Detailed explanation of Siemens PLC active rails - Solutions - Huaqiang Electronic Network

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1. **Definition of Hot Swap Function in Siemens PLC Control System** The hot swap function ensures that modules can be inserted or removed without affecting system operation. Key features include: - **Hardware protection**: The module remains undamaged during insertion or removal. - **CPU stability**: The CPU does not stop and only generates an alarm if necessary. - **I/O consistency**: The I/O values of the module remain unchanged, and other modules continue to operate normally. - **Interrupt handling**: The CPU triggers an interrupt organization block (OB) or uses DP diagnostic blocks to detect and handle module changes. 2. **Siemens PLC Support for Hot Swap** - **S7-200 series**: Does not support hot swap functionality. - **S7-300 CPU**: Does not support hot swapping when directly connected to I/O modules. However, when used as a PROFIBUS DP master with ET200M, ET200S, or ET200iS slaves, hot swap is supported. - Note: Software redundancy systems using S7-300 cannot fully implement all hot-swap functions. When a module is removed from ET200M, the CPU doesn’t stop, but the SF and BUSF lights flash, and I/O values are reset. - **S7-400 CPU**: Supports hot swapping of I/O modules directly. It also supports hot swap when connected to ET200M, ET200S, and ET200iS slaves. - With S7-400, you can configure hot swap in STEP7 by enabling the "Module Change During Operation" option. 3. **ET200M Active Bus Backplane Configuration** The ET200M is a common distributed slave station in industrial applications. To enable hot swap, the standard rail must be replaced with an **active bus backplane**. This allows modules to be inserted or removed while the system is running. - **Hardware Requirements**: - Use an active bus backplane instead of a standard S7-300 rail. - The IM153 interface module must be compatible (e.g., MLFB 6ES7 153-1AA02-0XB0). - Older IM153 models (before 2018) may not support hot swap. - **Software Requirements**: - Configure in STEP7 version 5.1 or higher. - In the properties window of the IM153, enable the "Replace Modules During Operation" option. - **Hot Swap Process**: - When a module is inserted or removed, the CPU triggers OB83, OB85, and OB122. - These blocks allow users to handle the event and adjust I/O values accordingly. - For S7-300 systems, OB82 and OB86 are also required to monitor and respond to module changes. - **Important Notes**: - Parameterized modules (like FM354 or CP340) will lose their settings upon hot swap unless the system is restarted. - Always check the module’s documentation to confirm hot swap compatibility. By implementing these configurations, operators can ensure safer and more reliable system operations during module replacements, reducing downtime and improving overall efficiency. --- Let me know if you need this translated into another language or formatted differently!

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