The Advance PLC: Simatic S7-1500

                                                    Simatic S7-1500 PLC 

Overview

• Modular, scalable, and universally usable system in IP20 level of protection
• The system solution for a variety of automation applications in discrete automation
• Highest performance with excellent usability
• Configurable exclusively in the Totally Integrated Automation Portal with STEP 7 Professional V12

Performance

• Performance increase through
  • Faster command execution
  • Language extensions
  • New data types
  • Faster backplane bus
  • Optimized code generation
• Powerful communication:
  • PROFINET IO (2-port switch) as standard interface
  • Optional additional PROFINET interface, e.g. for network separation
  • Expandable with communication modules for bus systems and point-to-point connection

Integrated technology

• Motion Control integrated without additional modules:
  • Standardized blocks (PLCopen) for connection of analog and PROFIdrive-capable drives
  • The Motion Control functionality supports speed-controlled and positioning axes as well as external encoders
• Comprehensive trace functions for all CPU variables for real-time diagnosis and sporadic error detection;
  for effective commissioning and quick optimization of drives and controls
• Comprehensive control functionalities:
  e.g. easily configurable blocks for automatic optimization of the control parameters for optimum control quality
• Additional functions through available technology modules:
  e.g. high-speed counting, position detection, or measurement functions for signals up to 1 MHz

Security Integrated

• Password-based know-how protection against unauthorized reading and modification of program blocks
• Copy protection for greater protection against unauthorized copying of program blocks:
  With copy protection, individual blocks on the SIMATIC memory card can be tied to its serial number so that the block can only be run if the configured memory card is inserted into the CPU.
• Rights concept with four different authorization levels:
  Different access rights can be assigned to various user groups. The new protection level 4 makes it possible to also restrict communication to HMI devices.
• Improved manipulation protection:
  Changed or unauthorized transfers of engineering data are detected by the controller.
• For use of an Ethernet CP (CP 1543-1):
  • Additional access protection by means of a firewall
  • Setup of secure VPN connections (V12 SP1 or higher)

Design and handling

• CPUs with display for plain text information:
  • Information about order numbers, firmware version, and the serial number of all connected modules can be displayed
  • Setting the IP address of the CPU and additional network settings directly on site, without programming device
  • Display of occurring error messages directly as plain text message, meaning reduction in downtime
• Uniform front connectors for all modules and integrated potential bridges for flexible potential group formation simplify stock keeping and reduce wiring costs
• Integrated DIN rail in the S7-1500 mounting rail:
  quick and easy installation of additional components such as miniature circuit breakers, relays, etc.
• Central expansion with signal modules:
  for flexible adaptation to any application
• System cabling for digital signal modules:
  for fast and clearly arranged connecting to sensors and actuators in the field and simple wiring inside the control cabinet
• Power supply:
  • Load current supply modules (power modules) to supply the module with 24 V
  • Power supply modules to supply power to the internal module electronics via the backplane bus
• Distributed expansion:
  • Use of up to 30 signal modules, communication modules, and technology modules via the PROFINET interface module IM 155-5 for the ET 200MP I/O system
  • No difference in terms of handling and system functions in central and distributed operation

Integrated system diagnostics

• Integrated system diagnostics for CPUs, activated by default:
  • Consistent plain text display of system diagnostic information in the display, TIA Portal, HMI, and web server, even for drive messages. Messages are updated even if the CPU is in STOP state.
  • System diagnostics integrated in the CPU firmware. Configuration by user not required. The diagnostics is automatically updated on configuration changes.

Datalog (archives) and recipes

• SIMATIC memory card:
  • Plug-in load memory
  • Permits firmware updates
  • Storage option for STEP 7 projects (including comments and symbols), additional documentation, or csv files (for recipes and archives)
  • Easy access to plant-relevant operating data and configuration data with Office tools via the SD Card reader (two-way data exchange from and to the controller)
• Integrated web server:
  - Easy access to plant-relevant operating data and configuration data via a Web browser

Approvals

At the start of delivery, the SIMATIC S7-1500 complies with national and international standards:

• CE
• cULus
• C-TICK
• CFMus
• ATEX
• EN 61000-6-4
• EN 60068-2-1/ -2/ -6/ -14/ -27/ -30/ -32
• EN 61131-2

Application

The SIMATIC S7-1500 is the modular control system for a variety of automation applications in discrete automation.

The modular and fan-free design, simple implementation of distributed structures, and convenient handling make the SIMATIC S7-1500 the cost-effective and user-friendly solution for the most diverse tasks.

Application areas of the SIMATIC S7-1500 include:

• Special machinery

• Textile machinery

• Packaging machinery

• General mechanical engineering

• Controller building

• Machine tool manufacture

• Installation systems

• Electrical/electronics industry and the skilled trades

• Automotive

• Water/wastewater

• F&B

In the first delivery stage, three CPUs of different performance levels and a comprehensive module range with many convenient functions are available. The modular design allows users to use only the modules they require for their applications. In the case of task expansions, the controller can be upgraded at any time by means of additional modules:

High industrial strength thanks to high electromagnetic compatibility and high resistance to shock and vibration enable universal use of the SIMATIC S7-1500.

Design

General

The S7-1500 automation system is modular in design. It has a comprehensive range of modules that can be combined individually.

A system includes the following:

• A controller:
  in the first delivery stage, three CPUs of different performance levels with integrated PROFINET interface or PROFINET and PROFIBUS interface are available.
• Signal modules for digital and analog inputs/outputs.
• Technology modules, e.g. for high-speed counting, position detection, or measurement functions.
• Communication modules and communications processors for expansion of controllers by communications interfaces

The following can also be used depending on requirements:

• Power supply modules (PS), to supply the internal electronics of the S7-1500 modules via the backplane bus, in case the output of the CPU to the backplane bus is not sufficient for all connected modules.
• Load current supply modules (PM) for connecting the SIMATIC S7-1500 to a supply voltage of 120/230 V AC.
• Interface modules to connect distributed I/O based on S7-1500.

Design

The simple design makes the SIMATIC S7-1500 flexible and service-friendly.

• Integrated backplane bus:
  The backplane bus is integrated into the modules. The modules are connected via U connectors plugged into the rear of the enclosures. This saves time during installation. An active backplane for the function "Reaction-free hot swapping" will be available soon.
• Module mounting on S7-1500 mounting rail:
  available in various lengths, including a version for cutting to length. A wide range of standard components such as additional terminals, miniature circuit breakers, or small relays can be snapped on due to the integrated DIN rail.
• Reliable and user-friendly wiring:
  • The I/O signals are connected via a uniform 40-pole front connector. The mechanical coding between the signal module and front connector prevents destruction of the electronics by accidental incorrect insertion.
  • For simple wiring of the front connector, it can be placed in the "prewiring position". In this position, the plug has no contact with the module electronics yet. This position can also be used to make changes during operation. The user is supported by a printed cabling diagram on the inside of the front flap.
  • At delivery start, the version with screw-type terminals will be available for the front connector. It permits the connection of wires with a cross-section from 0.25 mm² to 1.5 mm² (AWG 24 to AWG 16). A version with push-in terminals will be available soon.
  • In addition, system wiring via TOP Connect is available for digital signal modules. It allows the quick and clearly arranged connection to sensors and actuators from the field as well as simple wiring within the control cabinet.
  • For analog modules, the shielding can take place direct on the module; a shield connection set that can be installed without tools is included with the module.
• Plant-specific labeling:
  Labeling strips are available for the signal modules of the SIMATIC S7-1500. These DIN A4 sheets can be labeled using a standard laser printer. Automatic printing is possible from the TIA Portal without having to re-enter the symbols or addresses. The labeling strips are designed such that there is a 1:1 assignment of the labeling for channel or diagnostics display. If the front flap is opened, this 1:1 assignment of diagnostics display to terminal is retained.
• Variable and scalable station setup:
  • Signal modules and communication modules can be inserted in any way without restrictions. The system configures itself.
  • The maximum configuration comprises the CPU with 31 modules (30 modules + 1 power supply). The power supply (PS) is required to supply the internal electronics of the S7-1500 modules via the backplane bus, in case the output of the CPU to the backplane bus is not sufficient for all connected modules.
• Compact dimensions:
  The dimensions of the SIMATIC S7-1500 are such that it fits in the available installation space of a SIMATIC S7-300 or ET 200M without problems.
• Flexible installation:
  The SIMATIC S7-1500 and its modules can be installed both vertically and horizontally and thus provide an optimum fit to the available space.

I/O modules

The following module types are available for use on a SIMATIC S7-1500/ET 200MP:

• Digital input modules; 16 or 32 channels; 24 V DC; 230 V AC; active high or low
• Digital output modules; 8, 16, or 32 channels; 24 V DC; 230 V AC; rated current 0.5 A, 2 A, or 5 A per channel
• Analog input modules; 8 channels; measurement types: current, voltage, resistance, resistance thermometer; thermocouple
• Analog output modules; 4 or 8 channels; output ranges: current, voltage
  • Including High Speed (HS) analog modules with a minimum conversion time of 125 µs for 8 channels
• Technology modules for counting and positioning
• Communication modules for point-to-point communication
• Available soon: Fail-safe modules for safety-oriented applications

Various module classes are available to provide users with optimum scalability in their application. The modules themselves are labeled accordingly:

• BA (Basic): Simple, cost-effective modules, without diagnostics and without parameters
• ST (Standard): Modules with module-specific or load group-specific diagnostics and, if applicable, with parameters; for analog modules: accuracy class 0.3%
• HF (High Feature): Modules with channel-specific diagnostics and parameter setting; for analog modules: accuracy class 0.1%, increased immunity and galvanic isolation
• HS (High Speed): Modules with extremely short filter and conversion times and extremely fast applications; e.g. 8-channel analog modules with a conversion time of 125 µs

Accessories for I/O modules:

• Labeling sheets:
  For insertion in the I/O modules (10 DIN A4 sheets with 10 strips each, preperforated, for printing with a standard laser printer; available color: Al grey)
• Shield connection:
  A simple shield connection set that can be installed without tools is available for the SIMATIC S7-1500 system (analog modules and technology modules). This consists of a 24 V DC infeed element, a shield clamp, and a universal shield terminal. The latter is designed so that it can be used for a single thin trunk cable, several thin trunk cables, or a thick trunk cable. Consistent separation of 24 V DC infeed and measurement signals as well as a low-impedance connection between shield and signal cables ensure high EMC stability and high resistance to interference.
• Uniform 40-pole front connector
• Additional accessories such as the front doors for the I/O modules or the U connectors for the self-assembling backplane bus

Communication

The S7-1500 has different communication interfaces:

• PROFINET IO IRT interface (2-port switch), integrated in the CPU;
  for defined response times and high-precision plant behavior.
• Communication modules for connecting to the bus systems PROFIBUS and Industrial Ethernet (PROFINET available soon)
• Communication modules for point-to-point connections.

The CPU 1516-3 PN/DP features an additional integrated PROFINET interface with separate IP address, e.g. for network separation. For the CPU 1516-3 PN/DP, PROFIBUS nodes can be connected via the integrated PROFIBUS interface. The CPUs without integrated PROFIBUS interface can be easily expanded via a PROFIBUS CM.

Process communication via PROFINET IO

The SIMATIC S7-1500 is connected to the PROFINET IO bus system via the integrated PROFINET interface and permits a distribution automation configuration with defined response times and high-precision plant behavior.

The distributed I/O via PROFINET IO is treated just like a centralized I/O from the user's perspective (same configuring, addressing, and programming).

The following can be connected as IO controllers:

• SIMATIC S7-1500
• SIMATIC S7-1200
• SIMATIC S7-300 (via CPUs with PROFINET interface or PROFINET CPs)
• SIMATIC S7-400 (via CPUs with PROFINET interface or PROFINET CPs)
• SIMATIC ET 200 (via CPUs with PROFINET interface)

The following can be connected as IO devices:

• SIMATIC S7-1500
• SIMATIC S7-1200 (FW 4.0 or higher)
• ET 200S IM151-8 PN/DP CPU, ET 200pro IM154-8 PN/DP CPU
• SIMATIC S7-300 (via CPUs with PROFINET interface or PROFINET CPs)
• SIMATIC S7-400 (via CPUs with PROFINET interface or PROFINET CPs)
• ET 200 distributed I/O devices
• HMI devices which are operated as direct key modules
• Field devices

Process communication via PROFIBUS DP

The SIMATIC S7-1500 is connected to the PROFIBUS DP bus system via a communication module or the CPUs with integral PROFIBUS DP interface. The CPUs or communication modules with PROFIBUS DP interface enable distributed automation configuration with high speed and simple handling.

The distributed I/O via PROFIBUS DP is treated just like a centralized I/O from the user's perspective (same configuring, addressing, and programming).

The following can be connected as master:

• SIMATIC S7-1500
  (via CPUs with PROFIBUS DP interface or PROFIBUS DP communication modules)
• SIMATIC S7-300
  (via CPUs with PROFIBUS DP interface or PROFIBUS DP CPs)
• SIMATIC S7-400
  (via CPUs with PROFIBUS DP interface or PROFIBUS DP CPs)
• SIMATIC S5-115U/H, S5-135U and S5-155U/H with IM 308
• SIMATIC 505

The following can be connected as slaves:

• Distributed I/O devices, e.g. ET 200
• Field devices
• SIMATIC S7-200, S7-1200, S7-300
• C7-633/P DP, C7-633 DP, C7-634/P DP, C7-634 DP, C7-626 DP
• SIMATIC S7-400 (via CP 443-5 only)

However, PGs/PCs with STEP 7 or SIMATIC HMI Panels only use the PG and OP functions that also run in part via PROFIBUS DP.

Data communication via Ethernet

The S7-1500 can be connected to the Industrial Ethernet bus system via the integrated PROFINET interface or via a communication module. The following can be connected:

• SIMATIC S7-1200
• SIMATIC S7-300
• SIMATIC S7-400
• SIMATIC S5-115U/H, S5-135U, S5-155U/H
• Programming devices
• PCs, industrial PCs
• SIMATIC HMI operator control and monitoring systems
• Numerical controls
• Robot controls
• Drive controls
• Devices of other manufacturers

The Industrial Ethernet CP 1543-1 offers the following additional functionalities:

• 1 Gbit interface
• IPv6 support
• Security: access protection by means of hardware identification, IP/MAC access list, firewall, VPN tunnel (V12 SP1 or higher)
• Communication with S5 systems via the ISO protocol
• FTP (client/server), e-mail, SNMPv1/v3

Data communication via PROFIBUS

The SIMATIC S7-1500 can be connected to the PROFIBUS DP bus system via a communication module or the CPUs with integral PROFIBUS DP interface. The following can be connected:

• SIMATIC S7-1200
• SIMATIC S7-300
• SIMATIC S7-400
• SIMATIC S5-115U/H, S5-135U, S5-155U/H
• Programming devices
• PCs, industrial PCs
• SIMATIC HMI operator control and monitoring systems
• Numerical controls
• Robot controls
• Drive controls
• Devices of other manufacturers

Data communication via point-to-point communication modules

Powerful point-to-point connections can be implemented via the point-to-point communication modules. The following can be connected, for example:

• SIMATIC S7 and SIMATIC S5 automation systems and non-Siemens systems
• Scanners, barcode readers, identification systems
• Robot controls
• Printers

Protocols supported:

• Freeport: user-parameterizable telegram format for universal communication
• 3964(R) for improved transmission reliability
• Modbus RTU Master
• Modbus RTU Slave
• USS, implemented through instructions

Interface properties:

• RS 232 with auxiliary signals
• RS 422 for full-duplex connections
• RS 485 for half-duplex and multi-point connections
• Transmission rates from 300 to 115 200 bit/s
• Connection via sub D connector

Function

A host of features support users in programming, commissioning, and servicing the S7-1500.

• Performance
  • Faster command processing, depending on the CPU type, language extensions and new data types
  • Significantly shorter response times through optimized code generation
• Integrated technology
  • Simple, fast programming of motion sequences via standard PLCopen Motion blocks
  • Convenient diagnostic and commissioning tools provide support in commissioning drives
  • Automatic alarm messages to engineering system and HMI: Simplified troubleshooting saves time and effort in commissioning.
• Isochronous mode
  • Synchronous coupling of distributed signal acquisition, signal transmission, and program execution to the cycle of PROFIBUS and PROFINET with constant bus cycle time:
    the input signals are acquired and processed and output signals are output at fixed intervals (constant bus cycle time). A consistent process image partition is created at the same time.
  • Precisely reproducible and defined process response times due to synchronous signal processing with constant bus cycle times by the distributed I/O
  • In distributed automation solutions, the SIMATIC S7-1500 thus also permits high-speed processing operations and enables the achievement of maximum precision and reproducibility. This means increased production with optimal and constant quality.
  • Comprehensive range of components for complex tasks such as motion control, measured value acquisition, high-speed control, etc.
• Security Integrated
  • Password-based know-how protection against unauthorized readout and modification of program blocks (in combination with STEP 7)
  • Copy protection:
    Protection against unauthorized copying of program blocks. With copy protection, individual blocks on the SIMATIC memory card can be tied to its serial number so that the block can only be run if the configured memory card is inserted into the CPU.
  • 4-stage authorization concept:
    Different access rights can be assigned to user groups. The new protection level 4 makes it possible to also restrict communication to HMI devices. Improved manipulation protection allows changed or unauthorized transfers of engineering data to be detected by the controller.
• Design and handling
  • CPUs with integrated display:
    For convenient evaluation of module states for central and distributed modules or to set or change IP address(es) without programming device. System diagnostics and user alarms are shown in plain text on the display and help to respond to occurring error messages quickly and efficiently. The menu and message texts are available in multiple languages on the display.
• Integrated system diagnostics
  • System diagnostics information is displayed consistently and in plain text on the display, TIA Portal, HMI device and web server, including for messages from the drives, and are even possible in the CPU's STOP state. This functionality is integrated is the CPU firmware as a system feature and does not have to be configured separately by the user. If new hardware components are configured, the diagnostic information is updated automatically.
  • Simple and rapid diagnostics directly in the user program through the quality information:
    By activating the quality information (QI) of a module, the validity of the supplied process value can be queried and evaluated directly in the user program. Here, access is via the process image using simple binary or load commands. The prerequisite is that the module can be diagnosed and the quality information can be configured in the TIA Portal.
• Configuration by means of the SIMATIC STEP 7 Professional V12 engineering software
  • The SIMATIC S7-1500 controller family is programmed in the Totally Integrated Automation Portal using STEP 7 Professional V12 or higher. SIMATIC STEP 7 Professional V12 is the intuitively operated engineering system for the SIMATIC S7-1500.
• Compatibility
  • Migration:
    A migration tool integrated with SIMATIC STEP 7 Professional V12 provides support in switching from the S7-300/S7-400 to the S7-1500 controller and converts the program code automatically. Program code that cannot be converted automatically is logged and can be adapted manually. The migration tool is also made available as a standalone tool in the download area of Customer Support. STEP 7 V11 projects can continue to be used with STEP 7 V12 in compatibility mode. S7-1200 programs can also be transferred to the S7-1500 by means of copy&paste.
• SIMATIC memory card (required for operation of the CPU)
  • The SIMATIC memory card is used as plug-in load memory or for updating the firmware. STEP 7 projects including comments and symbols, additional documentation or csv files (for recipes and archives) can also be stored on the SIMATIC memory card. Data blocks can be created and data stored or read via SFCs on the SIMATIC memory card with the user program.