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SIMATIC TIA Portal Upgrade Course to S7-1500

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01
31
Contents 1

28
00
15
1. System Overview .................................................................................................... 1-2

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1.1. SIMATIC S7 Overview .......................................................................................................... 1-3

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1.2. TIA Portal Information Center ............................................................................................... 1-4

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1.3. Overview Controller .............................................................................................................. 1-5
1.3.1. Positioning the Modular S7 Controllers ................................................................................ 1-6

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1.4. Overview: New, Available Modules ...................................................................................... 1-7

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1.4.1. Overview of Available Central Modules ................................................................................ 1-7
et
1.4.2. Overview of Available Signal Modules (Central)................................................................... 1-8

20
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1.5. SIMATIC S7-1200: The Modular Mini-PLC........................................................................... 1-9
m

1.5.1. SIMATIC S7-1200: Modules ............................................................................................... 1-10

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1.5.2. SIMATIC S7-1200: Installation and Mounting Positions ..................................................... 1-11
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1.5.3. SIMATIC S7-1200: Signal, Communication or Battery Board ............................................ 1-12

01
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1.6. SIMATIC S7-1500: Modular Controller for the Mid to Upper Performance Range............. 1-13
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1.6.1. SIMATIC S7-1500: Modules ............................................................................................... 1-14
1.6.2. SIMATIC S7-1500: Installation and Mounting Positions ..................................................... 1-16
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1.6.3. SIMATIC S7-1500: Connection Technology / Front Connector.......................................... 1-17

28
1.6.4. SIMATIC S7-1500: CPU-Display → Overview ................................................................... 1-18
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1.6.5. SIMATIC S7-1500: CPU-Display → Menu and Colors ....................................................... 1-19

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1.7. SIMATIC S7-1200/1500: Memory Card(s) .......................................................................... 1-20

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1.8. Exercise 1: Display ............................................................................................................. 1-21

1.8.1. Exercise 2: Loading the Program onto the SMC ................................................................ 1-22
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1.8.2. Exercise 3: Diagnostics and Program Test......................................................................... 1-23

S7
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1.9. Additional Information ......................................................................................................... 1-24

1.9.1. ET 200SP and ET 200pro Controller .................................................................................. 1-25
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1.9.2. Software Controller ............................................................................................................. 1-26

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1.9.3. ET 200SP Open Controller “All in one” ............................................................................... 1-27

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1. System Overview

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28
At the end of the chapter the participant will ...

00
... be familiar with the concept of “Totally Integrated Automation” (T.I.A.)

15
... be familiar with the TIA Portal Information Center

7-
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… have an overview of the new SIMATIC S7-1200/1500 system family

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... have an overview of the available modules

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... be familiar with the S7-1200/1500 automation systems with Display and
SIMATIC Memory Card

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1.1. SIMATIC S7 Overview

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SIMATIC HMI SIMATIC PG SIMATIC Software

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SIMATIC PC

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7-
MPI - Network
SIMATIC NET

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Industrial Ethernet/PROFINET
PROFIBUS

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SIMATIC PC-based
SIMATIC
Controller
Controller

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PROFIBUS-DP
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PROFINET
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AS-Interface
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Introduction
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For the operation of machines, equipment and processes in almost all areas of manufacturing

28
Po

you require control elements in addition to energy supply. It must be possible to initiate, control,
monitor and end the operation of any given machine or process.
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Totally Integrated Automation
TI

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Production processes are no longer seen as individual partial processes, but rather as integral
IC

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components of an entire production process.

S7
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The total integration of the entire automation environment is today achieved with the help of:
• one common software environment that integrates all components and tasks into one uniform
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easy to use system

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• a common data management (central database)

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• a common communication between all participating automation components.

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1.2. TIA Portal Information Center

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https://support.industry.siemens.com

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Entry ID 65601780

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By entering the Product/Article No. (Entry ID) 65601780, you arrive at the start page “TIA Portal -
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An Overview of the Most Important Documents and Links”.

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Here you will find all important documents and links about the TIA Portal as well as the controllers
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S7-1200 and S7-1500.
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In addition, you can get to the “TIA Portal Information Center”. Through it you can also get to all
S7
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important links and information.

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Information includes:
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•
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Controller Software
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o Downloads/Updates for TIA Portal

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o Product Information/Licenses for TIA Portal

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o Manuals
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o FAQ’s
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o Training/Courses
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• Controller Hardware
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o Downloads/HSP (Hardware Support Package) for S7-1200/S7-1500

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o Product Information/Licenses for S7-1200/S7-1500

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o Manuals
o FAQ’s
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o Training/Courses
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1.3. Overview Controller

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Engineered with TIA Portal

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System performance

Advanced Controller
Software
SIMATIC S7-1500
Controller

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SIMATIC

7-
S7-1500

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Distributed
Controller

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Basic Controller SIMATIC

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ET 200

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SIMATIC S7-1200 et

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m

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Application complexity

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Depending on the complexity, different controllers from S7-1200 to S7-1500 can be used.
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S7
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1.3.1. Positioning the Modular S7 Controllers

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TIA Portal

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SIMATIC S7-400

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Advanced

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SIMATIC S7-1500

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SIMATIC S7-300

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Basic

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SIMATIC S7-200
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SIMATIC S7-1200
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SIMATIC S7
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The programmable logic controllers can be divided into the performance ranges Basic (S7-1200)

28
and Advanced (S7-1500).
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The product range of the S7-1200 and S7-1500 will be expanded in the next few years such that
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the S7-200, S7-300 and even the S7-400 can be completely replaced.
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IC

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S7
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1.4. Overview: New, Available Modules

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1.4.1. Overview of Available Central Modules

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00
S7-1200 S7-1500 S7-300 S7-400

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7-
Standard

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Fail-safe

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Compact et

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High
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availability
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Different functions
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Different
Technology functions T-CPU
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T-CPU
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More Information under the Link:

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TIA Portal Information Center > Product information > Controllers

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1.4.2. Overview of Available Signal Modules (Central)

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28
S7-1200 S7-1500 S7-300 S7-400

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DI/DQ

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AI/AQ

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F-DI/F-DQ

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F-AI
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More Information under the Link:
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TIA Portal Information Center > Product information > Controllers

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IC

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1.5. SIMATIC S7-1200: The Modular Mini-PLC

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Features
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• Modular compact control system for the low-end performance range

28
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• Scaled CPU range

•
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Extensive range of modules

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• Can be expanded to up to 11 modules (depends on the CPU)

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• Can be networked with PROFIBUS or PROFINET

S7
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• Slot rules
− CM left of the CPU (number depends on the CPU)
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− SM right of the CPU (number depends on the CPU)

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• "Total package" with CPU and I/O in one device

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− integrated digital and analog I/O

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− an expansion with signal board

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• "Micro PLC" with integrated functions

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1.5.1. SIMATIC S7-1200: Modules

31
Communication module(s) Signal module(s)

28
(max. 3 depending on CPU) (max. 8 depending on
CPU)

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...

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CPU
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DI, DQ, DI/DQ, AI, AQ, AI/AQ
CM/CP
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- Point-to-Point
(RS232, RS485) Optional signal, - DI, DQ, DI/DQ
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- PROFIBUS - AI, AQ, AI/AQ
communication - Point-to-Point (RS485)
- ASi
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- GPRS or battery board - Battery backup of real-time clock

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Slot Rules
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• CM left of the CPU (number depends on the CPU)

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• Signal modules (digital, analog) right of the CPU (number depends on the CPU)
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Signal Modules
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• Digital input, output or mixed modules (24VDC, relay)

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• Analog input, output or mixed modules (voltage, current, resistance, thermocouple)

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Communication Modules (CM - Communication Module, CP - Communication Processor)

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Point-to-point connection (RS232, RS485)

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• PROFIBUS
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• ASi-Master
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•
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Telecontrol (GPRS functionality)

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Expansion Board
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With this, the CPU can be expanded by onboard I/O or an interface.

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A battery board ensures the long-term battery backup (buffering) of the real-time clock.
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1.5.2. SIMATIC S7-1200: Installation and Mounting Positions

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Standard
mounting rail Bus
Busverbinder
connector

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Vertical

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1x expansion cable

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Alternative attachment

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Installation
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The modules are mounted on a standard mounting rail or alternatively screwed into the control

28
cabinet.
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S7-1200 Expansion Cable

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It offers additional flexibility in configuring the S7-1200 system. One expansion cable can be used
50

for each CPU system.

IC

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• Either between the CPU and the first SM or between two SMs
S7
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Bus Connector
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It is located as a mechanical slide on the left side of the SM modules.

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It is mechanically attached on the right side of the CMs/CPs.

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Mounting Positions
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A horizontal or vertical mounting is possible.

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Caution!
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With a vertical mounting, the maximum allowed ambient temperature is 10 °C lower.

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1.5.3. SIMATIC S7-1200: Signal, Communication or Battery Board

31
28
00
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R
Available boards:
m

20
● analog, digital
● RS485
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● battery

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Application
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These boards are used for application-specific adaptation of the CPU to the requirements of the

28
plant. The physical size of the CPU remains unchanged.
Po

Signal Board (SB)

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• Digital signal board
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− only inputs
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− only outputs
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− inputs and outputs

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• Analog signal board

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− only inputs
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− only outputs
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Communication Board (CB)

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• RS485 interface
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Battery Board (BB)

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A battery board (housing for CR1025 battery) ensures the long-term battery backup (buffering) of
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the real-time clock.

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• Buffering time without battery board typically 20 days / minimum 12 days at 40°C
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• Buffering time with battery board approximately 1 year

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1.6. SIMATIC S7-1500: Modular Controller
for the Mid to Upper Performance Range

31
28
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Highlights of the SIMATIC S7-1500 System

28
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• Highest performance of the entire system

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− High performance program execution in the CPU
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− High performance backplane bus

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− PROFINET interface with PROFINET IO IRT on every CPU

S7

− Automatically activated system diagnostics, right down to the

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IO channel
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• Trace for all CPU tags

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• CPU - Display for:

− Access to MLFB, FW version and serial number
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− Commissioning (e.g. Setting the IP address, station name)

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− Backup/Restore
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− Diagnostics
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• Simplified programming through user-friendly new

instructions in LAD/FBD/STL
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1.6.1. SIMATIC S7-1500: Modules

31
28
Single-tier assembly max. 32 central modules in rack
Multi-tier distributed ET 200MP

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...

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TM:

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PS/PM CPU DI, DQ, PS - Counting
(optional) new power - Position sensing
AI, AQ
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segment

20
CM/CP:
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- Point-to-Point max. 2 per rack
m

for backplane bus supply of

20
(RS232, RS485)
- PROFIBUS subsequent I/O modules
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- PROFINET

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Slot Rules
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• 1x PS/PM Slot 0

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• 1x CPU in Slot 1
• As of Slot 2 any
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Signal Modules
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• Digital input modules: 24VDC, 230VAC

S7
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• Digital output modules: 24VDC, 230VAC

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•
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Analog input modules: voltage, current, resistance, thermocouple

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• Analog output modules: voltage, current

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Communication Modules (CP - Communication Processor, CM - Communication Module)

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Point-to-Point connection
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• PROFIBUS
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• PROFINET
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CPs and CMs are both communication modules.

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CPs have, as a rule, somewhat more functionality than CMs (e.g. own web server,
firewall, or the like).
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Technology Modules (TM - Technology Module)

•
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Counting
• Position sensing
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Power Supply

31
I/O modules in the central rack of the S7-1500 require a system power supply via the backplane
bus (communication connection to the CPU) and a load power supply (input or output circuits for

28
sensors/encoders and actuators).
• PM - Power Module → Load Power Supply
supplies modules with 24VDC for input and output circuits as well as sensors/encoders and

00
actuators

15
If the CPU is supplied 24V via a load power supply (PM), it supplies the system power
supply of 12W for the first inserted I/O modules.

7-
• PS - Power System → System Power Supply

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supplies S7-1500 modules in the central rack via the backplane bus

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Each CPU offers a system power supply of 12W for the first inserted I/O modules.
Depending on the I/O modules used, further power segments have to be set up, as

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required.

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A system power supply (PS) can also supply the load circuit for 24VDC modules in
et
addition to the CPU.

20
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Power Supply and Power Segments of the I/O Modules
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20
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It is necessary to set up power segments in the central rack for larger configurations or

01
configurations with greater I/O module power requirements (as a rule, when using CP, CM, TM).
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A maximum of 3 power segments can be set up per rack (1xCPU segment plus 2 more).
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31
If the configuration includes additional power segments, additional system power supply modules
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(PS) are inserted to the right next to the CPU. The CPU continues to control all modules of the

28
rack. Only the system power supply of the I/O modules is subdivided here.
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Example of a Small S7-1500 Configuration

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IC

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Example of an S7-1500 Configuration with a 2nd. Power Segment

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Interface Modules for Expansion Rack

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There are no plans for a central multi-tier assembly. Expansion using Central I/O modules can be
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performed using the ET 200 MP distributed I/O system.

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1.6.2. SIMATIC S7-1500: Installation and Mounting Positions

31
28
Profile rail
with integrated mounting rail

00
15
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Vertical

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et Horizontal
Busverbinder
Bus connector

20
R
m

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te

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Installation
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The modules are mounted on an S7-1500 profile rail.

28
Po

Bus Connector
A

Modules are then connected with the U-connector.

0
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The U-connector establishes the mechanical and electrical connection between the modules and
is included with every I/O module.
IC

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S7
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Mounting Positions
A horizontal or vertical mounting is possible.
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Caution!
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With a vertical mounting, the maximum allowed ambient temperature is 20 °C lower

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in

(ambient temperature 0 to 40 °C).

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Integrated Mounting Rail

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For the S7-1500 CPU, there is a profile rail on which components can also be mounted according
to EN 60715. With that, even terminals, miniature circuit breakers, small contactors or similar
m

components can be mounted in addition to the S7-1500.

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1.6.3. SIMATIC S7-1500: Connection Technology / Front Connector

31
28
Release latch
Entriegelungslasche

00
15
4 jumper links

7-
can be inserted

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et Wiring position

20
R
Wiring position
m

20
Strain relief by means
Operating position
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of cable ties

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Properties of the Front Connector
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• In each case 40 terminals

28
Po

• Clamping techniques:
− Screw-type terminal
A

0
− SIMATIC TOP connect
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System wiring for the connection of sensors/encoders and actuators

→ S7-1500 front connector wired with 20 or 40 single conductors (prefabricated)
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S7
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Prewiring Position
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The front connector latches up in the front cover. In this position, the front connector still juts out
,
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of the module, but the front connector and the module are not yet electrically connected.
SI

i
in

Jumper Links
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The jumper links can be inserted in the front connector in four places for easier set up of load
et

groups. That is, looping the supply voltage to several potential groups.
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Only one connection from left to right exists!

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Automatic Coding of the I/O Modules

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This enables a faster and safer exchange of the front connector.

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Two Front Door Latching Positions

At the bottom of the front cover there are 2 different latching positions for different space
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requirements of the conductor bundle.

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• Cable storage space that grows with the need (AWG cabling)
American Wire Gauge (AWG) is an American standard measure for copper wires which
A

defines the wire strength and the allowed damping, whereby a lower AWG value represents a
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thicker wire. By swinging up the release latch, you can pull the front connector and remove it
from the module.
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1.6.4. SIMATIC S7-1500: CPU-Display → Overview

31
 Every S7-1500 CPU is delivered with a Display

28
 Two sizes depending on the CPU type
1.36” up to CPU1513
2.4” as of CPU1516

00
 Has its own MLFB

15
→ can be ordered as replacement part

7-
 CPU can be operated without the Display
(different front cover)

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 Removal and insertion possible during running operation

ng
→ CPU stays in RUN
 Multi-lingual display (menu)

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 Message/Alarm texts and comments can be loaded in 3
languages
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 Language can be switched during running operation

20
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 Alarm acknowledgement
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 Backup/Restore
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 Format SMC
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Operation
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Selecting the main menu item

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Shifting the selection of the submenu item

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Choosing the selected submenu item

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Go back one menu item

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Current main
menu item
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After choosing the menu item

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Edit setting
Selected
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submenu item Accept change

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Discard change
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Editable
submenu item
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01
1.6.5. SIMATIC S7-1500: CPU-Display → Menu and Colors

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Main menu items and their meaning:

28
Overview (Info on: CPU, program protection, memory card, fail-safe (operation)…)

00
Diagnostics (alarms, diagnostic buffer, message display, watch tables, cycle time, current memory)

15
Settings (addresses, date & time, operating mode, CPU Reset, unlock Display, Backup, FW update

7-
…)

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Modules (status, MLFBs, version, information,… of individual modules)

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Display (setting: brightness, language Display/diagnostic message,

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standby,…, Display infos: MLFB, version, …)

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Colors of status information and their meaning:
et
green RUN of CPU,

20
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yellow STOP or CPU HOLD
m

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red Error
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white Connection setup or connection to CPU lost

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Depending on the current CPU state, the color on the Display varies.
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Additional Symbols in the Status Information
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Password is configured but not entered

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Password is configured and entered

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An Alarm exists
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A Force job is active on the CPU

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et

Safety operation active (for fail-safe CPUs)

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With deactivated safety operation, the icon is greyed out.

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Fail-safe CPU (for fail-safe CPUs)

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S7-1500 Display Simulator

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Under the link “TIA Portal Information Center” > First steps > Getting Started > SIMATIC S7-1500
rta

and STEP 7 - Getting Started > Displays of the SIMATIC S7-1500 controller family” you can test
the S7-1500 display simulator as an online version or you can download it and test it offline.
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01
1.7. SIMATIC S7-1200/1500: Memory Card(s)

31
Serial number of the SMC card

28
1
2 Product version
3 Order number
4 Card size

00
5 Slide switch for write-protect (must not be write-protected)

15
Written with:
● Commercially available SD card reader

7-
● Field PG

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SIMATIC Memory Card in the S7-1200: SIMATIC Memory Card in the S7-1500:

ng
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● External load memory ● Load memory

i
● ●

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Distribution of programs Firmware update
● Firmware update et ● Documentation
● Documentation ● Memory Card Binding

20
R
● Memory Card Binding ● Unlinked DBs
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● ●

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Unlinked DBs Archiving of data
● ●
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Module exchange without PG Module exchange without PG

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Memory Card Binding – Copy Protection
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The executability of the program can be bound to the serial number of the card.

28
Po

Load Memory
A

•
0
S7-1500
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This has no integrated load memory and therefore it is imperative that a card is inserted.
•
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S7-1200
This has an integrated load memory. Here, an inserted memory card can replace (or expand)
S7
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the integrated load memory or the card can be used for program updates (distribution of
programs).
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Distribution of Programs ← only S7-1200

i
in

The use as Transfer card (card mode = "Transfer") is only supported by the S7-1200. Here, a
ra

program can be downloaded into the CPU without a PG if a card is inserted.

et

Archiving of Data ← only S7-1500

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It is possible to archive process values on the card.

m

The use of this functionality influences the operating life of the Memory Card
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1.8. Exercise 1: Display

31
28
Familiarize yourself with the Display!

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15
7-
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What to Do:
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1. Change the language and the brightness on the Display.

28
Po

2. Read-out the memory card type and how much memory still exists.
o Card Type:___________________________________________
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0
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50

o Memory Available:_____________________________________
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3. Take a look at the diagnostic buffer.

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4. Make a note of the MLFB (order number) and the Firmware of the central analog module.
o Order Number:________________________________________
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o Firmware Version:______________________________________
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5. Change the time (of day) of the CPU, the IP address of the Interface X1, and format the
in

memory card.
ra
et

Caution:
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When the write access for the Display was deactivated in the last project loaded,
formatting the card is not possible. (Setting of the CPU)
m
te

If this is the case, then the card can only be erased by means of Windows or in the TIA
Portal.
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01
1.8.1. Exercise 2: Loading the Program onto the SMC

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28
00
15
7-
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ini
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R
m

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What to Do:
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1. Set the CPU to STOP using the Display.

28
Po

2. Remove the SIMATIC Memory Card.

3. Insert the SMC in the SD card reader of the programming device (PC).
A

0
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4. Erase the card using Windows Explorer.

50
IC

-1

Attention: Don´t erase the hidden files!!!

S7
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5. Open the folder “C:\02 Archives\TIA-Portal\TIA-SYSUP\SMC-Project”.

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6. Extract (unzip) the ZIP file (Name according to the MLFB of the CPU) onto SIMATIC Memory
SI

Card.
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1.8.2. Exercise 3: Diagnostics and Program Test

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28
00
15
7-
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R
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What to Do:
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1. Insert the SIMATIC Memory Card in the CPU and wait until the MAIN-LED no longer flashes.

28
Po

2. Reset the CPU to factory defaults using the Display,

(since there could still be an old program on the CPU, all data should be deleted)
A

0
3. Switch the CPU to Run.
TI

50

4. Set the language.

IC

-1

5. Diagnostics using the Display: Check the Watchtables, Cycle time and Memory.
S7
AT

6. Check whether the broadband cable of your conveyor model is connected to the “S7-1500
DI/DO” socket on the back of your training case.
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7. Switch on your conveyor model. (green button)

i
in

8. Carry out a program test.

ra
et

Function Description
The distribution conveyor is used to transport parts and can be operated in two different
R

operating modes. (Manual and Automatic)

m

These can be set using the control panel buttons “Operation ON” and “Operation OFF”.
te

Manual Mode "Operation" = off

Now, the conveyor motor can be jogged to the right “Jog right” and to the left “Jog left”.
ys

Automatic Mode "Operation" = on

lS

On the conveyor model, parts can be transported from Bay 1, 2 or 3 to the right, right up to
the light barrier, using the appropriate button at the respective Bay. Only one Bay may be
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occupied (at a time).

The indicator lights at Bays 1, 2 and 3 show...
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− A continuous light at the bay at which the associated sensor detects a part,
however only as long as the conveyor has not yet been started.
A

− A 2Hz flashing light as long as the conveyor motor is running.

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1.9. Additional Information

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1.9.1. ET 200SP and ET 200pro Controller

31
28
• SIMATIC S7-1500 with the design
of a SIMATIC ET 200SP or

00
ET200pro

15
• for machines with distributed

7-
architecture and serial machines

,S
with limited space

ng
• Transfer of the intelligence from

ni
the central control cabinet to

i
Distributed Controller

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et
• Available in standard and fail-

20
R
safe version
m

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Further information under the Link:
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TIA Portal Information Center > Product information > Controllers > SIMATIC controllers in

28
general > Distributed Controllers
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01
1.9.2. Software Controller

31
28
• Use with industry-suitable SIMATIC IPCs

00
• Runs completely independently of the
Windows system (even with restart or

15
failure of Windows)

7-
,S
• Flexible controller for special-purpose
machines with high performance and

ng
functional requirements

i ni
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• Integration of user-specific functions via
et
open interfaces

20
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(for example C++ / Matlab)
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Further information under the Link:
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TIA Portal Information Center > Product information > PC-Based Automation > SIMATIC

28
Software Controller
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1.9.3. ET 200SP Open Controller “All in one”

31
28
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• - Controller with central, modular I/Os

20
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• - Visualization and Windows applications
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20
• - PC interfaces for monitor, mouse and keyboard
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• - Gigabit Ethernet

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Further information under the Link:
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TIA Portal Information Center > First steps > Getting Started > SIMATIC Open Controller -

28
Getting Started
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