System family High-performance and medium range The power PLC for manufacturing and process engineering Overwiev S7-400 Low-end and medium range S7-300 Micro PLC S7-200 + Programming devices + STEP 7 software + Communications + Human-machine interface

Fields of application of SIMATIC S7-400 Irrespective of your sector ... Overwiev Process Discrete Food & Beverages Pulp & Paper Cement & Glass Metal / Mining Pharmaceuticals Oil & Gas Automotive Chemicals Electronics Refinery Energy Water Siemens offers on the automation market as sole manufacturer a platform with which factory automation tasks as well as batch and continuous process applications can be implemented using PCS 7. The S7-400 is the controller that is used successfully in both of these important fields. Sectors with a substantial share of both such as the pharmaceuticals industry profit in particular from this characteristic of the S7-400. These hybrid industries can utilize one and the same system or even the same CPU type across the entire production workflow. This enables spare part costs to be saved, maintenance engineers only need to be trained for one system and the system is characterized by integrated horizontal communication. The S7-400 has proved that you can match the challenge of both major automation applications. A large number of references exist starting with power plants, refineries such as Shell, chemical plants, breweries such as Anheuser Bush, many further applications in the food and beverage industry and of course in the large automobile manufacturers throughout the world. There is hardly an industry in which the S7 is not represented. The´S7-400 is thus the only automation system for the manufacturing and process industries! SIMATIC S7-400 - the automation system for production and process engineering

Totall Integrated Automation ... from inbound logistics via discrete and process automated production to outbound logistics – with S7- 400 reduced complexity and optimized interoperation of all components. Overwiev Supplier Inbound Logistics Outbound Logistics Process Discrete Customer Production Workflow Reduce your engineering & training cost by reducing the required number of different software and hardware platforms. Integrate your production and business systems using open industry standards. Improve the efficiency and capability of your existing systems using application specific technologies. Migrate to modern technology incrementally as you need to upgrade and modernize your processes. Production workflow within the supply chain, from supplier to customer Within the production workflow, special emphasis is placed on the production stages within the company: It starts with inbound logistics where preprocessing and feeding into the next processing stage take place e.g. in beer production hops, malt, bottles, labels, bottle caps,... Then comes the process part of the cycle. In beer production this would be the actual brewing procedure which includes the brew house, fermenting and storage cellar and filtration phases. Next comes the classical manufacturing stage (discrete). In beer production this entails bottling and packing. Finally comes outbound logistics with warehousing and dispatch.

S7-400 overview S7-400 S7-400 H system S7-400 FH system Overwiev S7-400 S7-400 H system S7-400 FH system Process and production engineering Data-intensive tasks Coordination of complete plants High repeatability Flexible, reaction-free expansion Hot swapping of modules as well as expansions Primarily process engineering Avoidance of high restart costs Avoidance of down times Unmanned operation Switchover time less than 100 ms Maximum safety for man, machine, environment Also complies with EN 954 (up to category 4) and IEC 61508 (up to SIL 3) Coexistence of standard and fail-safe programs on one CPU (also fault-tolerant) The S7-400 is normally used to perform high-speed or data-intensive tasks. It's reproducibiity is excellent, i.e. there is little fluctuation. Irregular communication or test routines are executed without a measurable effect on the PLC cycle. In situations involving extremely complex applications, as many as four CPUs can be operated in parallel in the same subrack. The number of I/O channels is often in the thousands. As higher-order coordinating control unit and interface to the master computer, the S7-400 is normally equipped with one or more Ethernet cards. A high level of availability is guaranteed by even the standard system, in part through module replacement during operation (hot swapping). Based on standard controllers The S7-400H, as a high-availability (redundant) member of the S7-400 family, is a PLC which drastically reduces the risk of production downtimes. Thanks to its high-availability structure, the S7-400H is perfect for applications in which failures and downtimes must be largely avoided. High availability is achieved thanks to two parallel CPUs, redundant PROFIBUS DP lines, redundant I/O and redundant communication. In the event of a failure, switching is bumpless, i.e. the standby CPU takes over the control of the process at the point of interruption and without any loss of information. The CPU 414H and 417H CPUs are available for use in high-availability systems. Fail-safe SIMATIC S7-400F controllers assume or remain in a safe state the moment a fault occurs, thereby ensuring the highest level of safety for human, machine, environment and process. The safety functions are executed by the safety program in the CPU in conjunction with fail-safe I/O modules. Standard I/O and fail-safe I/O may be present in the same system. High-availability CPUs 414H/FH and 417H/FH are available for use in process automation, CPU 416F for use in production engineering.

Highlights - Engineering Efficient configuration and programming based on STEP 7 global standard IEC 61131-3 Highlights Highlights Higher availability due to powerful integrated diagnostics Availability Cost effective use of ingineering tools (CFC, S7- Graph,...) Graphic programming

Hot swapping Decentral Peripherie Highlights - Design Modular design without slot assignment rules Configuration run Highlights Rugged operation Pulling and pushing under the strain 0-60C operating temperatur Hot swapping Central expansion options and simple design of distributed structures with wide range of modules Decentral Peripherie

Highlights - Performance High processing speeds and deterministic response times for short machine cycle times 30ns / Binary instruction Highlights Highlights Scalable performance Graded range of CPUs Multicomputing Large quantity frameworks Communication included Standard interfaces integrated Connection to the IT world via Ethernet 4-port switch @

Graduated Performance Spectrum New since July 04! CPUs Type Memory Instr. processing Communicat. interfaces I/O Counters/timers PLC 412-1 412-2 144KB 256KB from 100ns MPI/DP PROFIBUS-DP PLC 414-2 414-3 512KB 1.4MB from 60ns MPI/DP PROFIBUS-DP PLC 416-2 416-3 2.8MB 5.6MB from 40ns MPI/DP PROFIBUS-DP PLC 417-4 20MB from 30ns MPI/DP PROFIBUS-DP The slide shows the new line of CPUs. The new CPUs will have the exact same list prices as the old CPUs, greatly improving the price-performance ratio. Sufficient digital and analog inputs/outputs possible 2048 / 2048 2048 / 2048 2048 / 2048 2048 / 2048 Technical Slides

System diagnostics Detailed fault reporting Optimum plan operation Faults in the automation system Programming fault Memory fault Module failure Channel fault... Detailed fault reporting CPUs System diagnostics in S7-400 Fault diagnostics from the CPU to the I/Os Internal CPU services (e.g. error messages with time stamp) Automatic signaling from CPU to HMI device or STEP 7 Optimum plan operation Technical Slides

Process diagnostics Fast faul identification Increased productivity Faults in the plant Interlocking not fulfilled Actuator timeout Motor protection triggered Limit switch fault... Fast faul identification CPUs Increased productivity Process diagnostics functions in S7-400 Monitoring of critical process signals using program Convenient CPU configuring using S7-PDIAG and ProAgent Automatic signaling from CPU to HMI device Operators do not have to be engineer to perform maintenance Technical Slides

Communications integrated MPI/DP Interface (12 Mbit/s) Integrated into every CPU Can be re-parameterized as DP master HMI services for connection of OP/OS No additional programming Minimum CPU cycle load All S7 components can be connected S7-400 (Master) CPUs PG (Master) OP (Master) S7-400 (Slave) S7-300 Programming from any location in the network (routing) Economical communication without additional hardware Technical Slides

Multicomputing Segmented Rack / Multicomputing Scaling Subdivision So that you can easily increase performance by plugging in additional CPUs Subdivision So that you can spread complex task over up to 4 CPUs Decoupling So that you can separate time-critical from non critical processes Segmenting So that you can assign I/O segments to specific CPUs with common communication CPUs Segmented Rack / Multicomputing Technical Slides

Latest functions Emphasis on process engineering Configuration in RUN Reaction-free modifications to configuration during operation with distributed I/O Applications Process engineering plants which must not be switched off Production plants with high restart costs Customer benefits Time-saving, low-cost plant modifications No restart procedure required High flexibility to modified process engineering requirements CPUs Prerequisites: S7-400 FW V3.1, STEP7 V5.2 Applications for CiR – Configuration in Run – are industrial plants with non-stop requirements, continuous processes which must not be halted or interrupted, and production plants with high restart costs. CiR enables non-reacting expansion and optimization of plants with distributed I/O while the plant is in operation. Plant modifications can thus be completed quickly and cost-effectively. Modifications in RUN mode permit an extremely flexible response to changes in and optimization of industrial processes. Even plants which have no non-stop requirements can shorten the time otherwise needed for modification and reconfiguration, since plants modified in RUN mode need not be reinitialized or resynchronized because of changes in the hardware configuration. The following changes can be made to a plant's hardware configuration during operation: Addition or removal of PROFIBUS DP-/PA slaves. Addition, removal, reparameterization or I/O modules in the ET200M I/O system. CiR is possible only for distributed I/O. All S7-400 standard CPUs as well as standalone high-availability S7-400H CPUs can be used. H-CiR is available for redundant H systems. CiR is possible using the following DP masters: CPU via integrated interfaces, CP443-5 ext (beginning version V5.0), module IF964-DP. Shortened start-up times Plant and process optimization Technical Slides

Latest functions Emphasis on production engineering Isochrone mode Linking of a SIMATIC automation solution to the equidistant PROFIBUS Synchronization of user program with I/O processing Equidistant and synchronous signal processing with distributed I/O Consistent transmission of input and data; all data of the process image have a logical and time relationship CPUs Prerequisites: S7-400 FW V3.1, STEP7 V5.2 Because they entail lower costs – less cabling, easier installation - distributed automation solutions are assuming increasing significance. Production processes and machining processes are getting faster and faster, and demands for precision are growing. Applications for isochrone mode: motion control, synchronous operation, closed-loop control, software-based cam control, multipoint measurement, rotational speed and flow measurement The user program is synchronized with the I/O, i.e. all procedures are chronologically coordinated. All input data are acquired at a defined point in time, and output data become effective at a defined point in time as well. The processing of all input and output data is equidistant, i.e. input data are always read in at specific intervals, and output data are always output at specific intervals. All input and output data are transferred in consistent form, i.e. all data in the process image belong together both logically and chronologically. High-speed time-based procedures in which reproducibility plays a decisive role can also be automated with distributed I/O. Safe control of fast processes Repeatable and defined process response times with distributed I/O Increased accuracy for controls, positioning, machines with continuous operation Increase in productivity Technical Slides

Signal modules (SM) - The right module for all common signals Signal modules for all common signals/ the most different technology  So you can connect up anywhere Signal modules with interrupts and diagnostics  So you can respond more quickly Connection techniques that simplify installation / maintenance  Säcrew-type/spring-loaded/crimp terminals Simple and fast module replacement  So you can replace the modules even during operation Highest packing density  To save you space Modules Modular design Hot swapping

Digital signal modules - For all applications Voltage range Current range Channels Sensors Reaction time Diagnostics Ex(i)* Digital inputs 24 - 60 V AC/DC 80 - 264 V DC 74 - 264 V AC ------ 16, 32 Switches 2-wire BEROs etc. from 100 µs Type A Type B No Yes NAMUR/Ex(i) Digitalausgaben 5 - 138V DC 5 - 264V AC 0,5/1/2A 8, 16, 32 elektronisch/Relais from 100 µs Typ A Typ B Nein Ja Namur/Ex(i) Modules (* via ET 200M) Technical Slides

Analog signal modules - For all applications Voltage range Current range Channels Sensors Resolution Conversion time Diagnostics* Ex(i)`* Analog inputs +/- 80 mV ... +/- 10 V +/- 20 mA, 4 ... 20 mA, and others 8, 16 Pt 100, Pt 1000, Ni 100, thermocouples 13 ... 16 bit incl. sign 0.05 ... 100 ms Type A Type B No Yes NAMUR/Ex(i) Analog outputs 0 ... 10 V, ... +/- 10 V +/- 20 mA, 4 ... 20 mA, and others 8 --- 12 bit incl. sign 0.4 ... 1 ms Type A Type B No Yes NAMUR/Ex(i) Modules (* via ET 200M) Technical Slides

Point-to-point CPs - For special interfaces Scanner, Barcodeleser, Identsysteme PG, PC, Rechner Roboter- steuerungen Opto-Elektronik Drucker S7-400 1 or 2 interfaces, up to 76 kbit/s Different physical transmission environment Standard or customer-specific protocols Modules Wägesysteme, Regler SIMATIC S5 und Automatisierungs- geräte auch vieler anderer Hersteller Simple and flexible PtP Communication

The scope of SIMATIC Technology „With our scope we offer SIMATIC customers smart solutions for all their technological tasks, i.e. multiple designs for simple machine component functions up to complex applications and complete machines." Modules SIMATIC Technology Reliable hardware Flexible software Proven systems Secure-investment solutions for industrial automation SIMATIC based technology Easy Motion Control V2.0 with gearbox synchronism; conforming with PLCopen Price: 400 € with / 270 € without data medium, only copy license certificate Start of delivery 03/03 FM 352-5 high-speed Boolean processor: with current-sourcing digital outputs and a cycle time of 1 µs Price: 930 € Start of delivery 03/03 FM 350-1 with period/frequency/speed measurement, isochronous mode Price 352 € Start of delivery 03/03 Technology CPU 317T (see S7-300)FM 458-1 DP isochronous mode, routing for e.g. diagnostics, Teleservice via interface Module price: 3850 € Start of delivery 04/03 EUR Special offer with SW: 4395 € (price advantage 2003 €)

Function modules for all technologies - The right choice when... Good choice when... ... very fast tasks have to be carried out ... great accuracy and reproducibility are necessary … special sensors or actuators have to be connected ...configuration of technological tasks must be as practice-oriented as possible Modules Counting/measuring, cam controlling, positioning, closed- loop control Technologies

FM 458-1DP application module For all types of highly dynamic closed-loop control tasks Freely-configurable using STEP 7 and CFC, optionally with SFC Comprehensive block library for technological tasks and motion control Expansion module for I/O and Communications Modules Particularly suitable for machine and plant construction

Maintenance - Just as simple as everything else Extremely simple replacement of application program without PG Memory card Update device Download using teleservice Modules Simple, reliable replacement of modules without PG Central data storage in the CPU CPU sets parameters of newly inserted modules Also allows you to replace modules during operation Reduced service times High availability Hot swap increase the availability of the plant

Installation - Nice and easy Simple swivel mounting on the rack Robust, enclosed modules Self-coding front connectors TOP Connect Simple and polarity-reversal- proof connection of actuators and sensors Via prefabricated cables All parameters are set via software - no DIP/DIL switches Insertion and removal of modules under process conditions Front connector with screw, Crimp or spring terminals Design flexibility Faster installation

TOP Connect - Prefabricated cables Direct connection of sensors and actuators using 2, 3 and 4-wire techniques Simple and polarity-reversal- proof thanks to the prefabricated cables Saves the intermediate terminal Terminal blocks on S7-400 standard I/O modules can be connected via front connectors Using spring-loaded or Screw-type terminals Distance max. 30m Design flexibility TOP Connect: terminal blocs Reduction of the expenditive wiring work TOP Connect: Terminal blocks Technical Slides

Unlimited expansion Migration Uniform use of multi-channel I/O modules (central and distributed)  Fewer modules required No additional power supply required for racks which are not too far away  Reduction in required modules Immediate reading is possible at any time using direct I/O access  System response times almost as short as when using I/Os only in central rack S5 expansion rack can be used further with S7-400 Design flexibility Migration

Expansion facilities with the S7-400 Central cabinet CR ER ER Max. 6 IM per CR Central expansion , line length 5 m, max. 4 ER per line ER Design flexibility ER ER Central expansion , line length 1,5m 1st ER without PS Distributed expansion , line length 102 m/ 605 m, max. 4 ER per line ER S5 ER S5 Expandable Distributed expansion, line length 605 m, max. 4 ER per line Technical Slides

Data communication with SIMATIC NET PROFIBUS and Industrial Ethernet IT communication Data Kommunikation/cell level Design flexibility Field communication Integrated

Data communication – also Internet access Management computer PG/PC Industrial Ethernet PG/PC PG/PC S5-115U S5-135U S5-155U S7-400 PROFIBUS Design flexibility S7-400 S7-400 S5-115U PROFIBUS DP, MPI, Ethernet @ S7-300 IT integration PG/OP

CP 443-1 Advanced More power and flexibility New Functions IP-Access list SNMP IP-Configuration More Communication Performance More connections At plant floor and IT communication Integrated 4-Port Switch Better Usability New IP-Address configuration Double IP-address indication Diagnostic buffer via WEB PROFINET PROFINET IO Controller PROFINET CBA Design flexibility

The window to your plant/process/machine SIMATIC HMI SIMATIC Panels: Push button panels, text displays, operator panels, touch panels or multi- panels via MPI or PROFIBUS-DP Multiple panels for an S7-400 One panel for several automation systems WinCC flexible- for simple PC-based visualization tasks WinCC V6- The powerful process visualization system Panel PC oder OS WinCC Design flexibility Multi Panels Push Button Panels Text Displays, Operator Panels, Touch Panels Easy parametization

Parameterization made easy Software parameterization of the complete S7-400 including the signal modules with STEP 7 Uniform No jumpers / switches to set Checking the parameter assignment data for plausibility Additional parameterization for individual values, e.g. conversion time parameterization saves valuable time All S7-400 parameterization data are stored in the CPU Parameterization is not necessary when replacing modules CPU checks the S7-400 configuration and the module settings Incorrect module signaled by diagnostics function  Efficient for user, from commissioning to maintenance Configuration and Programming Easy parameterization

Simulation-based engineering with SIMIT Early detection and clearance of configuration errors Simulation of the system Simulation of the units Simulation of the I/O signals Testing of the complete scope of automation Easy-to-use thanks to standardized coupling “The S7-400 simulation module connected to the PC replaces the central and distributed I/O” Training Training of commissioning and service personnel Configuration and Programming

S7-400 solves more complex tasks using the STEP 7 engineering tools S7-SCL (Structured control language) - The PLC high-level language S7-PDIAG/Pro Agent The double pack for process diagnostics S7-PLCSIM Program testing without hardware S7-GRAPH Definition using sequence controls Configuration and Programming CFC (Continues function chart) Graphical sequencing of complex functions S7-HiGraph Definition using status diagrams

S7-400 - The optimum target system Uses a common database Integrated and consistent The powerful S7-400 target system and the engineering tools work perfectly together as user-friendly, task-oriented configuring tools The perfect team Configuration and Programming S7-400 + E-Tools = Optimized for great applications

Shaoxin Sewage Treatment References Automobile Food & Beverage Parma / Chemical industry Semiconductor/ Textile industry References Glass/ Cement Legend Inc. Shaoxin Sewage Treatment Icoma FSB Miscellaneous References

SIMATIC S7-400 Totally Integrated Automation