Bit-modular distributed I/O system

Product Brief · March 2003

SIMATIC ET 200S  the multi-functional, extremely
flexible distributed I/O system
SIMATIC® ET 200®S is a distributed I/O
system with degree of protection IP20.
It combines extremely simple installa-
tion and maximum flexibility with
permanent savings in life-cycle costs.
Summary of features
· Bit-modular design for precise adap-
tation to the automation task
· Independent wiring
· Wide range of modules:
- Input/output modules
- Process modules
- Motor starters
- Control functionality with CPU inte-
gration
· Various connection possibilities for
the terminal modules
· Reserve modules for reservation of
unused module slots
· Replaceable terminal box
· Use also possible for time-critical
tasks
· Integration of "Safety Integrated"
· Replacement of electronics modules
and motor starters during operation
(hot swapping)
· Simple diagnostics for exact channel
permits high availability: High-feature
or standard; system faults, for
example a missing supply voltage, are
automatically signalled as plain text
using the bus without programming
input.
Applications
· The comprehensive range of modules
with uniform handling for config-
uring, installation and programming
mean that the ET 200S can be used as
a universal I/O system.
· The mechanical design of the ET 200S
permits use with increased mechan-
ical loading. The system properties
support high plant availability
requirements. The SIMATIC ET 200S is
therefore exceptionally suitable for
use with extremely time-critical appli-
cations.
2
Design
The bit-modular design permits fast and
optimum adaptation to the require-
ments of any automation system:
· No stocking of spares
· No superfluous channels
The plant setting-up times can be signif-
icantly reduced even with frequently
changing requirements by the replace-
ment or combination of various I/O
modules.
The ET 200S results in wiring savings of
up to 80% for the following reasons:
· All supply voltages are only
connected once, and automatically
connected to the next module when
mounting side by side.
· All motor starters are completely
prewired apart from the motor
connection (with a conventional
design, up to 15 connections must be
made.)
IM 151Interface
module
PM-E power module
Electronics modules
Terminal modules
Motor starters
TM-D t8
terminal module with
integral power bus
PE/N assembly
The bit-modular design of the SIMATIC ET 200S
· The power supply to the individual
motor starters is handled by a power
bus with a rating up to 50 A.
· All terminals have the characteristics
of terminal blocks - signal and motor
cables can therefore be directly
connected to the SIMATIC ET 200S
without intermediate terminals.
· Safety technology is also part of the
system - and thus also prewired as far
as possible.
The compact design, flush mounting
side by side, omission of various cable
ducts and the elimination of terminal
blocks mean that space savings are
guaranteed. This is also particularly
important when using motor starters.
With a completely distributed design
directly on the machine, only the power
supplies and host control systems are
usually required in the control room.
When comparing the ET 200S to estab-
lished solutions you can achieve up to
50% less space requirements in the
control cabinet and 80% saving in
wiring!
PM-D power module Bus terminating module
SIMATIC ET 200S 
simple installation and wiring
Installation
It’s impossible to be simpler!
· Snap the interface module onto the
standard rail.
· The terminal modules can then be
fitted side by side without tools.
· The self-coding prevents destruction
of the electronics as a result of an I/O
module being inadvertently plugged
into the wrong position.
You can watch a corresponding installa-
tion film on the Internet:
www.siemens.com/simatic-dp/et200s
Strip-free Fast Connect system
The insulation displacement system
without the need for wire stripping
presents even more advantages when
installing. The TM-P and TM-E elec-
tronics and power modules have been
extended by the Fast Connect insulation
displacement system without wire strip-
ping. All common conductor
cross-sections from 0.25 to 1.5 mm²
can be connected using the new
system. Preparation for installation is
unnecessary. In addition to the advan-
tages of the proven ET 200S system, the
new technology also enables:
· Time savings of up to 60% during
installation compared to conven-
tional connection systems
· No stripping or crimping necessary
· Simple and reliable installation using
a screwdriver
· Reduction in error rate during installa-
tion
· Definition of stripping length is
unnecessary
· Reliability with gas-tight connection
Terminal module with new strip-free Fast
Connect system
Snap on
Wire up, test
"Independent wiring"
The so-called independent wiring is a
specific characteristic of SIMATIC
ET 200S: the mechanical components
(terminal modules) are isolated from
the electronic components (electronics
modules, power modules, motor
starters). The independent wiring not
only facilitates design of the station, it
also has a positive effect on the avail-
ability during operation:
· Complete prewiring is possible prior
to fitting the electronics modules and
motor starters - either using screw or
spring-mounted terminals as well as
the Fast Connect system without
stripping.
· The subsequent wiring test is even
possible under power because endan-
gered electronics components have
not yet been inserted.
· Thanks to the self-assembling power
buses, much of the cross-wiring
belongs to the past - this reduces test
requirements and possible sources of
error.
· The terminal modules have been
designed with the form and function
of a commercially available terminal
block. This guarantees simple, clear
wiring with acquainted handling.
· The module inscriptions are not
hidden by the wiring.
· The removable terminal box permits
simple connection of simulation
computers for preliminary commis-
sioning.
Plug on  finished!
Hot swapping for maximum availability
Hot swapping of electronics modules
and motor starters is possible without
tools. The SIMATIC ET 200S can
continue operation during swapping,
meaning that the application remains
fully functional in many cases.
With motor starters, it is even possible
to omit isolation of the system which is
usually obligatory.
Accessories
The ET 200S is well equipped for prac-
tice with a versatile range of accesso-
ries:
· System-integrated shield connection
system with the following advan-
tages:
- Low-impedance connection via
3 x 10 mm busbar
- Individual lengths
- Simple, fast installation with plug on
technology
- Space-saving
- Cost-effective as result of standard
components
· Individual colored labels for the
terminals on the terminal modules
and for identification of slot numbers;
available in various colors and also
individually packed.
· Identification labels for numbering
the terminal modules: pre-labelled or
blank.
· DIN A4 labelling sheets in various
colors, pre-perforated, suitable for
printing with laser printer
More information available at:
www.s7-smartlabel.de
3
SIMATICT ET 200S 
increased safety with fail-safe signal modules
The ET 200S provides you with the
capability to design economical solu-
tions for safety-oriented applications for
the production industry. It comprises a
fail-safe CPU S7-315F, corresponding
fail-safe I/O modules for the ET 200S
distributed I/O system, and special
drivers for interfacing field devices from
other vendors.
Fail-safe components
The following fail-safe CPUs are avail-
able: CPU 315F of the S7-300®,
CPU 416F of the S7-400® and
IM 151-7F-CPU of the ET 200S.
Applications with the maximum safety
category 4 to EN954-1 can be imple-
mented in a simple manner using the
new fail-safe modules of the ET 200S
system and a SIMATIC F-CPU.
S7-400 F with F-CPU and stan-
dard I/Os
ET 200M with
fail-safe I/Os
Example of a configuration (fail-safe I/Os shown in yellow, standard I/Os in blue)
4
Safety signals, for example from light
barriers, EMERGENCY STOP buttons,
protective door switches etc., are
recorded on site by the distributed
fail-safe input module "4/8F-DI" of the
ET 200S system. The safety-oriented
data are then transmitted together with
the standard data to the host PLC via a
common PROFIBUS DP cable using the
PROFIsafe profile. A special bus cable,
or even an extra safety bus system, is no
longer necessary. "Safe" and "normal"
modules can be mixed together.
Advantages compared to conventional
safety systems
· Significant saving of components
(less hardware)
· Less assembly and installation work
· High flexibility
· When changes are necessary,
programming replaces wiring
SIMATIC ET 200S with fail-safe
· Implementable fail-safe and motor starter and S7-300F CPU
fault-tolerant motor starters
ET 200M with standard I/Os Operator panel
Light curtain
ET 200S with standard I/Os, fail-safe
I/Os and fail-safe motor starters Laser scanner
ET 200S 
Motor starters for every application
The ET 200S motor starters are used for
protecting and switching all kinds of AC
loads. The completely prewired devices
are available in a variety of performance
classes as direct, reversing or soft star-
ters up to a max. power of 7.5 kW. The
terminal modules contain the self-as-
sembling power bus (one-time infeed
for up to 20 motor starters) and the ter-
minals for direct connection of the mo-
tor cable. A motor starter can be
plugged/unplugged without isolating
the plant.
Motor starter of the ET 200S
Standard motor starter
· Circuit-breaker/contactor combinati-
on up to 5.5 kW
· Direct or reversing starter
· Self-assembling power bus up to 40 A
· SIGUARD safety technology optional
High-feature motor starter
· Combination of starter circuit-brea-
ker, electronic overload relay and
contactor or soft starter up to 7.5 kW
· Extensive diagnostics messages, e.g.
momentary current value
· Statistics, e.g. current of the last over-
load, can be read-out using the ES
motor starter service and startup soft-
ware switch
· Parameterization via bus
· Only two current setting ranges up to
7.5 kW
Graded safety concept
The motor starters of the ET 200S offer
a graded safety concept. Depending on
application it is possible to select the
optimum solution on a function/cost ba-
sis to suit each case in hand.
ET 200S SIGUARD
ET 200S SIGUARD saves a lot on wiring
on the basis of conventional safety re-
lays in less complex local safety applica-
tions. Power modules for Emergen-
cy-Stop or safety door applications are
available just like modules for time de-
lay and contact multiplication.
The safety sensors are connected direct-
ly on these local modules.
Function monitoring, e.g. for cross con-
nection, is implemented just like the
monitoring of the switching function of
the motor starters in the ET 200S
SIGUARD modules. ET 200S SIGUARD
modules automatically signal operating
and error states via PROFIBUS diag-
nostics to the higher-level controller.
Cascading of safety segments within an
ET 200S station is possible by corres-
ponding combination of SIGUARD mo-
dules or their terminal modules.
For Category 3 or 4, external redundan-
cy contactors are looped into the power
infeed of the power bus. These contac-
tors are also controlled and monitored
by the SIGUARD modules.
Fail-safe motor starter
As soon as more complex or physically
remote safety applications are involved,
the fail-safe motor starter is the opti-
mum solution in combination with the
power module PM-D F PROFIsafe. Sig-
nals from safe sensors are read in via
safe inputs at a random location in the
plant, transmitted via PROFIBUS and the
PROFIsafe message frame to the failsafe
controller and linked there in the user
program to the fail-safe motor starter or
the associated power module.
These motor starters based on the
high-feature motor starter offer a com-
pletely new and patented technology
for safety disconnection: whereas in
normal operation the contactor
performs disconnection, the integrated
double processor monitor also switches
off the circuit breaker in the event of a
fault, e.g. welded contactor contacts.
Each individual motor starter thus
achieves Category 4 or SIL 3 without an
additional redundancy contactor.
Since the fail-safe motor starters moni-
tor the contactor function regardless of
whether the application is safety-rele-
vant or not, these devices are also sui-
table for use in fault-tolerant processes.
Additional features for high availability
are:
· Type of coordination 2 over the entire
power range up to 7.5 kW
· Emergency Stop function permits im-
portant processes to be finished de-
spite reason to switch off, e.g.
overload.
Advantages in comparision to conventi-
onal safety technology:
· Considerably fewer components,
clearer design and much less hard-
ware configuring and wiring
· Easy installation thanks to simple con-
nection
· Motor starters have a high availability
and are fail-safe
· High flexibility through software-ori-
ented assignment of the safety
groups
· Minimum overhead when modifying
the safety application, since the
wiring remains the same
5
 SIMATIC ET 200S 
increased functionality with CPUs, IQ Sense
and power supply
Distributed intelligence -
intelligent CPU of the ET 200S
The IM 151-7 CPU can be used for
distributed automation solutions with a
medium program size. It permits distrib-
uted preprocessing of production data
on site.
The CPU communicates with the host
controller via the coexistent
MPI/PROFIBUS DP slave interface. This
results in the following advantages:
· Reduced loading on central controller
· Reduced response times to critical
local signals
· Programs become clearer and shorter
· Troubleshooting is facilitated
· Reduces loading on bus system
· Permits modular plant design and
preliminary commissioning - even at
different locations
Intelligent sensor module -
IQ Sense®
The four-channel IQ Sense® sensor
module together with the new
IQ Sense sensors provides a new
concept for intelligent linking of sensor
technology into automation tech-
nology. The ET 200S provides all func-
tions for any PROFIBUS DP master
modules.
Standard function blocks are offered for
simple handling on a SIMATIC S7.
Power supply
N A highly compact power supply measu-
ring a mere 90 mm wide is available for
the ET 200S. The ET 200S power supply
permits 2-phase connection of 240 or
400 V AC.
The stabilized output voltage of 24 V DC
can supply a maximum of 5A conti-
nuous current and is stable at no load
and is short-circuit resistant. With a high
efficiency of over 92% the ET 200S
power supply ensures efficient power
conversion and a cool switchbox. The
power supply can be set to standby
mode and the output side thus swit-
ched to voltage-free. Three LEDs
provide users at all times with clear
information on the present operating
status.
6
Using the new DP master module it is
possible to add an integrated DP master
interface to the IM 151-7 CPU and thus
implement an underlying PROFIBUS
line with additional distributed I/Os.
All this does not require additional soft-
ware handling, since SIMATIC ET 200S
can be configured, programmed and
diagnosed on the PROFIBUS from any
position using STEP 7. The STEP 7 Lite
programming tool is available for
non-networked applications.
Status/control functions are also
possible via the PROFIBUS. Thanks to
the plug-in SIMATIC Micro Memory
Card, the application program is imme-
diately available again following
module replacement. Thus SIMATIC
ET 200S with IM 151-7 CPU can be used
as a bit-modular small control system. IM 151-7 CPU interface module with integral
CPU (also available as an F-version) and
master module
Up to four sensors can be connected
with just two lines each, and parame-
terized using the Intelliteach® function.
Main applications are plants and
machines
· with high availability demands,
· with high probability of mutual influ-
encing of sensors
· with high flexibility or dynamic modi-
fications for the sensor parameters
IQ Sense sensor module
A plug-in terminal is used for the wiring,
which means that if the worst comes to
the worst the power supply can be
changed quickly and reliably without
rewiring. Due to its compact size the
power supply can also be used in distri-
buted applications independently of the
ET 200S.
Power supply for the ET 200S
SIMATIC ET 200S 
range of modules
Module type
Interface module
DP master module
Power modules for elec-
tronics modules and
motor starters
Terminal modules
Electronic modules
Provide the ET 200S with digital inputs and outputs; high-feature versions increase the plant availability and
offer supplementary functions and diagnostics
Digital input modules
Digital output modules
Analog input modules
Analog output modules
Reserve modules
IQ Sense sensor module
Process modules
Motor starters (also with
integrated safety tech-
nology)
Information Order No. group
· IM 151-1 BASIC: max. 12 modules IM 151-1: 6ES7151-1...
· IM 151-1 STANDARD: max. 63 modules IM 151-7 CPU:6ES7151-7...
· IM 151-1 FO STANDARD: similar to Standard, but with fiber-optic interface
(plastic, PCF) RS 485
· IM 151-1 HIGH FEATURE: max. 63 modules, DP V1 slave, isochrone mode
· IM 151-7 CPU: with integrated CPU 314 of the S7-300
· IM 151-7 F-CPU: with integrated CPU
· PROFIBUS DP master interface module for a low-level PROFIBUS line 6ES7138-4HA00-...
For power supply and monitoring of load and sensor voltage; voltage and/or
fuse failure; additional LEDs provide information on status of voltage and
fuse; different functions AC, DC, PROFIsafe
· PM-E 24 V DC or PM-E 24 V DC; with diagnostics 6ES7138-4CA..
· PM-E 24 V DC to 230 V AC with diagnostics and fuse 6ES7138-4CB..
· PM-E F 24 V DC PROFIsafe for electronics modules 6ES7138-4CF..
· PM-D F 24 V DC PROFIsafe for F-motor starters 3RK1903-0A..
For the electrical and mechanical connections of the I/O modules and
process wiring. Available with screw and spring-mounted terminals and with
the Fast Connect system without stripping
TM-P for power; TM-E for electronics; TM-D for motor starters 6ES7193-4.../3RK1903-0A..
· 2-channel and 4-channel 6ES7131-4...
· Available from 24 V DC to 230 V AC
· Different functionalities: standard, high-feature
· Fail-safe input module 4/8F-DI 24 V DC PROFIsafe 6ES7 138-4FA..
· 2-channel and 4-channel 6ES7132-4...
· Available from 24 V DC to 230 V AC; 0.5 to 5 A
· Different functionalities: standard, high-feature
· Electronics and relays
· Fail-safe output module 4F-DO 24 V DC/2A PROFIsafe 6ES7 138-4FB..
· 2-channel 6ES7134-4...
· Current and voltage inputs, thermocouple and resistance measurements
· Functionalities: standard, high-feature, high-speed
· 2-channel 6ES7135-4...
· Current and voltage outputs
· Functionalities: standard, high-feature
· As reserve module for unused slots within an ET 200S station 6ES7138-4...
· 4-channel 6ES7138-4...
· For connection of up to four IQ Sense sensors
· Expanded diagnostics and IntelliTeach® functionality
Intelligent modules operating independent of the CPU; use directly on site;
parameterization using STEP 7 or GSD files; serial interface
· Counter module: 24 V DC / 100 kHz or 5 V DC / 500 kHz 1 COUNT 6ES7138-4...
· SSI module 1 SSI 6ES7138-4...
· Positioning module for controlled positioning 1 POS 6ES7138-4...
· Stepper motor module 1 STEP 6ES7138-4...
· Pulse module (timer, pulse width modulation, stepper motor) 2 PULSE 6ES7138-4...
· Serial interface module 1 SI 6ES7138-4...
· Direct, reversing and soft starters 3RK1301-....
· Functionalities: standard, high-feature, fail-safe 3RK1301-....
· Up to 7.5 kW 3RK1903-....
7
Technical specifications
Technical specifications of the ET 200S - general
Degree of protection
Ambient temperature
Vibration resistance
· Number of I/O modules per
station, max
· Station width, max
· User data length, max
Master system requirements
·PROFIBUS DP master
·Parameter length
· User data length
· Diagnostics length, adjust-
able
Additional information on the
SIMATIC ET 200S can be found in the
Internet:
www.siemens.com/simatic-dp
Siemens AG
Automation and Drives
Postfach 4848, D-90327 Nürnberg
Federal Republic of Germany
IP 20
0 to 60 °C
up to max 5 g,
(max. 2 g for motor starters)
63
2m
244 byte each for inputs and
outputs
Corresponding to EN 50170
> 32 byte, according to number
and type of inserted modules
According to number and type
of inserted modules
Up to 64 byte
For personal consultation you can find
your local SIMATIC partner at:
www.siemens.com/automation/partner
www.siemens.com/simatic-dp
Order No.: 6ZB5310-0KG02-0BA1
Printed in the Federal Republic of Germany
26100/301388 SMT 03036.
Standards, approvals
· PROFIBUS EN 50 170, Volume 2
· IEC 1131 IEC 1131, Part 2
· UL According to standard UL508,
File No. E 116536/E 75310
(AC modules)
· CSA According to standard C22.2
No. 142. File No. LR 48323/
LR 44226 (AC modules)
· cULus According to standard UL 508
for hazardous locations File no. E 116536
According to hazardous locations
UL 1604
File No. E 222109
According to standard CSA C22.2
No. 142
· FM Standard Class No. 3611,
Class I Div. 2, Group A, B, C, D
Class I, Zone 2, Group IIC
(without motor starters)
· Marine engineering American Bureau of Shipping
Bureau Veritas
Det Norske Veritas
Germanischer Lloyd
Lloyds Register of Shipping
Nippon Kaiji Kyokai
· Ex approval Cat. 3 EN 50 021
(for zone 2 according to
ATEX-100a)
Accessories
Wide range of accessories, e.g. 6ES7193-4..
· Colored labelling strips, colored coding
labels
· System-integrated shield connection
system
· Manuals Product Brief with ® are registered
trademarks of the Siemens AG.
All designations marked in this
Using the A&D Mall you can immedi-
ately and directly order electronically
in the Internet:
www.siemens.com/automation/mall
© Siemens AG 2003
Subject to change without prior notice.