The Step7 Simatic Manager

Process

When you take a closer look at a process you want to automate, you will find

that it is made up of a multitude of smaller sections and sub-processes, which

are all interlinked and dependent on one another.

The first task is therefore to break down the automation process as a whole into

separate sub-tasks.

Hardware and Software

Each sub-task defines certain hardware and software requirements which the the automation system must fulfill:

• Hardware:

- Number and type of inputs and outputs

- Number and type of modules

- Number of racks

- Capacity and type of CPU

- HMI systems

- Networking systems

• Software:

- Program structure

- Data management for the automation process

- Configuration data

- Communication data

- Program and project documentation.

Project

In SIMATIC STEP7 all the hardware and software requirements of an automation

process are managed within a project.

A project includes the necessary hardware (+ configuration), network

(+ configuration), all the programs, and the entire data management for an

automation solution.

Imatic Step7 Project Structure

Multiproject

The multiproject folder is the folder for all projects and libraries of an automation

solution that contains one or more STEP7 projects and optionally, also libraries.

That way, the complete solution can be divided into individual, easy to follow

projects. The projects within the multiproject can contain objects with crossproject

interrelations (such as cross-project Step7 connections).

Project Structure

Data is stored in a project in the form of objects. The objects in a project are

arranged in a tree structure (project hierarchy). The tree structure displayed in

the project window is similar to that in the Windows Explorer. Only the icons for

the objects are different.

Project Hierarchy

1st. Level:

The first level contains the project icon. Each project represents a

database where all the relevant project data are stored.

2nd. Level:

• Stations (such as the Step7 - 300™ station) are where information

about the hardware configuration and parameter assignment

data of modules is stored.

Stations are the starting point for configuring the hardware.

• Step7 Program folders are the starting point for writing

programs. All the software for a parameter-assignable

module from the Step7 range is stored in an Step7 Program

folder. This folder contains further folders for the program

blocks and sources.

• Subnets (MPI,Profibus, Industrial Ethernet) are part of an

overall network.

3rd. and subsequent levels: Depends on the object type of the next-higher level.

Configuration of the Simatic Step7 - 400 Training Unit PS Default Address: CPU DI 32 28 Slot

Design
You can see the design of the Simatic Step7 - 400 training unit in the slide above.

Configuration
The UR 1 mounting rack is configured with the following modules:
Slot 1: Power supply 24V and 5V/20A
Slot 2: - " -
Slot 3: - " -
Slot 4: CPU 412 or other
Slot 5: vacant (when the CPU only has a single width)
Slot 6: vacant
Slot 7: vacant
Slot 8: Digital input 32x24V (from Simulator)
Slot 9: Digital input 32x24V (from Conveyor Model)
Slot 10: Digital output 32x24V 0.5A (to Simulator)
Slot 11: Digital output 32x24V 0.5A (to Conveyor Model)
Slot 12: Analog input 8X13 Bit (from Poti on the Simulator)
Slot 13: vacant
Slot 14: vacant
Slot 15: vacant
Slot 16: vacant
Slot 17: vacant
Slot 18: vacant

Addressing
You have the default addresses, as shown in the slide above, as long as no
configuration or parameter settings have been made.

PLC Simulator

Design

Two cables connect the simulator to the S7-300™ or S7-400™ training unit. The

simulator is divided into the following three sections:

• Binary section with 16 switches/momentary-contact switches and 16 LED's

• Digital section with 4 thumbwheel buttons and a digital display. The

thumbwheel and digital (BCD) display use BCD values,

• Analog section with a voltmeter for displaying the values at analog channels

0 and 1 or the analog outputs 0 and 1. You use the selector switch to choose

the voltage value you want to monitor. There are two separate

potentiometers for setting the values for the analog inputs.

Addressing

You use the following addresses to address the inputs and outputs in your user

program:

Sensor / Actuator	Version A (DI16, DO16)	Version B (DI32, DO32)	S7-400 (Default addresses
Switch / M.C.Sw.	IW 0	IW 0	IW 28
LEDs	QW 8	QW 4	QW 36
Thumb. buttons	IW 4	IW 2	IW 30
Digital display	QW 12	QW 6	QW 38
Analog channels	PIW 352/354	PIW 304/306	PIW 1216/1230

The Conveyor Model

Design

The slide shows a diagram of the conveyor model with its sensors and

actuators.

Addresses

S7-300 Ver. A (DI16, DO16)	S7-300 Ver. B (DI32, DO32)		S7-400 (Default Ad- dresses)	Sensor / Actuator	Symbol
I 16.0 I 16.1 I 16.2 I 16.3 I 16.4 I 16.5 I 16.6 I 16.7 Q 20.1 Q 20.2 Q 20.3 Q 20.4 Q 20.6 Q 20.7	I 8.0 I 8.1 I 8.2 I 8.3 I 8.4 I 8.5 I 8.6 I 8.7 Q 8.1 Q 8.2 Q 8.3 Q 8.4 Q 8.6 Q 8.7	I 32.0 I 32.1 I 32.2 I 32.3 I 32.4 I 32.5 I 32.6 I 32.7 Q 40.1 Q 40.2 Q 40.3 Q 40.4 Q 40.6 Q 40.7		Light Barrier at Conv. End Push Button at Bay1, M.C. Push Button at Bay2, M.C. Push Button at Bay3, M.C. Push Button at End C.MC. Proximity Sensor at Bay 1 Proximity Sensor at Bay 2 Proximity Sensor at Bay 3 Indicator Light at Bay 1 Indicator Light at Bay 2 Indicator Light at Bay 3 Indicator Light at Conv. End Run Conveyor Left Horn	LB T_PB1 T_PB2 T_PB3 T_PB4 BAY1 BAY2 BAY3 L_BAY1 L_BAY2 L_BAY3 L_END K_LT K_Horn

Configuration of the Simatic Step7 - 300 Training Unit

Configuration of Version A
The programmable controller is configured with the following modules:
Slot 1: Power Supply 24V/5A
Slot 2: CPU 314 or CPU 315-2 DP
Slot 4: Digital input 16x24V Inputs from the simulator
Slot 5: Digital input 16x24V Thumbwheel buttons
Slot 6: Digital output 16x24V 0.5A Outputs from the simulator
Slot 7: Digital output 16x24V 0.5A Digital display
Slot 8: Digital input 16x24V Conveyor model inputs
Slot 9: Digital output 16x24V 0.5A Conveyor model outputs
Slot 10: Analog module 4 AI/4 AO Adjustable from the simulator

Configuration of Version B
The programmable controller is configured with the following modules:
Slot 1: Power Supply 24V/5A
Slot 2: CPU 314 or CPU 315-2 DP
Slot 4: Digital input 32x24V Inputs from the simulatorand thumbwheel buttons
Slot 5: Digital output 32x24V/0.5A Outputs from the simulatorand digital display
Slot 6: Digital input and output Conveyor model module 8X24V/ 8x24V 0.5A
Slot 7: Analog input 2 AI Analog section from simulator

Addresses
Fixed slot addressing is used for the  Simatic Step7 - 300™ (CPU 312-314). The module
addresses are shown in the slide.
The starting addresses of the modules can be set by parameter assignment on
the CPU 315-2DP and for Simatic Step7 - 400™.

Setup of a Training Area with Simatic Step7 - 400

Contents of the Training Kit

The training kit consists of the following components:

• An Simatic Step7-400™ programmable logic controller with CPU 412 or CPU 413-2DP

• Digital input and output modules, analog modules

• Simulator with digital and analog sections

• Conveyor model

Note:

It is quite possible that your training area is not equipped with the conveyor

model shown in the slide above, but rather with the conveyor model

pictured below.

STEP7 Tools

SIMATIC  Manager
The SIMATIC  Manager manages the STEP7 projects. It is the main program
and also appears on the WINDOWS desktop.

Notes
"STEP7 - Readme" provides detailed information about the version, installation
procedure, etc.

LAD, STL, FBD
Tool for writing STEP 7 user programs in the "Ladder Diagram", "Statement List"
or "Function Block Diagram" programming languages

Memory Card Parameter Assignment.
You can save your user programs on EPROM cards by either using the programming device or an external prommer.Different drivers are required, depending on the application

Configuring Networks
Network configuration is discussed in the chapter on "Communication".

Setting the PG-PC Interface
This tool is used for setting the local node address, the transmission speed and the highest node address in the MPI network.

PID Control Parameter Assignment
The basic STEP7 software package also includes blocks for solving PID closed-loop) control problems. You choose "PID Control Parameter Assignment" to start the program for assigning parameters to the closed-loop control blocks.

Converting S5 Files
STEP5 programs can be converted into the corresponding STEP7 programs
with the help of the S5/S7 converter

Configure SIMATIC Workspace
This option provides facilities for configuring multi-user systems.

Converting TI Files
SIMATIC TI programs can be converted into the corresponding STEP7 program
with the help of the TI/S7 converter.

Setup of a Training Area with Simatic Step7 - 300

Contents of the Training Kit
The training kit consists of the following components:
• An S7-300™ programmable logic controller with CPU 314 or CPU 315-DP
• Digital input and output modules, analog modules
• Simulator with digital and analog sections
• Conveyor model

Note:
It is quite possible that your training area is not equipped with the conveyor
model shown in the slide above, but rather with the conveyor model
pictured below.

Programming Devices for Step7

Field PG
An industry-standard programming device. The Field PG is powerful and easy to
use, especially for maintenance and service. It is also appropriate for
programming and configuration - the ideal tool for shop floor applications.
Features:
• Dimensions in Notebook format
• 2 hour battery operation
• AT-compatible
• TFT color display
• Equipped with all necessary SIMATIC interface ports

Power PG
A portable programming device, ideal for all applications in an automation
project. It is also an extremely powerful, industry-standard PC.
Features:
• High-level system performance
• Excellent expansion facilities
• TFT color display
• Highly rugged design
• Equipped with all the necessary SIMATIC interface ports

Note
A hand-held programming device is also available for programming the
S7-200™ in STL (Statement List). This programming device is the PG702 =
approximately 230 grams, 144 x 72 x 27mm, 2 lines x 20 character LC display.

PG/PC Requirements for Installing STEP7

Operating system: Windows (all, except Win 3.1 and 3.11)

95/98 ME NT 2000/XP

Processor >= 80486 >= P150 >= Pentium >= P233

RAM >= 32 MB >= 64 MB >= 32 MB >= 128 MB

Memory on the Hard Drive: depending on the installation, between 200 MB and 380 MB

plus 128 to 256 MB minus the working memory for Windows Swap File

Mouse: yes

Interfaces: CP5611 (PCI) or

CP5511 / CP5512 (PCMCIA) or

PC adapter

Programming interface for Memory Card (optional)

Simatic Step7 - 400

Features

• The power PLC for the mid to upper performance range
• Performance-graded range of CPUs
• Extensive selection of modules
• Expandable design to over 300 modules
• Backplane bus integrated in the modules
• Can be networked with - Multipoint interface (MPI),
- PROFIBUS or
- Industrial Ethernet
• Central PG/PC connection with access to all modules
• No slot restrictions
• Configuration and parameter setting with the help of the "HWConfig" tool
• Multicomputing (up to four CPUs can be used in the central rack )

Simatic Step7 - 400 Modules

Signal Modules (SM)
• Digital input modules: 24 VDC, 120/230 VAC
• Digital output modules: 24 VDC, Relay
• Analog input modules: Voltage, current, resistance, thermocouple
• Analog output modules: Voltage, current.

Interface Modules (IM)
The IM460, IM461, IM463, IM467 interface modules provide the connection between various racks:
• UR1 (Universal Rack) with up to 18 modules
• UR2 (Universal Rack) with up to 9 modules
• ER1 (Expansion Rack) with up to 18 modules
• ER2 (Expansion Rack) with up to 9 modules.

Function Modules (FM)
Perform "special functions":
• Counting
• Positioning
• Closed-loop control.

Communication Processors (CP)
Provide the following networking facilities:
• Point-to-Point connections
• PROFIBUS
• Industrial Ethernet.

Simatic Step7-400 CPU Design

Fault LEDs

LEDs for the CPU‘s statuses and faults, both internal and external

Slot for

With the S7-400™ CPUs you can, depending on your requirements, insert RAM

or flash EPROM cards as external load memory :

Memory Cards

• RAM cards are available with a capacity of:

64KByte, 256KByte, 1MByte, 2MByte.

The CPU battery backs up the contents.

• Flash EPROM cards are available with a capacity of:

64KByte, 256KByte, 1MByte, 2MByte, 4MByte, 8MByte, 16MByte.

The contents are backed-up on the integrated EEPROMs.

Mode Selector

MRES = Memory reset function (Module RESet)

STOP = STOP mode, that is, no program execution and output disabled

("OD" mode = Output Disabled).

RUN = Program execution, read-only access possible from PG.

RUN-P = Program execution, read/write access possible from PG.

MPI / DP Interface

MPI / DP interface (parameter-assignable in HW-Config) for

• establishing the online connection to the programming device

• connecting to distributed peripherals (DP)

• data exchange with other stations (S7 Communication)

DP Interface

For connecting to distributed peripherals (DP, only for CPUs with 2 interfaces)

EXT-BATT

Additional external battery socket for a 5 VDC to 15 VDC source to back up the

RAM when the power supply is being replaced.

Simatic Step7 - 300

Features
• Modular small control system for the lower performance range
• Performance-graded range of CPUs
• Extensive selection of modules
• Expandable design with up to 32 modules
• Backplane bus integrated in the modules
• Can be networked with - Multipoint interface (MPI),
- PROFIBUS or
- Industrial Ethernet.
• Central PG/PC connection with access to all modules
• No slot restrictions
• Configuration and parameter setting with the help of the "HWConfig" tool.

Simatic Step7 - 300 Modules

Signal Modules (SM)
• Digital input modules: 24 VDC, 120/230 VAC
• Digital output modules: 24 VDC, Relay
• Analog input modules: Voltage, current,
resistance, thermocouple
• Analog output modules: Voltage, current

Interface Modules (IM)
The IM360/IM361 and IM365 make multi-tier configurations possible. The interface modules loop the bus from one tier to the next.

Dummy Modules (DM)
The DM 370 dummy module reserves a slot for a signal module whose parameters have not yet been assigned. A dummy module can also be used, for example, to
reserve a slot for installation of an interface module at a later date.

Function Modules (FM)
Perform "special functions":
-Counting
- Positioning
- Closed-loop control.

Communication Processors (CP)
Provide the following networking facilities:
- Point-to-Point connections
- PROFIBUS
- Industrial Ethernet.

Accessories
Bus connectors and front connectors

Simatic Step7 CPU Design

Mode Selector
MRES = Memory reset function (Module Reset)
STOP = Stop mode, the program is not executed.
RUN = Program execution, read-only access possible from PG.
RUN-P = Program execution, read/write access possible from PG.

Status Indicators (LEDs)
SF = Group error; internal CPU fault or fault in module with diagnostics capability.
BATF = Battery fault; battery empty or non-existent.
DC5V = Internal 5 VDC voltage indicator.
FRCE = FORCE; indicates that at least one input or output is forced.
RUN = Flashes when the CPU is starting up, then a steady light in Run
mode.
STOP = Shows a steady light in Stop mode.
Flashes slowly for a memory reset request,
Flashes quickly when a memory reset is being carried out,
Flashes slowly when a memory reset is necessary because a
memory card has been inserted.

Memory Card
A slot is provided for a memory card. The memory card saves the program
contents in the event of a power outage without the need for a battery.

Battery Compartment
There is a receptacle for a lithium battery under the cover. The battery provides
backup power to save the contents of the RAM in the event of a power outage.

MPI Connection
Connection for a programming device or other device with an MPI interface.

DP Interface
Interface for direct connection of distributed I/Os to the CPU.

Simatic Step7-200 CPU Design S7-22x Series

Mode Selector
For manual mode selection:
STOP = Stop mode, the program is not executed.
TERM = Program execution, read/write access possible from PG.
RUN = Program execution, read-only access possible from PG.

Status Indicators (LEDs)
SF = Group error; internal CPU fault; red
RUN = Run mode; green
STOP = Stop mode; yellow
DP = PROFIBUS-DP ( only CPU 215)

Memory Card
Slot for memory card. A memory card saves the program contents in the event
of a power outage without the need for a battery.

PPI Connection
The programming device, text display, or another CPU is connected here,
except for CPU 210 that is programmed in a programming system (PDS210)
and then transferred to each CPU via a memory submodule.
Higher end CPUs contain two ports allowing the programming device and text
display to be connected at the same time.

Simatic Step7-200 Modules S7-22x series

Expansion Modules (EM)
• Digital input modules:
- 24 VDC
- 120/230 VAC
• Digital output modules:
- 24 VDC
- Relay
• Analog input modules:
- Voltage
- Current
- Resistance
- Thermocouple
• Analog output modules:
- Voltage
- Current
CPUs of the S7-22x series (CPU 222/224/226) can only be expanded using
expansion modules of the S7-22x series. Note: Combined use of the S7-21x
series with the S7-22x series is NOT possible!

Communications Processors (CP)
On the S7-22x series you can use the CP 243-2 to connect the S7-200™ as master to an AS-Interface. The newer CP243-2 supports up to 62 AS-Interface
slaves being connected (max. 31 analog slaves). Up to three (CPU 224, CPU
226) CP243-2 processors can be operated simultaneously on these S7-200
CPUs.
The EM277 PROFIBUS-DP module allows connection of S7-22x series CPUs
(6ES7-22x-xxx21-xxxx and later) to PROFIBUS-DP (as a slave) and MPI.
Simultaneous operation is possible as a MPI slave and PROFIBUS-DP slave.
PROFIBUS-DP data transfer rates of up to 12 Mbits/second are supported.

Simatic Step7-200 CPU Design S7-21x Series

Mode Selector
For manual mode selection:
STOP = Stop mode, the program is not executed.
TERM = Program execution, read/write access possible from PG.
RUN = Program execution, read-only access possible from PG.

Status Indicators (LEDs)
SF = Group error; internal CPU fault; red
(LEDs) RUN = Run mode; green
STOP = Stop mode; yellow
DP = PROFIBUS-DP ( only CPU 215)

Memory Card
Slot for memory card. A memory card saves the program contents in the event
of a power outage without the need for a battery.

PPI Connection
The programming device, text display, or another CPU is connected here.

Simatic Step7 - 200

Features
• Modular small control system for the lowest performance range.
• Performance-graded range of CPUs (up to 8KB memory, 8-40 integrated
 I/O points onboard the CPU).
• Each CPU available in either 24 VDC or 120 VAC - 230 VAC supply voltage
versions.
• Expandable design with up to seven expansion modules depending on CPU
(none with CPU 210 or CPU 221).
• Extensive module selection. Note: Combined use of CPUs and modules of
the S7-21x series with those of the S7-22x series is NOT possible!
• CPU connected to modules by flexible integrated ribbon cables (S7-22x
series) and by bus connectors (S7-21x series).
• Network-capable with - RS 485 communication interface (Not CPU 210)
- PROFIBUS slave (CPU 215 or CPU 222 or
greater)
• Central PG/PC connection with access to all modules.
• No slot restrictions
• Uses its own S7 Micro/WIN32 software, therefore, STEP 7™ not required.
• “Total Package” (brick) with power supply, CPU and integrated I/O all in
one.
• Password protection of user program - 3 levels.

Simatic Step7 - 200 Modules S7-21x series

Expansion Modules (EM)
• Digital input modules:
Modules (EM) - 24 VDC
- 120/230 VAC
• Digital output modules:
- 24 VDC
- Relay
• Analog input modules:
- Voltage
- Current
- Resistance
- Thermocouple
• Analog output modules:
- Voltage
- Current
CPUs of the S7-21x series can only be extended with expansion modules of the
S7-21x series. Note: Combined use of the S7-21x series with the S7-22x series
is NOT possible

Communications Processors (CP)
You can use the CP 242-2 to significantly increase the number of inputs/outputs
Processors (CP) of the SIMATIC S7-200™ (S7-21x series). The CP acts as a master to an
actuator and sensor interface (AS-Interface). As a result, 31 AS-Interface slaves
can control up to 248 binary elements.

Accessories
Bus connector (S7-21x series only)

SIMATIC Overview

Introduction
In the past, control tasks were solved with individual isolated Programmable
Logic Controls (PLCs) controlling a machine or process. Today in order for
companies to remain competitive, it is not enough to automate only individual
processing stations or machines in isolation. The demand for more flexibility with
higher productivity can then be fulfilled when the individual machines are
integrated in the entire system.

Totally Integrated Automation
Totally Integrated Automation (TIA) provides a common software environment that integrates all components, in spite of the diversification of applied
technology, into one uniform system. This brings together everything you need
to program, configure, operate, handle data, communicate, and maintain your
control solutions.
Step7 SIMATIC Manager, running on Siemens PGs or PCs, provides an
integrated set of tools for all system components that allows easy creation,
testing, start-up, operation and maintenance of your control solutions. While you
are configuring and programming, the Siemens software puts all of your data in
a central database to which all of the tools have access.

Central Database
A common database of all components of Totally Integrated Automation means
that data only have to be entered once and are then available for the entire
project. The total integration of the entire automation environment is made
possible with the help of:
• One common software environment (Step7 SIMATIC Manager) that
integrates all components and tasks into one uniform easy to use system.
• Common data management
• Standard open busses such as Ethernet, PROFIBUS, MPI, AS-interface
connect all components to each other, from the management level to the
field.