for your Commu- nication Interface.

• Click the "Find CPUs" button to display all operational CPUs ("Found CPUs") on the RS485 network. All CPUs default their RS485 network settings to address 2 and 9.6 Kbps.

• Highlight a CPU, and then click "OK".

Note: You can open multiple copies of STEP 7-Micro/WIN SMART on a computer. Be aware that when you open a second copy of STEP 7-Micro/WIN SMART or use the "Find CPUs" button in either copy, the communication connection to the CPU in your first/other copy of STEP 7-Micro/WIN SMART might be disconnect-

For "Added CPUs" (CPUs on the RS485 network), use the "Communications" dialog to connect with your CPU:

• Select "PC/PPI cable.PPI.1" for your Commu- nication Interface.

• Click the "Add CPU" button.

• Enter the RS485 network address and baud

rate of a CPU that you wish to access directly on the RS485 network.

S7-200 SMART

You can add multiple CPUs on the RS485 network. As always, STEP 7-Micro/WIN SMART communicates with one CPU at a time. All CPUs default their RS485 network settings to address 2 and 9.6 Kbps.

• Highlight a CPU, and then click "OK".

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Getting started

2.2

Creating the sample program

LAD/FBD

STL

Description

Network 1 LDN M0.0 TON T33, +100

Network 2 LDW>= T33, +40 = M10.0

Network 3 LD T33 = M0.0

Timing diagram:

2.2 Creating the sample program

Entering this example of a control program will help you understand how easy it is to use STEP 7-Micro/WIN SMART. This program uses six instructions in three networks to create a very simple, self-starting timer that resets itself.

For this example, you use the Ladder (LAD) editor to enter the instructions for the program. The following example shows the complete program in both LAD and Statement List (STL). The description column explains the logic for each network. The timing diagram shows the operation of the program. There are no network comments in the STL program.

Table 2- 1 Sample program for getting started with STEP 7-Micro/WIN SMART

10 ms timer T33 times out after (100 x 10 ms = 1 s) M0.0 pulse is too fast to monitor with Status view.

Comparison becomes true at a rate that is visible with Status view. Turn on M10.0 after (40 x 10 ms =

0.4 s) for a 40% OFF / 60% ON waveform.

T33 (bit) pulse is too fast to monitor with Status view. Reset the timer through M0.0 after the (100 x 10 ms = 1 s) period.

•

① T33 (current) ② Current = 100 ③ Current = 40 ④ T33 (bit) and M0.0 ⑤ M10.0

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Getting started

Notice the project tree and the pr gram editor. You use the project tree to insert instructions into the networks of the program editor by dragging and dropping the instructions from the "Instructions" portion of the Project tree to the networks.

The ject tree contains all of the blocks of your program.

The program editor toolbar icons pr vide shortcuts to PLC commands and programming operation.

2.2.1

Network 1: Starting the timer

When M0.0 is off (0), this contact turns on and provides power flow to start the timer.

2.2 Creating the sample program

Program Block folder in the pro-

After you enter and save the program, you can download the program to the CPU.

To enter the contact for M0.0:

1. Either double-click the "Bit Logic" icon or click the plus sign (+) to display the bit logic instructions.

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2. Select the "Normally Closed" contact.

3. Hold down the left mouse button and drag the contact onto the first network.

4. Enter the following address for the contact: M0.0

5. Press the Return key to enter the address for the contact.

Getting started

2.2.2

Network 2: Turning the output on

When the timer value for T33 is grea er than or equal to 40 (40 times 10 contact provides power flow to turn on output M10.0 of the CPU.

2.2 Creating the sample program

To enter the timer instruction for T33:

1. Double-click the "Timers" icon to display the timer instructions.

2. Select the "TON" (on-delay timer) instruction.

3. Hold down the left mouse button and drag the timer onto the first network.

4. Enter the following timer number for the timer: T33

5. Press the Return key to enter the timer number and to move the focus to the preset time

(PT) parameter.

6. Enter the following value for the preset time: +100.

7. Press the Return key to enter the value.

To enter the Compare instruction:

1. Double-click the Compare icon to display the compare instructions. Select the ">=I"

instruction (greater-than-or-equal-to-integer).

2. Hold down the left mouse button and drag the compare instruction onto the second

network.

3. Click "???" above the contact and enter the address for the timer value: T33

4. Press the Return key to enter the timer number and to move the focus to the other value

to be compared with the timer value.

milliseconds, or 0.4 seconds), the

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5. Enter the following value to be compared with the timer value: +40

6. Press the Return key to enter the value.

Getting started

2.2.3

Network 3: Resetting the timer

When the timer reaches the preset value (100) and turns the timer bit on, the contact for T33 turns on. Power flow from this contact turns on the M0.0 memory location. Because t timer is enabled by a Normally Closed contact for M0.0, changing the state of M0.0 from off (0) to on (1) resets the timer.

2.2 Creating the sample program

To enter the instruction for turning on output M10.0:

1. Double-click the Bit Logic icon to display the bit logic instructions and select the output coil.

2. Hold down the left mouse button and drag the coil onto the second network.

3. Click "???" above the coil and enter the following address: M10.0

4. Press the Return key to enter the address for the coil.

To enter the contact for the timer bit of T33:

1. Select the "Normally Open" contact from the bit logic instructions.

2. Hold down the left mouse button and drag the contact onto the third network.

3. Click "???" above the contact and enter the address of the timer bit: T33

4. Press the Return key to enter the address for the contact.

To enter the coil for turning on M0.0:

1. Select the output coil from the bit logic instructions.

2. Hold down the left mouse button and drag the output coil onto the third network.

3. Click "???" above the coil and enter the following address: M0.0

4. Press the Return key to enter the address for the coil.

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Getting started

2.2.4

Setting the CPU type and version for your project

2.2 Creating the sample program

Configure your project for the CPU and version matching your physical CPU. If the project is not configured for the correct CPU and CPU version, then the download could fail or the program may not run.

To select your CPU, click the "CPU" field under the "Module" column to display the dropdown list button, and select your CPU from the dropdown list. Using the same procedure, select your CPU version in the "Version" column.

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Getting started

2.2.5

Saving the sample project

2.2 Creating the sample program

After entering the three networks of instructions, you have finished entering the program. When you save the program, you create a project that includes the CPU type and other parameters. To save the project in a file name and location that you specify:

1. Click the down arrow under the Save button from the Operations area of the File menu ribbon strip to display the Save As button.

2. Click the Save As button and provide a filename for saving your project.

3. Enter a name for the project in the "Save As" dialog.

4. Browse to a location where you want to save your project.

5. Click "Save" to save the project.

After saving the project, you can download the program to the CPU.

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Getting started

2.3

Downloading the sample program

To download all project comp nents, click the "Download" button from the "Transfer" area of the File or PLC menu ribbon strip, or alternatively press the shortcut key combination "CTRL+D".

Click the Download dialog "Dow load" button.

STEP 7 ies the complete program or pr gram components that you selected to the CPU.

Note Each project is associated with a CPU type. If the project type does not match the CPU to

which you are connected, STEP you to take an a

See also

2.3 Downloading the sample program

First, ensure that your network hardware and PLC connector cable for either Ethernet (Page 33) (standard CPUs only) or RS485 (Page 36) communications is working, and that PLC communication is operating properly.

-Micro/WIN SMART copo-

If your CPU is in RUN mode, a dialog prompts you to place the CPU in STOP mode. Clicking "Yes" sets the CPU to STOP mode.

7-Micro/WIN SMART indicates a mismatch and prompts

ction.

Hardware troubleshooting guide (Page 578) PLC fatal error codes (Page 796) Changing the operating mode of the CPU (Page 46)

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Getting started

2.4

Changing the operating mode of the CPU

Placing the CPU in RUN mode

Placing the CPU in STOP mode

2.4 Changing the operating mode of the CPU

The CPU has two modes of operation: STOP mode and RUN mode. The status LEDs on the front of the CPU indicates the current mode of operation. In STOP mode, the CPU is not executing the program, and you can download program blocks. In RUN mode, the CPU is executing the program; however, you can download program blocks.

1. Click the "RUN" button on either the PLC menu ribbon strip or on the program editor toolbar:

2. When prompted, click "OK" to change the operating mode of the CPU.

You can monitor the program in STEP 7-Micro/WIN SMART by clicking the "Program Status" button from the "Debug" menu ribbon strip, or from the program editor toolbar. STEP 7-Micro/WIN SMART displays the values for the instructions.

To stop the program, click the "STOP" button and acknowledge the prompt to place the CPU in STOP mode. You can also place a STOP instruction in your program logic to put the CPU in STOP mode.

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3.1

Guidelines for installing S7-200 SMART devices

WARNING

Safety requirements for installing S7-200 SMART PLCs

Separate the devices from heat, high voltage, and electrical noise

The S7-200 SMART equipment is designed to be easy to install. You can install the S7-200 SMART either on a panel or on a standard DIN rail, and you can orient the S7-200 SMART either horizontally or vertically. The small size of the S7-200 SMART allows you to make efficient use of space.

S7-200 SMART PLCs are Open Type Controllers. You must install the PLC in a housing, cabinet, or electric control room. Limit entry to the housing, cabinet, or electric control room to authorized personnel.

Failure to follow these installation requirements could result in death or serious injury to personnel, and/or damage to equipment.

Always follow these requirements when installing the PLC.

As a general rule for laying out the devices of your system, always separate the devices that generate high voltage and high electrical noise from the low-voltage, logic-type devices such as the PLC.

When configuring the layout of the PLC inside your panel, consider the heat-generating devices and locate the electronic-type devices in the cooler areas of your cabinet. Reducing the exposure to a high-temperature environment will extend the operating life of any electronic device.

Consider also the routing of the wiring for the devices in the panel. Avoid placing low-voltage signal wires and communications cables in the same tray with AC power wiring and highenergy, rapidly-switched DC wiring.

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Installation

Provide adequate clearance for cooling and wiring

CAUTION

Temperature considerations

①

Side view

③

Vertical installation

②

Horizontal installation

④

Clearance area

3.1 Guidelines for installing S7-200 SMART devices

S7-200 SMART devices are designed for natural convection cooling. For proper cooling, you must provide a clearance of at least 25 mm above and below the devices. Also, allow at least 25 mm of depth between the front of the modules and the inside of the enclosure.

Vertical mounting reduces the maximum allowable ambient temperature by 10 degrees C. Operating outside the maximum temperature range could result in erratic process operation and could result in minor personal injury.

If your installation includes expansion modules, mount the CPU below them as shown in the following figure. Follow the prescribed guidelines for mounting modules to ensure proper cooling.

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When planning your layout for the PLC, allow enough clearance for the wiring and communications cable connections.

Installation

3.2

Power budget

Note If the CPU power budget is exceeded, you may not be able to connect the maximum number

of modules allowed for your CPU.

WARNING

Connecting power supplies safely

3.2 Power budget

Your CPU has an internal power supply that provides power for the CPU, the expansion modules, signal boards, and other 24 V DC user power requirements. Use the following information as a guide for determining how much power (or current) the CPU can provide for your configuration. The new compact CPUs (CRs) do not support expansion modules or signal boards.

Refer to the technical specifications for your particular CPU to determine the 24 V DC sensor supply power budget, the 5 V DC logic budget supplied by your CPU and the 5 V DC power requirements of the expansion modules and signal boards. Refer to the Calculating a power budget (Page 787) to determine how much power (or current) the CPU can provide for your configuration.

The standard CPU provides the 5 V DC logic power needed for any expansion in your system. Pay careful attention to your system configuration to ensure that the CPU can supply the 5 V DC power required by your selected expansion modules. If your configuration requires more power than the CPU can supply, you must remove a module.

The standard CPU also provides a 24 V DC sensor supply that can supply 24 V DC for input points, for relay coil power on the expansion modules, or for other requirements. If your power requirements exceed the budget of the sensor supply, then you must add an external 24 V DC power supply to your system. You must manually connect the 24 V DC supply to the input points or relay coils.

If you require an external 24 V DC power supply, ensure that the power supply is not connected in parallel with the sensor supply of the CPU. For improved electrical noise protection, it is recommended that the commons (M) of the different power supplies be connected.

Connecting an external 24 V DC power supply in parallel with the 24 V DC sensor supply of the CPU can result in a conflict between the two supplies as each seeks to establish its own preferred output voltage level.

The result of this conflict can be shortened lifetime or immediate failure of one or both power supplies, with consequent unpredictable operation of the PLC system. Unpredictable operation could result in death or serious injury to personnel, and/or damage to equipment.

The DC sensor supply of the CPU and any external power supply should provide power to different points. A single connection of the commons is allowed.

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Installation

WARNING

Avoiding unwanted current flow

3.2 Power budget

Some of the 24 V DC power input ports in the S7-200 SMART system are interconnected, with a common logic circuit connecting multiple M terminals. For example, the following circuits are interconnected when designated as "not isolated" in the data sheets: the 24 V DC power supply of the CPU, the power input for the relay coil of an EM, or the power supply for a non-isolated analog input. All non-isolated M terminals must connect to the same external reference potential.

Connecting non-isolated M terminals to different reference potentials will cause unintended current flows that may cause damage or unpredictable operation in the PLC and any connected equipment.

Failure to comply with these guidelines could cause damage or unpredictable operation which could result in death or severe personal injury and/or property damage.

Always ensure that all non-isolated M terminals in an S7-200 SMART system are connected to the same reference potential.

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Installation

3.3

Installation and removal procedures

3.3.1

Mounting dimensions for the S7-200 SMART devices

S7-200 SMART module

Width A (mm)

Width B (mm)

CPU SR20, CPU ST20, and CPU CR20s

CPU SR30, CPU ST30, and CPU CR30s

110

CPU SR40, CPU ST40, and CPU CR40s

125

62.5

CPU SR60, CPU ST60, and CPU CR60s1

175

37.51

Transistor

EM 8DI/8DQ and EM 8DI/8DQ RLY

22.5

EM 16DI/16DQ and EM 16DI/16DQRLY

EM 2AI/1AQ and EM 4AI/2AQ

22.5

EM 2RTD, EM 4RTD

22.5

EM 4TC

22.5

EM DP01

mounting hole to the corresponding edge of the housing.

Note The compact serial CPUs (CPU SR20s, CPU SR30s, CPU SR40s, and CPU SR60s) do not

support expansion modules or signal boards.

3.3 Installation and removal procedures

The CPU and expansion modules include mounting holes to facilitate installation on panels.

Expansion modules: EM 4AI, EM 8AI, EM 2AQ, EM 4AQ, EM 8DI, EM 16DI, EM

8DQ, and EM 8DQ RLY, EM 16DQ RLY, and EM 16DQ

The CPU xx60 models have two sets of mounting holes. The width "B" dimension is measured from the center of each

45 22.5

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Installation

3.3.2

Installing and removing the CPU

①

DIN rail installation

③

Panel installation

②

DIN rail clip in latched position

④

Clip in extended position

WARNING

Remove power to PLC before installing or removing equipment

WARNING

Module replacement

3.3 Installation and removal procedures

The CPU can be easily installed on a standard DIN rail or on a panel. DIN rail clips are provided to secure the device on the DIN rail. The clips also snap into an extended position to provide a screw mounting position for panel-mounting the unit.

Figure 3-1 Installation on a DIN rail or on a panel

Before you install or remove any electrical device, ensure that the power to that equipment has been turned off. Also, ensure that the power to any related equipment has been turned off.

Attempts to install or remove the PLC or related equipment with the power applied could cause electric shock or faulty operation of equipment.

Failure to disable all power to the PLC and related equipment during installation or removal procedures could result in death or serious injury to personnel, and/or damage to equipment.

Always follow appropriate safety precautions and ensure that power to the PLC is disabled before attempting to install or remove the CPU or related equipment.

Always ensure that whenever you replace or install a device, you use the correct module or equivalent device.

If you install an incorrect module, the program in the CPU could function unpredictably. Failure to replace a device with the same model, orientation, or order could result in death

or serious injury to personnel, and/or damage to equipment. Replace the device with the same model, and be sure to orient and position it correctly.

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Note Install expansion modules separately after the CPU has been installed. The CPU model

CPU CR20s, CPU CR30s, CPU CR40s, and CPU CR60s do not support the use of expansion modules or signal boards.

Note The type of screw will be determined by the material upon which it is mounted. You

should apply appropriate torque until the spring washer becomes flat. Av excessive torque to the mounting screws. Do not use a flat head screw.

3.3 Installation and removal procedures

Consider the following when installing the units on the DIN rail or on a panel:

● For DIN rail mounting, make sure the upper DIN rail clip is in the latched (inner) position

and that the lower DIN rail clip is in the extended position for the CPU.

● After installing the devices on the DIN rail, move the lower DIN rail clips to the latched

position to lock the devices on the DIN rail.

● For panel mounting, make sure the DIN rail clips are pushed to the extended position. To install the CPU on a panel, follow these steps:

1. Locate, drill, and tap the mounting holes (M4 or American Standard number 8), using the

dimensions in the table, Mounting dimensions (mm) (Page 51).

2. Ensure that the CPU and S7-200 SMART equipment are disconnected from electrical

power.

3. Secure the module(s) to the panel, using a Pan Head M4 screw with spring and flat

washer. Do not use a flat head screw.

4. If you are using an expansion module, put it next to the CPU and slide together until the

connectors join securely.

oid applying

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Task

Procedure

Note Using DIN rail stops could be helpful if your CPU is in an environment with high vibration

potential or if the CPU has been installed vertically. Use an end bracket (8WA1 808 or 8WA1

805) on the DIN rail to If your system is in a high

mounting the CPU will provide a

greater level of vibrati

Task

Procedure

3.3 Installation and removal procedures

Table 3- 1 Installing a CPU on a DIN rail

Follow the steps below to install a CPU on a DIN rail.

1. Secure the rail to the mounting panel every 75 mm.

2. Snap open the DIN clip (located on the bottom of the module) and hook the back of the module onto the DIN rail.

3. Rotate the module down to the DIN rail and snap the clip closed. Carefully check that the clip has fastened the module securely onto the rail. To avoid damage to the module, press on the tab of the mounting hole instead of pressing directly on the front of the module.

on protection.

Table 3- 2 Removing a CPU from a DIN rail

Follow the steps below to remove a CPU from a DIN rail.

1. Remove power from the CPU and any attached I/O modules.

2. Disconnect all the wiring and cabling that is attached to the CPU. The CPU and most expansion modules have removable connectors to make this job easier.

3. Unscrew the mounting screws or snap open the DIN clip.

4. If you have expansion modules connected, slide the CPU to the left to disengage it from the expansion module connector. Note: unscrewing or unsnapping the DIN clips of the expansion modules can make it easier to disengage the CPU.

5. Remove the CPU.

ensure that the modules remain connected.

-vibration environment, then panel-

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3.3.3

Installing and removing a signal board or battery board

Task

Procedure

Task

Procedure

3.3 Installation and removal procedures

The CPU models CPU CR20s, CPU CR30s, CPU CR40s, and CPU CR60s do not support the use of expansion modules, signal boards or battery boards.

Table 3- 3 Installing a signal board on a CPU

Follow the steps below to install a signal board or battery board

1. Ensure that the CPU and all S7-200 SMART equipment are disconnected from electrical power.

2. Remove the top and bottom terminal block covers from the CPU.

3. Place a screwdriver into the slot on top of the CPU at the rear of the cover.

4. Gently pry the cover up and remove it from the CPU.

5. Place the signal board or battery board straight down into its mounting position in the top of the CPU.

6. Firmly press the module into position until it snaps into place.

7. Replace the terminal block covers.

Table 3- 4 Removing a signal board or battery board on a CPU

Follow the steps below to remove a signal board or battery board

1. Ensure that the CPU and all S7-200 SMART equipment are disconnected from electrical power.

2. Remove the top and bottom terminal block covers from the CPU.

3. Place a screwdriver into the slot on top of the module.

4. Gently pry the module up to disengage it from the CPU.

5. Remove the module straight up from its mounting position in the top of the CPU.

6. Replace the cover onto the CPU.

7. Replace the terminal block covers.

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Note The CPU models CPU CR20s, CPU CR30s, CPU CR40s, and CPU CR60s do not support

the use of expansion modules or signal boards.

Installing or replacing the battery in the SB BA01 battery board

3.3 Installation and removal procedures

The SB BA01 battery board requires battery type CR1025. The battery is not included with the SB BA01 and must be purchased.

To install the battery, follow these steps:

1. In the SB BA01, install the new battery with the positive side of the battery on top, and the negative side next to the printed wiring board.

2. The SB BA01 is now ready to be installed in the CPU. Follow the installation directions above.

To replace the battery, follow these steps:

1. Remove the SB BA01 from the CPU following the removal directions above.

2. Carefully remove the old battery using a small screwdriver. Push the battery out from under the clip.

3. Install a new CR1025 replacement battery with the positive side of the battery on top and the negative side next to the printed wiring board.

4. Re-install the SB BA01 battery board following the installation directions above.

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3.3.4

Removing and reinstalling the terminal block connector

Task

Procedure

Task

Procedure

3.3 Installation and removal procedures

The S7-200 SMART modules have removable connectors to make connecting the wiring easy.

Table 3- 5 Removing the connector

Table 3- 6 Installing the connector

Prepare the system for terminal block removal by removing the power from the CPU and opening the cover above the connector.

1. Ensure that the CPU and all S7-200 SMART equipment are disconnected from

2. Inspect the top of the connector and locate the slot for the tip of the screwdriver.

3. Insert a small screwdriver into the slot.

4. Gently pry the top of the connector away from the CPU. The connector will release

5. Grasp the connector and remove it from the CPU.

electrical power.

with a snap.

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Prepare the components for terminal block installation by removing power from the CPU and opening the cover above the connector.

1. Ensure that the CPU and all S7-200 SMART equipment are disconnected from electrical power.

2. Align the connector with the pins on the unit.

3. Align the wiring edge of the connector inside the rim of the connector base.

4. Press firmly down and rotate the connector until it snaps into place.

Check carefully to ensure that the connector is properly aligned and fully engaged.

Installation

3.3.5

Installing and removing an expansion module

Task

Procedure

3.3 Installation and removal procedures

Install expansion modules separately after the CPU has been installed. The CPU models CPU CR20s, CPU CR30s, CPU CR40s, and CPU CR60s do not support the use of expansion modules or signal boards.

Table 3- 7 Installing an expansion module

Follow the steps below to install an expansion module:

1. Ensure that the CPU and all S7-200 SMART equipment are disconnected from electrical power.

2. Remove the cover for the I/O bus connector from the right side of the CPU.

3. Insert a screwdriver into the slot above the cover.

4. Gently pry the cover out at its top and remove the cover. Retain the cover for reuse.

Connect the expansion module to the CPU.

1. Pull out the bottom DIN rail clip to allow the expansion module to fit over the rail.

2. Position the expansion module to the right of the CPU.

3. Hook the expansion module over the top of the DIN rail.

4. Slide the expansion module to the left until the I/O connector fully engages the connector on the right of the CPU and push the bottom clip in to latch the expansion module onto the rail.

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Task

Procedure

3.3 Installation and removal procedures

Table 3- 8 Removing an expansion module

Follow the steps below to remove an expansion module:

1. Ensure that the CPU and all S7-200 SMART equipment are disconnected from electrical power.

2. Remove the I/O connectors and wiring from the expansion module. Loosen the DIN rail clips of all the S7-200 SMART devices.

3. Physically slide the expansion module to the right.

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3.3.6

Installing and removing the expansion cable

Task

Procedure

3.3 Installation and removal procedures

The S7-200 SMART expansion cable provides additional flexibility in configuring the layout of your S7-200 SMART system. Only one expansion cable is allowed per CPU system. You install the expansion cable either between the CPU and the first EM, or between any two EMs.

Table 3- 9 Installing and removing the male connector of the expansion cable

To install the male connector:

1. Ensure that the CPU and all S7-200 SMART equipment are disconnected from electrical power.

2. Push the male connector into the bus connector on the right side of the expansion module or CPU.

3. The male connector is locked in place when it is fully seeded.

To remove the male connector:

1. Ensure that the CPU and all S7-200 SMART equipment are disconnected from electrical power.

2. Use your thumb to press down the latch on the top of the male connector to release it from the expansion module or CPU.

3. Remove the male connector from the expansion module or CPU by pulling it straight out.

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Task

Procedure

Remove the female connector from the expansion module by

Note Installing the expansion cable in a vibration environment

If the expansion cable is connected to modules that move or are not firmly fixed, the connection on the cable ends can gradually become loose.

Use a cable relief.

Avoid using excessive force when you pull the cable during installation. Ensure the cable module connection is in the correct position once installation is complete.

3.3 Installation and removal procedures

Table 3- 10 Installing and removing the female connector of the expansion cable

To install the female connector:

1. Ensure that the CPU and all S7-200 SMART equipment are disconnected from electrical power.

2. Push the female connector into the bus connector on the left side of the expansion module.

3. The female connector is locked in place when it is fully seeded.

To remove the female connector:

1. Ensure that the CPU and all S7-200 SMART equipment are disconnected from electrical power.

2. Use your thumb to press down the latch on the top of the female connector to release it from the expansion module.

3. pulling it straight out.

tie to fix the cable ends on the DIN-rail (or other place) to provide extra strain

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3.4

Wiring guidelines

Prerequisites

WARNING

3.4 Wiring guidelines

Proper grounding and wiring of all electrical equipment is important to help ensure the optimum operation of your system and to provide additional electrical noise protection for your application and the PLC. Refer to the technical specifications (Page 679) for the wiring diagrams.

Before you ground or install wiring to any electrical device, ensure that the power to that equipment has been turned off. Also, ensure that the power to any related equipment has been turned off.

Ensure that you follow all applicable electrical codes when wiring the PLC and related equipment. Install and operate all equipment according to all applicable national and local standards. Contact your local authorities to determine which codes and standards apply to your specific case.

Attempts to install or wire the PLC or related equipment with power applied could cause electric shock or faulty operation of equipment. Failure to disable all power to the PLC and related equipment during installation or removal procedures could result in death or serious injury to personnel, and/or damage to equipment.

Always follow appropriate safety precautions and ensure that power to the PLC is disabled before attempting to install or remove the PLC or related equipment.

Always take safety into consideration as you design the grounding and wiring of your PLC system. Electronic control devices, such as the PLC, can fail and can cause unexpected operation of the equipment that is being controlled or monitored. For this reason, you should implement safeguards that are independent of the PLC to protect against possible personal injury or equipment damage.

Control devices can fail in an unsafe condition, resulting in unexpected operation of controlled equipment. Such unexpected operations could result in death or serious injury to personnel, and/or damage to equipment.

Use an emergency stop function, electromechanical overrides, or other redundant safeguards that are independent of the PLC.

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Isolation guidelines

WARNING

Safe use of power converters

Grounding guidelines

3.4 Wiring guidelines

The AC power supply boundaries and I/O boundaries to AC circuits have been designed and approved to provide safe separation between AC line voltages and low voltage circuits. These boundaries include double or reinforced insulation, or basic plus supplementary insulation, according to various standards. Components which cross these boundaries such as optical couplers, capacitors, transformers, and relays have been approved as providing safe separation. Only circuits rated for AC line voltage include safety isolation to other circuits. Isolation boundaries between 24 V DC circuits are functional only, and you should not depend on these boundaries for safety.

The sensor supply output, communications circuits, and internal logic circuits of an S7-200 SMART with included AC power supply are sourced as SELV (safety extra-low voltage) according to EN 61131-2.

To maintain the safe character of the S7-200 SMART low voltage circuits, external connections to communications ports, analog circuits, and all 24 V DC nominal power supply and I/O circuits must be powered from approved sources that meet the requirements of SELV, PELV, Class 2, Limited Voltage, or Limited Power according to various standards.

Use of non-isolated or single insulation supplies to supply low voltage circuits from an AC line can result in hazardous voltages appearing on circuits that are expected to be touch safe, such as communications circuits and low voltage sensor wiring.

Such unexpected high voltages could result in death or serious injury to personnel, and/or damage to equipment.

Use only high-voltage-to-low-voltage power converters that are approved as sources of touch-safe, limited-voltage circuits.

The best way to ground your application is to ensure that all the common and ground connections of your PLC and related equipment are grounded to a single point. This single point should be connected directly to the earth ground for your system.

All ground wires should be as short as possible and should use a large wire size, such as 2 mm

When locating grounds, remember to consider safety grounding requirements and the proper operation of protective interrupting devices.

(14 AWG).

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Wiring guidelines

3.4 Wiring guidelines

When designing the wiring for your S7-200 SMART CPU, provide a single disconnect switch that simultaneously removes power from the CPU power supply, from all input circuits, and from all output circuits. Provide over-current protection, such as a fuse or circuit breaker, to limit fault currents on supply wiring. Consider providing additional protection by placing a fuse or other current limit in each output circuit.

Install appropriate surge suppression devices for any wiring that could be subject to lightning surges.

Avoid placing low-voltage signal wires and communications cables in the same wire tray with AC wires and high-energy, rapidly switched DC wires. Always route wires in pairs, with the neutral or common wire paired with the hot or signal-carrying wire.

Use the shortest wire possible and ensure that the wire is sized properly to carry the required current.

Use wire and cable with a temperature rating 30 °C higher than the ambient temperature around the S7-200 SMART CPU (for example, a minimum of 85 °C-rated conductors for 55 °C ambient temperature). You should determine other wiring type and material requirements from the specific electrical circuit ratings and your installation environment.

Use shielded wires for optimum protection against electrical noise. Typically, grounding the shield at the S7-200 SMART CPU gives the best results. You should ground communication cable shields to S7-200 SMART CPU communication connector shells using connectors that engage the cable shield, or by bonding the communication cable shields to a separate ground. You should ground other cable shields using clamps or copper tape around the shield to provide a high surface area connection to the grounding point.

When wiring input circuits that are powered by an external power supply, include an overcurrent protection device in that circuit. External protection is not necessary for circuits that are powered by the 24 V DC sensor supply from the S7-200 SMART CPU because the sensor supply is already current-limited.

All S7-200 SMART CPU modules have removable connectors for user wiring. To prevent loose connections, ensure that the connector is seated securely and that the wire is installed securely into the connector.

To help prevent unwanted current flows in your installation, the S7-200 SMART CPU provides isolation boundaries at certain points. When you plan the wiring for your system, you should consider these isolation boundaries. Refer to the technical specifications (Page 679) for the amount of isolation provided and the location of the isolation boundaries. Circuits rated for AC line voltage include safety isolation to other circuits. Isolation boundaries between 24 V DC circuits are functional only, and you should not depend on these boundaries for safety.

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Wiring rules for...

CPU and EM connector

SB connector

sections for standard wires

Wire strip length

6.4 mm

6.3 to 7 mm

Tightening torque* (maximum)

0.56 N-m (5 inch-pounds)

0.33 N-m (3 inch-pounds)

Tool

2.5 to 3.0 mm flathead screwdriver

2.0 to 2.5 mm flathead screwdriver

* To avoid damaging the connector, be careful that you do not over-tighten the screws.

Note Ferr

short circuits. Ferrules longer than the recommended strip length should include an insulating collar to prevent shorts due to side movement of conductors. Cross limits for bare conductors also apply to ferrules.

See also

Guidelines for lamp loads

Guidelines for inductive loads

3.4 Wiring guidelines

A summary of wiring rules for the S7-200 SMART CPUs, EMs, and SBs is shown below:

Table 3- 11 Wiring rules for S7-200 SMART CPUs, EMs, and SBs

Connectible conductor cross-

Number of wires per connection 1 or combination of 2 wires up to 2 mm2

2 mm2 to 0.3 mm2 (14 AWG to 22 AWG) 1.3 mm2 to 0.3 mm2 (16 AWG to 22 AWG)

(total)

ules or end sleeves on stranded conductors reduce the risk of stray strands causing

General technical specifications (Page 679)

1 or combination of 2 wires up to 1.3 mm2 (total)

-sectional area

Lamp loads are damaging to relay contacts because of the high turn-on surge current. This surge current will nominally be 10 to 15 times the steady state current for a tungsten lamp. A replaceable interposing relay or surge limiter is recommended for lamp loads that will be switched a large number of times during the lifetime of the application.

Use suppressor circuits with inductive loads to limit the voltage rise when a control output turns off. Suppressor circuits protect your outputs from premature failure caused by the high voltage transient that occurs when current flow through an inductive load is interrupted.

In addition, suppressor circuits limit the electrical noise generated when switching inductive loads. High frequency noise from poorly suppressed inductive loads can disrupt the operation of the PLC. Placing an external suppressor circuit so that it is electrically across the load and physically located near the load is the most effective way to reduce electrical noise.

S7-200 SMART DC outputs include internal suppressor circuits that are adequate for inductive loads in most applications. Since S7-200 SMART relay output contacts can be used to switch either a DC or an AC load, internal protection is not provided.

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Note The effectiveness of a suppressor circuit depends on the application and must be verified for

your particular usage. Ensure that all components are correctly rated and use an oscilloscope to observe the

Typical suppressor circuit for DC or relay outputs that switch DC inductive loads

In most appli across a DC inductive load is suitable, but if your application requires faster turn addition of a zener diode (B) is recommended. Be sure to size your zener diode properly for the amount of current

①

1N4001 diode or equivalent

②

8.2 V Zener (DC outputs), 36 V Zener (Relay outputs)

③

Output point

④

M, 24 V reference

3.4 Wiring guidelines

A good suppressor solution is to use contactors and other inductive loads for which the manufacturer provides suppressor circuits integrated in the load device, or as an optional accessory. However, some manufacturer provided suppressor circuits may be inadequate for your application. An additional suppressor circuit may be necessary for optimal noise reduction and contact life.

For AC loads, a metal oxide varistor (MOV) or other voltage clamping device may be used with a parallel RC circuit, but is not as effective when used alone. An MOV suppressor with no parallel RC circuit often results in significant high frequency noise up to the clamp voltage.

A well-controlled turn-off transient will have a ring frequency of no more than 10 kHz, with less than 1 kHz preferred. Peak voltage for AC lines should be within +/- 1200 V of ground. Negative peak voltage for DC loads using the PLC internal suppression will be ~40 V below the 24 V DC supply voltage. External suppression should limit the transient to within 36 V of the supply to unload the internal suppression.

turn-off transient.

cations, the addition of a diode (A)

-off times, then the

in your output circuit.

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Typical suppressor circuit for relay outputs that switch AC inductive loads

Ensure that the working voltage of the metal oxide varistor (MOV) is at least 20% greater than the nom nal line voltage.

Choose pulse ca cally metal film). Verify the components meet ave age power, peak power, and peak voltage requirements.

①

See table for C value

②

See table for R value

③

Output point

Inductive load

Suppressor values

I rms

230 V AC

120 V AC

Resistor

Capacitor

Amps

W (power rating)

0.02

4.6

2.4

15000

0.1

0.05

11.5

5600

0.25

470

0.1

2700

0.5

100

0.2

1500

150

0.5

115

560

2.5

470

230

120

270

1000 2 460

240

150

1500

Conditions satisfied by the table values:

Power factor of 0.3 assumed for typical inductive load

3.4 Wiring guidelines

-rated, non-inductive resistors, and

pacitors recommended for pulse applications (typi-

If you design your own suppressor circuit, the following table suggests resistor and capacitor values for a range of AC loads. These values are based on calculations with ideal component parameters. I rms in the table refers to the steady-state current of the load when fully ON.

Table 3- 12 AC suppressor circuit resistor and capacitor values

Maximum turn-off transition step < 500 V Resistor peak voltage < 500 V Capacitor peak voltage < 1250 V Suppressor current < 8% of load current (50 Hz) Suppressor current < 11% of load current (60 Hz)

Capacitor dV/dt < 2 V/μs Capacitor pulse dissipation : ∫(dv/dt)

Resonant frequency < 300 Hz Resistor power for 2 Hz max switching frequency

dt < 10000 V2/μs

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WARNING

Correct placement of external resistor/capacitor noise suppression circuit

3.4 Wiring guidelines

When you use relay expansion modules to switch AC inductive loads, you must place the external resistor/capacitor noise suppression circuit across the AC load to prevent unexpected machine or process operation. Unexpected machine or process operation could result in death or severe personal injury.

Always be sure to follow these guidelines in placing the external resistor/capacitor noise suppression circuit.

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4.1

Execution of the control logic

The figure shows a simple diagram of how an electrical relay diagram relates to the CPU. In this example, the state of the switch for starting the motor is combined with the states of other i puts. T then determine the state for the output that goes to the actuator which starts the motor.

The basic function of the CPU is to monitor field inputs and, based on your control logic, turn on or off field output devices. This chapter explains the concepts used to execute your program, the various types of memory used, and how that memory is retained.

The CPU continuously cycles through the control logic in your program, reading and writing data. The basic operation is very simple:

● The CPU reads the status of the inputs.

● The program that is stored in the CPU uses these inputs to evaluate the control logic.

● As the program runs, the CPU updates the data.

● The CPU writes the data to the outputs.

he calculations of these states

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PLC concepts

Tasks in a scan cycle

Scan cycle

Description

cal inputs to the process image input register.

in the various memory areas.

forms any tasks required for communications.

modules are working properly.

4.1 Execution of the control logic

The CPU executes a series of tasks repetitively. This cyclical execution of tasks is called the scan cycle. The execution of the user program is dependent upon whether the CPU is in STOP mode or in RUN mode. In RUN mode, your program is executed; in STOP mode, your program is not executed.

Table 4- 1 Tasks performed by the CPU in a scan cycle

Reading the inputs: The CPU copies the state of the physi-

Executing the control logic in the program: The CPU executes the instructions of the program and stores the values

Processing any communications requests: The CPU per-

Executing the CPU self-test diagnostics: The CPU ensures that the firmware, the program memory, and any expansion

Writing to the outputs: The values stored in the process image output register are written to the physical outputs.

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4.1.1

Reading the inputs and writing to the outputs

Reading the inputs

Writing to the outputs

4.1.2

Immediately reading or writing the I/O

Note When you read an analog input, the value is read immediately. When you write a value to an

analog output, the ou

4.1 Execution of the control logic

Digital inputs: Each scan cycle begins by reading the current value of the digital inputs and then writing these values to the process image input register.

Analog inputs: cycle. Instead, an analog value is read immediately from the device when your program accesses the analog input.

Digital outputs: At the end of every scan cycle, the CPU writes the values stored in the process-image output register to the digital outputs.

Analog outputs:

cycle. Instead, the analog outputs are written immediately when your program accesses the analog output.

The CPU instruction set provides instructions that immediately read from or write to the physical I/O. These immediate I/O instructions allow direct access to the actual input or output point, even though the image registers are normally used as either the source or the destination for I/O accesses. The corresponding process image input register location is not modified when you use an immediate instruction to access an input point. The corresponding process image output register location is updated simultaneously when you use an immediate instruction to access an output point.

The CPU does not read the analog input values as part of the normal scan

The CPU does not write analog output values as part of the normal scan

tput is updated immediately.

It is usually advantageous to use the process image register rather than to directly access inputs or outputs during the execution of your program. There are three reasons for using the image registers:

● The sampling of all inputs at the start of the scan synchronizes and freezes the values of

the inputs for the program execution phase of the scan cycle. The outputs are updated from the image register after the execution of the program is complete. This provides a stabilizing effect on the system.

● Your program can access the image register much more quickly than it can access I/O

points, allowing faster execution of the program.

● I/O points are bit entities and must be accessed as bits or bytes, but you can access the

image register as bits, bytes, words, or double words. Thus, the image registers provide additional flexibility.

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4.1.3

Executing the user program

4.1 Execution of the control logic

During the execution phase of the scan cycle, the CPU executes your main program, starting with the first instruction and proceeding to the last instruction. The immediate I/O instructions give you immediate access to inputs and outputs during the execution of either the main program or an interrupt routine.

If you use subroutines in your program, the subroutines are stored as part of the program. The subroutines are executed when they are called by the main program, by another subroutine, or by an interrupt routine. Subroutine nesting depth is 8 levels deep from the main and 4 levels deep from an interrupt routine.

If you use interrupts in your program, the interrupt routines that are associated with the interrupt events are stored as part of the program. The interrupt routines are not executed as part of the normal scan cycle, but are executed when the interrupt event occurs (which could be at any point in the scan cycle).

Local memory is reserved for each of 14 entities: the main program, eight subroutine nesting levels when initiated from the main program, one interrupt routine, and four subroutine nesting levels when initiated from an interrupt routine. Local memory has a local scope in that it is available only within its associated program entity, and cannot be accessed by the other program entities. For more information about Local memory, refer to Local Memory Area: L in this chapter.

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4.1 Execution of the control logic

The following figure depicts the flow of a typical scan including the Local memory usage and two interrupt events, one during the program-execution phase and another during the communications phase of the scan cycle. Subroutines are called by the next higher level, and are executed when called. Interrupt routines are not called; they are a result of an occurrence of the associated interrupt event.

Figure 4-1 Typical scan flow

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PLC concepts

4.2

Accessing data

Elements of a bit address

Description

Memory area identifier

Separator ("byte.bit")

Bit location of the byte (bit 4 of 8, bits numbered 7 to 0)

Bytes of the memory area

4.2 Accessing data

The CPU stores information in different memory locations that have unique addresses. You can explicitly identify the memory address that you want to access. This allows your program to have direct access to the information. To access a bit in a memory area, you specify the address, which includes the memory area identifier, the byte address, and the bit number (which is also called "byte.bit" addressing).

Table 4- 2 Bit addressing

B Byte address: byte 3

F Bits of the selected byte

In this example, the memory area and byte address ("M3") designates byte 3 of M memory, with a period (".") to separate the bit address (bit 4).

You can access data in most memory areas (V, I, Q, M, S, L, and SM) as bytes, words, or double words by using the byte-address format. To access a byte, word, or double word of data in the memory, you must specify the address in a way similar to specifying the address for a bit. This includes an area identifier, data size designation, and the starting byte address of the byte, word, or double-word value, as shown in the following figure.

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Representation

Byte (B)

Word (W)

Double Word (D)

16#00 to 16#FF

16#0000 to 16#FFFF

16#00000000 to 16#FFFFFFFF

Point)

4.2.1

Accessing memory areas

I (process-image input)

Bit:

[byte address].[bit address]

I0.1

ID20

Q (process-image output)

Bit:

[byte address].[bit address]

Q1.1

QD28

4.2 Accessing data

The following table shows the range of integer values that can be represented by the different sizes of data.

Table 4- 3 Decimal and hexadecimal ranges for the different sizes of data

Unsigned Integer

Signed Integer -128 to +127

Real (IEEE 32bit Floating

0 to 255

16#80 to 16#7F

Not applicable

Data in other memory areas (such as T, C, HC, and the accumulators) are accessed by using an address format that includes an area identifier and a device number.

The CPU samples the physical input points at the beginning of each scan cycle and writes these values to the process image input register. You can access the process image input register in bits, bytes, words, or double words:

Table 4- 4 Absolute addressing for I memory

0 to 65,535

-32,768 to +32,767 16#8000 to 16#7FFF

Not applicable

+1.175495E-38 to +3.402823E+38 (positive)

0 to 4,294,967,295

-2,147,483,648 to +2,147,483,647 16#8000 0000 to 16#7FFF FFFF

-1.175495E-38 to -3.402823E+38 (negative)

Byte, Word, or Double Word: I

At the end of the scan cycle, the CPU copies the values stored in the process image output register to the physical output points. You can access the process image output register in bits, bytes, words, or double words:

Table 4- 5 Absolute addressing for Q memory

Byte, Word, or Double Word: Q

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[size][starting byte address]

IB4,

IW7,

QB5, QW14,

PLC concepts

V (variable memory)

Bit:

[byte address].[bit address]

V10.2

VD2136

M (flag memory)

Bit:

[byte address].[bit address]

M26.7

T (timer memory)

4.2 Accessing data

You can use V memory to store intermediate results of operations being performed by the control logic in your program. You can also use V memory to store other data pertaining to your process or task. You can access the V memory area in bits, bytes, words, or double words:

Table 4- 6 Absolute addressing for V memory

Byte, Word, or Double Word: V

[size][starting byte address]

VB16,

VW100,

You can use the flag memory area (M memory) as internal control relays to store the intermediate status of an operation or other control information. You can access the flag memory area in bits, bytes, words, or double words:

Table 4- 7 Absolute addressing for M memory

Byte, Word, or Double Word: M

[size][starting byte address]

MB0, MW11,

MD20

The CPU provides timers that count increments of time in resolutions (time-base increments) of 1 ms, 10 ms, or 100 ms. Two variables are associated with a timer:

● Current value: this 16-bit signed integer stores the amount of time counted by the timer.

● Timer bit: this bit is set or cleared as a result of comparing the current and the preset

value. The preset value is entered as part of the timer instruction.

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Timer:

[timer number]

T24

C (counter memory)

Counter

[counter number]

C24

4.2 Accessing data

You access both of these variables by using the timer address (T + timer number). Access to either the timer bit or the current value is dependent on the instruction used: instructions with bit operands access the timer bit, while instructions with word operands access the current value. As shown in the following figure, the Normally Open Contact instruction accesses the timer bit, while the Move Word instruction accesses the current value of the timer.

Table 4- 8 Absolute addressing for T memory

Figure 4-2 Accessing the timer bit or the current value of a timer

The CPU provides three types of counters that count each low-to-high transition event on the counter input(s): one type counts up only, one type counts down only, and one type counts both up and down. Two variables are associated with a counter:

● Current value: this 16-bit signed integer stores the accumulated count.

● Counter bit: this bit is set or cleared as a result of comparing the current and the preset

value. The preset value is entered as part of the counter instruction.

You access both of these variables by using the counter address (C + counter number). Access to either the counter bit or the current value is dependent on the instruction used: instructions with bit operands access the counter bit, while instructions with word operands access the current value. As shown in the following figure, the Normally Open Contact instruction accesses the counter bit, while the Move Word instruction accesses the current value of the counter.

Table 4- 9 Absolute addressing of C memory

Figure 4-3 Accessing the counter bit or the current value of a counter

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HC (high-speed counter)

High-speed counter

[high-speed counter number]

HC1

AC (accumulators)

4.2 Accessing data

The high-speed counters count high-speed events independent of the CPU scan. Highspeed counters have a signed, 32-bit integer counting value (or current value). To access the count value for the high-speed counter, you specify the address of the high-speed counter, using the memory type (HC) and the counter number. The current value of the highspeed counter is a read-only value and can be addressed only as a double word (32 bits).

Table 4- 10 Absolute addressing of HC memory

The accumulators are read/write devices that can be used like memory. For example, you can use accumulators to pass parameters to and from subroutines and to store intermediate values used in a calculation. The CPU provides four 32-bit accumulators (AC0, AC1, AC2, and AC3). You can access the data in the accumulators as bytes, words, or double words.

The size of the data being accessed is determined by the instruction that is used to access the accumulator. As shown in the following figure, you use the least significant 8 or 16 bits of the value that is stored in the accumulator to access the accumulator as bytes or words. To access the accumulator as a double word, you use all 32 bits.

For information about how to use the accumulators within interrupt subroutines, refer to the Interrupt instructions (Page 322).

Table 4- 11 Absolute addressing of AC memory

Accumulator AC

[accumulator number]

AC0

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SM (special memory)

Bit:

[byte address].[bit address]

SM0.1

SMD1000

4.2 Accessing data

Figure 4-4 Accessing the accumulators

The SM bits provide a means for communicating information between the CPU and your user program. You can use these bits to select and control some of the special functions of the CPU, such as: a bit that turns on for the first scan cycle, a bit that toggles at a fixed rate, or a bit that shows the status of math or operational instructions. You can access the SM bits as bits, bytes, words, or double words:

Table 4- 12 Absolute addressing of SM memory

Byte, Word, or Double Word: SM

For more information, see the descriptions of the SM bits (Page 799).

[size][starting byte address]

SMB86,

SMW300,

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L (local memory area)

Bit:

[byte address].[bit address]

L0.0

LD20

4.2 Accessing data

The CPU provides 64 L memory bytes for each POU (program organizational unit) in a local memory stack. A POU's associated L memory addresses are accessible only by the currently executing POU (main, subroutine, or interrupt routine). When you use interrupt routines and subroutines, the L memory stack is used to preserve L memory values of a POU that temporarily suspends execution, so another POU can execute. The suspended POU can then resume execution with the L memory values that existed prior to giving execution control to another POU.

L memory stack maximum nesting limits:

● Eight subroutine nesting levels when initiated from the main program

● Four subroutine nesting levels when initiated from an interrupt routine

The nesting limits allow a 14 level execution stack in your program. For example, the main program (level 1) has eight nested subroutines (levels 2 to 9). During execution of the 9th level subroutine, an interrupt occurs (level 10). The interrupt routine contains four nested subroutines (levels 11 to 14).

L memory rules:

● You can use L memory for local scratchpad "TEMP" variables in all POU types (main,

subroutine, and interrupt routines)

● Only subroutines can use L memory for "IN" IN_OUT", and "OUT" variable types that are

passed to or from subroutines.

● If you are programming a subroutine in either LAD or FBD, only 60 bytes are allowed for

TEMP, IN, IN_OUT, and OUT variables. STEP 7-Micro/WIN SMART uses the last four bytes of local memory

Local memory symbols, variable types, and data types are assigned in the Variable table that is available when the associated POU is opened in the program editor. Absolute L memory addresses are automatically assigned when a POU is successfully compiled.

In most cases, use L memory symbol name references in your program logic, because you cannot know all the absolute L memory addresses until after the complete POU is successfully compiled. However, you can use absolute L memory addresses as shown in the following table.

Table 4- 13 Absolute addressing of L memory

Byte, Word, or Double Word: L

[size] [starting byte address]

LB33, LW5,

Local memory and to global V memory use a similar address syntax, but V memory has a global scope while L memory has a local scope. Global scope means that the same memory address can be accessed from any POU. Local scope means that the L memory allocation is associated with a particular POU and cannot be accessed by another program unit.

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Note Local memory value assignments are not always preserved for successive executions of a

POU L memory addresses are reused for the next execution sequence, after the current nested

sequence is completed. Depending on a POU's level in the execution stack and L memory assignments made since a POU's last execution, a POU's L memory assignments made in a previous execution may be overwritten with unexpected values.

Remember to reassign the correct values to L memory variables, in your program logic. Reinitialize all TEMP values before processing them and ensure that any output values (OUT a

AI (analog input)

Analog input

AIW

[starting byte address]

AIW4

AQ (analog output)

Analog output

AQW

[starting byte address]

AQW4

4.2 Accessing data

The local scope of L memory also affects symbol usage, when a global symbol and a local symbol use the same name. If your program logic references that symbol name, the CPU ignores the global symbol and processes the address assigned to the local memory symbol.

nd IN_OUT) are correct.

The CPU converts an analog value (such as temperature or voltage) into a word-length (16bit) digital value. You access these values by the area identifier (AI), size of the data (W), and the starting byte address. Since analog inputs are words and always start on evennumber bytes (such as 0, 2, or 4), you access them with even-number byte addresses (such as AIW0, AIW2, or AIW4). Analog input values are read-only values.

Table 4- 14 Absolute addressing of AI memory

The CPU converts a word-length (16-bit) digital value into a current or voltage, proportional to the digital value (such as for a current or voltage). You write these values by the area identifier (AQ), size of the data (W), and the starting byte address. Since analog outputs are words and always start on even-number bytes (such as 0, 2, or 4), you write them with evennumber byte addresses (such as AQW0, AQW2, or AQW4). Analog output values are writeonly values.

Table 4- 15 Absolute addressing of AQ memory

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S (sequence control relay)

Bit:

[byte address].[bit address]

S3.1

SD14

4.2.2

Format for Real numbers

Note Floating

maximum of 6 decimal places when entering a floating Calculations that involve a long series of values including very large and very small numbers

can produce inaccurate results. This can occu where

4.2.3

Format for strings

4.2 Accessing data

S bits are associated with SCRs, which you can use to organize machine or steps into equivalent program segments. SCRs allow logical segmentation of the control program. You can access the S memory as bits, bytes, words, or double words.

Table 4- 16 Absolute addressing of S memory

Byte, Word, or Double Word: S

[size][starting byte address]

SB4,

SW7,

Real (or floating-point) numbers are represented as 32-bit, single-precision numbers, whose format is described in the ANSI/IEEE 754-1985 standard. Real numbers are accessed in double-word lengths.

Figure 4-5 Format of a Real number

-point numbers are accurate up to 6 decimal places. Therefore, you can specify a

-point constant.

r if the numbers differ by 10 to the power of x,

> 6. For example: 100 000 000 + 1 = 100 000 000

A string is a sequence of characters, with each character being stored as a byte. The first byte of the string defines the length of the string, which is the number of characters. The following figure shows the format for a string. A string can have a length of 0 to 254 characters, plus the length byte, so the maximum length for a string is 255 bytes. A string constant is limited to 126 bytes.

Figure 4-6 Format for strings

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4.2.4

Assigning a constant value for instructions

Representation

Format

Sample

Decimal

[decimal value]

20047

Binary

2#[binary number]

2#1010_0101_1010_0101

ASCII

'[ASCII text]'

'ABCD'

-1.175495E-38 (negative)

String

"[stringtext]"

"ABCDE"

Note The CPU does not support "data typing" or data checking (su

constant is stored as an integer, a signed integer, or a double integer). For example, an Add instruction can use the value in VW100 as a signed integer value, while an Exclusive Or instruction can use the same value in VW100 as a

4.2.5

Addressing the local and expansion I/O

Note Process image register space for

(one byte). If a module does not provide a physical point for each bit of each reserved byte, these unused bits cannot be assigned to subsequent modules in the I/O chain. For input modules, the unu

Analog I/O points are always allocated in increments of two points. If a module does not provide physical I/O for each of these points, these I/O points are lost and are not available for assignment to

4.2 Accessing data

You can use a constant value in many of the programming instructions. Constants can be bytes, words, or double words. The CPU stores all constants as binary numbers, which can then be represented in decimal, hexadecimal, ASCII, or real number (floating point) formats.

Table 4- 17 Representation of constant values

Hexadecimal 16#[hexadecimal value] 16#4E4F

Real ANSI/IEEE 754-1985 +1.175495E-38 (positive)

ch as specifying that the

n unsigned binary value.

The local I/O provided by the CPU provides a fixed set of I/O addresses. You can add I/O points by connecting expansion I/O modules to the right side of the CPU or by installing a signal board. The addresses of the points of the module are determined by the type of I/O and the position of the module in the chain. For example, an output module does not affect the addresses of the points on an input module, and vice versa. Likewise, analog modules do not affect the addressing of digital modules, and vice versa.

digital I/O is always reserved in increments of eight bits

sed bits are set to zero with each input update cycle.

subsequent modules in the I/O chain.

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CPU

Signal board

Expansion module 0

Expansion module 1

Expansion module 2

Expansion module 3

Expansion module 4

Expansion module 5

AQ12

AQ16

AQ32

AQ48

AQ64

AQ80

AQ96

Note The CPU models CPU CR20s, CPU CR30s, CPU CR40s, and CPU CR60s do not support

the use of expansion modules or signal boards.

4.2.6

Using pointers for indirect addressing

4.2 Accessing data

The following table provides an example of the fixed mapping convention (established by STEP 7 Micro/WIN SMART and downloaded as part of the I/O configuration, in the system block).

Table 4- 18 CPU mapping convention

Starting address

I0.0 Q0.0

I7.0 Q7.0 AI12

I8.0 Q8.0 AI16

I12.0 Q12.0 AI32

I16.0 Q16.0 AI48

I20.0 Q20.0 AI64

I24.0 Q24.0 AI80

I28.0 Q28.0 AI96

Indirect addressing uses a pointer to access data in memory. Pointers are double word memory locations that contain the address of another memory location. You can only use V memory locations, L memory locations, or accumulator registers (AC1, AC2, AC3) as pointers. To create a pointer, you must use the Move Double Word instruction to move the address of the indirectly addressed memory location to the pointer location. Pointers can also be passed to a subroutine as a parameter.

An S7-200 SMART CPU allows pointers to access the following memory areas: I, Q, V, M, S, AI, AQ, SM, T (current value only), and C (current value only). You cannot use indirect addressing to access an individual bit or to access HC, L or accumulator memory areas.

To indirectly access the data in a memory address, you create a pointer to that location by entering an ampersand character (&) and the first byte of the memory location to be addressed. The input operand of the instruction must be preceded with an ampersand (&) to signify that the address of a memory location, instead of its contents, is to be moved into the location identified in the output operand of the instruction (the pointer).

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①

Creates the pointer by moving the address of VB200 (initial byte of VW200) to AC1

②

Moves the word value referenced by the pointer in AC1

①

Moves the word value referenced by the pointer in AC1

②

Moves the word value referenced by the pointer in AC1

4.2 Accessing data

Entering an asterisk (*) in front of an operand for an instruction specifies that the operand is a pointer. As shown in the following figure, entering *AC1 means that AC1 stores a pointer to the word-length value being referenced by the Move Word (MOVW) instruction. In this example, the values stored in both VB200 and VB201 are moved to accumulator AC0.

MOVD &VB200, AC1

MOVW *AC1, AC0

Figure 4-7 Creating and using a pointer

As shown in the following figure, you can change the value of a pointer. Since pointers are 32-bit values, use double-word instructions to modify pointer values. Simple mathematical operations, such as adding or incrementing, can be used to modify pointer values.

MOVD &VB200, AC1

Creates the pointer by moving the address of VB200 (initial byte of VW200) to AC1 MOVW *AC1, AC0

+D +2, AC1

Adds 2 to the accumulator to point to the next word location MOVW *AC1, AC0

Figure 4-8 Modifying a pointer

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Note When modifying the value of a pointer, remember to adjust for the size of the data that you

are accessing: to access a byt current value for a timer or counter, add or increment the pointer value by 2; and to access a double word, add or increment the pointer value by 4.

4.2 Accessing data

e, increment the pointer value by 1; to access a word or a

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4.2.7

Pointer examples

Using a pointer to access data in a table

LAD

STL

4.2 Accessing data

This example uses LD14 as a pointer to a recipe stored in a table of recipes that begins at VB100. In this example, VW1008 stores the index to a specific recipe in the table. If each recipe in the table is 50 bytes long, you multiply the index by 50 to obtain the offset for the starting address of a specific recipe. By adding the offset to the pointer, you can access the individual recipe from the table. In this example, the recipe is copied to the 50 bytes that start at VB1500.

Table 4- 19 Example: Using a pointer to access data in a table

To transfer a recipe from a table of recipes:

• Each recipe is 50 bytes long.

• The index parameter (VW1008)

identifies the recipe to be loaded.

Create a pointer to the starting address of the recipe table.

Convert the index of the recipe to a double-word value.

Multiply the offset to accommodate the size of each recipe.

Add the adjusted offset to the pointer.

Transfer the selected recipe to VB1500 through VB1549

Network 1 LD SM0.0 MOVD &VB100, LD14

ITD VW1008, LD18

*D +50, LD18

+D LD18, LD14

BMB *LD14, VB1500, 50

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Using an offset to access data

LAD

STL

Network 1

4.2 Accessing data

This example uses LD10 as a pointer to the address VB0. You then increment the pointer by an offset stored in VD1004. LD10 then points to another address in V memory (VB0 + offset). The value stored in the V memory address pointed to by LD10 is then copied to VB1900. By changing the value in VD1004, you can access any V memory location.

Table 4- 20 Example: Using an offset to read the value of any V memory location

Load the starting address of the V memory to a pointer.

Add the offset value to the pointer.

Copy the value from the V memory location (offset) to VB1900

LD SM0.0 MOVD &VB0, LD10

+D VD1004, LD10

MOVB *LD10, VB1900

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4.3

Saving and restoring data

4.3.1

Downloading project components

Note Downloading a program block, data block, or system block to the CPU completely overwrites

any pre block before performing a download.

CTRL+D

4.3 Saving and restoring data

-existing contents of that block in the CPU. Be sure that you want to overwrite the

To download project components from STEP 7-Micro/WIN SMART to the CPU, follow these steps:

1. Ensure that your Communication Interface and PLC connector cable for either Ethernet (Page 33) (standard CPUs only) or RS485 (Page 36) communications is working, and that PLC communication is operating properly.

2. Place the CPU in STOP mode (Page 46).

3. To download all project components, click the Download button from the Transfer area of the File or PLC menu ribbon strip, or alternatively press the shortcut key combination

4. To download selected project components, click the down arrow under the Download button, and then select the specific project component you want to download (Program Block, Data Block, or System Block) from the drop-down list.

5. After clicking the Download button, if you see a Communications dialog, select the Communication Interface and the Ethernet IP address or RS485 network address for the PLC to which you want to download.

6. From the Download dialog, set the download options for the blocks, and whether you want to be prompted on CPU transitions from RUN to STOP mode (Page 46) and STOP to RUN mode (Page 46).

7. Optionally click the "Close dialog on success" check box if you want the dialog to automatically close after a successful download.

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Note You can download project components that you originally created for use in an S7

SMART CPU with firmware version V1.x to a CPU with firmware version V2.0 or later. However, you cannot download project components that you origi CPU firmware version V2.0 or later to a CPU with firmware version V1.x, especially if the project components use functionality that firmware version V1.x did not support.

4.3 Saving and restoring data

8. Click the Download button.

STEP 7-Micro/WIN SMART copies the complete program or program components that you selected to the CPU. The status icon indicates informational messages, or whether potential problems or errors occurred with the download. The status message provides specific results of the operation.

-200

nally created for use in a

STEP 7-Micro/WIN SMART also supports program edit and download in RUN mode.

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What happens when you download

Step

Action

See also

4.3 Saving and restoring data

STEP 7-Micro/WIN SMART and the CPU perform the following tasks in sequence on your project components when you download:

1. Project components in the program editors serve as input for the download operation, based on the download objects you selected. The program editors can include new program data that you've entered, a saved and opened .smart project, or an uploaded

2. STEP 7-Micro/WIN SMART compile A compile or download command

starts the compiler. If the compile passes, control passes to the next step; if not, the compile or download

3. Send blocks to CPU across communication network for PLC compile.

4. PLC compile If PLC compile succeeds, control

passes to the next step; if not, download exits with error(s).

File open Range checking Project file I/O errors Program editor errors

All STEP 7-Micro/WIN SMART compiler errors are listed in the Output Window. Double-click the error and the editor scrolls to the error location. A successful compile shows the resulting block size of the program and data block.

Communication Errors To download (Editor to PLC) or upload (PLC to

Editor), PLC communication must be operating properly. Make sure your network hardware and

The PLC Compiler verifies that the PLC hardware supports all program instructions, ranges, and structure.

Click the PLC button from the Information area of the PLC menu to view the first compile error

5. Program is in CPU permanent memory and ready to be executed in RUN

If the download attempt produces compiler errors or download errors, correct the errors and reattempt the download.

Uploading project components (Page 92)

Hardware troubleshooting guide (Page 578)

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Fatal Errors (Page 796) and non-fatal run-time errors (Page 792) are accessible from the In-

PLC concepts

4.3.2

Uploading project components

CTRL+U.

4.3 Saving and restoring data

To upload project components from the PLC to a STEP 7-Micro/WIN SMART program editor, follow these steps:

1. Ensure that your network hardware and PLC connector cable (Ethernet (Page 33) or RS485 (Page 36)) are working, and that PLC communication is operating properly (Page 578).

2. To upload all project components, click the Upload button from the Transfer section of the File or PLC menu ribbon strip, or press the shortcut key combination

3. To upload selected project components, click the down arrow under the Upload button, and then select the specific project component you want to upload (Program Block, Data Block, or System Block).

4. If you see a Communications dialog, select the Communication Interface and the Ethernet IP address or RS485 network address of the PLC from which you want to upload.

5. From the Upload dialog, you can change your selection for which blocks to upload if you choose.

6. Optionally click the "Close dialog on success" check box if you want the dialog to automatically close after a successful upload

7. Click the "Upload" button to start the upload.

STEP 7-Micro/WIN SMART copies the complete program or program components that you selected for uploading from the PLC to the currently open project. The status icon indicates informational messages, or whether potential problems or errors occurred with the upload. The status message provides specific results of the operation.

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Note Uploading into a new project is a risk

and/or data block infor data. If you want to make use of material from a status chart or symbol table that are in another project, you can always copy that information in from the other project file

Uploading into an existing project is useful if you want to overwrite all modifications that have been made to the program since it was

) to the PLC. Uploading into an existing project does, however, overwrite any additi the project. Use this option, only if you want to completely overwrite your STEP

STEP with comments open in the program editor, the comments are retained. Take care if uploading over an existing project and use this method only if the projects are similar.

4.3.3

Types of storage

4.3 Saving and restoring data

If the upload is successful, you can save the uploaded program, or make further changes. The PLC does not contain symbol or status chart information; hence, you cannot upload a symbol table or status chart.

-free way to capture the program block, system block,

mation. Since the project is empty, you cannot inadvertently destroy

open a second instance of STEP 7-Micro/WIN SMART and

(Page 111).

downloaded (Page 89

ons or modifications you have made to

7-Micro/WIN SMART project with the project stored in the PLC. 7-Micro/WIN SMART does not upload comments, but if you currently have a program

The CPU provides a variety of features to ensure that your user program and data are properly retained.

● Retentive memory: selectable areas of memory that remain unchanged over a power

cycle. Retentive memory can be configured in the system data block. V, M, and current values to timers and counters are the only memory areas that can be configured to be retentive.

● Permanent memory: memory used to store the program block, data block, system block,

forced values, as well as values configured to be retentive.

● Memory card: removable microSDHC card for standard CPUs that you can use for the

following purposes: – To store the projects blocks as a program transfer card (Page 97) – To completely erase the PLC as a restore-to-factory-defaults card (Page 167) – To update the PLC and expansion module firmware as a firmware update card

(Page 94)

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4.3.4

Using a memory card

WARNING

Verify that the CPU is not actively running a process before installing the memory card.

Program transfer card

At the root level of the card

Folder: SIMATIC.S7S

A folder containing user program files to be transferred to the CPU

4.3 Saving and restoring data

The standard S7-200 SMART CPUs support the use of a microSDHC card for:

● User program transfer (Page 97)

● Reset CPU to factory default condition (Page 167)

● Firmware update of the CPU and attached expansion modules as supported

You can use any standard, commercial microSDHC card with a capacity in the range 4GB to 16GB.

The following CPU behaviors are common, regardless of the memory card usage:

1. Inserting a memory card into a CPU in RUN mode causes the CPU to automatically transition to STOP mode.

2. A CPU cannot advance to RUN mode if a memory card is inserted.

3. Memory card evaluation is performed only after a CPU power-up or warm restart. Therefore, program transfer and firmware update can only occur after a CPU power-up or warm restart.

4. The memory card can be used to store files and folders not related to program transfer and firmware update usage as long as their names do not conflict with the file and folder names used for program transfer and firmware update usage.

Installing the memory card will cause the CPU to go to STOP mode, which could affect the operation of an online process or machine. Unexpected operation of a process or machine could result in death or injury to personnel and/or property damage.

Before inserting the memory card, always ensure that the CPU is offline and in a safe state.

You can use a memory card to transfer user program content into the CPU permanent memory, completely or partially replacing content already in the load memory.

To be used for program transfer purposes, the memory card is organized as follows:

Table 4- 21 Memory card used for program transfer card

File: S7_JOB.S7S A text file containing the word TO_ILM

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Reset to factory defaults card

At the root of the card

File: S7_JOB.S7S

A text file containing the word RESET_TO_FACTORY

Firmware update card

At the root level of the card

File: S7_JOB.S7S

A text file containing the word FWUPDATE

Folder: FWUPDATE.S7S

A folder containing update files (.upd) for each device to be updated

Note Firmware update from STEP 7-Micro/WIN SMART

You can a port. Especially for CPU models that do not have a memory card, this method is valuable. Refer to the PLC menu section of the STEP instructions.

4.3 Saving and restoring data

You can use a memory card to erase all retained data, putting the CPU back into a factory default condition.

To be used for reset to factory default (Page 167) purposes, the memory card is organized as follows:

Table 4- 22 Memory card used to reset to factory defaults

You can use a memory card to update the firmware in a CPU and any connected expansion modules.

The file and folder organization of a firmware update memory card is as follows:

Table 4- 23 Memory card used for firmware update purposes

After power-up, if the CPU detects the presence of a memory card, it locates and opens the S7_JOB.SYS file on the card. If the CPU discovers the FWUPDATE string in that file, then the CPU enters a firmware update sequence.

The CPU examines each update file (.upd) in the FWUPDATE.S7S folder and if the order ID contained in the update file name matches the order ID (MLFB) of a connected device (CPU, expansion module or signal board), then the CPU updates the firmware of that device with the firmware content contained within the update file.

lso perform a firmware update from STEP 7-Micro/WIN SMART using the RS485

7-Micro/WIN SMART online help for

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4.3.5

Inserting a memory card in a standard CPU

Task

Procedure

4.3 Saving and restoring data

Table 4- 24 Inserting and removing a memory card in a standard CPU

Follow the steps below to insert the microSDHC memory card into the CPU.

1. Open the bottom terminal block connector cover.

2. Insert the microSDHC memory card in the memory card slot (marked X50) located above the terminal block connectors.

3. Replace the terminal block connector cover after inserting the card to ensure that the card is secure.

Follow the steps below to remove the microSDHC memory card from the CPU.

1. Open the bottom terminal block connector cover.

2. Grasp the microSDHC memory card from the CPU and pull it out of the card slot (marked Micro-SD X50).

3. Replace the bottom terminal block cover.

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4.3.6

Transferring your program with a memory card

WARNING

Verify that the CPU is not running a process before inserting the memory card.

Creating a program transfer memory card

4.3 Saving and restoring data

The standard S7-200 SMART CPU models support standard, commercial microSDHC cards with a capacity ranging from 4 GB to 16 GB using the FAT32 file system format. You can use a microSDHC card as a program transfer card for portable storage for your program and project data.

Inserting a memory card into a CPU in RUN mode causes the CPU to automatically transition to STOP mode.

Inserting a memory card into a running CPU can cause disruption to process operation, possibly resulting in death or severe personal injury.

Always ensure that the CPU is in STOP mode (Page 46) prior to inserting a memory card.

To program the memory card as a program transfer card, follow these steps:

1. Ensure that your network hardware and PLC connector cable are working, the CPU is powered on and in STOP mode, and that PLC communication is operating properly (Page 34).

2. If not already inserted, insert a microSDHC memory card in the CPU. You can insert or remove the memory card while the CPU is powered on.

3. Download (Page 45) the program to the PLC, if not already downloaded.

4. Click the Program button from the Memory Card area of the PLC menu ribbon strip.

5. Select which of the following blocks (or all) to store on the memory card: – Program block – Data block – System Block (PLC configuration)

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Note STEP

transferring the program to the card. Any other data on the card that you've stored u a card reader and Windows Explorer is left undisturbed.

Note also that you cannot change the CPU to RUN mode if a memory card is inserted.

Restoring the program from a program transfer memory card

4.3 Saving and restoring data

6. Click the Program button.

7. Enter the password (Page 143) if one is required for programming the memory card.

7-Micro/WIN SMART first erases any SIMATIC content on the card prior to

sing

To copy the contents of the program transfer card to the PLC, you must cycle the power to the CPU with the program transfer card inserted. The CPU then performs the following tasks:

1. Clears RAM

2. Copies the user program, the system block (PLC configuration), and the data block from the memory card to CPU permanent memory.

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Note Program transfer card compatibility

Restoring a to the differences in model types. During the restore process, the CPU validates the following characteristics of the program content stored on the memory card:

•

Note In addition to using a memory card as a program transfer card,

See also

4.3.7

Restoring data after power on

4.4 Changing the operating mode of the CPU

While the copy operation is in progress, the STOP and RUN LEDs on the S7-200 SMART CPU alternately flash. When the S7-200 SMART CPU completes the copy operation, the LEDs stop flashing.

program transfer card that you created on a different CPU model might fail due

Size of program block Size of V memory specified in the data block Quantity of onboard digital I/O configured in the system block (Page 133) Each retentive range that is configured in the system block Expansion module and signal board configurations in the system block Axis of Motion configurations in the system block Forced memory locations

Creating a reset-to-factory-defaults memory card (Page 167)

The CPU performs the following actions after a power cycle:

● Restores the program block and the system block from permanent memory

● Restores the retentive memory assignments

● Restores the non-retentive portions of V memory from the contents of the data block in

● Clears the non-retentive portions of other memory areas

you can also create a reset-

-factory-defaults memory card.

permanent memory

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4.4

Changing the operating mode of the CPU

Placing the CPU in RUN mode

Placing the CPU in STOP mode

4.4 Changing the operating mode of the CPU

1. Click the "RUN" button on either the PLC menu ribbon strip or on the program editor toolbar:

2. When prompted, click "OK" to change the operating mode of the CPU.

To stop the program, click the "STOP" button and acknowledge the prompt to place the CPU in STOP mode. You can also place a STOP instruction (Page 354) in your program logic to put the CPU in STOP mode.

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Siemens SIMATIC S7, SIMATIC S7-200 SMART System Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Preface

Table of contents

1.1 S7-200 SMART CPU

1.2 New features

1.3 CPU feature differences

1.4 S7-200 SMART expansion modules

1.5 HMI devices for S7-200 SMART

1.6 Communications options

1.7 Programming software

Connecting to the CPU

Configuring the CPU for communication

Overview

Establishing the Ethernet hardware communication connection

Setting up Ethernet communication with the CPU

Establishing the RS485 hardware communication connection

Setting up RS485 communication with the CPU

2.2 Creating the sample program

Network 1: Starting the timer

Network 2: Turning the output on

Network 3: Resetting the timer

Setting the CPU type and version for your project

Saving the sample project

2.3 Downloading the sample program

2.4 Changing the operating mode of the CPU

Guidelines for installing S7-200 SMART devices

3.2 Power budget

Mounting dimensions for the S7-200 SMART devices

3.3 Installation and removal procedures

Installing and removing the CPU

Installing and removing a signal board or battery board

Removing and reinstalling the terminal block connector

Installing and removing an expansion module

Installing and removing the expansion cable

3.4 Wiring guidelines

Execution of the control logic

Reading the inputs and writing to the outputs

Immediately reading or writing the I/O

Executing the user program

4.2 Accessing data

Accessing memory areas

Format for Real numbers

Format for strings

Assigning a constant value for instructions

Addressing the local and expansion I/O

Using pointers for indirect addressing

Pointer examples

Downloading project components

4.3 Saving and restoring data

Uploading project components

Types of storage

Using a memory card

Inserting a memory card in a standard CPU

Transferring your program with a memory card

Restoring data after power on

4.4 Changing the operating mode of the CPU