AS 410 modular systems

With the rugged all-round system AS 410, the SIPLUS PCS 7 process control system offers an exclusive automation system from the SIPLUS S7‑400 series, which can be used in all domains due to its versatility. For specific requirements, you can configure it as a:

• Standard AS 410S automation system
• High-availability AS 410H automation system

The innovative CPU 410‑5H Process Automation of the AS 410 with its high-performance hardware and optimized firmware covers the entire performance range of the conventional automation systems AS 412 to AS 417. Its automation performance can be scaled with System Expansion Cards based on the number of SIMATIC PCS 7 process objects (POs) as follows:

• 100 PO
• 500 PO
• 1 000 PO
• 1 600 PO
• ≥ 2 000 PO (PO 2k+)

The type reduction to a single CPU offers numerous advantages. It significantly simplifies selection and configuration of the automation system as well as spare part inventory and plant expansion.

Like all SIMATIC PCS 7 automation systems of the S7‑400 series, AS 410 automation systems are available as "AS bundles" as follows:

• Individual components bundled in one shipment for each system
• Pre-assembled and tested complete systems (no extra charge compared to delivery of individual components)

The AS bundles come furnished with the SIMATIC PCS 7 AS Runtime license for 100 process objects (PO). Based on this, the number of process objects can be extended with cumulative AS runtime licenses for 100, 1 000 or 10 000 POs.
The configuration of the AS bundles as well as the article numbers can be defined by selecting pre-configured ordering units. System-specific ordering configurations are available in tabular form for this purpose in the sections "Standard automation systems", "Fault-tolerant automation systems" and "Safety-related automation systems".

For interactive configuration of AS bundles, there are also two online configurators available in the Industry Mall:

• SIMATIC PCS 7 AS 410 Single Station configurator
• SIMATIC PCS 7 AS 410 Redundancy Station configurator

CPU, aluminum rack (except UR1), optional redundancy or redundant power supply modules (in 4 A and 10 A variants), communications modules and sync modules of the SIMATIC PCS 7 AS 410 bundles have an additional coating (conformal coating).

AS 410 bundles for operating temperatures up to 70 °C

The AS 410 bundles are normally designed for operating temperatures up to 60 °C. Additional versions are available for extreme conditions; these are permitted for operating temperatures up to 70 °C. Their components predominantly have the designation "XTR" (extended temperature range) in their name. All components of the "AS 410 bundles for the extended temperature range (XTR)" also have an additional coating (conformal coating).

The article numbers of the AS 410 bundles for the extended temperature range (XTR) can be defined in the sections "Standard automation systems", "High availability automation systems" and "Safety-related automation systems" by means of an individual configuration table.

Flexible and scalable availability

A particular characteristic of the modular S7-400 systems is the flexible and scalable availability of various components.

For a AS 410-type SIPLUS PCS 7 AS Single Station, you have the option of specifically increasing the availability by implementing a redundant configuration of the power supply or the Industrial Ethernet communications module, and combining these measures.

Even the AS Redundancy Station of the AS 410 type with its redundant CPUs offers significantly higher availability. It operates according to the 1oo2 principle, in which a switch is made from the active subsystem to the standby system in the event of a fault. Starting from here, you can double the power supply or the Industrial Ethernet communications module for each subsystem, and combine these measures.

CPU 410-5H Process Automation: the "all-rounder" for process automation

CPU 410-5H Process Automation

The CPU 410‑5H Process Automation is at the heart of standard automation systems as well as high-availability AS 410 automation systems. With system expansion cards for 100 PO, 500 PO, 1 000 PO, 1 600 PO and ≥ 2 000 PO (PO 2k+), you can define your performance for your specific application with up to around 2 600 PO.

If the performance limit defined by the system expansion card is reached during configuration, commissioning or operation, a subsequent increase in performance is possible without replacing the hardware by using an appropriate number of CPU 410 Expansion Packs 100 POs/500 POs.

As shown in the figure, CPU 410-5H Process Automation is equipped with two PROFINET IO interfaces (2-port switch in each case) for up to 250 I/O devices and a PROFIBUS DP interface for up to 96 PROFIBUS DP slaves. Two integrated slots allow the synchronization of two redundant subsystems via sync modules and sync cables (FOC).

CPU 410‑5H Process Automation supports NTP as well as S7 time synchronization.

Other features include:

• Integrated 48 MB load memory and 16 MB work memory each for program and data
• Cycle time up to 10 ms/9 process tasks
• Total number of I/Os (on PROFIBUS DP and PROFINET IO) approx. 7 500, 16 KB each for inputs and outputs
• Expanded temperature range during operation up to 70 °C (as of product version 2)
• High-precision time stamping
• Recessed RESET button
• Preset hardware parameters (PCS 7 skinning)
• Changes in the type of module during operation (TCiR) in association with the SIMATIC PCS 7 Engineering System V8.1 and higher

For detailed information about CPU 410-5H Process Automation, see "Technical specifications".

I/O connection via PROFIBUS DP

The distributed process I/O can be integrated into a PROFIBUS DP segment either directly or via a lower-level fieldbus (PROFIBUS PA or FOUNDATION Fieldbus H1). For details on this, see sections "PROFIBUS DP", "PROFIBUS PA" and "FOUNDATION Fieldbus H1" in the "Communication" chapter.

PROFIBUS DP segments with distributed process I/Os can be operated on a PROFIBUS DP interface in the CPU and on additive SIPLUS NET CP 443‑5 Extended PROFIBUS DP interfaces (6AG1443-5DX*). You can configure up to 4 individual or redundant SIPLUS NET CP 443‑5 Extended PROFIBUS DP interfaces (6AG1443-5DX*) for one automation system using the configurators for SIPLUS PCS 7 automation systems in the Industry Mall as well as in the “Standard automation systems” and “High-availability automation systems” catalog sections.

You can additionally implement further PROFIBUS interfaces using separately ordered CP 443-5 Extended PROFIBUS DP interfaces (conformal coating). According to the manual, up to 10 CP 443-5 Extended interfaces (conformal coating) can be operated in one automation system.

I/O connection via PROFINET IO

You can easily and efficiently connect AS 410 automation systems to remote I/O stations via the PROFINET IO interfaces integrated in the CPU 410‑5H Process Automation, for example, to remote SIPLUS ET 200M or SIPLUS ET 200SP I/O stations (see also the "PROFINET" section in the "Communication" chapter). PROFINET IO interfaces provided by additive communications modules of the SIPLUS NET CP 443-1 type (6AG1443-1*) cannot be used.

Backup batteries

AA-type, 2.3 Ah lithium backup batteries are used in the power supply modules of all SIPLUS PCS 7 automation systems in the S7‑400 series. Since lithium batteries are easily inflammable, more rigorous transport and storage regulations apply to them.

To avoid subjecting the automation systems to these more rigorous transport and storage regulations, the backup batteries must be ordered and delivered separately (Article No. 6ES7971-0BA00).

The following backup batteries are required depending on the configuration of the AS system:

• SIPLUS PCS 7 AS Single System with:
  • 1 power supply module: 2 units
  • 2 redundant power supply modules: 4 units
• SIPLUS PCS 7 AS Redundant System with:
  • 2 power supply modules: 4 units
  • 2 x 2 redundant power supply modules: 8 units