6941_en_04.pdf

Order No.:

AUTOMATIONWORX

INTERBUS SafetyController BoardIBS S7 400 ETH SDSC/I-T

26 99 53 2

User ManualUM EN IBS S7 400 ETH SDSC

Designation:

Revision:

Order No.:

This manual is valid for:

12/2005

AUTOMATIONWORX

6941_en_04 PHOENIX CONTACT

INTERBUS SafetyController BoardIBS S7 400 ETH SDSC/I-T

UM EN IBS S7 400 ETH SDSC

04

26 99 53 2

Designation Version Order No.

IBS S7 400 ETH SDSC/I-T HW/FW/COP-FWSIS

10/4.70/3.5204/2.00

28 19 55 8

IBS S7 400 ETH SDSC/I-T HW/FW/COP-FWSIS

11/4.71/3.5205/2.01

28 19 55 8

User Manual

IBS S7 400 ETH SDSC/I-T

PHOENIX CONTACT 6941_en_04

Please Observe the Following Notes

In order to ensure the safe use of the product described, we recommend that you read this manual carefully. The following notes provide information on how to use this manual.

User Group of This Manual

The use of products described in this manual is oriented exclusively to qualified electricians or persons instructed by them, who are familiar with applicable standards and other regulations regarding electrical engineering and, in particular, the relevant safety concepts.

Phoenix Contact accepts no liability for erroneous handling or damage to products from Phoenix Contact or third-party products resulting from disregard of information contained in this manual.

Explanation of Symbols Used

The attention symbol refers to an operating procedure which, if not carefully followed, could result in damage to hardware and software or personal injury.

The note symbol informs you of conditions that must strictly be observed to achieve error-free operation. It also gives you tips and advice on the efficient use of hardware and on software optimization to save you extra work.

The text symbol refers to detailed sources of information (manuals, data sheets, literature, etc.) on the subject matter, product, etc. This text also provides helpful information for the orientation in the manual.

We Are Interested in Your Opinion

We are constantly striving to improve the quality of our manuals.

Should you have any suggestions or recommendations for improvement of the contents and layout of our manuals, please send us your comments.

PHOENIX CONTACT GmbH & Co. KGDocumentation Services 32823 BlombergGermany

Phone +49 - 52 35 - 30 0Fax +49 - 52 35 - 34 20 21E-mail [email protected]


6941_en_04 PHOENIX CONTACT

General Terms and Conditions of Use for Technical Documentation

Phoenix Contact GmbH & Co. KG reserves the right to alter, correct, and/or improve the technical documentation and the products described in the technical documentation at its own discretion and without giving any notice.

The provision of technical documentation (in particular data sheets, installation instructions, manuals, etc.) does not constitute any further duty on the part of Phoenix Contact GmbH & Co. KG to furnish information on alterations to products and/or technical documentation. Any other agreement shall only apply if expressly confirmed in writing by Phoenix Contact GmbH & Co. KG. Please note that the supplied documentation is product-specific documentation only.

Although Phoenix Contact GmbH & Co. KG makes every effort to ensure that the information content is accurate, up-to-date, and state-of-the-art, technical inaccuracies and/or printing errors in the information cannot be ruled out. Phoenix Contact GmbH & Co. KG does not offer any guarantees as to the reliability, accuracy or completeness of the information provided. Phoenix Contact GmbH & Co. KG accepts no liability or responsibility for errors or omissions in the content of the technical documentation (in particular data sheets, installation instructions, manuals, etc.).

As far as is permissible by applicable jurisdiction, no guarantee or claim for liability for defects whatsoever shall be granted in conjunction with the information available in the technical documentation, whether expressly mentioned or implied. This information does not include any guarantees on quality, does not describe any fair marketable quality and does not make any claims as to quality guarantees or guarantees on the suitability for a special purpose. Phoenix Contact GmbH & Co. KG reserves the right to alter, correct, and/or improve the information and the products described in the information at its own discretion and without giving any notice.


PHOENIX CONTACT 6941_en_04

Statement of Legal Authority

This manual, including all illustrations contained herein, is copyright protected. Use of this manual by any third party is forbidden. Reproduction, translation, or electronic and photographic archiving or alteration requires the express written consent of Phoenix Contact. Violators are liable for damages.

Phoenix Contact reserves the right to make any technical changes that serve the purpose of technical progress.

Phoenix Contact reserves all rights in the case of patent award or listing of a registered design. Third-party products are always named without reference to patent rights. The existence of such rights shall not be excluded.

Internet

Up-to-date information on Phoenix Contact products can be found on the Internet at:

www.phoenixcontact.com

Make sure you always use the latest documentation. It can be downloaded at:

www.download.phoenixcontact.com

A conversion table is available on the Internet at:

www.download.phoenixcontact.com/general/7000_en_00.pdf

http://www.phoenixcontact.com

http://www.download.phoenixcontact.com

http://www.download.phoenixcontact.com/general/7000_en_00.pdf

6941_en_04 PHOENIX CONTACT i

Table of Contents

1 For Your Safety .......................................................................................................................1-1

1.1 General Safety Notes.........................................................................................1-2

1.2 Electrical Safety .................................................................................................1-4

1.3 Safety of the Machine or System .......................................................................1-5

1.4 Directives and Standards ...................................................................................1-6

1.5 Correct Usage ....................................................................................................1-7

1.6 Documentation ...................................................................................................1-8

1.7 System Requirements ........................................................................................1-9

1.8 Abbreviations Used .........................................................................................1-9

1.9 Trademarks ......................................................................................................1-10

1.10 Safety Hotline...................................................................................................1-10

2 Product Description .................................................................................................................2-1

2.1 Method of Operation of the Controller Board .....................................................2-2

2.2 Operating Elements and Indicators....................................................................2-52.2.1 Diagnostic Display and Keypad ..........................................................2-52.2.2 Operating Indicators of the Safe INTERBUS Controller .....................2-6

2.2.3 Ethernet Operating Indicators .............................................................2-82.2.4 Operating Indicators for the Battery Buffering

of the Internal Realtime Clock ............................................................2-9

2.3 Controller Board Input/Output Operation Modes..............................................2-102.3.1 Direct I/Q Operation Mode ................................................................2-11

2.3.2 Extended I/Q Operation Mode ..........................................................2-142.3.3 Selecting the I/Q Operation Mode ....................................................2-16

3 Mounting, Removal, Electrical Installation, and Replacement.................................................3-1

3.1 General ..............................................................................................................3-1

3.2 Setting the DIP Switches (Selecting the I/Q Operation Mode)...........................3-2

3.3 Mounting the IBS S7 400 ETH SDSC/I-T...........................................................3-3

3.4 Removing the IBS S7 400 ETH SDSC/I-T .........................................................3-4

3.5 Inserting/Removing the Parameterization Memory ............................................3-5

3.6 Connecting the Interfaces ..................................................................................3-63.6.1 Connecting the INTERBUS System ...................................................3-63.6.2 Connecting an Ethernet Network ........................................................3-7

3.6.3 Connecting the Connecting Cable to the PC ......................................3-7

3.7 Replacing the IBS S7 400 ETH SDSC/I-T..........................................................3-8


ii PHOENIX CONTACT 6941_en_04

4 Startup and Validation .............................................................................................................4-1

4.1 Initial Startup ......................................................................................................4-2

4.2 Restart After Replacing the Controller Board.....................................................4-4

4.3 Setting the IP Address .......................................................................................4-54.3.1 Setting the IP Address in Config+ ......................................................4-6

4.3.2 Setting the IP Address via the Keypad ...............................................4-8

4.4 Example Startup of the Controller Board .........................................................4-104.4.1 Example of an INTERBUS and Control System Configuration ........4-10

4.4.2 Example Startup of the Controller Board in Direct I/Q Operation Mode ................................................................4-11

4.4.2.1 Integration of the Controller Board in STEP 7 ...................4-114.4.2.2 Integration of the Controller Board in Config+ ...................4-124.4.2.3 Integration of the STEP 7 Driver Blocks and Startup

of the Controller Board .......................................................4-164.4.3 Example Startup of the Controller Board in

Extended I/Q Operation Mode ..........................................................4-214.4.3.1 Integration of the Controller Board in STEP 7 ...................4-21

4.4.3.2 Integration of the Controller Board in Config+ ...................4-214.4.3.3 Integration of the STEP 7 Driver Blocks and Startup

of the Controller Board .......................................................4-254.4.4 Integration of the Controller Board in SafetyProg .............................4-32

4.5 Diagnostic Function for Standard INTERBUS..................................................4-33

4.6 Diagnostic Function for INTERBUS Safety ......................................................4-334.6.1 Evaluating Diagnostic Data ..............................................................4-334.6.2 The FC 125 SIS_DIAG Safety Diagnostic Function .........................4-34

4.6.2.1 Call and Function Description ............................................4-344.6.2.2 Call Structure of FC SIS_DIAG in OB 1: ............................4-344.6.2.3 Description of the FC 125 Parameters ..............................4-35

4.6.2.4 Description of the S_IBDB Safety Data Block ...................4-364.6.3 Safety Function FC126 DEV_STAT .................................................4-41

4.6.3.1 Call and Function Description ............................................4-41

4.6.3.2 Call Structure of FC DEV_STAT in OB1 ............................4-414.6.3.3 Description of FC DEV_STAT Parameters ........................4-424.6.3.4 Call Structure of the Safety Diagnostic Function in OB1 ...4-43

5 Errors, Diagnostic Messages, and Removal ...........................................................................5-1

5.1 Critical System or Device Errors ........................................................................5-1

5.2 Parameterization and Configuration Errors ........................................................5-3

5.3 I/O Errors............................................................................................................5-4

Table of Contents

6941_en_04 PHOENIX CONTACT iii

6 Maintenance, Firmware Update, Repair, Decommissioning, and Disposal.............................6-1

6.1 Maintenance.......................................................................................................6-1

6.2 Updating the Controller Board Firmware............................................................6-1

6.3 Repair.................................................................................................................6-2

6.4 Decommissioning and Disposal .........................................................................6-2

7 Technical Data and Ordering Data ..........................................................................................7-1

7.1 System Data.......................................................................................................7-1

7.2 IBS S7 400 ETH SDSC/I-T ................................................................................7-1

7.3 Conformance With EMC Directive......................................................................7-3

7.4 Ordering Data.....................................................................................................7-4

7.4.1 Ordering Data for Accessories ...........................................................7-47.4.2 Ordering Data for Software .................................................................7-47.4.3 Ordering Data for Documentation ......................................................7-5

A Appendix: Controller Board Interfaces.................................................................................... A-1

A 1 Remote Bus Connection (REMOTE)................................................................ A-1

A 1.1 Fiber Optic Adapters .......................................................................... A-1A 1.2 Remote Bus Connector With IBS DSUB 9/L Solder Connection ....... A-2A 1.3 RS-232 Interface (V.24) ..................................................................... A-4

A 1.4 10/100BASE-T Ethernet Interface ..................................................... A-4

B Appendix: Checklists .............................................................................................................. B-1

B 1 Planning ........................................................................................................... B-2

B 2 Mounting and Electrical Installation ................................................................. B-4

B 3 Startup and Parameterization ......................................................................... B-5

B 4 "Initial Startup" Validation ................................................................................. B-6

B 5 "Restart" Validation .......................................................................................... B-7

C Index....................................................................................................................................... C-1

D Appendix: Revision History..................................................................................................... D-1


iv PHOENIX CONTACT 6941_en_04

For Your Safety

6941_en_04 PHOENIX CONTACT 1-1

1 For Your Safety

Purpose of This Manual

The information in this manual is designed to familiarize you with how the IBS S7 400 ETH SDSC/I-T controller board works, the operating and connection elements, and how it is integrated in the software tools listed in "Software requirements" on page 1-9. This information will enable you to use the controller board within an INTERBUS Safety system according to your requirements.

Validity of the User Manual

This manual is only valid for the IBS S7 400 ETH SDSC/I-T controller board with integrated safe INTERBUS controller (SIS) (referred to as "controller board" in this document) in the versions indicated on the inner cover page.


1-2 PHOENIX CONTACT 6941_en_04

1.1 General Safety Notes

Requirements Knowledge of the following is required:– INTERBUS and the components used in your application– INTERBUS Safety and the components used in your application

– Operation of the software tools specified under the software requirements– Safety regulations in the field of application

Qualified personnel In the context of the use of the INTERBUS Safety system, the following operations may only be carried out by qualified personnel:– Planning

– Configuration, parameterization, programming– Installation, startup, servicing– Maintenance, decommissioning

This user manual is therefore aimed at:– Qualified personnel who plan and design safety equipment for machines and systems

and are familiar with regulations governing safety in the workplace and accident prevention.

– Qualified personnel, who install and operate safety equipment in machines and systems.

In terms of the safety notes in this manual, qualified personnel are persons who, because of their education, experience and instruction, and their knowledge of relevant standards, regulations, accident prevention, and service conditions, have been authorized to carry out any required operations, and who are able to recognize and avoid any possible dangers.

Documentation You must observe all information in this manual as well as in the documents listed in "Documentation" on page 1-8.

Safety of personnel and equipment

The safety of personnel and equipment can only be assured if the controller board is used correctly (see "Correct Usage" on page 1-7).

Error detection Depending on the wiring and the corresponding setting of the safe I/O device parameters, the INTERBUS Safety system can detect various errors within the safety equipment.

Observe startup behavior The INTERBUS Safety system does not prevent automatic restart. The user must program this independently in the programming software for INTERBUS Safety (SafetyProg).

The controller board starts up immediately:– After power up, if a parameterization memory with a valid project is inserted.

– Following a reset if programmed accordingly.

The safety function is active immediately after the startup phase and the outputs of the safe and standard INTERBUS I/O devices can be used depending on the programming.

Controller board reset Only execute a controller board reset if the standard control system has been switched to the STOP state.

When working with the controller board within the INTERBUS Safety system, please observe all the safety notes included in this section.

For Your Safety


Do not carry out any repairs

Repair work may not be carried out on the controller board.

In the event that an error cannot be removed, please contact Phoenix Contact immediately, engage a service engineer or send the faulty controller board directly to Phoenix Contact.

Do not open the housing/security seal

It is strictly prohibited to open the controller board housing. In order to prevent the manipulation of the supplied controller board and to detect the unauthorized opening of the controller board, a security seal is applied to the controller board (see Figure 2-1 on page 2-1). This security seal is damaged in the event of unauthorized opening. In this case, the correct operation of the controller board can no longer be ensured.



1.2 Electrical Safety

Direct/indirect contact Protection against direct and indirect contact according to VDE 0100 Part 410 must be ensured for all components connected to INTERBUS. In the event of an error, parasitic voltages must not occur (single fault safety). This also applies to devices and components with hazardous contact voltages that are permanently connected to the network and/or diagnostic interfaces of INTERBUS devices.

Safe isolation Devices (whose connections can result in hazardous contact voltages) may only be used with safe isolation.

Power supply unit Only use power supply units with safe isolation and PELV according to EN 50178/VDE 0160 (PELV). This prevents short circuits between primary and secondary sides.

In particular, note the current consumption of the components in the SIMATIC S7 400 rack when selecting power supply units.

Only use SIMATIC S7 400 power supply modules that have an output value ≥ 10 A and a mains buffering time ≥ 20 ms.

Installation and configuration in INTERBUS

Please observe the instructions for installing and configuring INTERBUS in the IBS SYS PRO INST UM E user manual.

ESD

In order to ensure electrical safety, please observe the following points.

Disregarding instructions for electrical safety may result in hazardous body currents and the loss of functional safety.

The user is obliged to design the devices used and their installation in the system according to these requirements. This also means that existing plants and systems retrofitted with INTERBUS Safety must be checked and tested again in this respect.

Electrostatic discharge

The device contains components that can be damaged or destroyed by electrostatic discharge. When handling the device, observe the necessary safety precautions against electrostatic discharge (ESD) according to EN 61340-5-1 and EN 61340-5-2.

For Your Safety


1.3 Safety of the Machine or System

Draw up and implement a safety concept

In order to use the controller board described in this document, you must have drawn up an appropriate safety concept for your machine or system. This includes a hazard and risk analysis according to the directives and standards specified in "Directives and Standards" on page 1-6, as well as a test report (checklist) for validating the safety function (see "Appendix: Checklists" on page B-1).

The target safety integrity (SIL according to EN 61508 and category according to EN 954-1) is ascertained on the basis of the risk analysis. The safety integrity level or category ascertained determines how to use and parameterize the controller board within the overall safety function.

Within an INTERBUS Safety system, the IBS S7 400 ETH SDSC/I-T controller board can be used to achieve safety functions with the following requirements:– Up to SIL 3 according to standard EN 61508– Up to Category 4 according to standard EN 954-1

Hardware and parameterization testing

Carry out a validation every time you make a safety-related modification to your overall system. Use the "Validation" checklist in the UM EN INTERBUS-SAFETY SYS user manual to help you.

The machine/system manufacturer and the operator bear sole responsibility for the safety of the machine or system and the implemented application, in which the machine or system is used. The Machinery Directive must thus be observed.

Please also refer to the example description in the INTERBUS Safety system description UM EN INTERBUS-SAFETY SYS.



1.4 Directives and Standards

Directives and standards considered in the development of the controller board:

The manufacturers and operators of machines and systems, in which the controller board is used, are responsible for adhering to all applicable directives and legislation.

Directives Machinery Directive 98/37/EC

EMC Directive 89/336/EEC

Low Voltage Directive 73/23/EEC

Guideline for test and certification GS-ET-26: Bus systems for the transmission of safety-related messages

Standards DIN EN 61508-1:11.2002DIN EN 61508-2:12.2002DIN EN 61508-3:12.2002DIN EN 61508-4:11.2002DIN EN 61508-5:11.2002DIN EN 61508-6:06.2003DIN EN 61508-7:06.2003

Functional safety of electrical/electronic/programmable electronic safety-related systems

DIN EN 954-1:03.1997 Safety of machinery - Safety-related parts of control systems - Part 1: General principles for design

DIN EN ISO 13849-2:12.2003 Safety of machinery - Safety-related parts of control systems - Part 2: Validation

DIN EN 60204-1:11.1998 Safety of machinery - Electrical equipment of machines - Part 1: General requirements

DIN EN 61496-1:06.98 Safety of machinery - Electro-sensitive protective equipment - Part 1: General requirements and tests

DIN EN 61131-2:02.2004 Programmable controllers - Part 2: Equipment requirements and tests

DIN EN 61131-3:12.2003 Programmable controllers - Part 3: Programming languages

DIN EN 50254:07.1999 High efficiency communication subsystem for small data packages

DIN EN ISO 12100-1:04.2004 Safety of machinery - Basic concepts, general principles for design - Part 1: Basic terminology, methodology

DIN EN ISO 12100-2:04.2004 Safety of machinery - Basic concepts, general principles for design - Part 2: Technical principles

Preliminary standard DIN IEC 62061:06.2003 Safety of machinery - Functional safety of electrical, electronic and programmable control systems for machinery

BIA report 6/97 Categories for safety-related control according to EN 954-1 (see www.hvbg.de).

http://www.hvbg.de

For Your Safety


1.5 Correct Usage

The controller board can be used both in an INTERBUS Safety system and a standard INTERBUS system. It performs the task of a master (see DIN EN 50254), which controls, monitors, and diagnoses the overall INTERBUS structure, and is responsible for transferring data to and from a standard control system (Siemens SIMATIC S7 400).

The controller board can only perform its safety-related tasks in an INTERBUS Safety system if it has been integrated into the execution process correctly and in such a way as to avoid errors.

You must observe all information in this manual as well as in the documents listed in "Documentation" on page 1-8. In particular, only use the controller board according to the technical data and ambient conditions specified in Section 7, "Technical Data and Ordering Data" on page 7-1 and onwards.

Use the SafetyProg software to implement safety-related programming in your application.

Degree of protection Please note that the IBS S7 400 ETH SDSC/I-T controller board may only be used in SIMATIC S7 400 system racks.

Degree of protection of the controller board integrated in the rack: IP20.

To ensure correct operation, the controller board installed in a SIMATIC S7 400 system rack must be mounted in housing or a control cabinet with a minimum of IP54 protection.

Assembly guidelines The assembly guidelines for S7 400 control systems must be observed when installing the controller board in your SIMATIC S7 400 system (see Siemens SIMATIC S7 400 installation manual).

– Ensure the cable shield for Ethernet and INTERBUS is correctly secured in the connectors and when routing a cable through a control cabinet.

– Only use shielded data cables. As much of the shield as possible must be connected to ground on both sides.

– Immediately following entry in the control cabinet or housing, connect as much of the cable shield as possible to a shield/protective conductor bar and secure the shield with a cable clamp. Lead the shield to the board without interruption; connect it here but not to ground.

– The connection between the shield/protective conductor bar and the control cabinet/housing must have no impedance.

– Only use metal or metal-plated connector housing for shielded data cables.

Only use the controller board in accordance with the instructions in this section.

The safety function of the controller board is only available for use in an INTERBUS Safety system.

Please observe the following notes when using a shield connection clamp.



1.6 Documentation

Make sure you always use the latest documentation. Changes or additions to this document can be found on the Internet at www.download.phoenixcontact.com. A conversion table is available on the Internet at http://www.download.phoenixcontact.com/general/7000_en_00.pdf.

INTERBUS Safety When working on the INTERBUS Safety system and its components, you must always keep this user manual and other items of product documentation to hand and observe the information therein.

UM EN INTERBUS-SAFETY SYSINTERBUS Safety System Description

SAFETY INTRO UM EIntroduction to Safety Technology and Overview of Standards

UM QS EN SAFETYPROG and/or SafetyProg online help Quick Start Guide and/or online help for the SafetyProg software

User manuals– For INTERBUS Safety I/O devices

– For INTERBUS Safety function blocks

Standard INTERBUS When working on the INTERBUS system and its components, you must always keep the listed user manuals and other items of product documentation to hand and observe the information therein.

IBS SYS INTRO G4 UM EGeneral Introduction to the INTERBUS System

IBS SYS PRO INST UM EConfiguring and Installing INTERBUS

IBS SYS DIAG DSC UM EINTERBUS Diagnostics Guide for Generation 4 Controller Boards

UM QS EN CONFIG+ and/or Config+ online helpQuick Start Guide and/or online help for the Config+ software

IBS SYS FW G4 UM EFirmware Services and Error Messages

IBS SYS PCP G4 UM EPeripherals Communication Protocol (PCP)

Step 7 Driver Software

IBS S7 400 ETH DSC SWD UM EDescription of STEP 7 Driver Blocks for the Controller Board


For Your Safety


1.7 System Requirements

Hardware requirements In order to start up the IBS S7 400 ETH SDSC/I-T controller board according to this user manual, an S7 400 control system including the corresponding rack is required.

In order to reconstruct the examples illustrated in this user manual, corresponding INTERBUS I/O modules are required as INTERBUS devices.

Software requirements In order to ensure correct operation on your programming device, the software tools listed below must be installed according to the specifications in the software documentation. For information on the versions required, please refer to "Ordering Data for Software" on page 7-4.– Config+ Configuration software for INTERBUS

– SafetyProg Programming software for INTERBUS Safety– Diag+ Diagnostic software for INTERBUS– STEP 7 Software for Siemens SIMATIC control systems

– Driver blocks for STEP 7

1.8 Abbreviations Used

Abbreviation In Full Standard Example

SIL Safety Integrity Level DIN EN 61508 SIL 2, SIL 3

Cat. Category DIN EN 954-1 Cat. 2, Cat. 4

Abbreviation In Full

EUC Equipment Under Control

SIS Safe INTERBUS controller

FO Fiber optics

Please note that the meaning of the abbreviation SIS (safe INTERBUS controller) used in this document differs from the meaning used in standard IEC 61511 (SIS = Safety Instrumented Systems).



1.9 Trademarks

SIMATIC, STEP Trademarks of SIEMENS AGWINDOWS Trademark of the Microsoft Corporation

Please note that software/hardware designations and brand names of the companies mentioned are, as a rule, protected by copyright, trademark or patent.

1.10 Safety Hotline

Should you have any technical questions, please contact our 24-hour hotline.

– Phone: +49 - 52 35 - 31 98 70– E-mail: [email protected]

Product Description


2 Product Description

Figure 2-1 Front and rear view of the IBS S7 400 ETH SDSC/I-T

1 Locking screws2 LCD3 Keypad (for operating instructions, please refer to the IBS SYS DIAG DSC UM E

Diagnostics Guide)

4 Operating indicators of the safe INTERBUS controller (RUN, FS)5 Ethernet operating indicators (LINK, TRC)6 Cover

7 Slot for the parameterization memory8 RS-232 interface (V.24, 9-pos. D-SUB male connector)9 HW/FW/COP FW/SIS revision

10 Remote bus connection (REMOTE: 9-pos. D-SUB female connector)11 Operating indicators for the internal realtime clock battery (LOAD, FAULT)12 Ethernet interface (10/100BASE-T; RJ45 female connector)

13 System connector to connect the controller board to the S7 400 control system backplane bus

14 DIP switches for configuring the controller board15 Security seal16 Ethernet address (MAC address)

17 Serial number

� � � � � � � �

�

�

�

� � �

�

� � �

� �

� �

�

� � �

� � �

�

�

� ��

�

��

�

�

��

� � � � �

�



2.1 Method of Operation of the Controller Board

Behavior in the INTERBUS Safety System

The IBS S7 400 ETH SDSC/I-T controller board extends a standard INTERBUS system together with safe INTERBUS I/O devices to include freely programmable safety functions. In addition to the standard controller board, which is used to connect INTERBUS to Siemens SIMATIC control systems and Ethernet systems, the IBS S7 400 ETH SDSC/I-T includes a safe control part, the integrated safe INTERBUS controller.

This safe INTERBUS controller processes the input data of the safe INTERBUS I/O devices and the output data of the standard control system to provide safe output data according to the safety programming (see the description for the "Enable principle" in the UM EN INTERBUS-SAFETY SYS user manual).

The controller board transfers the input data of the standard INTERBUS I/O devices to the standard control system (S7 400). Here, the data is processed to provide output data and transferred back to the controller board according to the standard application program. The controller board then forwards this output data to the outputs of the standard INTERBUS I/O devices, where it is output.

Demand of a programmed safety function

Following the demand of a programmed safety function (e.g., open safety door), the safe INTERBUS controller executes the programmed safety function. The relevant safe outputs of the safe INTERBUS I/O devices are set to zero.

Behavior in the event of an error/safe state (failure state)

The high-quality integrated diagnostics function detects errors that have occurred. All serious errors in the controller board, which can lead to the loss of or adversely affect the programmed safety function, switch the device to the safe state with failure state. In this state, the safe outputs of the safe INTERBUS I/O devices are set to zero.

This state is indicated by the FS LED (failure state) (see Figure 2-5 on page 2-6).

For descriptions of error states, associated effects, and appropriate measures for error removal, please refer to "Errors, Diagnostic Messages, and Removal" on page 5-1.

Block diagram offunction units

Figure 2-2 Block diagram of the controller board

� � �

� � � � � � � � � � � � � � � � � � � � � � � � � � �

� � � � � � �

��

� � � � � � � �

� � � � � � � � � � � � ! " # �

$ � � # % # &� ' ( � ' ' � ) � * �

+ , (

, - � � � � .

� � � � �

Product Description


Firmware (IBS G4) The firmware on the controller board performs the function of an operating system. It controls the data traffic (the protocol) on the INTERBUS system. Data is exchanged between the controller board and the INTERBUS devices via firmware services. A distinction is made between the cyclic transmission of I/O data via the process data channel and the transmission of longer data records via the INTERBUS parameter channel (PCP).

Safe INTERBUScontroller (SIS)

The safe INTERBUS controller monitors and controls the safe part in an INTERBUS Safety System. Its function is to decide whether or not a safe output may be set. The safe INTERBUS controller is integrated in the IBS S7 400 ETH SDSC/I-T controller board.

S7 interface The controller board provides the S7 control system with the INTERBUS data via a transfer memory and receives data from the S7 control system in the opposite direction. This data is either made available to the control program directly via the S7 process image or via S7 driver blocks or is retrieved there. Depending on the amount of data to be transmitted and the number of controller boards used in the application, the data is transferred either directly to/from the process image of the S7 control system or via STEP 7 driver blocks to/from data block(s) and/or bit memory area(s). For more detailed information on the transmission options, please refer to "Controller Board Input/Output Operation Modes" on page 2-10.

Display elements (LED/display)

Diagnostic information can be displayed directly on the controller board via the diagnostic display (LCD) without additional software. The required entries are made via the keypad.

Information about the status of the safe INTERBUS controller, the status of the Ethernet connection, and the status of the battery buffering of the internal realtime clock (RTC) is indicated via LEDs.

Ethernet connection (10/100BASE-T)

This interface (RJ45 female connector) can be used to connect the controller board to an Ethernet network via a twisted pair cable (Ethernet cable according to Cat. 5 of IEEE 802.3). The connection assignment of this interface is illustrated in "10/100BASE-T Ethernet Interface" on page A-4.

The controller board can be parameterized/programmed via this interface. Furthermore, the INTERBUS configuration, monitoring, and diagnostic functions can be executed by a higher-level computer system. For this, a valid IP address must be stored on the controller board for the relevant network.

Please note that no IP address has been preset on the controller board by default upon delivery. Therefore, when the S7 400 control system is powered up for the first time, the message "SC 21 12" appears in the display. For the steps involved in setting an IP address, please refer to "Setting the IP Address" on page 4-5.



RS-232 interface (V.24) This interface can also be used to parameterize/program the controller board completely if the Ethernet interface cannot be used. This also applies to the INTERBUS configuration, monitoring, and diagnostic functions. This standard interface can thus be used at any time (even during operation) to directly access all the controller board functions and diagnostic options via a connecting cable. In addition, updated parts for the controller board firmware that are not safety-related can be downloaded (see "Updating the Controller Board Firmware" on page 6-1).

The interface is a 9-pos. D-SUB male connector. The connection assignment is illustrated in "RS-232 Interface (V.24)" on page A-4.

INTERBUS remote bus connection (REMOTE)

The overall INTERBUS structure (safe and standard devices) is connected to the controller board via this interface.

Use the corresponding interface converter to convert the 9-pos. D-SUB female connector to fiber optics. For the ordering data for the fiber optic converter, please refer to "Ordering Data for Accessories" on page 7-4 in the Appendix.

The connection assignment of the remote bus interface is illustrated in "Remote Bus Connection (REMOTE)" on page A-1.

Parameterization memory A system-specific parameterization of the INTERBUS system and the controller board are stored on the plug-in parameterization memory (Compact Flash card). This includes the INTERBUS configuration, the Ethernet configuration, and the safety program.

Realtime clock (RTC) A battery-buffered realtime clock is integrated on the controller board. This is used to provide a time stamp for internal diagnostic information and events that are saved to the parameterization memory in a file.The realtime clock is set during runtime in the SafetyProg software through synchronization with the programming device (PC) clock, on which SafetyProg runs.

Please note that the controller board requires a parameterization memory to be inserted for correct operation, where the parameterization specific to your application is stored.

Only cards from the Phoenix Contact range of accessories can be used, as these cards are specially tested and approved for correct operation.

For additional information on setting the realtime clock, please refer to the INTERBUS Safety system description UM EN INTERBUS-SAFETY SYS or the online help for the SafetyProg software.

Product Description


2.2 Operating Elements and Indicators

2.2.1 Diagnostic Display and Keypad

The LCD is used to indicate the operating and error states of the controller board and INTERBUS.

Figure 2-3 Diagnostic display

The keypad consists of six keys and enables menu-driven operation of the controller board.

Figure 2-4 Keypad

For information on the diagnostic display and the operation of the keypad, please refer to the IBS SYS DIAG DSC UM E Diagnostics Guide.

� � � �

�

�

�

�

�

�

�

�

�

�

�

�

� � � � � �

�

� � � � � � � �

� � � � � � � �



2.2.2 Operating Indicators of the Safe INTERBUS Controller

Figure 2-5 Operating indicators of the safe INTERBUS controller

FS (red LED) The FS LED indicates errors detected by the safe INTERBUS controller. The FS LED flashes in debug mode or during safe INTERBUS controller startup.

RUN (green LED) The RUN LED indicates the operating state of the safe INTERBUS controller. If cyclic operation of the safety program has been stopped, the RUN LED flashes.

The following table describes the operating states of the safe INTERBUS controller and the corresponding LED indicators.

Observe user rights in SafetyProg

The operating states described in the following table can only be set and changed in the SafetyProg software depending on the set user rights.

For example, only the administrator or programmer can switch the safe INTERBUS controller between safe mode (Run [safe], Stop [safe]) and standard debug mode (Run [debug], Stop/Halt [debug]) to validate the safety program during the EUC startup phase.

For additional information on the operating states of the safe INTERBUS controller, please refer to the online help for the SafetyProg software.

� � � � � � �

Table 2-1 Operating states of the safe INTERBUS controller

RUN (Green) FS (Red) Meaning

OF

F

OFF OFF Supply voltage not present.

The safe INTERBUS controller is not operating.

Product Description


Sta

rtu

p/In

itia

lizat

ion OFF Flashing at

1 HzThe safe INTERBUS controller is starting up or is not parameterized. Errors were not detected.

Following POWER ON of the S7 control system, the safe INTERBUS controller performs a selftest and the initialization (e.g., the safety program (boot project) stored on the parameterization memory is checked and loaded in the safe INTERBUS controller).

Saf

e M

od

e

ON OFF Run [safe]

The safe INTERBUS controller is in safe mode. The safety program is executed cyclically. The outputs of the safe INTERBUS I/O devices can be set. The programmed safety function is executed on demand.

Flashing at 1 Hz

OFF Stop [safe]

The safe INTERBUS controller is in safe mode. The cyclic processing of the safety program is stopped. All safe outputs of the safe INTERBUS I/O devices are set to zero.

Sta

nd

ard

Deb

ug

Mo

de

ON Flashing at 1 Hz

Run [debug], observe user rights

The safe INTERBUS controller is in error-free standard debug mode. The safety program is executed cyclically. The outputs of the safe INTERBUS I/O devices can be set. The safe outputs of the safe INTERBUS I/O devices can also be overwritten and enforced with SafetyProg.

Flashing at 1 Hz

Flashing at 1 Hz

Stop/Halt [debug], observe user rights.

The safe INTERBUS controller is in error-free standard debug mode. The cyclic processing of the safety program is stopped. All safe outputs of the safe INTERBUS I/O devices are set to zero. Only simulated output signals are shown in SafetyProg.

Failu

reS

tate

OFF, flashing (1 Hz) or ON

ON The safe INTERBUS controller has detected internal critical errors and switches the controller board to the safe state.

Table 2-1 Operating states of the safe INTERBUS controller

RUN (Green) FS (Red) Meaning

Please note, in this state your machine/system may present a danger.

Please note, in this state your machine/system may present a danger.

The state of the green RUN LED is irrelevant in the failure state and may vary.

For information on errors and error messages, please refer to "Errors, Diagnostic Messages, and Removal" on page 5-1.



2.2.3 Ethernet Operating Indicators

Figure 2-6 Ethernet operating indicators

The LINK and TRC (Transmit Receive Collision) LEDs indicate the state of the Ethernet interface. The LEDs indicate the following:LINK (yellow LED) The LINK LED indicates the state of the twisted pair cable.

This LED is active when a cable is connected properly between two devices.

TRC (green LED) The TRC LED lights up when data is being transmitted or received via the Ethernet interface.

� � � � � � �

Product Description


2.2.4 Operating Indicators for the Battery Buffering of the Internal Realtime Clock

These LEDs indicate the state of the battery buffering of the realtime clock (RTC) on the controller board. Buffering is implemented by a rechargeable lithium battery.

Figure 2-7 Operating indicators of the internal buffer battery

Battery Operating Indicators

LOAD This (green) LED indicates that the internal battery is charging. It always lights up when the controller board is supplied with power.

FAULT This (red) LED indicates that the remaining battery power is no longer sufficient to buffer the realtime clock for the guaranteed period if the controller board supply voltage is switched off.

Battery buffer times of the integrated realtime clock

As long as the FAULT LED does not light up, the realtime clock typically runs for 250 days and guarantees a further 10 days after the supply voltage is switched off.

Supply the controller board with power if the FAULT LED lights up while the supply voltage is switched on. If this LED continues to light up following approximately 10 hours of charging, there is a hardware fault. Send the controller board to your nearest Phoenix Contact representative.

� � � � � � � �



2.3 Controller Board Input/Output Operation Modes

Due to the system, the controller board provides a direct input/output operation mode and an extended input/output operation mode (I/Q operation mode). In these operating modes, data records are exchanged via direct and extended addresses of the standard control system (S7 CPU).

A data record is always defined as a consistent data block with a maximum length of 128 bytes. Up to eight data records are available for both inputs and outputs in both operating modes. The number, length, and destination address of the data records are configured in Config+.

INTERBUS operating modes

The controller board supports a synchronized bus mode (asynchronous with synchronization pulse) and an asynchronous bus mode. These bus modes have no effect on the addressing mechanisms or the data record definition. However, they do affect the structure of the application program and the consistency of the transmitted data.

I/Q Operation Mode Form of Addressing Data Records

Direct Direct addressingExtended addressing

44

Extended Extended addressing 8

For additional information on the bus modes and their effect on the application program, please refer to the IBS S7 400 ETH DSC SWD UM E driver manual.

Product Description


2.3.1 Direct I/Q Operation Mode

S5 adapter In "Direct I/Q Operation Mode", the controller board is inserted as an "S5 adapter (S5 ADAPTER)" in the S7 control system hardware configurator. I/O data is read and written directly via S7 I/O address commands.

Direct addresses In this operating mode, a maximum of 504 bytes of I/O data is supported for each controller board. The data records used (maximum of 4) are either in the process image or the I/O address area of the standard control system.

STEP 7 driver blocks are not required for direct I/O data exchange. The most important commands (start bus, switch devices) can be executed via the INTERBUS standard register.

Coupling areas/DIP switches

The DIP switches on the rear of the controller board (see Figure 2-1 on page 2-1) must be set to select the S5 coupling area emulated for this controller board (P, Q, IM3, IM4). When parameterizing the controller board in the Config+ software, the coupling area set by the DIP switches must be accepted in the "extended settings" of the controller board so that the addressing of the data records matches.

For a description of the DIP switch settings, please refer to "Setting the DIP Switches (Selecting the I/Q Operation Mode)" on page 3-2.

Communication register For each controller board used, a communication register must be addressed in the I/O address area of the S7 CPU, outside the process image. The communication register (CREG) is used by the INTERBUS-specific STEP 7 driver blocks for firmware services for the controller board and to parameterize intelligent field devices via the Peripherals Communication Protocol (PCP).

In each coupling area, the communication register always occupies the highest 4 bytes and thus reduces the maximum data length to 252 bytes per coupling area.

If several controller boards (S5 adapter boards) are used in the S7 control system, please note that a coupling area selected for one controller board is no longer available for other controller boards.



Figure 2-8 Direct addresses in direct I/Q operation mode

Key:

MEM = I/O address area (* = Size depends on the CPU type)PI = Process image (** = Size depends on the CPU type/STEP 7 setting)

CREG = Communication register (IN and OUT address area)

� / � � / � � � / �

� � � �

� � � #

� � � %

� � � �

� � �

� � #

� � %

� � �

� � �

� � #

� � � � � ( 0

� � %

� � �

� � � � � ( 0

0

�

� � � � � ( 0

'

1 ' %

'

� # 2

# 1 #

1 � � 3 3

4 � '

� ' ' '

� ' ' �

� ' 5 4 3

�

6 6

� � � � � � � �

Table 2-2 Address settings in Figure 2-8 on page 2-12

Data Record S7 Address S5 Address Length Coupling Area

IN 1 0 0 128 P

IN 2 128 128 124 P

IN 3 252 0 128 Q

IN 4 640 128 124 Q

OUT 1 0 0 128 P

OUT 2 128 128 124 P

OUT 3 252 0 128 Q

OUT 4 640 128 124 Q

CREG 1000 252 4 P/Q

Product Description


Extended addresses For data exchange with the integrated safe INTERBUS controller or for additional controller board I/O data (> 512 bytes, controller board firmware Version 4.6x or later), a further four data records can be defined in direct I/Q operation mode, which are then exchanged with the application program via STEP 7 driver blocks. The STEP 7 driver blocks copy this I/O data (data records) automatically to and from the addressed area (process image, bit memory area, data block area). This mechanism is identical to the data exchange in the "Extended I/Q Operation Mode" described in Section 2.3.2 on page 2-14.

Figure 2-9 Extended addresses in direct I/Q operation mode

Key:

M = Bit memory areaDB = Data block areaMEM = I/O address area (* = Size depends on the CPU type)

PI = Process image (** = Size depends on the CPU type/STEP 7 setting)CREG = Communication register (IN and OUT address area)

� / � � / � � � / �

� � � �

� � � 2

� � � �

� � �

� � 2

� � �

� � %

� � �

� � � � � ( 0

1 ' %

'

1 � � 3 3

4 � '

� ' ' '

� # 1 4

� ' 5 4 3

�

6 6

� � � 1 � � 1# ' ' '

� � � 4 � � 4# � # 2

� � # 2

� % 2 �

6 7 �, �

� � 1

� � 4

1 ' �

� � �

� � 2

� ' ' 2

0

� � � � � � � �

Table 2-3 Extended address settings in Figure 2-9 on page 2-13

Data Record S7 Address Offset Length

IN 5 I 2000 128

IN 6 I 2128 128

IN 7 Q 1000 128

IN 8 Q 1256 128

OUT 5 I 2000 128

OUT 6 I 2128 128

OUT 7 Q 1128 128

OUT 8 Q 1384 128



2.3.2 Extended I/Q Operation Mode

FM 451 FIXED SPEED POS In extended I/Q operation mode, the INTERBUS controller board is inserted in the S7 control system hardware configurator as "FM 451 FIXED SPEED POS.". The controller board thus occupies 24 bytes in the I/O address area of the S7 control system above the process image. 8 data records can be copied in each data direction in the process image, bit memory area or data block area.

DIP switches This operating mode must be set via a DIP switch on the rear of the controller board before the controller board is installed (see Figure 2-1 on page 2-1).

Base address/INTERBUS standard register

When parameterizing the controller board in the Config+ software, the base address of the controller board set in the STEP 7 software must be consistently transferred to the "extended settings" of the controller board. The base address determines the location of the INTERBUS standard register (see Figure 4-13 on page 4-23).

For a description of the DIP switch settings, please refer to "Setting the DIP Switches (Selecting the I/Q Operation Mode)" on page 3-2.

Figure 2-10 Address area in extended I/Q operation mode

Key:

M = Bit memory areaDB = Data block area

MEM = I/O address area (* = Size depends on the CPU type)PI = Process image (** = Size depends on the CPU type/STEP 7 setting)BA = Base address of the controller board (= 512 in Figure 2-10 on page 2-14)

� / � � / � � � / �

''

1 � � 3 3

� # 2

% 2 �

4 � '

� ' 5 4 3

�

6 6

1 � #

� 4 2

6 7 �, �

1 � �

� ' # �

� � �

� � #

� � %

� � �

� � 1

� � 4

� � �

� � 2

� � �

� � #

� � %

� � ��

� � � %

� � � #

� � � �

� )

# 1 4

% 2 �

� � � 1

� � � 4

� � 1

� � 4

� � �

� � � �

� � 2

� � � 2

'

� # 2

# 1 4

2 5 4

1 � #� )

� � � � � � � �

Product Description


Table 2-4 Extended address settings in Figure 2-10 on page 2-14

Data Record S7 Address Offset Length

IN 1 I 0 128

IN 2 I 128 128

IN 3 I 256 128

IN 4 I 384 128

IN 5 M 256 128

IN 6 M 384 128

IN 7 M 512 128

IN 8 M 768 128

OUT 1 Q 0 128

OUT 2 Q 128 128

OUT 3 Q 256 128

OUT 4 Q 384 128

OUT 5 M 0 128

OUT 6 M 128 128

OUT 7 M 640 128

OUT 8 M 896 128



2.3.3 Selecting the I/Q Operation Mode

This section provides assistance with selecting the I/Q operation mode required for your application.

Direct I/Qoperation mode

If you want to access the controller board directly using the I/O access of your S7 control system (L PIW, etc.), direct I/Q operation mode should be used. An advantage of this operating mode is the shorter program runtime, as STEP 7 driver blocks are not required for data transfer. I/O data is directly written to and read from the process image of the S7 control system.

Extended I/Qoperation mode

If the coupling areas (P, Q, IM3, IM4) are already occupied by other controller boards in your application, extended I/Q operation mode must be used. An advantage of this operating mode is that the entire I/O address area of the S7 control system can be used if the process image of the S7 control system is insufficient for data transfer on larger systems.

The following table compares direct I/Q operation mode and extended I/Q operation mode.

Product Description


Table 2-5 Comparison of controller board input/output operation modes

Direct Extended

Hardware catalog in STEP 7 S5 ADAPTOR FM 451 FIXED SPEED POS.

Data exchange Via the process image/I/O access and also via STEP 7 driver blocks

STEP 7 driver blocks

Data width of each controller board in the S7 address area

1 - 2 controller boards/rack:– 504 bytes, maximum for direct

addresses– 512 bytes, maximum for extended

addresses

3 - 4 controller boards/rack:

– 252 bytes, maximum for direct addresses

– 512 bytes, maximum for extended addresses

1 - 4 controller boards/rack:– 1024 bytes for I/O data (8 data records

with a maximum of 128 bytes each)

Communication register 4 bytes in the I/O address area (but not in the process image)

4 bytes in the I/O address area from the base address onwards (4 bytes within the 24 bytes occupied by the controller board)

Diagnostic register Can be freely addressed in the I/O address area of the S7 control system (also in the process image)

12 bytes in the I/O address area from the base address onwards (12 bytes within the 24 bytes occupied by the controller board)

Number of controller boards per rack

4, maximum 4, maximum

S7 address areas

– Direct addresses Process image/I/O address area Not required

– Extended addresses Process image, bit memory area, data block area

Process image, bit memory area, data block area

Data consistency in "asynchronous" bus mode

8 bits/16 bits via direct I/O access 8 bits

Data consistency in "asynchronous with synchronization pulse" bus mode

Yes, over the length of the extended addresses

Yes, over the entire address area

Data exchange between the standard control system and the safe INTERBUS controller

Yes Yes

Advantages/properties – Process data can also be read/written repeatedly in the program outside the I/O cycle via I/O commands

– Fast data exchange (for direct addresses) through direct access to the backplane bus

– Only 24 bytes occupied in the S7 CPU I/O address area

– All data records are exchanged via STEP 7 driver blocks and a communication register

– All data records can be freely addressed in the system outside the S7 CPU I/O address area (bit memory area and data block area)



Mounting, Removal, Electrical Installation, and Replacement


3 Mounting, Removal, Electrical Installation, and Replacement

3.1 General

– Ensure the cable shield for Ethernet and INTERBUS is correctly secured in the connectors and when routing a cable through a control cabinet.

– Only use shielded data cables. As much of the shield as possible must be connected to ground on both sides.

– Immediately following entry in the control cabinet or housing, connect as much of the cable shield as possible to a shield/protective conductor bar and secure the shield with a cable clamp. Lead the shield to the board without interruption; connect it here but not to ground.

– The connection between the shield/protective conductor bar and the control cabinet/housing must have no impedance.

– Only use metal or metal-plated connector housing for shielded data cables.

Only qualified personnel should pack and unpack the controller board while observing the following ESD regulations.

Electrostatic discharge

The device contains components that can be damaged or destroyed by electrostatic discharge. When handling the device, observe the necessary safety precautions against electrostatic discharge (ESD) according to EN 61340-5-1 and EN 61340-5-2.

Do not mount or remove the device while the power is connected

Before mounting and removing the controller board, disconnect the power to the S7 400 control system.

Please note that the controller board may only be used in the SIMATIC S7 400 system racks.

Degree of protection of the controller board when installed: IP20.

To ensure correct operation, the controller board installed in a SIMATIC S7 400 system rack must be mounted in housing or a control cabinet with a minimum of IP54 protection.

When mounting/removing the controller board, please refer to the assembly guidelines for S7 400 control systems (see Siemens SIMATIC S7 400 installation manual) .

Please observe the following notes when using a shield connection clamp.



3.2 Setting the DIP Switches (Selecting the I/Q Operation Mode)

Location of the DIP switches

Use the DIP switches to select the I/Q operation mode of the controller board.

Figure 3-1 Location of the DIP switches

DIP switch settings The following I/Q operation modes and coupling areas can be set using the DIP switches:

Figure 3-2 DIP switch settings

DIP switch functions

� � � � � �

1) Direct I/Q operation mode 2) Extended I/Q operation mode1a) Coupling areas

� � �

� �

� �� # &� � �

� �

� &

� � � � � � � �

� ��

� � &

! � " ! �

! �

! �

# " $

#

$

� �

� �

� �

� �

� �

� �

� �

� � �

� � � � � �

� � �

� � �

� � � � � �

� � ��

� � � � � �

��

Position Description of the Function

Sw

itch

6 -

8 ON/OFF Reserved

3 -

5 ON/OFF Activation/deactivation of the coupling areas (see Figure 3-2 on page 3-2).

2

OFF:Direct I/Q operation mode

See "Direct I/Q Operation Mode" on page 2-11.

ON:Extended I/Q operation mode

See "Extended I/Q Operation Mode" on page 2-14.

1 ON/OFF Reserved



3.3 Mounting the IBS S7 400 ETH SDSC/I-T

Installing the Controller Board in the S7 Control System

Figure 3-3 Removing the cover

Figure 3-3 illustrates how to remove the controller board cover in order to reach the lower mounting screw. Remove the cover by lightly pressing the locking lever downwards (A). Swivel the cover in the direction of arrow (B) as shown. To remove the cover, withdraw it with the clips from the openings at the bottom of the front panel.

Figure 3-4 shows you how to proceed. Place the controller board onto the upper rail of the rack (A). Swivel the controller board downwards in the backplane bus connector until it reaches the rack (B).

Figure 3-4 Installing the controller board

Lock the controller board on the rack with two slotted-head screws at the top and bottom of the front plate.

1. Switch off the S7 control system supply voltage. 2. Place the controller board directly in the S7 control system.

�

�

� � � � � � � �

�

�

�

� � � � � � �



Figure 3-5 Locking the mounting screws

3.4 Removing the IBS S7 400 ETH SDSC/I-T

Remove the controller board in the reverse order to mounting (follow the instructions in "Replacing the IBS S7 400 ETH SDSC/I-T" on page 3-8 up to step 5).

Make sure that the backplane bus connector is well-contacted and the controller board securely placed and locked on the rack.

5469A011



3.5 Inserting/Removing the Parameterization Memory

Inserting the parameterization memory

If present, remove the controller board cover as illustrated in Figure 3-3 on page 3-3 in order to reach the slot for the parameterization memory. Insert the parameterization memory into the slot provided as illustrated in Figure 3-6, with the female connector to the front. When pressed lightly, the parameterization memory slots in and the ejector moves outwards (A).

Removing the parameterization memory

Press the ejector. The parameterization memory is ejected from the slot. It can then be removed from the front (B).

Figure 3-6 A: Inserting the parameterization memoryB: Removing the parameterization memory

Replacing the parameterization memory

Remove the old parameterization memory according to the method described above and insert the new parameterization memory.

Please note that the parameterization memory may not be inserted or removed during operation. If the parameterization memory is removed during operation, the controller board switches to the safe state (failure state).

Always disconnect the power supply to the S7 control system before inserting or removing the parameterization memory.

As the parameterization memory is inserted, ensure that the card is located in the guide rails on both sides of the card holder. Make sure that the parameterization memory is properly aligned and never force the it into the slot.

� � � � � � �

) �



3.6 Connecting the Interfaces

3.6.1 Connecting the INTERBUS System

Remote bus cable Connect the remote bus cable, which goes to the first INTERBUS remote bus device to the remote bus connection (REMOTE) on the controller board.

For information on bus cable assembly, please refer to "Remote Bus Connector With IBS DSUB 9/L Solder Connection" on page A-2 and "Remote Bus Connector With SUBCON 9/M-SH Screw Connection" on page A-3.

Fiber optic adapter As an alternative to the remote bus cable connector, the 9-pos. D-SUB female connector can be connected to an adapter for converting to fiber optics.

For information on fiber optic adapters, please refer to "Fiber Optic Adapters" on page A-1. For the ordering data, please refer to "Ordering Data for Accessories" on page 7-4.

Figure 3-7 Connecting the remote bus cable

During installation, please refer to the "Configuring and Installing INTERBUS" user manual IBS SYS PRO INST UM E.

� � � � � � � �



3.6.2 Connecting an Ethernet Network

Connect the Ethernet cable to the Ethernet interface (RJ45 female connector) (designation 10/100BASE-T) of the controller board. It connects the controller board to a higher-level Ethernet network. Use an Ethernet cable according to Cat. 5 of IEEE 802.3.

Figure 3-8 Cable connection between an Ethernet network and the controller board

For the ordering data for the Ethernet cable, please refer to "Ordering Data for Accessories" on page 7-4.

3.6.3 Connecting the Connecting Cable to the PC

Connect the connecting cable (RS-232) to the RS-232 interface (V.24) on the controller board. It connects the controller board to your PC (COM1 to COM4).

Figure 3-9 Cable connection between the PC and the controller board

For the ordering data for the connecting cable, please refer to "Ordering Data for Accessories" on page 7-4.

� � � � � � � �

� � � � � � � �

� % & % & � � � & ' ( ) & % � % � " * (

� � " " "

� � � � � � % & & % & � � � & ' ( ) & % � % � " * (

� � � + � � + , & � � & � � & & �

� 6 � � � � � # % #

�

4

1

�

%

#

�

'

�

4

1

�

%

#

�

'

� � � �

� �

�

�

�

�

+ � 8

� � �

� ' ( � ' '� ) � * �

� �

� �

� ) + �

+ � ) ,

� � � � � � .

9 � �

6 � � � � .

� � � �

� ��

. �� :

� �� -

: ;



3.7 Replacing the IBS S7 400 ETH SDSC/I-T

1. Switch off the power supply to the S7 400 control system.

2. Remove the remote bus connector.

Figure 3-10 Removing the remote bus connector

3. If present, remove the connecting cable connector.

Figure 3-11 Removing the RS-232 connector

Only qualified personnel should pack and unpack the controller board while observing the ESD regulations in Section 1.2.

Only replace the controller board with a controller board with the same hardware/firmware revision or a compatible controller board approved by Phoenix Contact. Information on compatible controller boards can be found on the Internet at www.phoenixcontact.com.

Do not replace the controller board while the power is connected.

Do not remove the controller board until:

– The controller board has been disconnected from the power supply and it has been ensured that it cannot be switched on again

– The remote bus connector has been disconnected– The connecting cable connector (RS-232) has been disconnected (if present)– The Ethernet cable connector has been disconnected (if present)

� � � � � � � �

� � � � � � � �




4. If present, remove the Ethernet cable connector.

Figure 3-12 Removing the RJ45 connector

5. Unscrew the mounting screws with a flat-bladed screwdriver. Swivel the controller board upwards and remove it from the rack.

Figure 3-13 Removing the controller board

6. Take the controller board to be installed out of its packaging.7. Set the DIP switches of the new controller board to the same positions as those on the

controller board to be replaced.8. Install the new controller board in the control system rack and tighten the mounting

screws according to "Mounting the IBS S7 400 ETH SDSC/I-T" on page 3-3. Make sure that the system connector is well-contacted and the controller board securely placed and locked on the rack.

9. Remove the parameterization memory from the old controller board and insert it in the new controller board.

10. Insert and lock the remote bus cable.

� � � � � � � �

5469A022



Figure 3-14 Connecting the controller board to the remote bus

11. Insert and lock the connecting cable connector (RS-232) (if present).12. Insert the RJ45 connector of the Ethernet cable (if present).

13. To restart once the controller board has been replaced, first carry out a validation. Follow the instructions and corresponding notes in "Restart After Replacing the Controller Board" on page 4-4.

Do not connect the standard control system supply voltage yet.

Take appropriate measures to ensure that your machine/system does not present any danger for the time it takes to carry out the validation required below.

� � � � � � � �

Startup and Validation


4 Startup and Validation

Take appropriate measures to ensure that there is no danger from your system/machine during startup and validation.



4.1 Initial Startup

– Knowledge of the previous section of this user manual is essential in order to carry out the steps listed in the following table correctly. Therefore, if you have not done so already, please read the previous section carefully. The section in the Appendix of this manual that corresponds to the previous section, must also be observed.

– The controller board starts up immediately:– After power up, if a parameterization memory with a valid project is inserted.

– Following a reset if programmed accordingly. The safety function is active immediately after the startup phase and the outputs of the safe and standard INTERBUS I/O devices can be used depending on the programming.

For initial startup, proceed as described in Table 4-1.

The following information for the startup and operation of the controller board must be observed.

The following table describes all the steps from unpacking the controller board through mounting/installation to startup.

Table 4-1 Steps for initial startup

Step Relevant Section and Literature

Remove the controller board from the packaging while observing the ESD regulations.

"General" on page 3-1

Set the DIP switches on the controller board according to the required I/Q operation mode.

– "Controller Board Input/Output Operation Modes" on page 2-10

– "Setting the DIP Switches (Selecting the I/Q Operation Mode)" on page 3-2

Mount the controller board in your SIMATIC S7 400 system. – "Mounting, Removal, Electrical Installation, and Replacement" on page 3-1

– Siemens SIMATIC S7 400 installation manual (assembly guidelines for S7 400 control systems)

Connect the controller board to the INTERBUS remote bus. "Mounting, Removal, Electrical Installation, and Replacement" on page 3-1Connect the controller board to an Ethernet network if this

connection has been provided.

Connect the controller board to a PC via the RS-232 interface (V.24) if this connection has been provided.

Insert the parameterization memory. "Inserting/Removing the Parameterization Memory" on page 3-5

Connect the power supply to the SIMATIC S7 400 control system.

– Notes on using PELV power supply units in "Electrical Safety" on page 1-4




Switch on the power supply for the controller board/S7 400 control system.

If necessary, set the IP address of the controller board. "Setting the IP Address" on page 4-5

Carry out the necessary controller board programming in the STEP 7 and Config+ software tools.

Direct I/Q operation mode– "Integration of the Controller Board in STEP 7" on

page 4-11, – "Integration of the Controller Board in Config+" on

page 4-12

Extended I/Q operation mode– "Integration of the Controller Board in STEP 7" on

page 4-21– "Integration of the Controller Board in Config+" on

page 4-21

Integrate the STEP 7 driver blocks of the controller board that are not safety-related for data transfer and diagnostics.

Direct I/Q operation mode"Integration of the STEP 7 Driver Blocks and Startup of the Controller Board" on page 4-16

Extended I/Q operation mode"Integration of the STEP 7 Driver Blocks and Startup of the Controller Board" on page 4-25

Carry out the necessary controller board parameterization in the SafetyProg software.

"Integration of the Controller Board in SafetyProg" on page 4-32

Carry out the validation using the checklist ""Initial Startup" Validation" on page B-6.

"Appendix: Checklists" on page B-1

Table 4-1 Steps for initial startup


Take appropriate measures to ensure that your system/machine does not present any danger.

Please note that the controller board requires approximately 2 minutes to start up. This is due to the comprehensive selftests the controller board must perform. The status is indicated in the controller board display. A successful selftest and initialization phase is indicated by "SIS INIT 0..100". If present, the application program is then loaded and started up. Loading and starting is indicated in the display by BOOT and the relevant executed G4 firmware service.

Safety-related steps

The following steps include safety-related operations in the SafetyProg software and the safety validation of the INTERBUS Safety system.



4.2 Restart After Replacing the Controller Board

To restart the controller board after it has been replaced, proceed according to Table 4-2. Please ensure that:– The old controller board has been removed from the rack

– The parameterization memory of the old controller board has been removed

The controller board does not have to be parameterized again following a restart (see Table 4-1 "Steps for initial startup"). If a parameterization memory is inserted, which contains the configuration project created for your application, the configuration is still available when switching on the power supply to the S7 control system. However, your application must not have been modified.

Table 4-2 Steps for restarting


Remove the controller board from the packaging while observing the ESD regulations.

"General" on page 3-1

Set the DIP switches on the controller board according to the DIP switch settings on the old controller board.

– "Controller Board Input/Output Operation Modes" on page 2-10

– "Setting the DIP Switches (Selecting the I/Q Operation Mode)" on page 3-2

Mount the controller board in your SIMATIC S7 400 system. – "Mounting, Removal, Electrical Installation, and Replacement" on page 3-1


Connect the controller board to the INTERBUS remote bus. "Mounting, Removal, Electrical Installation, and Replacement" on page 3-1Connect the controller board to an Ethernet network if your

application requires you to do so.

Connect the controller board to a PC via the RS-232 interface (V.24) if your application requires you to do so.

Insert the parameterization memory removed from the old controller board.

"Inserting/Removing the Parameterization Memory" on page 3-5

Switch on the power supply for the controller board/S7 400 control system. Take appropriate measures to ensure that

your system/machine does not present any danger.



4.3 Setting the IP Address

By default upon delivery, the controller board has no preset IP address. Therefore, a valid IP address must be set upon initial startup when the "SC 21 12" message appears in the display, once the controller board has been installed and the S7 400 control system supply voltage has been switched on.

The IP address of the controller board can be set via Config+ or via the keypad on the controller board. In both cases, the IP address is stored on the parameterization memory of the controller board without a project reference and reloaded on each power on. If no parameterization memory is inserted in the controller board, communication via Ethernet is not possible. "SC 21 12" then appears in the display.

– The IP address is only stored on the parameterization memory without a project reference. The address is not stored in the controller board.

– The IP address is transferred from the parameterization memory following a controller board power on/reset.

– If you wish to delete the IP address from the parameterization memory, you must specify the IP address 0.0.0.0 in Config+ (see "Setting the IP Address in Config+" on page 4-6) or via the keypad.

– During formatting of the parameterization memory, the IP address is stored temporarily by the safe INTERBUS controller and then rewritten to the parameterization memory. It is not deleted.

Carry out the validation using the checklist ""Restart" Validation" on page B-7.

"Appendix: Checklists" on page B-1

Table 4-2 Steps for restarting


Please note that the controller board requires approximately 2 minutes to start up. This is due to the comprehensive selftests the controller board must perform. The status is indicated in the controller board display. A successful selftest and initialization phase is indicated by "SIS INIT 0..100". If present, the application program is then loaded and started up. Loading and starting is indicated in the display by BOOT and the relevant executed G4 firmware service.

Safety-relevant step

The following step includes the safety validation of the INTERBUS Safety system.

Please note that when setting the IP address described below, the parameterization memory must be inserted in the controller board.

Please observe the following notes if the controller board is operated in an Ethernet network and/or communicates with the programming device via the Ethernet interface:



If you wish to use the Ethernet interface as a communication path to the programming device, the "TCP/IP (Ethernet/Localhost)" communication path and the IP address of the controller board set above must be entered in the "Communication" tab in Config+. If you are online with the controller board, the connection to the programming device can be tested with "Test".

To set the IP address, proceed as described below.

4.3.1 Setting the IP Address in Config+

Once the controller board has been added to the relevant I/Q operation mode in Config+, (see Section 4.4.2.2 on page 4-12 and Section 4.4.3.2 on page 4-21), open the "IBG4Service_SDSC.slb" pre-defined service library in the "IB G4 Service Editor" tab.

Figure 4-1 "Open Service Library" dialog box

This library provides pre-defined firmware services for the controller board.

Select the "IP address setup/erasure for IBS S7 400 ETH SDSC I-T" service. The firmware service is displayed in the "Request" window. Now edit the corresponding entries for the IP address, subnet mask, and router address in the "Request" window and send the service to the controller board by clicking "Send". The values set are transferred following a controller board power on.

The IP address must be set for the first time using Config+ via the RS-232 interface (V.24) of the controller board. Once this has been set, modifications can also be made via an existing Ethernet connection. The new network settings are then valid after the next controller board power on.



Figure 4-2 Firmware service for setting/deleting the IP address

To execute the service, the parameterization memory must be inserted in the controller board. Successful execution of the service is displayed in the "Confirmation" window (see Figure 4-2 on page 4-7).



4.3.2 Setting the IP Address via the Keypad

Key functions

Figure 4-3 Keypad keys

Key:

1 Arrow keys2 Enter key (confirm menu selection)3 Escape key (exit menu item)

Setting First, press and hold down the Escape key on the controller board and then switch on the S7 400 control system supply voltage. Release the Escape key if the message "SC INIT SM 0" appears in the display. After the message "SC RDY SM 0" has been displayed for around 2 minutes, please carry out the following steps in the specified order to set the IP address.

� �

��

� � � � � � �



Display in the LCD

Action:Please Press:

Meaning

SC RDY SM 0 Right arrow key

MODE Enter

CFG Left arrow key

OPT Enter

SCANTIME Left arrow key

2. IP ADDR Left arrow key Reserved

1. IP ADDR Enter Sets the first IP address

IP1 Up/down arrow key; right arrow key

Sets the IP address

IP2 -"-

IP3 -"-

IP4 -"-

SUB1 -"- Sets the subnet mask

SUB2 -"-

SUB3 -"-

SUB4 -"-

RTR1 -"- Sets the router address/standard gatewayRTR2 -"-

RTR3 -"-

RTR4 Up/down arrow key; Enter

SAVE NO Right arrow key

SAVE YES Enter

SAVE WAIT Saves the settings on the parameterization memory.

PRESS RESET Switch the control system off and back on again (control system POWER ON).

Resets the control system/controller board and transfers the settings. The system starts up with the preset addresses.

Please note that the controller board must be disconnected from the power supply for at least 5 seconds.



4.4 Example Startup of the Controller Board

4.4.1 Example of an INTERBUS and Control System Configuration

To make your introduction to working with the IBS S7 400 ETH SDSC/I-T controller board as straightforward as possible, the descriptions in later sections are based on the following INTERBUS and control system configuration. This example is also used in the UM EN INTERBUS-SAFETY SYS system description and in the Quick Start Guide for SafetyProg.

Example Configuration

Figure 4-4 Example configuration

� � � � � � � ' ' � � < � � , � � ( * �

� � � � - � � �

� � � � + � # � � � , � � � ( � ( 2 * + 8

� , & � . / & 0 � � � 1 2

� � � � + � # � � , � � � ( # ( � * + 8 * # 6 � ,

� , & � � . / & 0 � � � 1 2

� # 3

� � � � � � % & & % & � � � & ' ( ) & % � % � " * (

� � � + � � + , & � & � � & � � �

� 6 � � � � � # % #

�

4

1

�

%

#

�

'

�

4

1

�

%

#

�

'

� � � �

# %

+ � 8

� � �

� �

� �

+ � ) ,

� ) + �

� � � � � � .

� ' ( � ' '� ) � * �

6 � � � � .

� � � �

9 8 �

��

�

� � � * � �

� 3 (

�

4 ' ! � ( ' & �

4 ' ! � ( ' & � 3 (

� � ��

� 3 (

�

� � �

� � �

� �

4 �

4 �5 �

� 6 * 5 6

3 53 !

# 7 4 & �

� � � + � # � � � , � � � ( � ( �

� , & � � . / & 0 � � 1 2

� � + � # � � � = � � � * � ) �

� � � + � # � � � 8 * + 8 ( � 1 * # 6 � ,

� , & � � . / & 0 � � � 1 2

� � + � # � � , � � # * # ) * # 6 � ,

� , & � � . / & 0 � � � � 1 2

� � � � � � � � � * 6 ) ( 6 ( � *+ 8 * � � � * # 6 � ,

� , & � � . / & 0 � � � 1 2

� �

� �



4.4.2 Example Startup of the Controller Board in Direct I/Q Operation Mode

4.4.2.1 Integration of the Controller Board in STEP 7

Integrating the controller board

1. Integrate the controller board as an S5 ADAPTOR SIMATIC component in a new project in the hardware configuration for S7 400 (SIMATIC 400\IM-400\S5 ADAPTOR directory in the hardware catalog).

Configuring I/O addresses in STEP 7

2. Configure the input and output addresses of the controller board (S5 ADAPTOR) in the S7 400 system in the STEP 7 parameterization mask. Enter the S7 and S5 addresses (inputs and outputs) and the length of the data records to be transmitted in the STEP 7 parameterization mask. Assign the coupling area set with the DIP switches to each of the entries. Enter the base address, the length, and the area of the communication register separately.

Downloading to the S7 control system

Once all the settings have been made in the STEP 7 parameterization mask, the hardware configuration data can be transmitted to the standard control system to check the selected settings.

Example The following section shows typical entries in the STEP 7 parameterization mask for direct I/Q mode of the controller board in coupling areas P and Q. 512 bytes are available for INTERBUS process data. 4 bytes in each coupling area (8 bytes in total) are reserved for the communication register.

Input addresses in STEP 7 Controller board address entries in the STEP 7 parameterization mask:

The output addresses are assigned according to the input addresses.

Make sure that the S7 base address of the communication register is always outside the process image of the CPU type used.

Switch 1 2 3 4 5 6 - 8

Position OFF OFF OFF OFF

Function Reserved Direct I/Q operation mode

P/Q Reserved

Entry S7 Address S5 Address Length Part of PI

Coupling Area

1 0 0 128 0 P

2 128 128 124 0 P

3 256 0 128 0 Q

4 384 128 124 0 Q

5 512* 252 4 0 Q

* Please note that the address of the communication register must be outside the process image of the CPU used.



Using these address assignments, the following address areas are reserved for INTERBUS in the S7 400 control system:

Figure 4-5 Occupied address areas in direct I/Q operation mode

4.4.2.2 Integration of the Controller Board in Config+


1. In Config+, add the "IBS S7 400 ETH SDSC/I-T" controller board from the device catalog to a new project.

Make the following settings for the parameterization of the controller board in the "Device Details" window. Switch to the "Extended Settings" tab.

Basic settings 2. Set "Direct I/Q Operation Mode" in the basic settings of the controller board.

Figure 4-6 Setting "Direct I/Q Operation Mode"

For additional information on parameterizing the addresses, please refer to the STEP 7 software online help.

For more detailed information on operating the Config+ software, please refer to the online help or the Quick Start Guide for the software.

� � / � � � / � � / � �

�

� �

� �

�

� �

�

� � � � � �

� � 8 9 : � � ; & � � � & #

� � 8 9 : � � ; & � � � & $

� � � � 8 � � 1 � � � � � & � ; � < � �

The settings in the following screenshots are example illustrations according to the example configurations shown in Figure 4-4 on page 4-10. When the dialog box is opened, Config+ offers settings, which must be checked according to your application and adjusted, if necessary.



Setting the data records/communication register

3. Enter the coupling area and direct addresses (S7 address and length of the data record), which have been set in the STEP 7 hardware configuration. Do not forget the address for the communication register. If you do not wish to use the extended addresses in your application, activate the corresponding data records. Data record no. 8 (indicated with "SIS") is set by default to exchange data that is not safety-related between the safe INTERBUS controller and the standard control system.

Figure 4-7 Setting: Coupling area and direct/extended addresses

Key:No./Data Direction A maximum of eight input data records and eight output data

records are available.S7 Address Start address of the I/O data of your INTERBUS configuration

in the S7 address area.For extended addresses, data block area DBx, bit memory area M or the I/O address area can be set according to your application.

S5 Address S5 coupling area addressOffset (byte) Specify a byte address as an offset. The area set under the

S7 address starts from this point.Length (byte) Number of I/O bytes in your INTERBUS configuration. Enter

the length of the area entered under the S7 address in bytes.SIS Select the checkbox if you wish to exchange data between

the safe INTERBUS controller (SIS) and the standard control system via the area set.



INTERBUS standard register addresses

4. Check the addresses of the INTERBUS standard and diagnostic registers suggested by Config+ in the "Device Details... Registers" dialog box or modify these addresses according to your application.

Figure 4-8 Communication register and INTERBUS register addresses

Please note:– The coupling area set must correspond to the DIP switch settings on the controller

board.– The settings for the "direct addresses" must be made according to the hardware

configuration specifications in STEP 7.– The parameterized data records must not overlap (length).– To transmit data records via the extended addresses (see Figure 4-7), the READ_DS

and WRITE_DS driver blocks must always be integrated according to your application in your application program (see "Read Function FC 31 READ_DS" on page 4-30 and "Write Function FC 41 WRITE_DS" on page 4-31).

Register addresses are assigned in the I/O area of the S7 control system within the process image.



Configuring devices 5. Configure the INTERBUS devices.You can select either automatic or manual configuration of the INTERBUS devices in your project:

Automatic configuration – Following selection of the IBS S7 400 ETH SDSC/I-T controller board, Config+ reads in the connected bus configuration, creates the entire configuration automatically by linking the FDCML files of the devices read, and addresses all the INTERBUS devices.

Manual configuration – You generate the configuration yourself and assign the addresses observing any existing software standards.

6. Check the configuration by performing steps 7 through 9.7. Save the configuration on the parameterization memory.

Data consistency:

To provide the S7 control system with consistent data of more than one word (16 bits), the "Asynchronous With Synchronization Pulse" bus mode can be used. In Config+, select this bus mode in the "Device Details... INTERBUS Settings" dialog box. In the driver blocks, set this bus mode with the MODE parameter of FC 20 INIT_IB (controller board operating mode).

Access the consistency areas in the preset data width in your STEP 7 program, e.g., 16-bit consistency with word commands.

Please refer to the IBS S7 400 ETH DSC SWD UM E user manual for additional information on data consistency.

Advantage: Highly simplified INTERBUS configuration, requiring little system knowledge.

Disadvantage: All the INTERBUS devices must be fully installed and powered up. Incorrectly connected devices (e.g., devices whose connecting cable is not plugged in) will not be included. Automatic addressing means that in the event of later extensions to the system (e.g., the addition of a new device) all the subsequent addresses in the application program will change.

When using automatic configuration, all the addresses of the INTERBUS register will be overwritten with the process data of the INTERBUS devices. You must adjust the driver software and the register settings accordingly.

Check your project settings and, in particular, the bus configuration of the safe INTERBUS devices once the connected bus devices have been automatically read in.

Advantage: The system can be optimized to meet your specifications and the structure of your control program. Free addresses in the I/O areas of the S7 control system used can also be reserved for future system extensions.

Disadvantage: The configuration requires greater effort.



8. Save the Config+ file on your local drive.

9. Once the configuration has been saved successfully to the parameterization memory, reset the controller board with the configuration software or with a S7 control system POWER ON, in order to check the proper execution of the saved configuration.

After successfully activating the stored configuration, the controller board displays "RUN". If the configuration could not be started, an appropriate error message appears in the display (see Section 5). When the INTERBUS system is activated, the parameterized inputs and outputs of the controller board become available. This completes the configuration and startup of the standard INTERBUS system.

4.4.2.3 Integration of the STEP 7 Driver Blocks and Startup of the Controller Board

Installing driver blocks The documentation CD for the S7 controller boards includes driver blocks in the STEP 7 programming language. In addition to these driver blocks for operating the controller board, the CD contains example programs that can be directly integrated in your application program. Preprogrammed controller board functions are described using the example programs.

Insert the documentation CD in the drive. If the CD does not start automatically, start by double-clicking on the "Index-html" file in Windows Explorer. Select the language and the corresponding controller board in the browser interface. Then switch to the window for selecting the Readme file or installing the driver blocks by clicking "Function Blocks... Show". Save and extract the "DRV_S7400DSC_4xx.EXE" driver block file to the required directory.

The driver blocks and example applications are automatically extracted to the specified directory (default setting: "C:\") if "UNZIP" is selected.

Switch the standard control system to the STOP state before executing a POWER ON.


Additional information on the examples and driver blocks can be found in the IBS S7 400 ETH DSC SWD UM E driver manual, as text files, and as the data pre-header in the examples on the CD.

Please ensure that the name of the EXE file contains at least 4xx = 417 for versions ≥ 417.

If the file provided corresponds to an earlier version, please visit www.phoenixcontact.com for information about the latest driver version.




File path The IBSWD4xx.S7P STEP 7 project file, which includes all controller board driver blocks, can be found under:

(Destination drive):\INTERBUS.S7\S7400DSC_4xx\ENGLISH\IBSWD4xx\IBSWD4xx.

For direct I/Q operation mode, example applications for transmitting I/O data and for PCP operation can be found under:

(Destination drive):\INTERBUS.S7\S7400DSC_4xx\ENGLISH\EX_DOM.

Example IOASYNCH.BCP (direct I/Q operation mode)

The following example informs you how to parameterize the functions for an I/O coupling between INTERBUS and the S7 400 control system in direct I/Q operation mode.

Startup OB The controller board is started when the power supply to the S7 400 control system is switched on using the INTERBUS configuration stored on the parameterization memory. This procedure is processed independently of the standard control system and must be synchronized with the STEP 7 application program. A driver block (FC 20, see page 4-29) called during control system startup (OB 100) performs the synchronization.

Config+: Loading the example

1. Load the IOASYNCH.BCP example file in Config+ (path: "(Destination drive):\INTERBUS.S7\S7400DSC_4xx\ENGLISH\EX_DOM."). The example file parameterizes the following bus configuration (see also Figure 4-4 on page 4-10):

Figure 4-9 Example bus configuration

If you use a bus configuration, which differs from the example bus configuration, you must parameterize the bus configuration yourself as described in "Integration of the Controller Board in Config+" on page 4-12.

Please note that the parameterization preset in the example will be lost when the bus configuration is read in automatically. You must then carry out all the steps for setting the addresses described in "Integration of the Controller Board in Config+" on page 4-12.

Parameterize the addresses of the INTERBUS standard and diagnostic registers according to the following table. Avoid double assignment in your application.



INTERBUS register addresses in the example

Preset addresses in the example

2. After formatting the parameterization memory, save your configuration there.

3. Switch the S7 400 control system power supply off and back on again (POWER ON) or reset the controller board via Config+. The controller board transfers the current data from the parameterization memory and enters the RUN state, if the configuration was parameterized correctly. In the event of an error, please check your configuration.

STEP 7:Loading the example

4. Load the IOASYNCH.S7P example file (path: (Destination drive):\INTERBUS.S7\S7400DSC_4xx\ENGLISH\EX_DOM\IOASYNCH.) in STEP 7. The example file parameterizes the control system configuration example in Figure 4-4 on page 4-10.

5. Perform an overall reset of the S7 CPU.

S5/S7 addresses in the example

Input addresses (the values for the output addresses are the same):

Loading the configuration/starting the standard control system

6. Load the hardware configuration in the standard control system.

7. Load the example project in the standard control system.8. Start the standard control system.

Register Address in I/O Area

Diagnostic status register IW244

Diagnostic parameter register IW246

Extended diagnostic parameter register IW248

Standard function start register QW248

Standard function status register IW250

Standard function parameter register QW250

Switch the standard control system to the STOP state before executing a POWER ON. Please note that the controller board must be disconnected from the power supply for at least 5 seconds.

If you use a configuration, which differs from the example configuration in Figure 4-4 on page 4-10, you must carry out the steps described in "Integration of the Controller Board in STEP 7" on page 4-11 yourself. Please note that the parameterization preset in the example will then be lost.

Entry S7 Address S5 Address Length Part of PI

Coupling Area

1 4 0 124 0 P2 128 128 124 0 P3 256 0 128 0 Q

4 384 128 124 0 Q5 512* 252 4 0 P/Q

* In the example, the S7 address of the communication register is 512. If an S7 CPU with a larger process image is used, please assign this address outside the process image.



The INTERBUS I/O module data is now available in the S7 CPU from the S7 addresses parameterized in the example or that you have parameterized according to your configuration.

If the input data indicated by the LEDs can be seen on your output module (the input data is transmitted to the outputs 1:1), you have started up the control system and INTERBUS without any errors.

Call Description of FC 20 in OB 100

The initialization function (FC 20) is called during S7 control system startup (OB 100). Its task is to synchronize the control system with the controller board. In addition, it enters operating parameters required by other functions (FC) in the INTERBUS data block, which was specified when calling FC 20 (e.g., transfer of base addresses, etc.). The function calls the FC 125 SIS_DIAG safety diagnostic function via set bit 27 of the CONFIGURATION parameter. Once the controller board and the INTERBUS system have been started, the function is terminated.

To start FC 20 in OB 100, an activation bit must be set (BUSY parameter). This parameter remains set as long as the function is active. After parameterizing the controller board and starting INTERBUS, the function resets the activation bit (BUSY = 0). The result is displayed in the RET bit. If RET = 0, INTERBUS has been started and is operating. If the RET bit is set (RET = 1), an error has occurred. The diagnostic display and Config+ indicate the cause.

Program sequence of OB 100 in direct I/Q operation mode and description of the example parameters in FC 20:

For additional information, please refer to the IBS SYS DIAG DSC UM E Diagnostics Guide.

During standard control system startup (OB 100), the safety function in the FC INIT_IB must be enabled via the CONFIGURATION parameter (bit 27).

UN M10.0

S M10.0 // Set activation bit

CALL FC20 // Call initialization function

IBDB := DB20 // INTERBUS data block

COM_ADR := 512 // S7 base address of the communication register, which was parameterized in STEP 7

DIAG_STATE := 244 // S7 address of the diagnostic status register

DIAG_PARA := 246 // S7 address of the diagnostic parameter register

FKN_START := 248 // S7 address of the standard function start register

FKN_PARA := 250 // S7 address of the standard function parameter register

FKN_STATE := 250 // S7 address of the standard function status register

MEM_READ := 0 // Not relevant



MEM_WRITE := 0 // Not relevant

LOAD := 0 // Loads the configuration from the parameterization memory

BOOT := 0 // INTERBUS startup from the configuration

MODE := 0 // Controller board operating mode: The INTERBUS cycle on the controller board runs asynchronously to the control system.

TIMER_NR := T1 // Timer used by this function.

SOURCE := 0 // Number of the parameterization data block, if LOAD = 0 is not relevant.

CONFIGURATION := DW#16#800000F

// Configuration of blocks: The controller board is operating in direct mode.All additional error data is entered in the IBDB.Bit 27 = 1, calls safety diagnostics

RET := M10.1 // Result bit:= 0: The function was executed without errors.= 1: An error has occurred.

BUSY := M10.0 // Activation bit:Activate FC 20

UN M100.7 // Setting the START_UP bit. This

S M100.7 // bit must be set during startup (see description of FC 24 in IBS S7 400 ETH DSC SWD UM E).

//UN M10.0 // If FC 20 has not been

//UN M10.1 // processed correctly, the

//BEB // program can be

//CALL SFC 46 // stopped here.



4.4.3 Example Startup of the Controller Board in Extended I/Q Operation Mode

4.4.3.1 Integration of the Controller Board in STEP 7


1. Integrate the controller board as a standard FM 451 FIXED SPEED POS. (FMPOS3C, 6ES7 451-3AL00-0AE0) SIMATIC component in a new project in the hardware configuration for S7 400 ("SIMATIC 400\FM-400" directory in the hardware catalog).

The controller board is emulated as FM 451 FIXED SPEED POS. in the analog area of the S7 400 control system with 24 bytes of inputs and outputs. Please note that DIP switch 2 must be set to ON (see Section 3.2 on page 3-2).

Configuring STEP 7 addresses

2. Check the base address of the controller board in the "Properties - FM 451 FIX. SPEED" window.

Downloading to the S7 control system

Once all the settings have been made in the STEP 7 parameterization mask, the hardware configuration data can be transmitted to the standard control system to check the selected settings.

4.4.3.2 Integration of the Controller Board in Config+


1. In Config+, add the "IBS S7 400 ETH SDSC/I-T" controller board from the device catalog to a new project.

Make the following settings for the parameterization of the controller board in the "Device Details" window. Switch to the "Extended Settings" tab.

Basic settings 2. Set "Extended I/Q Operation Mode" in the basic settings of the controller board.

Figure 4-10 Setting "Extended I/Q Operation Mode"

If using the example configuration in Figure 4-4 on page 4-10, transfer the address suggested to avoid address overlaps. Please note that the base address must be outside the process image of the CPU used.

For more detailed information on operating the Config+ software, please refer to the online help or the Quick Start Guide for the software.

The settings in the following screenshots are example illustrations according to the example configurations shown in Figure 4-4 on page 4-10. When the dialog box is opened, Config+ offers settings, which must be checked according to your application and adjusted, if necessary.



Setting data records 3. In the following dialog box, activate the data records required for your application to transfer INTERBUS process data between the controller board and the S7 control system. Data record no. 8 (indicated with "SIS") is set by default to exchange data that is not safety-related between the safe INTERBUS controller and the standard control system.

Figure 4-11 Controller board data records

Key:No./Data Direction A maximum of eight input data records and eight output data

records are available.Activated Activation of the data record

S7 Address Start address of the I/O data of your INTERBUS configuration in the S7 address area. The data block area DBx, bit memory area M or the I/O address area can be set according to your application.

Offset (byte) Specify a byte address as an offset. The area set under the S7 address starts from this point.

Length (byte) Number of I/O bytes in your INTERBUS configuration. Enter the length of the area entered under the S7 address in bytes.

SIS Select the checkbox if you wish to exchange data between the safe INTERBUS controller (SIS) and the standard control system via the area set.

Please note:

– The base address of the controller board set in the hardware configuration in STEP 7 must be transferred to Config+ (see following section).

– The parameterized data records must not overlap (length).– To transmit data records, the READ_DS and WRITE_DS driver blocks must always

be integrated according to your application in your application program (see "Read Function FC 31 READ_DS" on page 4-30 and "Write Function FC 41 WRITE_DS" on page 4-31).



Base address and INTERBUS standard register

4. Check the base address of the controller board entered in the "Controller Board... Registers" dialog box. If necessary, adapt this address to your application according to the base address specified in the hardware configuration under STEP 7.

Figure 4-12 "Controller Board... Registers" dialog box

Location of the INTERBUS standard register

According to the following illustration, the location of the INTERBUS standard register depends on the base address.

Figure 4-13 Location of the INTERBUS standard register

Key:BA = Base address (here: 512)res. = Reserved

a = Diagnostic status register (2 bytes)b = Diagnostic parameter register (2 bytes)

c = Standard function start register (2 bytes)d = Standard function parameter register (2 bytes)e = Standard function status register (2 bytes)

g = Communication register (4 bytes)

� �

� #

� '

2

4

�

#

'

� � �

�

�

�

�

�

� � � "

� � � "

� � � "

� � � "

�

�

; � � � � � �

� � � "

:

:

:

:

� )

1 � #



Communication register The controller board communication register is used as an interface for the driver blocks. This register must not be overwritten.

Configuring devices 5. Configure the INTERBUS devices. You can select either automatic or manual configuration of the INTERBUS devices in your project:

Automatic configuration – Following selection of the IBS S7 400 ETH SDSC/I-T controller board, Config+ reads in the connected bus configuration, creates the entire configuration automatically by linking the FDCML files of the devices read, and addresses all the INTERBUS devices.

The controller board occupies 24 bytes of inputs and 24 bytes of outputs in the analog S7 control system area from the base address (512 in the example). The INTERBUS standard registers are located here.

Data consistency:

To provide the S7 control system with consistent data of more than one word (16 bits), the "Asynchronous With Synchronization Pulse" bus mode can be used. In Config+, select this bus mode in the "Device Details... INTERBUS Settings" dialog box. In the driver blocks, set this bus mode with the MODE parameter of FC 20 INIT_IB (controller board operating mode).

Access the consistency areas in the preset data width in your STEP 7 program, e.g., 16-bit consistency with word commands.

Please refer to the IBS S7 400 ETH DSC SWD UM E user manual for additional information on data consistency.

Advantage: Highly simplified INTERBUS configuration, requiring little system knowledge.

Disadvantage: All the INTERBUS devices must be fully installed and powered up. Incorrectly connected devices (e.g., devices whose connecting cable is not plugged in) will not be included. Automatic addressing means that in the event of later extensions to the system (e.g., the addition of a new device) all the subsequent addresses in the application program will change.

When using automatic configuration, all the addresses of the standard and diagnostic registers will be overwritten with the process data of the INTERBUS devices. You must adjust the driver software and the register settings accordingly.

Check your project settings and, in particular, the bus configuration of the safe INTERBUS devices once the connected bus devices have been automatically read in.



Manual configuration – You generate the configuration yourself and assign the addresses observing any existing software standards.

6. Check the configuration by performing steps 7 through 9.7. Save the configuration on the parameterization memory.8. Save the Config+ file on your local drive.

9. Once the configuration has been saved successfully to the parameterization memory, reset the controller board with the configuration software or with a S7 control system POWER ON, in order to check the proper execution of the saved configuration.

After successfully activating the stored configuration, the controller board displays "RUN". If the configuration could not be started, an appropriate error message appears in the display (see Section 5). When the INTERBUS system is activated, the parameterized inputs and outputs of the controller board become available. This completes the configuration and startup of the INTERBUS system.

4.4.3.3 Integration of the STEP 7 Driver Blocks and Startup of the Controller Board

Installing driver blocks The documentation CD for the S7 controller boards includes driver blocks in the STEP 7 programming language. In addition to these driver blocks for operating the controller board, the CD contains example programs that can be directly integrated in your application program. Preprogrammed controller board functions are described using the example programs.

Insert the documentation CD in the drive. If the CD does not start automatically, start by double-clicking on the "Index-html" file in Windows Explorer. Select the language and the corresponding controller board in the browser interface. Then switch to the window for selecting the Readme file or installing the driver blocks by clicking "Function Blocks... Show". Save and extract the "DRV_S7400DSC_4xx.EXE" driver block file in the required directory.

Advantage: The system can be optimized to meet your specifications and the structure of your control program. Free addresses in the I/O areas of the S7 control system used can also be reserved for future system extensions.

Disadvantage: The configuration requires greater effort.

Switch the standard control system to the STOP state before executing a POWER ON. Please note that the controller board must be disconnected from the power supply for at least 5 seconds.

Additional information on the examples and driver blocks can be found in the IBS S7 400 ETH DSC SWD UM E driver manual, as text files, and as the data pre-header in the examples on the CD.

Please ensure that the name of the EXE file contains at least 4xx = 417 for versions ≥ 417.

If the file provided corresponds to an earlier version, please visit www.phoenixcontact.com for information about the latest driver version.




The driver blocks and example applications are automatically extracted to the specified directory (default setting: "C:\") if "UNZIP" is selected.

File path The IBSWD4xx.S7P STEP 7 project file, which includes all controller board driver blocks, can be found under:

(Destination drive):\INTERBUS.S7\S7400DSC_4xx\ENGLISH\IBSWD4xx\IBSWD4xx.

For extended I/Q operation mode, example applications for transmitting I/O data and for PCP operation can be found under:

(Destination drive):\INTERBUS.S7\S7400DSC_4xx\ENGLISH\EX_EOM.

Example IOASYNCH.BCP (extended I/Q operation mode)

The section below describes an example of asynchronous data transfer between INTERBUS and the S7 400 control system in extended operation mode. In the example, the data from the input module is copied to the output module.

Startup OB The controller board is started when the power supply to the S7 400 control system is switched on using the INTERBUS configuration stored on the parameterization memory. This procedure is processed independently of the standard control system and must be synchronized with the STEP 7 application program. A driver block (FC 20, see page 4-29) called during control system startup (OB 100) performs the synchronization.

Config+: Loading the example

1. Load the IOASYNCH.BCP example file in Config+ (path: (Destination drive):\INTERBUS.S7\S7400DSC_4xx\ENGLISH\EX_EOM.). The example file parameterizes the following bus configuration (see also Figure 4-4 on page 4-10).

Figure 4-14 Example bus configuration

In the example the base address of the controller board is address 512. The start address of the input data word (16-bit INTERBUS input module) is DB2.DBB0 and the start address of the output data word (16-bit output module for INTERBUS) is DB3.DBB0.

If you want to use the example provided without making any changes, please ensure that your configuration matches the configuration in the example.

If your bus configuration does not match the example bus configuration, parameterize your bus configuration and assign the addresses for input and output data according to the example.



2. Format the parameterization memory and then save your configuration.

3. Switch the S7 400 control system power supply off and back on again (POWER ON) or reset the controller board via Config+. The controller board transfers the current data from the parameterization memory and enters the RUN state, if the configuration was parameterized correctly. In the event of an error, please check your configuration.

STEP 7:Loading the example

4. Load the IOASYNCH.S7P example file (path: (Destination drive): \INTERBUS.S7\S7400DSC_4xx\ENGLISH\EX_EOM\IOASYNCH.) in STEP 7. The example file parameterizes the control system configuration example in Figure 4-4 on page 4-10.

5. Perform an overall reset of the S7 CPU.

Loading the configuration/starting the standard control system

6. Load the hardware configuration in the standard control system.7. Load the example project in the standard control system.

8. Start the standard control system.

The data from the INTERBUS I/O modules is available in the data record parameterized in Config+.

If the output data (1:1 image of the input data) can be seen on your output module (displayed by the LEDs on the module), you have started up the standard control system and INTERBUS without any errors.

Switch the standard control system to the STOP state before executing a POWER ON.


If you use a configuration, which differs from the example configuration, check the base address of the controller board according to "Integration of the Controller Board in STEP 7" on page 4-21. Please note that the parameterization preset in the example will be lost.

Input data word: DB2.DBB0 and onwards

Output data word: DB3.DBB0 and onwards



Description of the Driver Blocks in the Example

The following section describes the driver blocks used in the example:

These driver blocks control the interaction between the controller board and the S7 control system.

Initialization Function FC 20:

The controller board is started when the power supply is switched on via the parameterization memory. This procedure is processed independently of the control system and must be synchronized with the application program in the standard control system. Driver block FC 20, called during S7 control system startup (OB 100), performs the synchronization.

Call description:

The initialization function (FC 20) is called during S7 control system startup (OB 100). Its task is to synchronize the control system with the controller board. In addition, it enters operating parameters required by other functions (FC) in the INTERBUS data block, which was specified when calling FC 20 (e.g., transfer of base addresses, etc.). The function calls the FC 125 SIS_DIAG safety diagnostic function via set bit 27 of the CONFIGURATION parameter. Once the controller board and the INTERBUS system have been started, the function is terminated.

To start FC 20 in OB 100, an activation bit must be set (BUSY parameter). This parameter remains set as long as the function is active. After parameterizing the controller board and starting INTERBUS, the function resets the activation bit (BUSY = 0). The result is displayed in the RET bit. If RET = 0, INTERBUS has been started and is operating. If the RET bit is set (RET = 1), an error has occurred. The diagnostic display and Config+ indicate the cause.

– FC 20 IB_INIT Initialization function

– FC 31 READ_DS Read function– FC 41 WRITE_DS Write function

For additional information, please refer to the IBS SYS DIAG DSC UM E Diagnostics Guide.

During standard control system startup (OB 100), the safety function in the FC INIT_IB must be enabled via the CONFIGURATION parameter (bit 27).



FC 20 in OB 100 Program sequence of OB 100 in extended I/Q operation mode and description of the example parameters in FC 20:

UN M10.0


CALL FC20 // Call initialization function


COM_ADR := 512 // S7 base address of the controller board

DIAG_STATE := 0 // Not relevant

DIAG_PARA := 0 // Not relevant

FKN_START := 0 // Not relevant

FKN_PARA := 0 // Not relevant

FKN_STATE := 0 // Not relevant

MEM_READ := 21 // Internal number of MEM_READ function

MEM_WRITE := 22 // Internal number of MEM_WRIT function

LOAD := 0 // Loads the configuration from the parameterization memory.

BOOT := 0 // INTERBUS startup from the configuration.

MODE := 0 // Controller board operating mode:The INTERBUS cycle on the controller board runs asynchronously to the control system.

TIMER_NR := T1 // Timer used by this function.

SOURCE := 0 // Not relevant

CONFIGURATION := DW#16#8800000F

// Configuration of blocks:The controller board is operating in extended mode.All additional error data is entered in the IBDB.

Bit 27 = 1, calls safety diagnostics


BUSY := M10.0 // Activation bit:Activate FC 20

UN M100.7 // Setting the START_UP bit. This

S M100.7 // bit must be set during startup (see description of FC 24 in IBS S7 400 ETH DSC SWD UM E).

//UN M10.0 // If FC 20 has not been

//UN M10.1 // processed correctly, the

//BEB // program can be

//CALL SFC 46 // stopped here.



Read Function FC 31 READ_DS

Call description:

Function FC 31 READ_DS reads consistent data blocks (data records) from the controller board buffer and copies them to the selected address area of the S7 control system.

FC 31 in OB 1 Program sequence of OB 1 and description of the example parameters in FC 31:

When the result bit is set (RET=1), the cause of an error is indicated by the error number in data word DBW58 of DB20 (IBDB).

Please note that all input data records that were configured in Config+ are copied (see Figure 4-11 on page 4-22).

In direct I/Q operation mode, FC31 only processes input data records 5 to 8, which access the extended addresses of the S7 control system (see Figure 4-7 on page 4-13).

UN M11.0


CALL FC31 // Call read function



BUSY := M11.0 // Activation bit: Activate FC 31

Error Number Description Remedy

3No valid input data

record foundCheck your

configuration



Write Function FC 41 WRITE_DS

Call description:

Function FC 41 WRITE_DS copies consistent data blocks (data records) from the selected address area of the S7 control system and writes them to the controller board buffer.

FC 41 in OB 1 Program sequence of OB 1 and description of the example parameters in FC 22:

When the result bit is set (RET=1), the cause of an error is indicated by the error number in data word DBW60 of DB20 (IBDB)

Please note that all output data records that were configured in Config+ are copied (see Figure 4-11 on page 4-22).

In direct I/Q operation mode, FC41 only processes output data records 5 to 8, which access the extended addresses of the S7 control system (see Figure 4-7 on page 4-13).

UN M12.0


CALL FC41 // Call write function



BUSY := M12.0 // Activation bit: Activate FC 41

Error Number Description Remedy

3No valid output data

record foundCheck your

configuration

For additional information on the driver blocks and examples, please refer to the IBS S7 400 ETH DSC SWD UM E driver manual.



4.4.4 Integration of the Controller Board in SafetyProg

Use the SafetyProg software to implement safety-related programming in your application.

The integration of the controller board in the SafetyProg software is the same in both direct and extended I/Q operation mode.

When creating a new project in the "Project Wizard", select the desired bus configurator project (".bcp file") and the relevant controller board with integrated safe INTERBUS controller (IBS S7 400 ETH SDSC/I-T in the example).

For detailed information on operating the SafetyProg software, please refer to the online help or the Quick Start Guide for the software.

Once the Config+ project (.bcp file) has been imported into the bus navigator view, check your project settings and the bus configuration, in particular, of the safe INTERBUS devices.

For detailed information on the configuration, parameterization, and programming of INTERBUS Safety, please refer to the UM EN INTERBUS-SAFETY SYS system description and/or the Quick Start Guide or the online help for SafetyProg.



4.5 Diagnostic Function for Standard INTERBUS

4.6 Diagnostic Function for INTERBUS Safety

4.6.1 Evaluating Diagnostic Data

In addition to the standard INTERBUS diagnostic function and the diagnostic functions in the Config+ and SafetyProg software tools, two additional STEP 7 diagnostic driver blocks are available for INTERBUS Safety. FC 125 SIS_DIAG can be used by the standard control system and the application program operating within it to diagnose the safe INTERBUS I/O devices and the operating state of the safe INTERBUS controller. FC 126 DEV_STAT evaluates the diagnostic data of FC SIS_DIAG.

For a description of both functions, please refer to the following pages. The functions are integrated when installing the function blocks as described in Section "Integration of the STEP 7 Driver Blocks and Startup of the Controller Board" on page 4-16 for direct I/Q operation mode and Section "Integration of the STEP 7 Driver Blocks and Startup of the Controller Board" on page 4-25 for extended I/Q operation mode.

The diagnostic function of standard INTERBUS FC24 IB_DIAG is described in the STEP 7 driver manual IBS S7 400 ETH DSC SWD UM E.

For detailed information on system error messages and their display via the LCD and/or the LEDs, please refer to the IBS SYS DIAG DSC UM E Diagnostics Guide.

Blocks FC 21 MEM_READ and FC 22 MEM_WRIT must be in handshake mode to integrate FC 125 SIS_DIAG and FC 126 DEV_STAT.

For additional information on the driver, please refer to the IBS S7 400 ETH DSC SWD UM E Driver Manual and the data pre-header in the examples for the data carrier.



4.6.2 The FC 125 SIS_DIAG Safety Diagnostic Function

4.6.2.1 Call and Function Description

The FC 125 SIS_DIAG function, which operates in the cyclic program (OB 1), establishes the connection to the safe INTERBUS controller. The diagnostic data of the safe INTERBUS controller and the safe I/O devices is copied to the specified S_IBDB by the FC 125 and is available there for evaluation and further processing. During standard control system startup (OB 100), the safety function in the FC INIT_IB must be enabled via the CONFIGURATION parameter (bit 27).

The entry of the first (FIRST_OK) and last (LAST_OK) location ID specifies which safe INTERBUS I/O devices should be diagnosed. The diagnostic registers in the safe INTERBUS controller are cyclically updated with the latest diagnostic data from the safe INTERBUS I/O devices until an error occurs. In the event of an error, the state of the diagnostic register is frozen. The information is available in the S_IBDB (see "Description of the S_IBDB Safety Data Block" on page 4-36). Once the FC SIS_DIAG has read all the diagnostic information, the BUSY bit is reset. The BUSY bit must be reset in the cyclic program in order to restart the FC 125. The diagnostic registers are then cyclically updated again. The evaluation of the information in the S_IBDB must be programmed independently.

4.6.2.2 Call Structure of FC SIS_DIAG in OB 1:

************************************

**** Application program ****

************************************

BE

Error acknowledgmentFor information on error acknowledgment, please refer to the notes in section 5, "Errors, Diagnostic Messages, and Removal".

Error evaluationPlease note that errors are not evaluated in standard debug mode (Run [debug], Stop/Halt [debug])

The diagnostic block described below is part of the driver examples for the controller board.

CALL FC 125 // Call safety diagnostic function


S_IBDB := DB11 // Number of the safety data block

S_IBDB_DW := 0 // Start address in the safety data block

FIRST_OK := 1 // First location ID

LAST_OK := 126 // Last location ID

TIMER_NR := T 10 // Timer used

RET := M10.1 // Result bit

BUSY := M10.0 // Activate FC 125



4.6.2.3 Description of the FC 125 Parameters

IBDB Global INTERBUS data block (in the example: DB 20) with a length of 1062 bytes.

S_IBDB Safety data block, which contains the diagnostic information of the safe I/O devices and the safe INTERBUS controller.

S_IBDB_DW This parameter is used to define the data word start address in the safety data block (e.g., DBW0).

FIRST_OK This parameter is used to specify the location ID of the first safe I/O device, whose state is to be diagnosed by FC 125.

LAST_OK This parameter is used to specify the location ID of the last safe I/O device, whose state is to be diagnosed by FC 125.

TIMER_NR Number of the timer used by FC 125 (e.g., T 10).RET This flag bit indicates whether the function was carried out without errors

(RET = 0). If an error occurred, the function is exited and the parameter is set to "1".

An error number indicates the error cause in data word DBW62 of the IBDB.

Error number:

1: TimeoutThe time to read the device states (preset in DBW96 of the IBDB: 2 seconds) has elapsed. Check whether errors are indicated in the standard INTERBUS diagnostic status register that is not safety-related.

2, 4: Incorrect confirmation codeThe confirmation received does not correspond to the transmitted service.

3, 5: Negative resultThe function was not executed successfully. For example, a ser-vice was parameterized incorrectly or a system function was pro-cessed negatively.

6: First location ID invalid (FIRST_OK)Check the value of the first location ID and correct, if necessary

7: Last location ID invalid (LAST_OK)Check the value of the last location ID and correct, if necessary

BUSY To call FC 125, set this flag bit via a positive edge. After processing, the function resets the bit.



4.6.2.4 Description of the S_IBDB Safety Data Block

Table 4-3 Contents of the S_IBDB safety data block

Address Parameter Data Type Description

DBB00 Schrittkette SIS_DIAG BYTE Used by the block (step counter)

DBB01 Schrittkette DEV_STAT BYTE Used by the block (step counter)

DBB02 Reserved

DBB03 Reserved

DBB04 First_OK BYTE First location ID

DBB05 Last_OK BYTE Last location ID

DBW06 SIS_DIAG_STATE WORD Diagnostic status register of the safe INTERBUS controller (see "Diagnostic Status Register of the Safe INTERBUS Controller" on page 4-38)

DBW08 SIS_DIAG_PARA1 WORD Diagnostic parameter register 1 of the safe INTERBUS controller (see Table 5-1 on page 5-2)

DBW10 SIS_DIAG_PARA2 WORD Diagnostic parameter register 2 of the safe INTERBUS controller (see Table 5-1 on page 5-2)

DBW12:DBW20

Reserved

DBW22 LEN WORD Length of the confirmation

DBW24 DATA_OK_1 WORD Data for the 1st location ID

DBW26 GN_1 WORD Group number for the 1st location ID

DBW28 DATA_OK_2 WORD Data for the 2nd location ID

DBW30 GN_2 WORD Group number for the 2nd location ID

: : : :

DBW272 DATA_OK_126 WORD Data for the last location ID

DBW274 GN_126 WORD Group number for the last location ID

Please note that DBW0 of S_IBDB must be deleted during S7 control system startup (OB100).

The device-specific diagnostic and error messages of the safe INTERBUS I/O devices are located in the DATA_OK_1 up to a maximum of 126 parameters according to the location ID.

The group number that is assigned to the corresponding location ID can be entered in the GN_1 up to a maximum of GN_126 parameters. This entry is evaluated by FC DEV_STAT. Therefore make sure that the contents are "0" if no group number has been assigned.

Please refer to the device-specific user documentation for detailed information on these messages.

For additional information on group numbers, please refer to the user manual for the device state function block UM EN IB FB DEVICE-STATE.



4.6.2.5 Call Structure of the Safety Diagnostic Function in OB1

CALL FC 31 // Driver call to read input data




CALL FC 21 // Handshake mode call


MODE := 10 // Handshake mode


DEST_AREA := 0 // Not relevant

DEST_AREA_NR := 0 // Not relevant

DEST_OFFSET := 0 // Not relevant

DEST_LENGTH := 0 // Not relevant



CALL FC 125 // Calls the safety diagnostic function












SOURCE_AREA := 0 // Not relevant

SOURCE_AREA_NR := 0 // Not relevant

SOURCE_OFFSET := 0 // Not relevant

SOURCE_LENGTH := 0 // Not relevant

DESTINATION := 0 // Not relevant



CALL FC 41 // Driver call to write output data






4.6.2.6 Diagnostic Status Register of the Safe INTERBUS Controller

The diagnostic status register of the safe INTERBUS controller (SIS_DIAG_STATE) contains the status information for the safe INTERBUS controller (SIS). It mirrors the state of the safe INTERBUS controller at all times including any error states that have occurred on the safe INTERBUS controller. Additional information and error parameters, in particular in the failure state (FS), are included in the relevant diagnostic parameter registers of the safe INTERBUS controller (SIS_DIAG_PARA1 and 2).

Bits 0 to 4

Bits 0 to 4 indicate the startup status of the safe INTERBUS controller. The startup sequence of the safe INTERBUS controller is divided into the following five steps:

PON Power ON process complete

This bit is set as soon as the SIS is supplied with power and the firmware has been loaded and started up. The comprehensive selftest routines of the device have been completed successfully.

INIT Initialization of the SIS complete

This bit is set as soon as the safe SIS operating system has been initialized without any errors and the SIS is in the ON state.

PRO Program loaded

This bit is set as soon as the safety-related application program, which was created with SafetyProg, has been loaded and started without any errors in the safe SIS operating system.

SYN Synchronization with INTERBUS master complete

This bit is set as soon as the safe INTERBUS controller has synchronized with the INTERBUS master part of the controller board.

I/O I/O channel communication initialized

This bit is set as soon as the initialization of INTERBUS Safety communication with the safe INTERBUS I/O devices has been completed without any errors.

Table 4-4 Diagnostic status register of the safe INTERBUS controller (SIS_DIAG_STATE)

Bit 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0

FS res. res. EST DD res. res. res. res. DBG RUN I/O SYN PRO INIT PON



Bits 5 and 6

The RUN and DBG bits indicate the operating state of the safe INTERBUS controller.

RUN RUN mode of the SIS

This bit is set when the SIS executes the safety-related application program and is in one of the two RUN states (SAFE RUN or DEBUG RUN). This bit is not set in the SAFE STOP and DEBUG STOP/SINGLE states.

DBG Standard debug mode of the SIS

This bit is set when the SIS is in one of the two DEBUG states (DEBUG RUN or DEBUG STOP/SINGLE). This bit is not set in the SAFE STOP and SAFE RUN states.

Bit 11

DD The DD (device diagnostics) bit indicates that diagnostic and error messages for safe INTERBUS I/O devices are preset.

This bit corresponds to a group message of all device diagnostic messages. When there is no longer a diagnostic message for a safe INTERBUS I/O device, this bit is reset to zero. The FC 125 SIS_DIAG diagnostic block evaluates this bit and outputs the latest diagnostic messages for the safe INTERBUS I/O devices in the S_IBDB in the event of a group message.

Table 4-5 Contents of bits 5 and 6 and corresponding LED indicators

RUN Bit DBG Bit State RUN LED FS LED

0 0 Startup sequence (bit 0 to 4) or SAFE STOP

OFF

Flashing

Flashing

OFF

0 1 DEBUG STOP/SINGLE Flashing Flashing

1 0 SAFE RUN ON OFF

1 1 DEBUG RUN ON Flashing

For possible diagnostic and error messages for the safe INTERBUS I/O devices, their effect, and possible remedies, please refer to the user documentation for the safe INTERBUS I/O devices.



Bit 12

EST The EST (error stack) bit indicates that diagnostic and error messages for the safe SIS operating system are present. These messages can only be read and evaluated by SafetyProg.

This bit is always set if at least one entry is included in the error memory of the safe operating system. As soon as the error memory has been read and emptied via SafetyProg, this bit is automatically set to zero.

Bit 15

FS Failure state

This bit is set as soon as an error has been detected, which sets the SIS to the failure state. The corresponding additional error code is included in this state in diagnostic parameter registers 1 and 2 of the SIS (SIS_DIAG_PARA1 and 2).

res. Reserved



4.6.3 Safety Function FC126 DEV_STAT

4.6.3.1 Call and Function Description

The diagnostic data of the safe INTERBUS controller, which was provided by FC 125 in S_IBDB, is evaluated by FC DEV_STAT and made available for acknowledgment.

Inputs IN_OK_UP and IN_OK_DWN can be used to select the location IDs in S_IBDB, for which errors were reported.

4.6.3.2 Call Structure of FC DEV_STAT in OB1

************************************

**** Application program ****

************************************

BE

Error evaluationPlease note that errors are not evaluated in standard debug mode (Run [debug], Stop/Halt [debug])

The diagnostic block described below is part of the driver examples for the controller board.

CALL FC 126 // Call FC DEV_STAT



IN_OK_UP := M12.0 // Increment location ID for which errors were reported

IN_OK_DWN := M12.1 // Decrement location ID for which errors were reported

OUT_ERROR := MB100 // Specification of location ID, for which errors were reported

OUT_ERR_DATA := MW102 // Error code of location ID, for which errors were reported

OUT_NO-SELECT := MB104 // Specification of location ID (for which errors were reported) or the assigned group number

OUT_RET := M10.2 // Result bit



4.6.3.3 Description of FC DEV_STAT Parameters

S_IBDB Safety data block, which contains the diagnostic information of the safe I/O devices and the safe INTERBUS controller.

S_IBDB_DW This parameter is used to define the data word start address in the safety data block (e.g., DBW0).

IN_OK_UP This parameter is used to search the location IDs entered in S_IBDB in ascending order for reported errors.

IN_OK_DWN This parameter is used to search the location IDs entered in S_IBDB in descending order for reported errors.

OUT_ERROR This parameter contains the found location ID, for which an error was reported. The value is used for information purposes and can be transferred to the safe INTERBUS controller.

OUT_ERR_DATA This parameter contains the error code according to the location ID indicated in the OUT_ERROR parameter.

OUT_NO_SELECT This parameter contains

– the location ID contained in the OUT_ERROR parameter or– the group number assigned to the specified location ID.

Requirement: A group number has been entered in S_IBDB for the GN_x parameter assigned to this location ID.

This value can be transferred to the safe INTERBUS controller in order to evaluate error messages.

OUT_RET This flag bit indicates whether FC DEV_STAT has found location IDs (for which errors were reported) in S_IBDB. If no entry is found, the function is exited and this parameter is set to "1".



4.6.3.4 Call Structure of the Safety Diagnostic Function in OB1

CALL FC 31 // Driver call to read input data








DEST_AREA := 0 // Not relevant

DEST_AREA_NR := 0 // Not relevant

DEST_OFFSET := 0 // Not relevant

DEST_LENGTH := 0 // Not relevant



CALL FC 125 // Calls the safety diagnostic function









CALL FC 126 // FC DEV_STAT call



IN_OK_UP := M12.0 // Increment location ID for which errors were reported

IN_OK_DWN := M12.1 // Decrement location ID for which errors were reported

OUT_ERROR := MB100 // Specification of location ID, for which errors were reported

OUT_ERR_DATA := MW102 // Error code of location ID, for which errors were reported

OUT_NO_SELECT := MB104 // Specification of location ID (for which errors were reported) or the assigned group number

OUT_RET := M10.2 // Result bit






SOURCE_AREA := 0 // Not relevant

SOURCE_AREA_NR := 0 // Not relevant

SOURCE_OFFSET := 0 // Not relevant

SOURCE_LENGTH := 0 // Not relevant

DESTINATION := 0 // Not relevant



CALL FC 41 // Driver call to write output data




Please note that DBW0 of S_IBDB must be deleted during S7 control system startup (OB100).

Errors, Diagnostic Messages, and Removal


5 Errors, Diagnostic Messages, and Removal

The INTERBUS Safety system and thus also the IBS S7 400 ETH SDSC/I-T controller board make a distinction between the error categories described in the following sections.

5.1 Critical System or Device Errors

Critical system or device errors include all results and errors, which lead to the failure state of the safe INTERBUS controller. The high-quality diagnostics and monitoring function integrated in the safe INTERBUS controller detects errors that have occurred. All serious errors in the safe INTERBUS controller, which can lead to the loss of or adversely affect the programmed safety function, switch the device to the failure state. In this state, the outputs of the safe INTERBUS I/O device are set to zero within the parameterized shutdown time for the relevant output. The INTERBUS Safety system switches to the safe state.

Table 5-1 on page 5-2 provides an overview of possible errors, their causes, effects, and remedies.

The error codes are shown as a hexadecimal value in the diagnostic parameter registers of the safe INTERBUS controller (SIS_DIAG_PARA1 and SIS_DIAG_PARA2) and as plain text error messages in the controller board display (please note the information above regarding display priority). Corresponding error messages are also displayed in the SafetyProg and Diag+ software tools.

For information on INTERBUS standard G4 firmware diagnostic and error messages that are not safety-related, which are indicated in the controller board display, their meaning, and possible remedies, please refer to the IBS SYS DIAG DSC UM E Diagnostics Guide.

Please note that safe INTERBUS controller error messages are usually displayed in the controller board display with priority over standard INTERBUS error messages.

Please note that the failure state can only be exited by executing a reset in the SafetyProg software or by switching the S7 control system supply voltage back on again (power on).

For errors, which occur during the BOOT process of the safe INTERBUS controller, the failure state can also be exited by downloading the project again and then carrying out an automatic restart.



Table 5-1 Critical system and device errors

Error Cause Error Code (Hex)

LED Remark Effect Remedy or Response

Hardware error or failure in the safe INTERBUS controller.

1) FS ON The error is detected by the internal hardware monitoring function and the internal diagnostics.

The safe INTERBUS controller enters the failure state.

The FS bit in the SIS_DIAG_STATE register is set.

Replace controller board and restart including validation. See "Repair" on page 6-2.

Temporary EMI above the permissible limit values.

1) FS ON See "Correct Usage" on page 1-7 and "Technical Data and Ordering Data" on page 7-1.

Check ambient conditions (e.g., equipotential bonding and grounding concept; detect and remove sources of interference).

The parameterization memory is not inserted or was removed during operation.

4395 FS ON Insert parameterization memory with the project valid for the application and restart including validation.

If the parameterization memory is inserted when the supply voltage is switched on, error code 4396hex is indicated.

No Phoenix Contact Compact Flash card detected.

438F Only use Compact Flash cards approved by Phoenix Contact.

Invalid firmware service sequence:1. Stop_Data_Transfer_Request

(0702hex)2. Start_Data_Transfer_Request

(0701hex)

4550 FS ON The service sequence is not permitted for this controller board.

Stop the INTERBUS data transfer with firmware service: Alarm_Stop_Request (1303hex).

Error opening a project file. 4B25 An error occurs if no project is loaded.

Load the project.

Errors, which result from operation, configuration, and adverse effects of communication between SafetyProg and the SIS. E.g., disregard of specified operating procedures or required entries, incomplete program download, etc. (see also Section 5.2).

Any FS ON The error is detected by the internal hardware monitoring function and the internal diagnostics.

Execute the action again in the required way or remove the cause of the adverse effects.

Errors, Diagnostic Messages, and Removal


5.2 Parameterization and Configuration Errors

Parameterization and configuration errors are handled between the SafetyProg software and the controller board or the safe INTERBUS I/O devices and are indicated in corresponding dialog boxes within the software.

This error class includes errors, which are detected by the controller board and the safe INTERBUS I/O devices during the plausibility tests of the parameterization and configuration data. Once these errors have been detected, the controller board and the safe INTERBUS I/O devices enter the safe state not the failure state. This means that they can still receive parameterization or configuration data and/or report diagnostic information. Operation can only be continued once the incorrect parameterization and configuration data has been corrected.

The board has overheated and switched to the failure state.

4A16 FS ON See "Correct Usage" on page 1-7 and "Technical Data and Ordering Data" on page 7-1.

Check ambient conditions (e.g., sufficient ventilation in the control cabinet) and operate the controller board in the specified range.

The temperature of the controller board is outside the permissible range.

4A18

Table 5-1 Critical system and device errors

Error Cause Error Code (Hex)

LED Remark Effect Remedy or Response

1) In the event of an error, inform the Phoenix Contact Service/Support personnel immediately of the error codes, which are displayed in the SIS_DIAG_PARA1 and 2 diagnostic parameter registers, in the controller board display or in the SafetyProg and/or Diag+ software tools. These details provide important information for error analysis and repair.

Please observe and follow the error messages and corresponding remedies displayed in SafetyProg and, in particular, the error descriptions for the safe INTERBUS I/O devices specified in the user documentation.

Please refer to the detailed information on parameterization and configuration errors in the user documentation for the safe INTERBUS I/O devices and the online help or Quick Start Guide for SafetyProg.



5.3 I/O Errors

I/O errors cannot occur on the controller board itself. I/O errors are detected by safe INTERBUS I/O devices and indicated to the safe INTERBUS controller. The safe INTERBUS controller compiles the error messages and makes them available to the software tools (SafetyProg, INTERBUS Safety function blocks (IB FB DEVICE State), and S_IBDB in the application program on the S7 control system) for further evaluation, display, and acknowledgment, if necessary.

I/O errors can be caused by the following:– Short/cross circuits at the safe inputs or outputs– Exceeding the permissible bouncing time of an input signal

– Exceeding the permissible simultaneity of two input signals– Exceeding the permissible maximum response time parameterized for each safe

output

For each I/O error that occurs, the error cause must first be removed and then the error must be acknowledged, if necessary. For information on error removal and acknowledgment, please refer to the notes in the user documentation for the safe INTERBUS I/O devices.

Maintenance, Firmware Update, Repair, Decommissioning, and Disposal


6 Maintenance, Firmware Update, Repair, Decommissioning, and Disposal

6.1 Maintenance

The controller board does not require maintenance.

The controller board does not require repeat testing within the duration of use.

6.2 Updating the Controller Board Firmware

Certain parts of the firmware that are not safety-related (integrated software on the controller board) can be updated via the V.24 (RS-232) interface. These firmware part updates are exclusively used for adding new functions that are implemented in the controller board firmware that is not safety-related within the scope of continuous product improvement (see "IBS G4" in Figure 2-2 on page 2-2).

Please note that only combinations of firmware and controller board revisions that have been approved by Phoenix Contact may be created.

No firmware update is required for normal system operation.

Firmware updates may only be carried out by Phoenix Contact authorized personnel. To update the controller board firmware, please contact your nearest Phoenix Contact representative.

Information on compatible and approved firmware versions for your controller boards can be found on the Internet at www.download.phoenixcontact.com.




6.3 Repair

Repair work on the controller board is not permitted. Send faulty controller boards with detailed error information (see "Errors, Diagnostic Messages, and Removal" on page 5-1) to Phoenix Contact.

6.4 Decommissioning and Disposal

To decommission a system, only proceed according to the procedures specified by the machine or system manufacturer.

When decommissioning an INTERBUS Safety system or parts thereof, ensure that the safe INTERBUS devices used:– Are correctly reused in another system.– Are disposed of according to the applicable environmental regulations, and in this case

can never be reused.

Ensure that existing INTERBUS projects and IP address settings are deleted from the parameterization memory when decommissioning your application. Only then may the parameterization memory be used in another controller board. Please also refer to the operation of the IP address as described in "Setting the IP Address" on page 4-5.

Do not open the housing

It is strictly prohibited to open the controller board. In order to prevent the manipulation of the supplied controller board and to detect the unauthorized opening of the controller board, a security seal is applied to the controller board (see Figure 2-1 on page 2-1). This security seal is damaged in the event of unauthorized opening. In this case, the correct operation of the controller board can no longer be ensured.

Technical Data and Ordering Data


7 Technical Data and Ordering Data

7.1 System Data

7.2 IBS S7 400 ETH SDSC/I-T

For the system data, please refer to the following user manuals:INTERBUS IBS SYS PRO INST UM E

IBS SYS INTRO G4 UM EINTERBUS Safety UM EN INTERBUS-SAFETY SYS

General Data

Bus system INTERBUS/INTERBUS Safety

Control system Siemens SIMATIC S7 400

Mounting In the rack of an S7 400 control system

Space required 2 slots

Weight 1000 g

Transmission speed 500 kbps and 2 Mbps

Data Interfaces

Control system SIMATIC S7 400 P bus

INTERBUS Remote bus, 9-pos. D-SUB female connector

Serial, local RS-232 (V.24), 9-pos. D-SUB male connector

Ethernet 10/100BASE-T, direct twisted pair connection (RJ45 female connector)

Supply

Connection Via SIMATIC S7 400 P bus

Voltage 5.1 V DC, typical (corresponds to the nominal value of the SIMATIC voltage supplies)

Current consumption 2.7 A, typical3.5 A, maximum

Select the correct power supply units

In particular, note the current consumption of the components in the rack when selecting the power supply unit. The notes in "Electrical Safety" on page 1-4 must be observed.

Only use SIMATIC S7 400 power supply modules that have an output value ≥ 10 A and a mains buffering time ≥20 ms.



Ambient Conditions

Ambient temperature

Operation 0°C to +60°C

Storage/transport -25°C to +70°C

Humidity

Operation 10 to 75%, no condensation

Storage/transport 5 to 75%, no condensation

Air pressure

Operation 80 kPa to 108 kPa (up to 2000 m above sea level)

Storage/transport 66 kPa to 108 kPa (up to 3500 m above sea level)

Degree of protection IP20, when installed within a SIMATIC S7 400 system

Pollution degree 2, when installed in housing or a control cabinet with IP54 protection or higher

Air and creepage distances According to IEC 60439-1

Class of protection III (SELV with SIMATIC S7 400 power supply)

To ensure correct operation, the controller board must be mounted in housing or a control cabinet with a minimum of IP54 protection.

Mechanical Requirements

Vibration according to IEC 60068-2-6 Operation: 1g, criterion 1

Shock according to IEC 60068-2-27 15g, criterion 1

Safety Characteristic Data According to IEC 61508/DIN EN 61508, EN 60204, and DIN EN 954-1

Achievable safety integrity level SIL 3 according to IEC 61508/DIN EN 61508,Cat. 4 according to DIN EN 954-1

PFH, Probability of a hazardous failure per hour according to IEC 61508 for the device

< 10-9, or < 1% of 10-7 for SIL 3

PFD, Average probability of a hazardous failure on demand according to IEC 61508 for the device

< 10-5, or < 1% of 10-3 for SIL 3

HFT, Hardware fault tolerance of the device

1

Maximum duration of use No restrictions

Supported stop category according to EN 60204 0

Buffer Times of the Integrated Realtime Clock (RTC)

Typical buffer time 250 days

Guaranteed buffer time 10 days



7.3 Conformance With EMC Directive

LED Indicators

FS (failure state) Red LED

RUN Green LED

LINK Yellow LED

TRC Green LED

LOAD (battery) Green LED

FAULT (battery) Red LED

Conformance With EMC Directive 89/336/EEC

Noise Immunity Test According to DIN EN 61000-6-2

Electrostatic discharge (ESD) EN 61000-4-2/IEC 61000-4-2

Class 3, criterion B

Electromagnetic fields EN 61000-4-3IEC 61000-4-3

Criterion A, field strength 10 V/m

Fast transients (burst) EN 61000-4-4/IEC 61000-4-4


Surge voltage EN 61000-4-5/IEC 61000-4-5


Conducted interference EN 61000-4-6IEC 61000-4-6

Criterion A, test voltage 10 V

Noise Emission Test According to DIN EN 61000-6-4

Noise emission of housing EN 55011 Class A, industrial applications



7.4 Ordering Data

7.4.1 Ordering Data for Accessories

7.4.2 Ordering Data for Software

Description Order Designation Order No.

INTERBUS Safety controller board with integrated safe INTERBUS controller

IBS S7 400 ETH SDSC/I-T 28 19 55 8


Plug-in parameterization memory IBS CF FLASH 32MBIBS CF FLASH 64MB

27 37 07 027 37 05 4

Remote bus connector with solder connection IBS DSUB 9/L 27 58 47 3

Remote bus connector with screw connection SUBCON 9/M-SH 27 61 50 9

Connecting cable to connect the controller board with the PC (RS-232), 3 m in length

IBS PRG CAB 28 06 86 2

Fiber optic adapter for REMOTE interface, polymer fiber

– 500 kbps, unregulated– 2 Mbps, regulated– 500 kbps, regulated

IBS OPTOSUB-MA/M/R-LKIBS OPTOSUB-MA/M/R-LK-OPC-2MBDIBS OPTOSUB-MA/M/R-LK-OPC

27 50 12 527 31 45 827 32 63 5

Refer to the package slips of the following items and the Fiber Optic Installation Guidelines when assembling fiber optic cables, or order pre-assembled cables from Phoenix Contact.


SAFETYPROG 2 PRO includes the following software tools: SAFETYPROG 2 PRO 28 76 13 5

– SafetyProg, programming software for INTERBUS Safety, Version 2.2 or later

– Config+, configuration software for INTERBUS, Version 1.00 or later

– Diag+, diagnostic software for INTERBUS, Version 1.21 or later

Siemens SIMATIC STEP 7, Version 5.3 or later (recommended)

See Siemens SIMATIC product catalog



7.4.3 Ordering Data for Documentation

Make sure you always use the latest documentation. It can be downloaded at www.download.phoenixcontact.com. A conversion table is available on the Internet at http://www.download.phoenixcontact.com/general/7000_en_00.pdf.


INTERBUS S7 400 General

Driver Manual for STEP 7 Driver Software for INTERBUS S7 400 Controller Boards

IBS S7 400 ETH DSC SWD UM E 27 43 99 6

INTERBUS Safety

Introduction to Safety Technology and Overview of Standards SAFETY INTRO UM E 26 99 20 2

INTERBUS Safety System Description (Planning, Configuration, Installation, and Startup)

UM EN INTERBUS-SAFETY SYS 26 99 49 3

General INTERBUS

General Introduction to the INTERBUS System IBS SYS INTRO G4 UM E 27 45 21 1

Configuring and Installing INTERBUS IBS SYS PRO INST UM E 27 43 80 2

INTERBUS Diagnostics Guide for Generation 4 Controller Boards

IBS SYS DIAG DSC UM E 27 47 29 3

Quick Start Guide for Config+ Software UM QS EN CONFIG+ 26 99 69 7

Firmware Services and Error Messages IBS SYS FW G4 UM E 27 45 18 5

Peripherals Communication Protocol (PCP) IBS SYS PCP G4 UM E 27 45 16 9

Fiber Optic Installation Guidelines DB GB IBS SYS FOC ASSEMBLY 94 23 43 9

CD-ROM with all INTERBUS user manuals CD IBS UM ELDOC 27 45 61 9

CD-ROM with all INTERBUS data sheets CD IBS DB ELDOC 27 45 60 6




Appendix A

6941_en_04 PHOENIX CONTACT A-1

A Appendix: Controller Board Interfaces

A 1 Remote Bus Connection (REMOTE)

The following diagram shows the configuration of the remote bus connection and the remote bus cable (D9/D9 cable type).

Figure A-1 Remote bus connection and example of a remote bus cable

The braided shield of the remote bus cable connected to the metal-plated connector housing via the strain relief creates a conductive connection with functional earth ground (FE) on the controller board.

A 1.1 Fiber Optic Adapters

Your INTERBUS system can be fitted with fiber optic technology using fiber optic adapters for the remote bus connection. For information on the fiber optic adapters available for the controller board, please refer to "Ordering Data for Accessories" on page 7-4. The "OPTOSUB..." fiber optic adapters must not be supplied with power.

Phoenix Contact provides pre-assembled remote bus cables in popular lengths.

When selecting the fiber optic adapters, please ensure that they are suitable for the transmission speed required in your application.

Make sure that the power supply to the control system is switched off before plugging the fiber optic adapter into the controller board.

When using the fiber optic adapters, the cover must not be on the front plate.

�

�

�

�

�

�

�

� =

� � !

� < +

� < +

� < +

��

�

��

��

- � �

# � � >

? : : � �

- � �

� � � � �

� �

� � !

�

�

�

� �

% � � � � �� : � �

�

�

� � !

��

�

% � � � � �� : � �

��

��

�

� �

�

�

�

�

�

�

5 * � � � " � , * � �

� � � � � � � � � � � � � � �

, * � � �

� � � � � � � � � � � � � � � � �

� � � � � � � � � � � � � � � � � � - � �

% � : � � & < � � % � : � � & < � �

� � � � � � � � / � � � � � � � � � - � �� :

1 � � � 1 � � � & < � �

5 * � � � " � , * � �

� � � � � � � � � � � � � � � � � � � � � � � � �

� < + & @ & � < � � �


A-2 PHOENIX CONTACT 6941_en_04

A 1.2 Remote Bus Connector With IBS DSUB 9/L Solder Connection

Figure A-2 D-SUB connector cabling

1. Strip 20 mm off the cable sheath and shorten the braided shield to 8 mm. Strip 3 mm off the wire ends and connect the signal lines according to the drawing.

2. Fold the braided shield back over the cable sheath.3. Clamp the braided shield under the strain relief according to Figure A-2, so that a

conductive connection to the metal-plated connector housing is created, thus creating a connection to functional earth ground (FE).

Only use metal-plated connectors recommended by Phoenix Contact.

- � �

# � � >

? : : � �

- � �

� � � � �

� �

� � !

�

�

�

� �

% � � � � �� : � �

�

�

� � !

��

�

% � � � � �� : � �

��

��

�

� �

� � & � � &0 � + � & � � + 2

� & � � & 0 � + � � & � � + 2

� & � � & 0 � + � � & � � + 2

5 * � � � " � , * � �

� � � � � � � � � � � � � � �

5 * � � � " � , * � �

� � � � � � � � � � � � � � � � �

� � � � � � � � / � � � � � � � � $ , 5 ( , 5 &% � : � �< � �

% � : � �< � �

�

#

%% � � � � � & � : � �

� � � � � �

�

�

�

�

�

�

Appendix A

6941_en_04 PHOENIX CONTACT A-3

Remote Bus Connector With SUBCON 9/M-SH Screw Connection

Figure A-3 SUBCON connector cabling

1. Strip 50 mm off the cable sheath and shorten the braided shield to 10 mm. Strip 5 mm off the wire ends and connect the signal lines according to the drawing.

2. Fold the braided shield back over the cable sheath.3. Clamp the braided shield under the strain relief according to Figure A-3, so that a

conductive connection to the metal-plated connector housing is created, thus creating a connection to functional earth ground (FE).

Only use metal-plated connectors recommended by Phoenix Contact.

- � �

# � � >

? : : � �

- � �

� � � � �

� �

� � !

�

�

�

� �

% � � � � �� : � �

�

�

� � !

��

�

% � � � � �� : � �

��

��

�

� �

5 * � � � " � � � � � �

� � � � � � � � � � � � � � �

5 * � � � " � � � � � �

� � � � � � � � � � � � � � � � �

� � � � � � � � / � � � � � � � � $ � � � � � � 5 ( � � � � � � 5 &

�

#

%% � � � � � & � : � �

�

��

��

��

1��%��#��

5��2��4

� & � � & 0 � + � & � � + 2

� � & � � &0 � + � � & � � + 2

& � � & 0 � + � � & � � + 2

� � � � � � �


A-4 PHOENIX CONTACT 6941_en_04

A 1.3 RS-232 Interface (V.24)

The following diagram shows the configuration of the RS-232 interface and the connecting cable (RS-232).

Figure A-4 Diagnostic interface and RS-232 connecting cable

The braided shield of the connecting cable connected to the metal-plated connector housing via the strain relief creates a conductive connection with functional earth ground (FE) on the controller board.

A 1.4 10/100BASE-T Ethernet Interface

The following diagram shows the configuration of the Ethernet interface (RJ45 female connector).

Figure A-5 10/100BASE-T Ethernet interface

! " # � � $ � � * # % # & � � � � � �

5 * � � � " � , * � �

� � � � � � � � � � � � � � � � �

% � : � � & < � �

�

�

�

5 * � � � " � , * � �

� � � � � � � � � � � � � � � � �

% � : � � & < � �

�

�

�

� � � � � � � �

% � � � � �� : � �

�

�

% � � � � �� : � �

�

�

5 * � � � " � , * � �

� � � � � � � � � � � � � � �

# � � & < � �

4 A � �

� ( % �

- � �

( A � �

4 ( %

�

�

�

, - � : � � � � - � � � � � � � � � �

� * 9 � < + & 4 B � � � � : & 1 � � � 1 � � �

4 1 � � & � � � � & �

( � � � < � � � & � � � � & *

( � � � < � � � & � � � � & ��

�

�

�

*

*

&

�

*

*� � � � � � � �

� ' ( � ' ' � ) � * �

�

�

� 4 1 � � & � � � � & *

Appendix B

6941_en_04 PHOENIX CONTACT B-1

B Appendix: Checklists

The checklists listed in this section provide support during the planning, mounting and electrical installation, startup, parameterization, and validation of the IBS S7 400 ETH SDSC/I-T controller board.

Archive the completed checklists to use as reference for recurring tests.

The checklists do not replace the validation, initial startup, and regular testing performed by qualified personnel.

The following section of a checklist shows an example of a completed checklist.

These checklists may be used as planning documentation and/or as verification to ensure the steps in the specified phases are carried out carefully.

For more comprehensive checklists, please refer to the UM EN INTERBUS-SAFETY SYS user manual.

Checklist . . .Device Type/Equipment Identification IBS S7 400 ETH SDSC/I-T/BK15NA11Version: HW/FW/COP FW

SIS10/4.70/3.5103/102

Date 03/07/05

Test Engineer 1 John Smith Test Engineer 2 Jane BrownRemark System XXX has been checked for engine hood productionNo. Requirement (Mandatory) Yes RemarkX . . .

No. Requirement (Optional) Yes No RemarkY . . .

Key:

Equipment Identification Enter the device type and/or the equipment identification for the relevant device.

Version: HW/FW/COP FWSIS

Enter the hardware, firmware, COP firmware, and SIS version of the device (see Figure 2-1 on page 2-1).

Date Enter the date on which you began to fill in this checklist.

Test Engineer 1/2 Enter the names of the test engineers.

Remark Enter a remark, if necessary.

Requirement (Mandatory) These requirements must be met for a safety application, in order to complete the relevant phase using the checklist.

Requirement (Optional) These requirements are optional. For points that are not met (No), please enter an appropriate remark in the relevant field.


B-2 PHOENIX CONTACT 6941_en_04

B 1 Planning

Checklist for Planning the Use of the Controller Board With SIS

Device Type/Equipment Identification


Date

Test Engineer 1 Test Engineer 2

Remark

No. Requirement (Mandatory) Yes Remark1 Has the current controller board user manual been used as the basis

for planning?2 Has the power supply been planned according to the specifications for

SELV in accordance with PELV?3 Are measures planned to prevent simple manipulation?

4 Have measures been planned for parameterization, mounting and electrical installation, startup, and validation?

5 Has it been ensured that any person intentionally starting hazardous movements has a direct view of the danger zone?

6 Does the planned use correspond to the intended use?

7 Are the ambient conditions observed according to the technical data?

8 Has the degree of protection been observed?

No. Requirement (Optional) Yes No Remark1 Are all measures that are based on applicable standards planned?

2 Have the accessories to be used been planned according to the ordering data in this user manual (cables, connectors, fiber optic adapters)?

3 Is the transmission speed observed?

4 Have specifications for mounting and electrical installation been defined (e.g., EPLAN) and communicated to the relevant personnel?

5 Have specifications for parameterization been defined and communicated to the relevant personnel?

6 Have specifications for startup been defined and communicated to the relevant personnel?

7 Is the technical data of the interfaces observed?

8 Do the cables (bus and supply voltage) correspond to the specification?

9 Are requirements for interface wiring and cable installation observed and is the corresponding implementation planned?

10 Has decommissioning been defined in accordance with the maximum duration of use?

11 Have test intervals been defined?

Appendix B


12 Are specifications from the controller board user manual described for replacing the controller board?

Date Signature (test engineer 1)


No. Requirement (Optional) Yes No Remark



B 2 Mounting and Electrical Installation

Checklist for Mounting and Electrical Installation of the Controller Board With SIS



Date


Remark

No. Requirement (Mandatory) Yes Remark1 Was mounting and electrical installation completed according to the

specifications (specifications from the planning phase and/or according to the controller board user manual)?

2 Have the specifications for SELV been observed in accordance with PELV?

3 Have measures been taken to prevent simple manipulation?

No. Requirement (Optional) Yes No Remark1 Was the transmission speed observed when selecting the fiber optic

adapter?2 Do the cables (bus and supply voltage) correspond to the

specification?Date Signature (test engineer 1)


Appendix B


B 3 Startup and Parameterization

Checklist for Starting Up and Parameterizing the Controller Board With SIS



Date


Remark

No. Requirement (Mandatory) Yes Remark1 Was startup completed according to the specifications (specifications

from the planning phase and/or according to the controller board user manual)?

2 Has it been ensured that there is no danger from the connected bus configuration/connected I/O devices when switching on the controller board supply voltage?

3 During startup, is it ensured that any person starting hazardous movements intentionally can only do so with a direct view of the danger zone?

4 Have all the steps from Table 4-1 "Steps for initial startup" in "Initial Startup" on page 4-2 been carried out?

5 Does the parameterization of the address settings correspond to the planned application?

No. Requirement (Optional) Yes No Remark1 Has a valid IP address been set for the controller board according to

the specifications in the controller board user manual?Date Signature (test engineer 1)




B 4 "Initial Startup" Validation

Carry out a validation every time you make a safety-related modification to the INTERBUS Safety system.

Checklist for Validation on Initial Startup of the Controller Board With SIS



Date


Remark

No. Requirement (Mandatory) Yes Remark1 Have all the mandatory requirements for the "Planning" checklist been

met?2 Have all the mandatory requirements for the "Mounting and Electrical

Installation" checklist been met?3 Have all the mandatory requirements for the "Startup and

Parameterization" checklist been met?4 Has a function test been performed to check all safety functions, in

which the controller board is involved?5 Does the voltage supply correspond to the specifications for SELV in

accordance with PELV?6 Do all cables correspond to the specifications?



9 Have the address settings been parameterized?

10 Does the CRC of the safety control system (controller board with integrated safe INTERBUS controller) match the CRC of the PC in the "Safety Control System Info" dialog box?



Appendix B


B 5 "Restart" Validation

Carry out a validation every time you make a safety-related modification to the INTERBUS Safety system.

Checklist for Validation on Restart of the Controller Board With SIS



Date


Remark

No. Requirement (Mandatory) Yes Remark1 Was the controller board replaced according to the specifications

(specifications according to the controller board user manual)?2 Was the controller board started up according to the specifications

(specifications according to the controller board user manual)?3 Have the address settings been parameterized?

4 Has a function test been performed to check all safety functions, in which the controller board is involved?


6 Does the voltage supply correspond to the specifications for SELV in accordance with PELV?

7 Do all cables correspond to the specifications?


9 Does the CRC of the safety control system (controller board with integrated safe INTERBUS controller) match the CRC of the PC in the "Safety Control System Info" dialog box?





Appendix C

6941_en_04 PHOENIX CONTACT C-1

C Index

AAbbreviations ..............................................................1-9

CChecklists .................................................................. B-1

"Initial Startup" validation ..................................... B-6"Restart" validation............................................... B-7Mounting and electrical installation ...................... B-4

Planning ............................................................... B-2Startup and parameterization............................... B-5

Config+

Integration of the controller board (direct I/Q operation mode) .................................4-12

Integration of the controller board (extended I/Q operation mode) ...........................4-21

Controller boardBehavior in the event of an error...........................2-2Diagnostic display .................................................2-5

DIP switch functions..............................................3-2Ethernet operating indicators ................................2-8Front and rear view ...............................................2-1

Function units........................................................2-2Inserting/removing the parameterization memory.3-5Keypad..................................................................2-5

Method of operation ..............................................2-2Mounting ...............................................................3-3Operating indicators for the internal battery ..........2-9

Operating indicators of the safe INTERBUS controller ....................................2-6

Product description ...............................................2-1Removal ................................................................3-4Replacement .........................................................3-8

S5 adapter...........................................................2-11S7 interface ...........................................................2-3Safe state (failure state) ........................................2-2

Setting the DIP switches .......................................3-2Controller board input/output operation modes ........2-10

Comparison.........................................................2-17

Direct I/Q operation mode...................................2-11Extended I/Q operation mode .............................2-14Selection .............................................................2-16

Setting the DIP switches .......................................3-2

Controller board interfaces ........................................ A-1

10/100BASE-T ..................................................... A-4Ethernet interface................................................. A-4Remote bus connection (REMOTE) .................... A-1

Remote bus connector with screw connection..... A-3Remote bus connector with solder connection .... A-2RS-232 interface .................................................. A-4

DDecommissioning .......................................................6-2

Diagnostic functionFC 125 SIS_DIAG...............................................4-34Standard INTERBUS ..........................................4-33

Direct I/Q operation mode.........................................2-11Disposal ......................................................................6-2

EElectrical installation

Connecting an Ethernet network...........................3-7

Connecting the connecting cable to the PC..........3-7Connecting the INTERBUS system ......................3-6Replacing the IBS S7 400 ETH SDSC/I-T ............3-8

EMC directive .............................................................7-3Errors

I/O errors...............................................................5-4

Messages and removal.........................................5-1Parameterization and configuration errors............5-3System or device errors ........................................5-1

Example startup (direct I/Q operation mode of the controller board)..............................................4-11

Integration in Config+..........................................4-12Integration in STEP 7..........................................4-11Integration of the STEP 7 driver blocks ..............4-16

Example startup (extended I/Q operation mode of the controller board)..............................................4-21

Integration in Config+..........................................4-21Integration in STEP 7..........................................4-21Integration of the STEP 7 driver blocks ..............4-25

Example startup of the controller boardINTERBUS and control system configuration .....4-10

Extended I/Q operation mode...................................2-14


C-2 PHOENIX CONTACT 6941_en_04

FFiber optic adapters ................................................... A-1

FirmwareUpdating................................................................6-1

For your safety

Correct usage........................................................1-7Directives and standards.......................................1-6Documentation ......................................................1-8

Electrical safety .....................................................1-4General safety notes .............................................1-2Safety of the machine or system...........................1-5

GGeneral

Mounting/removal/electrical installation ................3-1

IIBS S7 400 ETH SDSC/I-T

Ethernet connection ..............................................2-3FM 451 FIXED SPEED POS...............................2-14

INTERBUS remote bus connection.......................2-4Parameterization memory .....................................2-4Realtime clock.......................................................2-4

RS-232 interface ...................................................2-4INTERBUS

Operating modes.................................................2-10

Internal realtime clockBuffer times ...........................................................2-9

IP address

Set.........................................................................4-5Set in Config+ .......................................................4-6Set via the keypad.................................................4-8

MMaintenance ...............................................................6-1

MountingLocation.................................................................3-1

Mounting/removal

Mounting the controller board ...............................3-3Removing the controller board ..............................3-4

OOrdering data..............................................................7-4

Accessories...........................................................7-4Documentation......................................................7-5Software................................................................7-4

RRepair .........................................................................6-2

SSafe INTERBUS controller

Operating indicators..............................................2-6Operating states....................................................2-6

Safety hotline............................................................1-10

SafetyProgIntegration of the controller board .......................4-32Safe programming tool........................................4-32

User rights.............................................................2-6Startup

Initial startup..........................................................4-2

Restart ..................................................................4-4STEP 7 driver blocks

FC 125 SIS_DIAG...............................................4-34

FC 126 DEV_STAT.............................................4-41FC 20 INIT_IB ............................................4-19, 4-28FC 31 READ_DS ................................................4-30

FC 41 WRITE_DS...............................................4-31System requirements

Hardware and software.........................................1-9

TTechnical data

Buffer times of the realtime clock..........................7-2Conformance with EMC directive..........................7-3IBS S7 400 ETH SDSC/I-T ...................................7-1

Safety characteristic data......................................7-2System data ..........................................................7-1

Appendix D

6941_en_04 PHOENIX CONTACT D-1

D Appendix: Revision History

Revision Date Contents

02 03/2005 First publication of the document for controller board revision:HW/FW/COP FW 10/4.70/3.52

SIS 04/2.00

03 08/2005 New error message 4550hex in Table 5-1 "Critical system and device errors".

This version of the document was not published.

04 12/2005 Revision of the document for controller board version:HW/FW/COP-FW 11/4.71/3.52

SIS 05/2.01


D-2 PHOENIX CONTACT 6941_en_04

Date post:	19-Dec-2015
Category:	Documents
Upload:	uriac86
View:	2 times
Download:	0 times

6941_en_04.pdf

Documents